Toyota7FBEU15 207FBEHU18 PDF

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
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

Every Every Every Every
Item
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
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
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
Replacement cycle
weeks 3 months 6 months 12 months
Item
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.
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
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 - - -

(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]
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
Approx. OV
(90, MHI) (51, LS-) tion
Connector No.-Connector No. Conditions Standard: Remarks
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-)
(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 - - -

(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]
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)
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
CN102-7 CN102-22 Approx. 3.3V
Change when the lift lever is
(21, POTL2) (51, POT-) 2.3V to 4V
CN102-8 CN102-22 Approx. 1.3V
Change when the tilt lever is
(22, POTTI) (51 0.5V to 2.2V
. CN102-9 CN102-22 Approx. 3,3V
Change when the tilt lever is
(23, POTT2) 2.3V to 4V
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
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
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-)
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)
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)
CN103-1 - -
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
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
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
(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)
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
Approx. 752
(4, SOL b l ) (3, SOL1+) battery plug disconnected
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
backward with the lever in the
(6, SOL2+) (81 b2) 2V to 8V
neutral position
Approx. 7R
(7, SOL a2) (6, SOL2+) battery plug disconnected
Approx. 7R
(8, SOL b2) (6, SOL2+) battery plug disconnected
CN104-9 CN104-22 Approx. 48V
CN104-10 CN104-22 Approx. 48V
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
Approx. 7R
Approx. 7Q
(11, SOL b3) (9, SOL3+) battery plug disconnected
CN104-14 CN104-22 Approx. 48V
CN104-15 CN104-22 Approx. 48V
Change when attachment 2
(34, SOL4+) (35' a4) 2V to 8V
lever is tilted forward
CN104-16 CN O4-I Approx. OV
Change when attachment2
(34, SOL4+) (36' b4) 2V to 8V
lever is tilted backward
Approx. 7R
Approx. 7R
(36, SOL b4) (34, SOL b4) battery plug disconnected
Approx. 1V
(1, MB+) (2, MB-) contact with CN104-20
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
Approx. 11V
(12, SOLP+) (13, SOLP-) contact with CN104-27
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
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
Approx. 36V
(39, FAN-) (N2, N2) FAN ON
Approx. OV
Approx. 48V
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
CN 105-5 CN104-22
(131, FAN2) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
CN105-6 CN104-22
(132, FAN3) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
CN105-7 CN104-22
(133, FAN4) (N27N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
CN105-8 CN104-22
(134, FANS) (N2' N2) vehicle condition) (Approx. 48V)
(Approx. 36V)
Approx. 48V
CN105-9 CN104-22
(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)
CN107-1 CN107-2 -
Unused
(127, FANR+) (128, FANR-)
CN107-2 - -
Unused
(128, FANR-)
CNlOO connector basic conditions (battery plug connected, key switch ON)
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)
Approx. 20R
(55, CPR) (p2, p2) battery plug disconnected
CN26-2 - - -
(P2, P2)
Traveling AC driver 2
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
CN109-7 N2 Approx. 48V
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+)
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
CN110-7 N2 Approx. 48V
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)
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
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

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
Approx. O n
(PI, P I ) (PI, P I ) 27 disconnection
CN27-3 P2 terminal Battery plug OFF and CN
Approx. OR
(p2, p2) (p2, p2) 27 disconnection
Approx. OR
(101, F4) (PI, P I ) 27 disconnection
Approx. O n
(41, F5) (PI, PI) 27 disconnection
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
Approx. 11V
(PI, P I ) (2, MB-) contact with CN136-1
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
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
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.
TRAVELING AC DRIVER
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).
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
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.
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
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
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
CNllO
Traveling AC
Pump Motor Input Voltage Measurement
Measuring method Procedure
(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.
(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 Procedure
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.
Point Operations
[POINT I]
Disassembly:
Use the SST to remove the steering wheel.
SST 09950-76003-71
(09950-50012)
2-36
DISASSEMBLYeINSPECTION lREASSEMBLY
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.
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
Character indication
and indicator blink
H 2. Buzzer for 5 2.Buzzer continues
2. No buzzer
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
S 3. Restrict drive
throttle
output
1. Character indication and indicator blink

STD P 2. Buzzer continues
3. Restrict material handling output
S
Character indication
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
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*.
(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.
(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

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

(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.
f \
.' J
~utton(3) Button (4)
Press button (3)
'. 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

\
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

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
(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).
(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
/ \
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
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
A:Key ON hour meter H:Ma~ntenancehour meter
,' J
B:Traveling hour meter

C:Material handling hour meter G:Trip meter
---------------
RESET- lSW

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.
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.
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.
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
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.
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.
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.

\ I
f
L
.' /
\ 1
0 Press button (3)
:-..-.....--...~-..--------------------------
0
L J '
. 1

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
(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
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
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
'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
kl-1 Al-I C/R: High voltage C/R
power steering disabled
(solenoid off)
Diag
Displayed Detection
'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
A1-4 A1-4 PCR: High voltage PCR
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
.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
AC AC Semiconductor switch abnormality CIR
.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
'Ode controller
code
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
CB-1 CB-1 MB contactor abnormality CIR
(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
'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
EE-2 EE-2
to CIR (2)
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
F1-I F1-l
Display ( I )
Display only Display
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)
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
'Ode controller
code
H4-2 *2 H4-2 "2
(2)
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
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
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
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

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
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
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)
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
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)
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

6. ACTIVE TEST screen
Press button (I) or
\ , (2) to switch screen.
2. 110 MONITOR1 screen
>
L
\ 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
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
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.
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
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
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.
'
. /
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.
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
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.
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)
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
and 110 2-1 to 110 2-6 are displayed sequential every
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
.....................
~ P O T A0 7 l S W A C
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)

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) / /
2. Press button (2) three times.
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
1 Button (3)
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
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)
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.
(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 \
\
A1 (SOL): Attachment 1 proportional valve solenoid
current (A)
Judge the output quality to attachment ( I ) proportional
valve solenoid by attachment 1 lever operation.
\ 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
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
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)
\ /
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)

ONIOFF state of knob steering synchronizer and other switches and the analog input value from each
sensor are indicated.
Operating Procedure
Button (1)
2. Press button (2) four times.
and 110 4-1 to 110 4-4 are displayed sequential every
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
L?T-?---!-L! --------- -@ ANALYZER MENU screen.
Other screen cannot be displayed from I10 MONITOR4
\ J
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
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)

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)
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
Other screen cannot be displayed from ACTIVE TEST
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
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
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)

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
23
Adjusts acceleration during lift lowering operation.
Weak I4
I
a
w t j Strong
I I
I I
I I
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
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
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
Adjusts acceleration during forward tilt operation.
Weak
I
14 w
A
* I
Strong
I I
I I
I I
I I
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
43 Adjusts acceleration during lowering operation of Weak I4

I
a
* I Strong
attachment 1. I I
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
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

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
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
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
53 Adjusts acceleration during lowering operation of Weak I+ a

v t Strong
I I
attachment 2. I I
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
I I
56 Adjusts inching speed during raising operation of Slow I4 a

v b I Fast
I I
attachment 2. 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
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)
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
TUNING MENU screen
f
/ This function changes the tuning level of the lift lever.
OPERATING PROCEDURE
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)
set.
are as follows:
0 Press button (3)

\
*: Press button (3) on the TUNING No.29 setting screen to
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
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
\ setting screen.
~ u t t b (3)
n
0 Press button (3)
set.
are as follows:
0 Press button (3)

*: Press button (3) on the TUNING No.39 setting screen to
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
This function changes the tuning level of the attachment 1
lever.
OPERATING PROCEDURE
2. Press button (1) or (2) to display "4.TUNING4 A T T I V
setting screen.
set.
#<TUN> are as follows:
L / Button (3): Enter (to the next item screen)
0 Press button (3) *: Press button (3) on the TUNING No.49 setting screen to
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
TUNING MENU screen This function changes the tuning level of the attachment 2
f
lever.
OPERATING PROCEDURE
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.
are as follows:
0 Press button (3) *: Press button (3) on the TUNING No.59 setting screen to
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
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-21 - 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

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
*: 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)
Press
button (3)
OPT-2 (HIM START) hour meter starting method:
pressed
Press button (2) while keeping button (I)
-
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
Not used
/
Press button (3) 0 Press button (3)
Not used
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)

Tire angle sensor output in the straight travel position is stored in the
*I .*5
controller.
-Mini lever Matching ltems and Conditions (OPT)

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

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.

M A S K MENU screen
.............................. a
a
a
a
a
a
\ !
~utton(3)
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
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
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.
(2) Connect SST19 and CNllO (CN109, CN111) and connect CN1 and CN3 of SST19.
(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
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
AD-3 AD-3 4-41
abnormality
AD-4 AD-4 4.42
abnormality
Material handling AC driver + main controller
AD-5 AD-5 4-43
Material handling AC driver + main controller
AD-6 AD-6 4-44
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
Diag memory
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
H3-1,2 H3-1,2 Attachment 1 lever potentiometer abnormality 4-73
H3-3 H3-3 Attachment 1 lever potentiometer abnormality 4-78
H4-1,2 H4-1,2 Attachment 2 lever potentiometer abnormality 4-82
Diag memory
code
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 CN104.
Continuity
CN 104-3(3) b Harness defect
$ Continuity check
CN 104-4(4)
No continuity
7
CPU board defect

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
-

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 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)
CN89-2(7)
Less than 5 V

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 CN89.
Connect battery plug and turn key 65-2 error is

indicated
switch ON. Operate the tilt lever to w Tilt solenoid defect
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
not indicated
switch ON. Operate the tilt lever to + Connector connection defect
1
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 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 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

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
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 CN19, CN101.
Main harness defect CN101-24(312)
Continuity check
CN101-16(51)
c t
No continuity
CPU board defect

72-2
I

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

Remain 1
Check the STS2 input value
Remain 0
t
r - - - - - - - - - - - - - - - - - - - -

I I
I Short between CN19-2 and CN19-4 I
I I
I key switch ON. I

I
I
II
Check the STS2 input value
Remain 0
I,
Change to 1
)Steering angle sensor defect

Disconnect CN101.
(SST2 is connection state.)
CN101-30(313)
No continuity
, Main harness defect
$ Continuity check 7
I
CN101-16(51)
I
Continuity Disconnect CN19.
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

$ 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
1 Remain 0
.
172-3 error is
I
not indicated
Remain 1
Connector connection check
r - - - - - - - - - - t- ---------
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 CN101.
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

Steering angle sensor defect Check the STSC input value
I '
Remain 1

$ Continuity measurement
CN101-16(51)
No continuity
CPU board defect

72-4
kev switch ON.

+- I
,72-4 error is
not indicated Connector connection check
r
Disconnect CN19.
Connect battery plug.
-
I7
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
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 CN98.
t
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
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 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 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 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

Output when the acceleration ON signal is detected upon battery plug ON.
Was the accelerator pedal operated

Normal
upon battery plug connection?
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

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
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
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
N1 [Tester probe +]
0 Open circuit

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
N1 [Tester probe +]
I I
Open circuit
t
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
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)
N1
N1
Less than
Disconnect battery plug, disconnect defect
CN112 Other than
CN 104-25(42)
CN112-1 I s than 15 V
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)
-
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 )
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
$ 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.)
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
-

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

) 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
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)
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

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
replaced? * connection condition
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
7 Less than
CN104-25 (42)
CN112-2 15 v
$ Voltage check
120 l o n N1
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)
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 -

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
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
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
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
(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
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
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)
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 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

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)
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
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.
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 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

Output when abnormality of EEP-ROM element is detected.
CPU board defect
EF-3 Main controller CPU abnormality
Related portion
CPU board

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

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
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 -)
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
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 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
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 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 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 CNlOl and CN102.
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 - - - - - - - - - -

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.
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
---------
t I
I I
I Disconnect CN41. (SST8 is the connection state.) 1. NO continuity
I H1-2 error is
1. CN102-18 (28)
I
II
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
Turn key switch ON.
H I - I changes
to H2-1 Sub-harnLs defect
t
HI-2
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. H1-2 changes
Disconnect CN 101 No continuity
Disconnect CN41. to H1-1.
+ CN101-34 (51)
$ Continuity check
key switch to ON. CN41-10 (51)
H I-2 remains. Continuity
'I
Main harness
defect
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.
H I-3 Lift lever potentiometer abnormality
H1-3 error is
not indicated.
I Lift lever operation.
I
.
H1-3 error is
indicated.
v
Replace the connectors of the lift
lever (CN77) with the tilt lever
(CN78).
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 CN102.
Return the lift lever connector
(CN77) and the tilt lever connector
(CN78) to the original connection.
switch ON.

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.
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
.
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
-

Output when the lift lever voltage value is outside the specified neutral range (lever operated) upon key
switch ON.
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
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.
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
-

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

H2-1 error is
not indicated.
Tilt lever at neutral position.
I I
H2-1 error is
indicated.
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 ---------
I I
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) -)
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

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 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
I with SST8.
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
$ 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
t
CPU board defect
r - - - - - - - - - - t- --------- Disconnect battery plug.

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
t
CPU board defect
Connect CN41.
Replace the connectors of lifi lever H2-1 ~ - ~ - ~ a i n s .
Turn key switch ON.
H2-1 changes
to H I - I . Sub-harne!s defect

t
H2-2
H2-2 error is
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 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)
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.
H2-3 error is
not indicated.
Turn key switch ON. bCheck connector connection
I Tilt lever operation.
.
i H2-3 error is
indicated

f
lever (CN77) with the tilt lever
(CN78).
key switch to ON.

Within (*I) * 0.2 V Tilt lever potentiometer
voltage. defect
I II
Below or above (*I) 0.2 V*

- -

Disconnect CN102.
(CN77) and the tilt lever connector
(CN78) to the original connection.
switch ON.

0.3 V or more
Chek the tilt lever potentiometer )CPU board defect
voltage
0.3 V or less
r - - - - - - - - - - t- - - - - - - - - -
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
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.
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
CPU board
Output when tilt lever neutral matching value is outside the specified range.
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

Output when the voltage of the attachment 1 lever potentiometer is outside the specified range (open or
short).
H3-1 Attachment 1 lever potentiometer open
H3-2 Attachment 1 lever potentiometer short
H3-1
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
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 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
I Turn key switch ON. I Turn key switch ON.
t
L - - - - - - - - - - - - - - - - - - - - d I
not indicated. to H I - I . Sub-harness defect
d t
Attachment 1 potentiometer
-
Disconnect CNl 01 and CN102. defect
(SST8 is the connection state.) I. No 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 CN41.
+
r - - - - - - - - - - - - - - - - - - - -
I
I
I H3-2 error is
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
I
I
Connect battery plug. I Connect battery plug.
L _ _ - - - - - - - - - - - - - - - - - - A

c Disconnect battery plug.

v
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
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.
I
I
CN102-10 (24)
2. CN102-10 (24)
1
I
L - - - - - - - - _ - - - - - - - - - - - d
H3-2 error is CN101-34 (51)

7
CPU board defect
------ --- -I- ------- - -, Disconnect battery plug.

I Disconnect battery plug. I Disconnect CNlOl and CN102.
I I
I
1
Disconnect CN41.
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
2. CN102-11 (25)
L - - - - - - - - - - - - - - - - - - - - J
I 2 Continuity check
H3-2 error is I I

t
CPU board defect
Connect CN41.
Replace the connectors of the lift H3-1 remains.
lever (CN79).
Turn key switch ON.
t
Sub-harness defect
to HI- I.
t
-
H3-2
H3-2 error is
Turn key switch ON. Check connector connection
Attachment 1 lever at neutral
position.
indicated.

Disconnect battery plug. H3-2 changes
Disconnect CNl 01 No continuity
Disconnect CN41. CN101-34 (51)
Connect battery plug and turn the $ Continuity check
I
H3-2 remains Continuity
I
Main harness
defect
1
1. CN102-20 (30) 1. Continuity Connect CN41.
2. Continuity Replace the connectors of the lift ~ 3 - remains.
2
$ Continuity check
CN102-10 (24)
2. CN102-20 (30) lever (CN79).
$ 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 CN102.
(CN77) and the attachment 1 lever
connector (CN79) to the original
connection.
switch ON.
.
.
0.3 V or more
Chek the attachment 1 lever CPU board defect
v
r - - - - - - - - -

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/
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
8 3
CN101-34(51,POT-)
-
10 4
-

Output when the attachment 1 lever voltage value is outside the specified neutral range (lever operated)
upon key switch ON.
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
defect
CPU board

Output when attachment 1 lever neutral matching value is outside the specified range.
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
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).
H4-1 Attachment 2 lever potentiometer open
H4-2 Attachment 2 lever potentiometer short
H4-1
Turn key switch ON. not indicated.
Attachment 2 lever at neutral b Check connector connection
position.
H4-1 error is
indicated.
t
0.3 V. 0.3 V. than 0.3 V.

r - - - - - - - - - - t- - - - - - - - - -
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
I
I
Connect battery plug. I
L _ _ _ _ _ _ _ - - - - - - - - - - - - - J

c Disconnect battery plug.

t
Disconnect CNlOl and CN102. defect
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 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
j Connect battery plug. I
I
L - - - - - - - - _ _ _ - - - - - - - - - d

not indicated. to H I - I . Sub-hamis defect
t t
Disconnect CN 101 and CN102. defect
$ 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
i
r - - - - - - - - - - - - - - - - - - - -
I Short between CN42-3 (31) and
I CN42-2 (26) (at main harness side)

I
I
; H4-2indicated,
I error is
+
I . CN102-21 (31)
5 Continuity check
1. No continuity
2. Continuity
I with SST8. I CN102-12 (26)

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

I I
I
I
Disconnect SST8 from CN41.
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
I
2. CN102-13 (27)
L - - - - - - - - - - - - - - - - - - - - J
CN101-34 (51)
H4-2 error is
v
t
CPU board defect
h
Connect CN41, CN42.
Replace the connectors of the lift ~ 4 - remains.
1
lever (CN80).
Turn key switch ON.
t
Sub-harness defect
to H I - I .
t
defect
H4-2
- H4-2 error is
Turn key switch ON. )Check connector connection
Attachment 2 lever at neutral
position.
indicated.

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
I
H4-2 remains.
Continuity
Main harness
defect
1. CN102-21 (31) 1. Continuity Connect CN41, CN42.
2. Continuity Replace the connectors of the lift H4-2 remains.
1 Continuity check
CN102-12 (26)
lever (CN80).
1
2. CN102-21 (31)
$ Continuity check
Turn key switch ON.
to HI-2.
v
Sub-harness defect
+
CPU board defect
defect
Related portion
CN42 CN80
- CN102-21(31,POTAT2+)
3 1
CN102-12(26,POTAT21)
1 2
CPU Attachment 2
2 3
CN41
CN101-34(51,POT-)
10 4
-

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.
H4-3 error is
not indicated.
I Attachment 2 lever operation. I
.
H4-3 error is
indicated

potentiometer voltage. (*I)

lever (CN80).
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 CN102.
(CN77) and the attachment 2 lever
connector (CN80) to the original
connection
switch ON.
III ANL : I10 MONITOR3 1103-7

0.3 V or more
CPU board defect
L
0.3 V or less
r - - - - - - - - - - t- - - - - - - - - -
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
I elated portion /
CN42 CN80
-
CN102-21(31,POTAT2+)
3 . 1
CN102-12(26,POTAT21)
1 2
CPU Attachment 2
2
CN41
CN101-34(51,POT-)
10 4
-

Output when the attachment 2 lever voltage value is outside the specified neutral range (lever operated)
upon key switch ON.
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
defect
Related portion
CPU board
Output when attachment 2 lever neutral matching value is outside the specified range.
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
-

Output when open or short circuit is detected in the lift solenoid line from CPU board to the lift solenoid
(raise andlor lower).
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
.
Check connector connection
I
_
Lift raising operation.
I
A
II 1
H5-1 error is indicated.

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
Harness defect
H5-2
H5-2 error is

Disconnect CN74.
H5-1 error is
indicated.
Turn key switch ON. b Lift b l (UP) solenoid defect

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
Turn key switch ON.
Lift lowering operation.
not indicated.
* Check connector connection
0.1 A or more
Check lift solenoid current (during b CPU board defect
-
r
---------
-
I
I (Use SST 20) I

I

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

Disconnect CN75.
7
H5-3 error is
indicated.
Turn key switch ON. b Lift a1 (DOWN) solenoid defect
II Lift lowering operation. I
I

CN104-3 (3) w Harness defect
$ Continuity check
CN104-5 (5)
No continuity
CPU board defect

w Check connector connection
Lift raisingllowering operation.
H5-5 error is
indicated.

Disconnect CN104.
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).
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
Forward tilt operation.

0.1 A or more
Check tilt solenoid current (during CPU board defect
forward tilt operation).
II
10.1 Aor less
r - - - - - - - - - 9- - - - - - - - - - ,
I
I (Use SST 20) I

I

Forward tilt operation. (note that Tilt a2 (FRONT) solenoid defect
mast is tilted backward on the
vehicle.)
Harness defect
I
(
I
----
I
L
Turn key switch ON.
Disconnect CN75.
CN104-7 (7)
7

Turn key switch ON.

Disconnect CN104.
CN104-6 (6)
Continuity check

Turn key switch ON.
No continuity
CPU board defect
Backward tilt operation.
Check tilt solenoid current (during
------
Replace CN74 with CN75.
(Use SST 20)
---------
.
I
I
I
I
I
I
I
I
H6-2 error is
not indicated.
H6-1 error is
indicated.
Continuity
H6-3 error is
not 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

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
-
- H6-4 error is
not indicated.
Backward tilt operation.
-
Disconnect CN74.
H6-3 error is
indicated.
Turn key switch ON. + Tilt b2 (REAR) solenoid defect

CN104-6 (6) + Harness defect
Continuity check
CN104-8 (8)
No continuity
CPU board defect
H6-5
H6-5 error is
not indicated.
Turn key switch ON. w Check connector connection
Forwardlbackward tilt operation.
H6-5 error is
indicated.

Disconnect CN104.
Tilt lever at neutral position. b Harness defect
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
.
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).
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
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 - - - - - - - - - - - - - - - - - - - -

j (Use SST 20) I

I

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
not indicated.
Attachment 1 raising operation.

Disconnect CN74.
H7-1 error is
Turn key switch ON.
Attachment 1 raising operation.
indicated.
* Attachment 1 a3 solenoid defect

Disconnect CN104.
CN104-11 (9)
Continuity
* Harness defect
Continuity check
CN104-12 (10)
No continuity
CPU board defect
H7-3
H7-3 error is
not indicated.
Attachment 1 lowering operation.
Check attachment 1 solenoid

current (during attachment 1
0.1 A or more
* CPU board defect
lowering operation).
- -- -------
I
I (Use SST 20) I

I

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
not indicated.

Disconnect CN75.
H7-3 error is
Connect battery plug. indicated.
Turn key switch ON. b Attachment 1 b3 solenoid defect

CN104-11 (9) + Harness defect
Continuity check
CN104-13 (11)
No continuity
CPU board defect
H7-5
Attachment 1 raisingllowering
operation.
H7-5 error is
indicated.

Disconnect CN104.
switch ON.
Attachment 1 lever at neutral 10 V or more
b Harness defect
position.
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).
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.

Check attachment 2 solenoid 0.1 A or more
current (during attachment 2 b CPU board defect
-------- -
I Replace CN74 with CN75.

I
I
I (Use SST 20) I

I
Connect battery plug and turn key error is

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
not indicated.
I
I
Attachment 2 forward tilt operation. I
J

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.

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.
Attachment 2 backward tilt
1
I
operation.
I
I
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 (Use SST 20) I

I
Connect battery plug and turn key H8-3 error is

Attachment 2 backward tilt ) Attachment 2 b4 solenoid defect
operation. (note that the attachment
2 is tilted forward on the vehicle.)
Harness defect
Turn key switch ON.
I
L
operation. I
I

Disconnect CN74.
t
Turn key switch ON. indicated.
) Attachment 2 b4 solenoid defect
operation.

Disconnect CN104.
CN104-16 (34)
Continuity check
Continuity
* Harness defect
CN 104-18 (36)
No continuity
CPU board defect

Turn key switch ON.
Attachment 2 forwardlbackward
not indicated.
* Check connector connection
operation.

Disconnect CN104.
switch ON.
Attachment 2 lever at neutral 1 0 V o r more
b Harness defect
position.
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

Output when open or short circuit is detected in the unload valve solenoid line from the CPU board to the
unload valve solenoid.
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 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)
Other than 9.9klQ

(at 25°C)
1
Unload valve solenoid defect
ON in the ACTIVE TEST.
switch ON.)
H9-2 error is
- Check connector connection

Disconnect CN76.
-
H9-2 error is
ON in the ACTIVE TEST. + Unload valve solenoid defect
switch ON.)
-
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
switch ON.)

Disconnect CN104.
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.
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
I Less than 15 V
MB contactor defect
I 15 V or more

F1 fuse check
1 5 ~ 0more
t
r

30-2 Traveling AC driver 2 low voltage
rr PI P2 F1 P3
n
Traveling
AC driver 2
I
I -
I
I

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
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
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
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.
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
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
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
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
: Voltage check
-
No error
Less than 23 V
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

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'
B48V : Voltage check
Less than 23 V
CPU board defect

Check the battery voltage
PI 23 V or more
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

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
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

I
pss than 23
II
t
CPU board defect

PI 23 V or more
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

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

Check the CPR resistance
VBKS : Voltage check
Approx. 20 Q Other than
approx. 20 R I Less than 23 V
t t
I ANL : I10 MONITOR 1 1/01-8
Less than 23 V
CPU board defect
+ .
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

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
t
Traveling AC driver 1 connector
t
Normal
check (ID signal)
32-2 Traveling AC driver 2 EEPROM abnormality

I
Related portion
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
t
Traveling AC driver 2 connector
v
Normal
check (ID signal)
1 32-3 Material handling AC driver EEPROM abnormality
I
Related portion
*
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
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)
-
7
w
CN110-4(146, CANL)
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.

33-2 Main controller + Traveling AC driver 2 communication abnormality
CN103-l(145, CANH) -- CN109-3(145, CANH)

CN 103-2(146, CANL)
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
Output when the traveling AC driver 2 cannot receive data from the CPU board within specified time.

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
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

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

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
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
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

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 )
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

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
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
NO
f
A2-3 Material handling AC driver board overheat
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
I J
NO
AA-2 Traveling AC driver 1 board thermo-sensor abnormality:
PCB Thermo-sensor
u
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
PCB Thermo-sensor
-El--

Output when abnormality of the traveling AC driver 2 thermo-sensor is detected.
AA-4 Material handling AC driver board thermo-sensor abnormality
PCB Thermo-sensor
--El---
Output when abnormality of the material handling AC driver thermo-sensor is detected.
To correct, replace the material handling AC driver.
C1-1 Traveling AC driver 1 current sensor offset abnormality
Related portion
pGGq
Output when abnormality is detected for current sensor offset adjustment when starting 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

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
C1-3 Traveling AC driver 2 current sensor offset abnormality
p i G q

Output when abnormality is detected for current sensor offset adjustment when starting the traveling AC
driver 2.
C1-4 Traveling AC driver 2 overcurrent
Related portion
P71
0
Traveling AC P81
driver 2 0
P91
0

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
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

Output when the drive motor 1 thermo-sensor output value is outside the specified range (disconnection
or short circuit)
CN110-13 (87)
Disconnect battery plug. Except $ Continuity check No continuity
Disconnect CN110. 300-2k R CN58-2 (87)
CN110-13 (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)
key switch ON. 300-2k R Except 300-2k R
CN110-13
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)
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)
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
Connect battery plug and turn the CN52-1 (at sensor side)
key switch ON.
CN109-13 300-2k R Except 300-2k R
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

Output when abnormality of the traveling AC driver 1 heat sink thermo-sensor exceeds the specified
level.
C3-2 Traveling AC driver 2 main drive circuit thermo-sensor abnormality

I
Related portion
Thermo-sensor

Output when abnormality of the traveling AC driver 2 heat sink thermo-sensor exceeds the specified
level.
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

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
Disconnect CN59.
NG (all 8 V - 13 V) CN59-1[+],2[+],4[+]
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

Output when the traveling AC driver 2 detects the abnormality of the drive motor 2 rpm sensor.
r - - - - - - - - - - - - - - - - - - - -

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
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
pizi-q
Output when abnormality is detected for current sensor offset adjustment when starting the material han-
dling AC driver.
E l-2 Material handling AC driver overcurrent
0
Material handling
AC driver

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
I Pump motor overheat
- -
Related portion
Output when the pump motor thermo-sensor value is above the specified level.
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)
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)
$ Continuity check
CN55-1 (86) 7
Harness defect
Continuity (0 R)
Connect CN111, disconnect CN55.

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
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
Thermo-sensor

Output when abnormality of the material handling AC driver heat sink thermo-sensor exceeds the
specified level.
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 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[+]
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
-

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
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
I
I
key switch ON. I
-- - - - - - - - - - - - - - - - - - - - -
61-2 error is not indicated.
t
Disconnect CN102.
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
CN90, connect battery plug, and Change to 61-1 error.
turn the key switch ON.
T-
-
61-2 error remains.

Disconnect CN102 No continuity
CN102-17 (58) )CPU board defect
1 Continuity check
CN102-5(59)
i .,- --- ----

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
CN86, connect battery plug, and Change to 62-1 error.
turn the key switch ON.
62-2 error remains.
Disconnect CN102.
CN102-16 (57)
,
Continuity check
CN fO2-4 (i6)'
v
Continuity
I
1
1
No continuity
CPU board defect
I
I Disconnect CN102.
Short between CN86-2 and CN86-3
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

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

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 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 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
--- ------ -.- -
--------
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

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
- -

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)
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
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
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[+]
NI[-I Other than OK
P1 5[+]
NIL-]
P1 6[+]
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
-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
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
GENERAL .................................... 5-10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
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
T=N.m (kgf.cm) [ft.lbf]
Removal Procedure
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).
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
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
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
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.
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
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.
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
l

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

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
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)
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
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
DISASSEMBLY INSPECTION REASSEMBLY . . . . . 7-10
REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
REAR AXLE CYLINDER ASSY . . . . . . . . . . . . . . . . . 7-16
0
TIRE ANGLE SENSOR (OPT) . . . . . . . . . . . . . . . . . . 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
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.
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 200N (10 20kgf) [22.1 - 44.1 Ibfl
Installation:
When correct value is obtained, securely caulk the lock
nut.
[POINT 61
Removal:
Temporarily hoist the rear axle as shown in the
illustration.
T=N.m (kgfcm) [ftdbfl
1 Remove the lock nut.
2 Remove the upper bearing.
3 Disconnect the rear axle cylinder W/ holder ASSY and rear axle ASSY.
4 Remove the lower oil seal. [Point I]
5 Remove the lower bearing outer race. [Point 21
6 Remove the upper bearing outer race. [Point 31
7 Remove the lower bearing. [Point 41
8 Remove the oil seal and inner bearing. [Point 51
Point Operations
[POINT I]
Reassembly:
SST 09700-30200-71
[POINT 21
Disassembly:
Use the SST to remove the lower bearing outer race.
SST 09950-76014-71
(099950-40011)
Reassembly:
Use the SST to install the lower bearing outer race.
SST 09320-10410-71......(1)
SST 09950-76020-71.. ....(2)
(09950-70010)
[POINT 31
Disassembly:
Use the SST to remove the upper bearing outer race.
SST 09700-30200-71
Reassembly:
Use the SST to install the upper bearing outer race.
SST 09950-76019-71.. ....(1)
(09950-60020)
SST 09950-76020-71 ......(2)
(09950-70010)
[POINT 41
Disassembly:
Use the SST to remove the lower bearing.
SST 09950-76014-71...... (1)
(09950-40011)
SST 09950-76018-71......(2)
(09950-60010)
Reassembly:
Use the SST to install the lower bearing
SST 09370-10410-71
[POINT 51
Disassembly:
Use the SST to remove the inner bearing.
SST 09950-76014-71
(09950-40011)
Reassembly:
Use the SST to install the inner bearing.
SST 09316-76008-71
(09316-60011)
Reassembly:
SST 09700-30200-71
REAR AXLE HUB
Removal Procedure
1 Jack up the vehicle. [Point I]
2 Remove the hub caps.
3 Remove the rear wheel and outer bearing. [Point 21
4 Remove the oil seal and inner bearing. [Point 31
Note:
Apply grease before installation.
Outer bearing Inner bearing Inside rear wheel
1 STD MP grease
I Type I
Cold storage
spec.
-
14 19
Esso beacon 325
11 -- 150.03) 22 -- 0.06)
27
Amount g(lb) (0.03-0.04) (0.02 (0.05
After tightening the castle nut, fill MP grease (Esso beacon 325) in 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 the SST to remove the inner bearing.
SST 09950-76014-71
(09950-40011)
Reassembly:
Use the SST to install the inner bearing.
SST 09316-76008-71
(09316-60011)
Reassembly:
SST 09700-30200-71
REAR AXLE CYLINDER ASSY
Removal Procedure
1. Remove the rear axle ASSY. (See page 7-6.)
2. Remove the rear axle cylinder ASSY. [Point I]
Point Operations
[POINT I]
Installation:
Adjust the installation of the steering cylinder
(1) Apply MP grease thoroughly to the moving face (inside and outside) until the excess grease can be
seen from the clearance of the moving face.
( 2 ) Position the white tooth of the rack between the two white teeth of the pinion.Apply Moly cote
grease 321R evenly and thoroughly in the area of more than 180" of the engagement of the pinion
and rack.
(3) Tighten the lock nut and caulk the lock nut in two places to ensure the starting force of the rear axle.
(4) Tightening torque of frame installation: 250 to 350N.m(2500 to 3500kgf.cm)
250-350N. m
(2500- 3500kgf mcm) (100- 200kgf- cm)
[7.4-14.8ft- Ibfl
(reference value)
7-18
1. Remove the steering cylinder end.
2. Remove the piston.
3. Remove the bushing.
4. Remove the rack.
5. Remove the steering torque cylinder. [Point I]
Note:
Apply hydraulic oil to each part before installation.
Replace O-ring, U-packing and dust seal.
Point Operations
[POINT I]
Inspection:
Measure the steering cylinder bore.
Inside diameter standard: 70.0mm (2.76in)
Wear limit: 70.35mm (2.77in)
TIRE ANGLE SENSOR (OPT)
Removal Procedure
3 Disconnect the wiring connector.
4 Remove the tire angle sensor and joint. [Point I]
5 Remove the tire angle sensor plate. [Point 21
6 Remove the bracket.
7 Remove the joint cover.
Caution:
Align the tapping screw axis and the sensor plate hole straight for installation. If screwed out of
position, replace the sensor plate with a new one.
When the tapping screw is removed, the sensor plate should be replaced with a new one.
Note:
Be sure to set the tires to the straight traveling position before tire angle sensor installation.
Apply Approx. 2 cc of MP grease to the inside of the joint cover for installation.
Perform matching when the tire angle sensor is removed, installed or replaced. (See page
16-11.)
Point Operations
[POINT I]
Installation:
After positioning the sensor as the illustration to the left,
rotate it by Approx. 110" to align the holes.
[POINT 21
Installation:
Use the SST to adjust the concentricity of the rear axle
and sensor plate holes.
SST 09580-10920-71
(1) Temporarily secure the bracket and sensor plate.
(2) Securely set the tip of the SST at the hole at the top of
the rear axle shaft and position the bracket and
sensor plate.
(3) Securely tighten the bracket and sensor plate bolt and
remove the SST.
Installation:
Apply MP grease from the sensor plate hole of the rear
axle shaft groove.
STEERING
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
STEERING WHEEL MAST JACKET. . . . . . . . . . 8-9
DISASSEMBLY REASSEMBLY . . . . . . . . . . . . . . . . . . 8-11
HYDROSTATIC STEERING VALVE ASSY . . . . . . 8-12
TROUBLESHOOTING .......................... 8-12
INSPECT AND ADJUST
THE RELIEF PRESSURE . . . . . . . . . . . . . . . . . . 8-18
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
COMPONENTS ................................ 8-19
STEERING KNOB SYNCHRONIZER VALVE (OPT)8-23
GENERAL
SPECIFICATIONS
\
Model
Item
Steering wheel diameter
-
mm(in)
All Models
360(14.2)
Steering wheel play mm(in) 20 - 50(0.79 - 1.97)
Power steering type Hydrostatic steering
Discharge: cc(cm3)[cu.in(in3)] 50.0[3.1]
Rated flow rate: L.min 8(2.1)
Hydrostatic steering
(US gal.min)
valve
Relief set pressure
MPa(kgf.cm2)[psi]
10.6 - 11.1(108 - 113)[1535.8 - 1606.91
COMPONENTS
2
P
r." .
...
I
x
0
V)
I P
I
I
L... ...
J
I
8-9
STEERING WHEEL MAST JACKET

Removal Procedure
2 Remove the steering wheel. [Point I]
3 Remove the direction cover (front and rear).
4 Remove the column cover (rear).
5 Disconnect the connectors of the display, direction switch and turn signal switch.
6 Disconnect the connectors of the lamp switch and key switch.
7 Remove the column covers (upper and lower).
8 Remove the display and direction switch.
9 Remove the return spring.
10 Remove the tilt lock mechanism. [Point 21
11 Remove the tilt steering lock release lever.
12 Remove the steering valve set bolts and set the steering valve free.
13 Remove the mast jacket ASSY.
Caution:
Cover the brake with cloth to prevent hydraulic oil adhesion.
Note:
Apply MP grease to each sliding portion of the tilt lock mechanism and tilt steering lock release
lever.
Add MP grease at the coupling between the steering shaft and steering valve.
Point Operations
[POINT I]
Removal:
SST 09950-76003-71
(09950-50012)
Installation:
Steering wheel installation procedure
(1) Before removing the steering wheel, make a
positioning mark at the top of the steering shaft.
(2) Apply rubber grease to the sliding portion of the turn
signal switch.
(3) Install the steering wheel by referring to the
positioning mark made in (1).
(4) Turn the steering wheel after installation.Turning the
steering wheel will automatically position the three
pins of the turn signal switch at the pin holes of the
steering wheel.
[POINT 21
Installation:
Install so that the lines of the tilt lever and column cover
are parallel as illustrated, and check that tilt lock
operation is normal.
DISASSEMBLYm REASSEMBLY
1 Remove the snap ring.
2 Remove the steering shaft.
3 Remove the bearing.
4 Remove the direction switch bracket.
8-12
HYDROSTATIC STEERING VALVE ASSY

TROUBLESHOOTING
Only hydraulic related items are listed. (For electrical troubles, see section 4)
Symptom Probable cause Action
The piping is damaged. Replace
The steering wheel cannot
be rotated The steering valve drive shaft is installed Inspect and correct or
incorrectly or damaged. replace.
Tire pressure is low. (For Pneumatic tire) Adjusting the tire pressure
lnspect and adjust the relief
The oil pressure does not rise.
The steering wheel is heavy. pressure.
The high and low pressure pipes are
and correct,
connected in reverse.
The high and low pressure pipes are
lnspect and correct.
connected in reverse.
The relief valve is faulty or not closed. lnspect and correct.
The oil pressure does not
lnspect and correct or
rise. Oil pump function is deteriorated.
replace.
Priority valve spool fused. Overhaul
Hydraulic oil level is low. Add
Tire pressure is low. (For Pneumatic tire) Adjusting the tire pressure
The steering wheel does not The steering valve spool does not move Correct or replace the steer-
return properly. smoothly. ing valve ASSY
The rear axle sliding motion is improper. Add lubricant or correct.
The steering valve spool does not move Correct or replace the steer-
smoothly. ing valve ASSY
The steering wheel pulls to The steering valve drive shaft is dam- Replace the steering valve
one side when released aged. ASSY.
The piping is blocked (crushed or Inspect and correct or
clogged). replace.
Replace the steering valve
Oil moves in the steering valve.
ASSY.
The steering valve spool does not move Correct or replace the steer-
Play is excessive and the smoothly. ing valve ASSY
vehicle wobbles
lnspect and correct or
Air is sucked from the piping.
replace.
The steering shaft is defective. Inspect and correct.
The steering wheel shim- The steering valve drive shaft is installed
lnspect and correct.
mies. incorrectly.
Symptom Probable cause Action
The tires are The cylinder piping is connected in

site to the steering wheel Inspect and correct.
reverse
operated direction.
lnspect the pressure and
The relief valve is defective.
correct or adjust.
Abnormal noise is gener- Inspect and correct or
Air is sucked from the piping.
ated. replace.
The piping is blocked (crushed or Inspect and correct or
clogged). replace.
The following removal and inspection procedures are described about the vehicle with the knob
synchronizer valve (OPT).
Removal Procedure
2 Remove the direction lever (front and rear).
3 Remove the column covers (upper, lower and rear).
4 Remove the instrument panel.
5 Remove the steering valve ASSY.
6 Remove the knob synchronizer valve. (Only on the vehicle with the knob synchronizer valve)
7 Remove the fitting. [Point I]
Caution:
Note:
Add MP grease at the coupling between the steering shaft and steering valve.
Point Operations
[POINT I]
Reassembly:
Install the fitting with the angle shown in the illustration
to the left.
Note:
Clean dirt from ports and joints before disassembly and perform operation in a clean place.
T=N.m (kgfcm) [ftlbfl
1 Remove the end cap. [Point I]
2 Remove the star, rotor and drive shaft. [Point 21
3 Remove the spacer plate and check valve.
4 Remove the spool and sleeve ASSY. [Point 31
5 Remove the pin from the spool and sleeve ASSY. [Point 41
6 Remove the centering spring.
7 Remove the dust seal and bearing.
8 Remove the relief valve. [Point 51
Note:
Wash each part with clean hydraulic oil before assembly.
Point Operations
[POINT I]
Disassembly:
Make match marks.
Reassembly:
Align match marks when reassembling.
Disassembly:
When removing each retainer screw, operate carefully
so as not to lose the steel ball.
Reassembly:
Position the retainer screw and steel ball as shown in
the illustration.
[POINT 21
Reassembly:
Reassemble the drive shaft and star as follows:
(1) Rotate the spool and sleeve ASSY to bring the pin
parallel with the housing port surface.
(2) Install the O-ring in the housing and place the spacer
plate by aligning the match marks made before
removal.
(3) Insert the drive and fit the pin.

(4) Install the rotor and O-ring.
(5) Match the star gears and rotor groove.
(6) While keeping the drive shaft and star fitted together,
Install the rotor by aligning the match marks made
before removal.
Reassembly:
Be sure to install on the correct side of the spacer plate.
Spacer plate side End cap side

[POINT 31
Reassembly:
Install the spring as shown in the illustration.
Reassembly:
Install the bearing by positioning the race bearing as
shown in the illustration.
[POINT 41
Reassembly:
Assemble the spool ASSY by aligning the positioning
mark.
Disassembly:
If the positioning mark for the spool and sleeve is not
provided, provide it with a marker.
Reassembly:
Install the spool and sleeve by holding the cross pin with
the flange facing downward.
[POINT 51
Disassembly:
Measure the relief valve length before removal.
Caution:
Remove the relief valve only when abnormality of relief
valve is found.
8-18
Reassembly:
Make sure that the relief valve length is the same length
as before the removal.Adjust the relief valve length
when not meeting the standard.
INSPECT AND ADJUST

THE RELIEF PRESSURE.
1. Install a pressure gauge on the P port of the priority
valve.
(1) Disconnect the hose from the P port and connect the
adapter.
SST 09450-23320-71
(2) lnstall the pressure gauge.
Fitting size: PT118
2. Set the steering synchronizer solenoid to ON in the

analyzer mode.(See page 3-34.)
3. When the steering wheel is rotated to the end, relief
state is achieved, so read the pressure on the pressure
gauge at that time.
Standard:
All Models 10.6 to 11.1 (108 to 113)
MPa (kgf.cm2) [psi] [1535.8 to 1606.91
4. If the relief pressure is out of the standard range,
remove the steering valve and adjust at the adjusting
section.
PRIORITY VALVE
COMPONENTS
8-21
T=N.m (kgf.cm) [ft.lbfl
Removal Procedure
1 Remove the toe board (front and rear) and tilt cover.
2 Disconnect the piping.
3 Remove the priority valve.
Caution:
Point Operations
[POINT I]
Reassembly:
Install the priority valve fitting with the angle shown in
the illustration to the left.
8-22

1 Remove the plug.
2 Remove the plug.
3 Remove the shaft.
STEERING KNOB SYNCHRONIZER VALVE (OPT)
Removal Procedure
2 Remove the column cover (lower).
3 Remove the left instrument panel.
5 Remove steering synchronizer valve ASSY WI fitting.
6 Remove the fitting and O-ring. [Point I]
Note:
When disconnecting the piping, cover the brake with cloth to prevent hydraulic oil adhesion.
Point Operations
[POINT I]
Installation:
The fitting angle should be as illustrated for reassembly.
BRAKE
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
DISK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 9-11
BRAKE DISC WHEEL ......................... 9-12
BRAKE PEDAL ............................... 9-14
BRAKE PEDAL ADJUSTMENT ................... 9-15
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
PARKING BRAKE ADJUSTMENT ................. 9-17
GENERAL
SPECIFICATIONS
Model
All models
Item
Foot brake type Mechanical disc brake
Parking brake type Mechanical disc brake
mm Diameter 203 (8.0)

Brake wheel
(in) Thickness 9.0 (0.4)
35.28 x 2 x 2
Area cm2(in2)
Brake pad (5.468 x 0.079 x 0.079)
Thickness mm(in) 6 (0.2)
COMPONENTS
PARKING BRAKE
BRAKE PEDAL
4701
(WIDE PEDAL)
21
4701-215A
DISC BRAKE
4716
01[RH]
02[LH]
r===
I
I
I
I I
I I
I I
L1-= 111.1
4716-037
DISC BRAKE
Removal Procedure
Raise the inner mast and securely fix it to prevent lowering. [Point I]
Remove the brake cover.
Remove the toe board (front and rear) and tilt cylinder cover.
Remove the instrument panel.
Disconnect the links from the brake pedal and parking brake.
Disconnect the brake rods between frame and brake ASSY (LH and RH).
Remove the brake ASSY (LH).
Remove the brake ASSY (RH).
Point Operations
[POINT I]
Removal:
Raise the inner mast and support it by putting wooden
block inside the outer mast rail to prevent the inner mast
lowering.
9-10

T=N-m (kgfcm) [ftdbfl
1 Remove the pin, castle nut and lever.
2 Separate the lever ASSY No.1 and 2. [Point I]
Point Operations
[POINT I ]
Inspection:
Measure the pad thickness.
Standard: 6.0 mm (0.24 in)
Limit: 3.5 mm (0.14 in)
DISK BRAKE ADJUSTMENT

1. Adjust the pad clearance with adjusting bolt.
Pad clearance: 9.8 to 10.2 mm (0.39 to 0.40 in)
2. Adjust the clearance between the brake disc wheel and pad evenly with an adjusting bolt.
Clearance: 0.4 to 0.6 mm (0.016 to 0.024 in)
A=0.4 to 0.6 mm (0.016 to 0.024 in)

B=9.8 to 10.2 mm (0.39 to 0.40 in)
C=9 mm (0.35 in)
-- -
BRAKE DISC WHEEL

Removal Procedure
1 Remove the disc brake ASSY. (See page 9-8.)
2 Remove the brake disc wheels (LH and RH). [Point I]
Point Operations
[POINT I ]
Removal:
Raise the inner mast and support it by putting wooden
block inside the outer mast rail to prevent the inner mast
lowering.
[POINT 21
Inspection:
Inspect the brake disc wheel thickness.
Limit: 8.0 mm(0.31 in)
9-14
BRAKE PEDAL
REMOVAL e INSTALLATION
Removal Procedure
1 Remove the toe board (front and rear) and tilt cylinder cover.
3 Remove the brake pedal set bolt.
4 Disconnect the link and remove the brake pedal.
5 Disconnect the parking brake wire.
6 Remove the brake pedal adjusting nut.
7 Remove the brake pedal link.
8 Remove the parking brake adjusting nut.
9 Remove the parking brake link.
10 Remove the brake ASSY link.
11 Remove the brake link ASSY.
12 Remove the brake link ASSY pin.
Note:
Inspect the bushing for wear and damage and replace it if necessary.
BRAKE PEDAL ADJUSTMENT
1. Inspect brake pedal height A (from pedal to the upper
side of the pedal).
Standard: A = 110 to 115 mm [4.3 to 4.5 in]
Adjust if the pedal height is outside the specified range
with a stopper bolt.
2. Tighten the adjusting nut until the equalizer is securely

fixed. Adjust the pedal stroke B when the clearance
between the brake pad and disc is within the standard
(0.4 to 0.6 mm[0.016 to 0.024 in]).
(Reference value): B = 30 to 35 mm [ I . I 8 to 1.38 in]
3. After the adjustment, inspect the ground clearance C
(from the toe board to the top of the pedal) with fully
depressing the brake pedal. If the ground clearance C is
standard or below, adjust the clearance between the
brake pad and disc.
Standard: C = 55mm [2.17 in]
9-16
PARKING BRAKE
Removal Procedure
2 Disconnect the parking brake wire.
3 Remove the parking brake ASSY.
PARKING BRAKE ADJUSTMENT
1. Adjust the parking brake so that the front pole fits at the third or fourth notch of the sector when the
parking brake lever operating force is at 150 N (15.3 kg) [33.7 Ib] (measure at the point in the
illustration).
2. When the disc brake drags, adjust it so that the front pole fits at the fifth notch.
BODY & FRAME
Page
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
BATTERY HOOD ASSY . . . . . . . . . . . . . . . . . . . . . . . 10-7
.
COUNTERWEIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
•
OPERATOR'S SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

•
FUSES ....................................... 10-10

FUSE INSTALLATION LOCATIONS ............... 10-10
NAMES (APPLICABLE FUNCTIONS)
AND CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
COMPONENTS
Frame & Weight
5101
(2OSD,FRONT COVER)
[STOPPER]
5101-362A
5101
[UNDER COVER]
5101-363
5301
[EZ PEDAL]
5301-323
5308
cc +BG
26
7
BG-@
01
,."' "'1
20
JS [RH]
JS [LH]
L...
PE
... A
EA-e
5308-2436
BATTERY HOOD ASSY
Removal Procedure
2 Open the battery hood
3 Use string to tie the battery hood ASSY Wlseat ASSY to the head guard rear pillar.
4 Disconnect the wiring of the seat switch.
5 Disconnect the battery hood damper (on the frame side).
6 Close the battery hood
7 Remove the battery hood hinge set bolt.
8 Remove the battery hood ASSY WI seat ASSY.
COUNTERWEIGHT
Note:
See page 0-11 for counterweight and select an appropriate wire rope for the counterweight.
T=N.m (kgf-cm) [ft-lbfl
Removal Procedure
3 Remove the draw bar and temporarily hoist the counterweight by slinging with a wire rope.
4 Remove the counter weight set bolt.
5 Remove the counterweight. [Point I]
Point Operations
[POINT I]
Installation:
Be sure to keep the balance when installing the
counterweight.
10-9
OPERATOR'S SEAT
Removal Procedure
1 Disconnect the wiring of the seat switch.
2 Open the battery hood
3 Remove the operator's seat set nuts. (Be careful not to drop the operator's seat.)
4 Remove the operator's seat.
FUSES
FUSE INSTALLATION LOCATIONS
Fuses F1 and F4 to F6 are located in the lower portion of the rear right controller box.FI is a module type
and F4 to F6 are glass tube type fuses. Previously F1 was for traveling and F2 was for material handling,
but they are integrated to F1 as travelinglmaterial handling fuse.
F4 F5 F6
A view
NAMES (APPLICABLE FUNCTIONS) AND CAPACITIES
7FBEU15,18,20,7FBEHU18
F1 For drive and material handling 500A

F4 For lights 1OA
F5 For controller circuit 1OA
F6 SAS, for solenoid 1OA
Caution for fuse replacement

Before fuse replacement, be sure to disconnect the battery plug and completely discharge CO
(overall condenser) with Approx. 100R resistor between P3-N2.
Page
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
RETURN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
NATURAL DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . 11-7
NATURAL FORWARD TILT TEST . . . . . . . . . . . . . . 11-7
OIL LEAK TEST............................... 11-8
LIFT CYLINDER ............................... 11-8
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11-2
HYDRAULIC CIRCUIT
-
-
Lift Cylinder
- -
f Oil controi valve
r t---t
Oil tank
\
Tilt cylinder
-
-
-
-
-
-
-
-
Steering valve
- --------
Oil pump
Priority
valve
u
\ Pump motor
u
COMPONENTS
11-4
V.FV Mast
FSV Mast
FV Mast
FSV Mast
RETURN FILTER
Removal procedure
2 Remove the toe boards (front and rear) and tilt cylinder cover.
3 Disconnect hoses from the front and rear of the return filter.
4 Remove the return filter.
Installation procedure
Caution:
NATURAL DROP TEST
1. Set the mast in the vertical position with the standard
load on the fork, lift the fork by 1 to 1.5 m (39.3 to 59.1
in), and turn the key switch to OFF.
2. Draw datum lines on the inner and outer masts, and

measure the drop after 15 minutes.
Limit: A=45 mm (1.77 in)
NATURAL FORWARD TILT TEST

load on the fork, lift the fork by 50 m (19.7 in), and turn
the key switch to OFF.
2. Measure the tilt cylinder rod extension after 15 minutes.

Model Natural forward tilt mm (in)
7FBEU15 , 18
15 (0.6) or less
7FBEHU18
7FBEU20 20 (0.8) or less
OIL LEAK TEST
LIFT CYLINDER
load on the fork, lift the fork by I.O to 1.5 m (39.3 to 59.1
in).
Tilt the mast forward slowly. After waiting 5 minutes with
the key switch OFF, disconnect the oil control valve to oil
tank hose and measure the amount of oil that leaks in
one minute.
Standard (lift port section): 8 cm3 (0.49 in3) or less
Note:
If the natural drop is great even though the oil leak
amount is within the standard range, either the lift lock
valve or the lift cylinder packing is defective.
TILT CYLINDER
load on the fork, lift the fork by 50 m (19.7 in), and turn
the key switch to OFF.
2. After waiting 5 minutes with the key switch OFF,
disconnect the oil control valve to oil tank hose and
measure the amount of oil that leaks in one minute.
Standard (total amount for lift and tilt):
16 cm3 (0.98 in3) or less
3. The leak amount at the tilt port is the total leak amount
less the leak amount from the lift port.
Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard range, either the tilt lock
valve or the tilt cylinder packing is defective.
MAST
Page
V MAST ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
.
REMOVAL INSTALLATION (WILIFT BRACKET) . . . . 12-6
•
MAST ASSY DISASSEMBLY INSPECTION

• REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
LlFT BRACKET DISASSEMBLY INSPECTION

• REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
MAST ADJUSTMENT (V MAST) . . . . . . . . . . . . . . . . . . 12-11

MAST ROLLER REMOVAL INSTALLATION. . . . . . . . 12-16
•
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
INSPECTION ................................. 12-17
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
FORK ........................................ 12-18
REMOVAL .................................... 12-18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
INSPECTION ................................. 12-18
FV FSV MAST ASSY ......................... 12-19
I
COMPONENTS ................................ 12-19

.
MAST ADJUSTMENT (FV FSV) ................. 12-23
LlFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) . . . . . . . . 12-27
V MAST ASSY
COMPONENTS
MAST ASSY (V)
LIFT BRACKET ASSY
6301
FV
02 02
-
02K
r"'
:
-"-i r...-...q
h 42C AE
L... -....I L... -... 4
,
408
I
FSV
BE
BG
~
02
408
6301-5768
CHAIN AND CHAIN WHEEL ASSY

- -
Removal Procedure
1 Set the mast in the vertical position and fully lower the fork.
2 Disconnect the chain. [Point I ]
3 Remove the chain wheel. [Point 21
4 Remove the lift bracket ASSY. (Raise the inner mast until it comes off the lift bracket, and slowly run
the vehicle in reverse to detach from the lift bracket.)
5 Disconnect the lifting height switch, remove the load sensor clamp and disconnect the wiring.
6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift
cylinder.)
7 Slightly hoist the mast.
8 Remove the tilt cylinder front pin. [Point 31
9 Remove the mast support cap.
10 Remove the mast ASSY.
Note:
Apply chassis grease special to the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced. (See page 12-27.)
Adjust the chain tension after installation. (See page 12-18.)
When the mast is replaced, perform SAS matching after installation. (See section 16.)
Point Operations
[POINT I]
SST 09630-23600-71
[POINT 21
Removal:
If the fitting is stiff, use the SST for removal.
SST 09950-76014-71
(09950-40011)
[POINT 31
Removal:
Make match marks to clarify the relative positions of the
front pin, stopper plate and lock bolt. Match marks,
however, are unnecessary when the mast or mast ASSY
is replaced as mast tilt angle adjustment is to be done
after replacement.
Removal:
If the fitting is stiff, use the driver for removal.
Inspection:
Measure the mast support bushing thickness.
Limit: I.Omm (0.039in)
REMOVAL INSTALLATION (WILIFT BRACKET)
Removal Procedure
Set the mast in the vertical position.
Remove the fork. (See page 12-18.)
Disconnect the lifting height switch, remove the load sensor clamp and disconnect the wiring.
Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift
cylinder.)
Tie the lift bracket and outer mast tie beam with a wire rope.
Slightly hoist the mast.
Remove the tilt cylinder front pin. [Point I]
Remove the mast support cap.
Remove the mast ASSY Wllift bracket.
Note:
Apply chassis grease special to the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced. (See page 12-27.)
Adjust the chain tension after installation. (See page 12-18.)
When the mast is replaced, perform SAS matching after installation. (See section 16.)
Point Operations
[POINT I]
Removal:
front pin, stopper plate and lock bolt.Match marks,
after replacement.
Removal:
Inspection:
Measure the mast support bushing thickness.
Limit: I.Omm (0.039in)
MAST ASSY DISASSEMBLY INSPECTION REASSEMBLY
I
Remove the lifting height switch.
Remove the hose cover.
Disconnect the high pressure hose.
Remove each cylinder rod end set bolt, and take each rod end off. [Point I]
Remove each cylinder support. [Point 21
Remove each cylinder bottom set bolt, and remove each lift cylinder.
Slide the inner mast downward, and remove the lift rollers.
Remove the mast strip. [Point 31
Remove the outer mast.
Point Operations
Shim
[POINT I ]
Disassembly:
Shim adjustment is made at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Keep a record of where the adjustment is made and the
number of shims used.
[POINT 21
Disassembly:
Y
Keep a record of the number of cylinder support shims
used.
Shim Reassembly:
Perform cylinder support shim adjustment if the mast or
, either cylinder is replaced.
With the cylinder rod end inserted to the inner mast,
eliminate any clearance between the cylinder support
and outer mast by inserting shim.Shims should be
slightly thicker than the clearance.
[POINT 31
Inspection:
Measure the mast strip thickness.
Limit: 1.5mm (0.059in)
12-10
LIFT BRACKET DISASSEMBLY INSPECTION REASSEMBLY
1 Remove the lift rollers. [Point I ]
2 Remove side rollers. [Point 21
3 Remove the back rest.
Point Operations
[POINT I ]
Disassembly:
SST 09950-76014-71
(09950-40011)
[POINT 21
Reassembly:
Install side rollers in the correct direction.
The greater chamfering on the outside of the roller
should be on the vehicle front side.
12-11
MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast
1. lnner mast roller clearance adjustment
Outer mast Inner mast
into
into
These rollers
(1) Adjust the mast overlap to approx. 450mm (17.7 in).

(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, and measure on the
opposite side the clearance between the roller side
face and mast at the point where they are the closest.
- -
Standard: A=O 0.8 mm (0 0.031 in)
If the standard is not met, adjust by changing the
inner mast roller shim thickness. (See removal and
installation of mast roller (See page 12-16))
Shim thickness: 0.5 . 1.0 mm (0.020 0.039 in)
(3) Distribute shims equally to the left and right rollers.

I (4) After adjustment, check that the inner mast moves
Shims
smoothly in the outer mast.
12-12
2. Outer mast roller clearance adjustment
These rollers
Outer mast Inner mast
(1) Adjust the mast overlap to approx. 450mm (17.7 in).

(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, and measure on the
opposite side the clearance between the roller side
face and mast at the point where they are the closest.
- -
Standard: B=O 0.5 mm (0 0.020 in)
If the standard is not met, adjust by changing the
outer mast roller shim thickness. (See removal and
installation of mast roller (See page 12-16))
(4) After adjustment, check that the inner mast moves
smoothly in the outer mast.
Roller Adjustment at Lift Bracket
1. Middlellower lift roller and side roller clearance adjustment
Bring into contact

100mm (3.94 in)
Bring into contact

Inner mast
outer mas 8 !I
Lift bracket
(1) Bring the center of the upper lift roller in the lift bracket
to 100 mm (3.94 in) from the top of the inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and measure the
clearance of the middle and lower lift rollers when the
clearance between the opposite rollers and the mast
is minimum. (No adjustment is necessary for the
upper lift rollers as they are fastened by snap rings)
Standard:
- -
C=O 0.8 mm (0 0.031 in)
If the standard is not met, adjust by changing the lift
roller shim thickness.
Shim thickness: 0.5 1.0 mm (0.020 0.039 in)
(5) Install side rollers.
Shim
(6) After adjusting the middle and lower lift rollers, bring
the side roller on one side into contact with the side of
the mast and measure on the opposite side the
clearance between the side roller and the innermost
side face.
Standard:
- -
D=O 0.6 mm (0 0.024 in)
If the standard is not met, adjust by changing the side
roller shim thickness.
Shim thickness: 0.5 - 1.0 mm (0.020 . 0.039 in)
(7) Distribute shims equally to the left and right side

rollers.
(See "Lift Bracket Disassembly . Inspection .
Reassembly" section for the side roller installation
rnethod.Shim replacement is possible on the vehicle)
(8) After adjustment, check that the lift bracket moves
smoothly along the entire length of the mast.
-- - --- --
Mast Strip Adjustment

1. Mast strip clearance adjustment
Bring into contact
- Out ward
(1) Fully lower the inner mast.

(2) With the inner mast in contact with the outer mast
roller, measure the clearance between the mast strip
and inner mast.
- -
Standard: E=0.5 1.0 mm (0.020 0.039 in)
If the standard is not met, adjust by changing the mast
strip shim thickness. (See removal and installation of
mast roller. (See page 12-16))
Shim thickness: 0.5 - 1.0 mm (0.020 . 0.039 in)
Note:
The strip is of tapered shape, thicker side of the width
must be placed outward.
(3) After adjustment, check the mast for smooth
movement.
MAST ROLLER REMOVAL INSTALLATION
1. Remove the lift bracket. (See steps 1 to 4 of the mast
ASSY removal procedure on page 12-6)
2. Jack up the vehicle and support with wooden blocks
under the tires.Chock the wheels.
3. Remove the lift cylinders. (See page 13-7)
4. Remove mast rollers.

I (1) Remove wooden blocks under the inner mast, and
slowly lower the hoisted inner mast until mast rollers
Shims
can be seen.
(2) Support the bottom of the inner mast with wooden
blocks.
(3) Remove the inner mast rollers and shims.
(4) Remove the outer mast rollers and shims.

5. The installation procedure is the reverse of the removal
procedure.
CHAIN
INSPECTION
1. lnspect the chain elongation using the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement scale differs according
to the chain type, set the corresponding scale on the
chain as illustrated.
(2) Check the chain no. of the chain to be inspected, and
check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, it has reached the limit; replace the chain.
Chain link pitch standard
Note:
Perform measurement without removing the chain
from the vehicle.
lnspect elongation over the entire chain length as it
may be localized.
REASSEMBLY
1. Installing direction
Applicable
FV: Lift bracket
mast and V: Lift bracket FSV: Inner mast
FSV: Lift bracket
section
Outside of Backward of
vehicle vehicle
e
Split pin Split pin

Rough sketch
Install with the split pin direct- Install with the split pin direct- Install with the split pin direct-
ing toward the center of the ing outside the vehicle. ing backward of the vehicle.
vehicle.
2. Chain adjusting nut tightening procedure
-
(1) Tighten nut (a), (b).T=49.0 78.0 N.m (500
(2) Tighten nuts (c).
- 800 kgf.cm) [36.1 - 57.5 ft.lbfl
Applicable
FV: Front cylinder
mast and V: Outer mast FSV: Outer mast
FSV: Front cylinder
section
Rough
sketch
i) (a)
c ' u m ~
(a)
b $& (b)
(a)
ADJUSTMENT
1. Park the vehicle on a flat surface and set the mast in the vertical position.
2. Lower the fork to the ground, and adjust to eliminate any chain sag by turning the adjusting nut.
3. Check to see that the chain tension is equal on the left and right sides.
4. Check that the chain is not twisted.
5. Check that the lifting height meets the standard.
6. In the uppermost position, check that the lift bracket fall-out prevention stopper at the inner mast upper
beam is not in contact with the lift bracket.
FORK
REMOVAL
1. Raise the fork to approx. 20 cm (7.9 in) from the ground.
2. Place a wooden block under the notched section of the
fork rail.
3. Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1. Inspect misalignment of the fork tip ends.
Limit: 10 mm (0.39 in)
If the limit is exceeded, inspect individual fork bend,
looseness of fork installation and lift bracket finger bar
distortion.
FV FSV MAST ASSY
COMPONENTS
MAST ASSY (FV)
12-20
MAST ASSY (FSV)

12-21
LIFT BRACKET ASSY (FV, FSV)

6301
V FV
02 02
- 43A 42
02K
42C AE
I
b ...-... 4 b ...-... 4
408
FSV
02
408
6301-5766
CHAIN & CHAIN WHEEL (FV)

12-22
CHAIN & CHAIN WHEEL (FSV)

-
MAST ADJUSTMENT (FV FSV)

Lift Roller Adjustment at Mast
1. lnner mast roller (FV . FSV) and middle mast lower roller (FSV) clearance adjustment
where the roller

is the closest to the FSV mast)
FV mast FSV mast

lnner mast lnner mast
Outer mast
Middle mast
These rollers
These rollers
(1) Adjust the mast overlap to approx. 450 mm (17.7 in).

(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and measure on
the opposite side the clearance between the roller side face and mast at the point where they are
the closest.
- -
Standard: A=O 0.8 mm (0 0.031 in)
If the standard is not met, adjust by changing the shim thickness.
(4) After adjustment, check that mutual mast movement is smooth.
12-24
2. Outer mast roller (FV . FSV) and middle mast upper roller (FSV) clearance adjustment
Bring into contact
ontact
where the roller

is the closest to the FSV mast)
FV mast FSV mast

These rollers
These rollers
lnner mast
lnner mast
(1) Adjust the mast overlap to approx. 450 mm (17.7 in).

(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on
the opposite side the clearance between the roller side face and mast at the point where they are
the closest.
- -
Standard: B=O 0.5 mm (0 0.020 in)
If the standard is not met, adjust by changing the outer mast roller shim thickness.
(4) After adjustment, check that mutual mast movement is smooth.
12-25
Lift and Side Roller Adjustment at Lift Bracket

FV . FSV mast
Lower side roller
Bring into contact
FV mast FSV mast

100mm (3.94in)
Lift bracket
(1) For adjustment, raise the lift bracket fully in case of FSV or position the center of the upper lift roller
at 100mm from the top of the inner mast in case of FV.
(2) No adjustment is necessary for the upper lift rollers and middle lift rollers (FV only) as they are
fastened by snap rings.
(3) Shift the lift bracket to one side to bring the lower lift roller and side roller into contact with the inner
mast, and measure on the opposite side the clearance between the roller side face and the mast at
the point where they are the closest.
-
Standard: C=O 0.5 mm (0 0.020 in)-
If the standard is not met, adjust by changing the shim thickness.(Distribute shims equally to the left
and right side rollers.)
Shim thickness: 0;5 1.0 mm (0.020 . 0.039 in)
(4) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers.
Bring the side roller on one side into contact with mast side surface, and measure on the opposite
side the clearance between the side roller and the inner mast side surface.
- -
Standard: D=O 0.5 mm (0 0.020 in)
If the standard is not met, adjust by changing the shim thickness.(Distribute shims equally to the left
and right side rollers.)
Shim thickness: 0.5 . 1.0 mm (0.020 . 0.039 in)
(5) After the above adjustment, check that the lift bracket moves smoothly along the entire length of
the mast.
12-26
Mast Strip Adjustment

1. Mast strip clearance adjustment
FV mast
Bring into contact
Outer mast
FSV mast
- Out ward
Bring into contact
Outer mast
E
- Out ward
(I)Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.
- -
Standard: E=O 0.8 mm (0 0.031 in)
If the standard is not met, adjust by changing the shim thickness.
Shim thickness: 0.5 1.0 mm (0.020 0.039 in)
(3) After adjustment, check the mast for smooth movement.
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
Perform inspection and adjustment when any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY and inner mast SUB-ASSY.
After adjustment, perform SAS matching. (See section 16.)
1. Inspection method
Slowly raise the inner mast, and observe the stopping
condition of the left and right cylinder rods at the
moment when the inner mast reaches the maximum
height.
(1) Normal case
Both the left and right rods stop almost
simultaneously with almost no shaking of the inner
mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast, attach the SST to the outer
mast tie beam, and lower the inner mast until it comes
into contact with the SST.
SST 09610-22000-71
(2) Remove the cylinder rod end set bolt on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end, and slowly raise
the cylinder rod end into the inner mast.
(5) Install the cylinder rod end set bolt.
(6) Raise the inner mast again for reinspect ion.
(7) Repeat the inspection and adjustment until the
number of shims is determined.
Shim thickness: 0.5 1.0 mm (0.020 . 0.039 in)
CYLINDER
Page
LlFT CYLINDER (V) .
REAR LIFT CYLINDER (FV FSV) . . . . . . . . . . . . 13-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
REMOVAL rn INSTALLATION . . . . . . . . . . . . . . . . . . . . . 13-7
DISASSEMBLY rn INSPECTION REASSEMBLY . ..... 13-9
FLOW REGULATOR VALVE (V FV FSV) ..... 13-15 . .
•
SAFETY DOWN VALVE ........................ 13-1 7

REMOVAL . INSTALLATION (V) .................. 13-18
REMOVAL INSTALLATION (FV . FSV) . . . . . . . . . . . . 13-19
•
FRONT LIFT CYLINDER (FV FSV) ............ 13-20

GENERAL .................................... 13-20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
COMPONENTS ................................ 13-21
•
DISASSEMBLY • INSPECTION REASSEMBLY .

. . . . . 13-23
TILT CYLINDER ............................... 13-25
GENERAL .................................... 13-25
SPECIFICATIONS .............................. 13-25
COMPONENTS ................................ 13-26
•
DISASSEMBLY INSPECTION . REASSEMBLY ..... 13-30

.
MAST FORWARD BACKWARD TlLT ANGLE ADJUSTMENT
(PREVENTION OF UNEVEN TILTING) ............ 13-32
LlFT CYLINDER (V) , REAR LlFT CYLINDER (FV FSV)
GENERAL
Lift Cylinder (V)
Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSV)
13-4
SPECIFICATIONS
Lift Cylinder (V)
7FBEU15 7FBEU18 7FBEU20 7FBEHU18
Cylinder type Single-acting type

Cylinder bore mm (in) 44.45 (1.75) t t t
Piston rod outside diameter mm (in) 34.93 (1.38) t t t
Piston seal type U packing
Rod seal type U packing
Others Built-in safety down valve (RH, LH)

Cylinder bore mm (in) 45 (1.77) t t t
Piston rod outside diameter mm (in) 32 (1.26) t t t
Others Built-in safety down valve (LH)

=iston seal type U packing
Others Built-in safety down valve (LH)
6503
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Removal Procedure
1 Set the mast in the vertical position and fully lower the fork.
2 Remove the lift cylinder rod end set bolt.
3 Hoist the inner mast by slinging with wire and disconnect the lift cylinder rod end.[Point I ]
4 Hoist the mast until the lift cylinder ASSY can be removed toward the front side of the vehicle.
5 Support the bottom of the inner mast with wooden blocks and fix the outer mast with string.
6 Remove the hose cover.
7 Disconnect the hose.
8 Remove the load sensor cover and disconnect the wiring. (FV . FSV)
9 Remove the lift cylinder bottom end set bolt.
10 Remove the lift cylinder support. [Point 21
11 Remove the lift cylinder ASSY.
Note:
After installing the lift cylinder, follow the steps below.
1. Without a load, repeat full-stroke raising and lowering of the cylinder to bleed air and check normal
functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect lift cylinders for uneven lifting, and make any necessary adjustment. (See page 13-32.)
Point Operations
[POINT I]
Removal:
Perform shim adjustment at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Record at which cylinder the adjustment is made and
also the number of shims used.
[POINT 21
Installation:
Temporarily fasten the cylinder support, and eliminate
any clearance between the cylinder support and outer
mast by shim insertion after connecting the rod end.
(The shim thickness should be slightly greater than the
clearance)
13-9
DISASSEMBLYmINSPECTION REASSEMBLY l
Lift Cylinder (V)

1 Remove the safety down valve.
2 Remove the cylinder cover. [Point I ]
3 Remove the seals from the cylinder cover.
4 Remove the piston rod. [Point 21
5 Remove the seals on the piston rod.
6 Remove the check valve from the piston rod. [Point 31
7 Remove the cylinder. [Point 41
Note:
l Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the cylinder cover
before tightening.
Point Operations
[POINT I]
Disassembly . Reassembly:
V mast
SST 09620-10100-71
[POINT 21
Inspection:
Measure the piston rod outside diameter.
Unit: mm (in)
Standard Limit
All Models 34.93 (1.375) 34.85 (1.3720)
[Point 31
Reassembly:
Install the check valve arrow pointing to the lower side of
the cylinder.
[Point 41
Inspection:
Measure the cylinder bore.
Unit: mm (in)
I Standard Limit I
All Models
I
1 44.45 (1.750)
I
1 44.65 (1.7579) 1
13-11

T = N-m(kgf-cm) [ft-lb]
LH Rear Lift Cylinder
5 Remove the wear ring.
6 Remove the bleed screw.
RH Rear Lift Cylinder
1 Loosen the cylinder cover. [Point I ]
3 Remove the piston. [Point 31
4 Remove the piston seals.
5 Remove the cover and the seals.
6 Remove the bleed screw.
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
before tightening.
Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following
sequence:
(1) Extend the FV rear lift cylinder.
(2) Set the key switch t o OFF.
(3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.
Point Operations
[POINT I ]
Disassembly.Reassembly:
SST SST 09620-10100-71
[POINT 21
Inspection:
Measure the piston rod outside diameter
Unit: mm (in)
Standard Limit
All Models 32.0 (1.260) 31.92 (1.2567)
Inspection:
Measure the piston rod bend.
Limit: 2.0 mm (0.079 in)
[POINT 31
Disassembly-Reassembly:
Follow the procedure view.
1. Fix the boss portion at the tip end of the piston rod in a
vise.
2. Use a screwdriver and rotate the piston to remove the
wire.
3. The installation is the reverse.
[POINT 41
Inspection:
Unit: mm (in)
Standard Limit
All Models 45.0 (1.772) 45.2 (1.7795)
T = N.m (kgf-cm) [ft-lbfl
5 Remove the piston seals, and the check valve. [Point 31
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
before tightening.
Point Operations
[POINT I ]
V mast
SST 09620-10100-71
[POINT 21
Inspection:
Unit: mm (in)
Standard Limit I
All Models
I
1 34.93 (1.375)
I
1 34.85 (1.3720) 1
Inspection:
Limit: 2.0 mm (0.079 in)
[POINT 31
Reassembly:
Install the check valve arrow pointing to the lower side of
the cylinder.
[POINT 41
Inspection:
Unit: mm (in)
Standard Limit
All Models 44.45 (1.750) 44.65 (1.7579)
FLOW REGULATOR VALVE (V FV FSV)
IN port
Lowering Speed Specifications

Unit: mmlsec (fpm)
.. .
V mast FV mast FSV mast

Model
No-load 550 ( I08) 450 (89) 450 (89)
7FBEU15
Load 500 (98) 480 (94) 480 (94)
No-load 550 (108) 450 (89) 450 (89)
7FBEU18
Load 500 (98) 480 (94) 480 (94)
No-load 500 (98) 420 (83) 450 (89)
7FBEU20
Load 500 (98) 480 (94) 480 (94)
No-load 500 (98) 420 (83) 450 (89)
7FBEHU18
Load 500 (98) 480 (94) 480 (94)
V,FV FSV
Removal Procedure
1 Hoist the inner mast. (V , FV) [Point I]
2 Remove the flow regulator valve ASSY. (FSV)
3 Remove the flow regulator valve.
Point Operations
[POINT I]
Hoist the inner mast by slinging with wire, set the SST
on the inner mast tie beam, and lower the inner mast
until it comes into contact with the SST.
SST 09610-22000-71
SAFETY DOWN VALVE
I
I
I
I
I I
L--A
Cartridge type
Internal type
13-18
REMOVAL INSTALLATION (V)

T=N.m (kgf-cm) [ft-lbfl
Removal Procedure
2 Hoist the inner mast. [Point I]
3 Remove the front hose cover and load sensor bracket.
4 Remove the lift cylinder (LH) bottom end set bolt.
5 Loosen the lift cylinder (LH) support set bolt.
7 Remove the load sensor cover.
8 Disconnect the load sensor connector and remove the load sensor.
9 With the lift cylinder (LH) hoisted slightly upward, remove the three-way.
Point Operations
[POINT I]
Hoist the inner (middle) mast by slinging with wire, set
the SST on the inner (middle) mast tie beam, and lower
the inner mast until it comes into contact with the
SST 09610-22000-71
REMOVAL INSTALLATION (FV FSV)
Removal Procedure
2 Hoist the inner mast. [Point I]
3 Remove the lift cylinder (LH) bottom end set bolt.
4 Loosen the lift cylinder (LH) support set bolt.
Point Operations
[POINT I]
Hoist the inner (middle) mast by slinging with wire, set
the SST on the inner (middle) mast tie beam, and lower
the inner mast until it comes into contact with the SST.
SST 09610-22000-71
13-20
FRONT LlFT CYLINDER (FV FSV)

GENERAL
FRONT LlFT CYLINDER (FV . FSV)
SPECIFICATIONS
FV Mast

Cylinder bore mm (in) 70 (2.76) t t t
Others Built-in safety down valve
FSV Mast

Others Built-in safety down valve
13-21
COMPONENTS
FV mast
13-22
FSV mast
01
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I
I
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I
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L... '9.4
Removal Procedure
1 Remove the lift bracket Wlfork.
2 Disconnect the piping.
3 Remove the front lift cylinder.
Note:
After installing the lift cylinder, follow the steps below.
1. Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Adjust the lift chain tension equally on the left and right sides.
13-23

FV FSV
T=305 - 373 T=305 - 373
- 7
3 Remove the cover seals.
5 Remove the piston seals.
6 Remove the check valve. [Point 31
Note:
Apply MP grease or hydraulic oil to packings, O-rings and dust seal lips.
Apply sealant (08833-00080) to the threaded portion of the rod guide before tightening.
Add the amount of hydraulic oil specified below to the cylinder from its top before installing the
rod guide.
Vehicle model Amount cm3 (in3)
All Models 80 (4.88)
Point Operations
[POINT I ]
SST 09620-10100-71
[POINT 21
Inspection:
Unit: mm (in)
Standard Limit
All Models 50.8 (2.0) 50.72 (1.9969)
Inspection:
Limit: 2.0 mm (0.079 in)
[POINT 31
Reassembly:
Install the check valve so that the arrow will direct
Check
valve
downward of the front lift cylinder.
[POINT 41
Inspection:
Unit: mm (in)
Standard Limit
All Models 70.0 (2.756) 70.35 (2.7697)
13-25
TILT CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double acting type
Cylinder bore mm (in) 70 (2.76)
Piston rod outside diameter mm (in) 30 (1.18)

13-26
COMPONENTS
6511
(TILT BOOTS)
BU
6511-255
Removal Procedure
Remove the toe board (front and rear) and tilt cover.
Remove the instrument panel.
Remove the fender cover and step.
Slightly hoist the mast.
Disconnect the hose. (After releasing the residual pressure in the tilt cylinder by operating the tilt lever
several strokes).
Disconnect the tilt angle sensor link. (RH)
Remove the tilt cylinder front pin. [Point I]
Remove the tilt cylinder rear pin.
Remove the tilt cylinder ASSY.
Note:
Apply MP grease to the insertion portions of the tilt cylinder front and rear pins before
installation.
After installation, slowly tilt the mast forward and backward a few times to check normal
functioning.
Check the hydraulic oil level and add if insufficient.
After installation, perform SAS matching. (See section 16.)
Point Operations
[POINT I]
Removal:
front pin, stopper plate and lock bolt. Match marks,
after replacement.
Removal:
13-30

1 Remove the Fitting.
2 Loosen the rod guide. [Point I ]
3 Extract the piston rod Wlpiston.
4 Remove the tilt cylinder. [Point 21
5 Remove the bushing.
6 Remove the piston.
7 Remove the rod guide.
Note:
Apply MP grease or hydraulic oil to packings, O-rings and dust seal lips.
Apply sealant (08833-76002-71 (08833-00080)) to the threaded portion of the rod guide before
reassembly.
Point Operations
[POINT I ]
SST 09620-10100-71
[POINT 21
Inspection:
Limit: 70.35 mm (2.770 in)
[POINT 31
Inspection:
Limit: 29.92 mm (1.178 in)
Inspection:
Measure the bend of the piston rod.
Limit: I.0 mm (0.039 in)
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (PREVENTION OF
UNEVEN TILTING)
Note:
Adjust the mast forward and backward tilt angles (to prevent uneven tilting) when the tilt
cylinder and mast ASSY are replaced or overhauled.
After adjustment, perform SAS matching. (See section 16.)
1 With the mast in the neutral position, set the tilt cylinder pin eccentric direction on the lower side and
install the stopper.
Eccentric direction
2 Inspect the forward and backward tilt angles and unevenness in tilting at the pin position above.
Standard:
Mast forward tilt angle: Standard set angle -36' t o +96'
Mast forward tilt angle: Standard set angle -48' to +36'
Uneven tilting: 1 mm (0.04 in) or less
3 When the standard is not met, adjust with the eccentric pin at the two holes on the pin fixing plate at
the front and rear sides by trying four ways of adjustment. (Turning the eccentric pin to move the joint
center axis +4 mm (k0.16 in).)
4 After adjustment, tighten the stopper set bolt to lock the front pin.
OIL PUMP
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . 14-4
DISASSEMBLY INSPECTION REASSEMBLY. 14-5
TEST METHOD ............................... 14-8
GENERAL
7FBEU15 to 20
Vehicle model
7FBEHU18
Oil pump name Single gear pump
Oil pump type TMGIA21A3H5-L (Shimadzu)
Drive system Direct motor drive
Delivery (pump at 1500rpm) I (US gal) Imin 30.8 (8.14)
Theoretical discharge cm3 (in3) /rev 21.9 (1.336)
14-3
COMPONENTS
6701
FIG. 1402-01
6701-193A
6701
01
r--- . . . ,
O1K=(INCL..):
AD
AE
L... ... A
6701-194A
14-4
Removal Procedure
2 Remove the toe board (front and rear) and tilt cover.
3 Remove the return filter set bolt and set the filter free.
4 Disconnect the pump outlet hose at the oil pump side.
5 Remove the oil pump set bolts.
6 Disconnect the pump inlet hose at the oil pump side.
7 Remove the oil pump ASSY W/ fitting.
Note:
Apply chassis grease at the spline section of the oil pump before installation.
Clean the flange that meets the motor before installation.
14-5

7 Make match marks between the front cover and body and between the rear cover and body. [Point I ]
2 Place the front cover face downward, and remove the bolts (4 pcs.).
3 Remove the rear cover ASSY (rear cover, bushing, gasket and figure 3 gasket). [Point 21
4 Remove the body and side plate. [Point31
5 Remove the drive gear, driven gear and side plate. [Point 41
6 Remove the oil seal. [Point 51
Note:
Wash each part, blow compressed air and apply hydraulic oil before installation.
Always use new seals for reassembly.
Match mark Match mark Point Operations

between front between rear [POINT I ]
cover and body cover and body Disassembly:
Make match marks between the front cover and body
and between the rear cover and body.
Reassembly:
Rear cover
[POINT 21
Inspection:
The bushing inner surface should not be roughened and
should not be worn to the extent that the metal on the
rear side is visible.
Wear limit:O.l5mm
[POINT 31
(0.0059 in) or less Inspection:
The side plate surface (LBC surface) in contact with
LBC surface
gears should not be worn beyond the limit shown at left.
Erosion by cavitation Strong contact

around this portion around here
Wipe depth Inspection:

Discharge 0.01 0-.06mm Inspect the body inner surface for the wipe mark.
Port Normal wipe depth: 0.01 to 0.06 mm
(0.0004 to 0.0024 in)
Wipe mark
[POINT 41
Inspection:
Make match marks on the tooth flanks of the drive and
driven gears.
Reassembly:
Inspection:
Check the gear side surface for wear and the tooth
flanks for roughening.
Shaft diameter limit: 21.997 mm (0.86602 in)
Tooth width limit: 25.5 mm (1.004 in)
[POINT 51
Inspection:
(I)Check that there is no wear (that makes edge
rounded portion invisible) or damage at oil seal lip.
(2) Check that the figure 3 gasket is not damaged.
(3) Check that the outward leak-preventing gasket is not
damaged.
(4) Check that seals are not swollen.
Gasket Figure 3 gasket

TEST METHOD
A bench test should be conducted for strict testing, but as it is generally impossible in practical service
operation, install the oil pump on the vehicle and judge the oil pump discharge performance by means of
cylinder operation.
Check that the battery charge is sufficient by observing the battery charge indicators.
Check that the oil control valve set relief pressure is as specified.
(See PIS-11)
Measure the time of full stroke of the lift cylinder with the hydraulic oil temperature at 50 55 "C (122 - -
131OF) and calculate the lifting speed.
However, due to soft start by material handling chopper circuit, lifting speed is 10 20 mmlsec (2.0
3.9 fpm) lower than the value obtained from the table.The lifting speed can be calculated more
- -
accurately by measuring the full stroke operation time excluding the soft start period.
The lifting speed may differ depending on the conditions of the battery, hydraulic oil temperature and mast
adjustment.
The values below are based on a certain condition.
Lifting speed <reference value>
36V mmls (fpm)
V- mast FV-mast FSV-mast
Vehicle model
No load Load No load Load No load Load
H 490 (97) 340 (67) 450 (89) 320 (63) 450 (89) 320 (63)
7FBEU15 Lift P 440 (87) 300 (59) 420 (83) 280 (55) 420 (83) 280 (55)
S 400 (79) 260 (51) 390 (77) 250 (49) 390 (77) 250 (49)
H 490 (97) 310 (61) 450 (89) 300 (59) 450 (89) 300 (59)
7FBEU18
Lift P 440 (87) 270 (53) 420 (83) 260 (51) 420 (83) 260 (51)
7FBEHU18
S 400 (79) 240 (47) 390 (77) 230 (45) 390 (77) 230 (45)
H 490 (97) 300 (59) 450 (89) 290 (57) 450 (89) 290 (57)
7FBEU20 Lift P 440 (87) 250 (49) 420 (83) 240 (47) 420 (83) 240 (47)
S 400 (79) 220 (43) 390 (77) 210 (41) 390 (77) 210 (41)
48V mmls (fpm)

V-mast FV-mast FSV-mast
Vehicle model
No load 1 Load No load I Load No load 1 Load
7FBEU15 1 Lift I P j 540 (106) j 360 (71) j 490 (97) j 350 (69) j 490 (97) j 350 (69) 1
H 610 (120) 420 (83) 560 (110) 390 (77) 560 (110) 390 (77)
7FBEU18
Lift P 540 (106) 340 (67) 490 (97) 320 (63) 490 (97) 320 (63)
7FBEHU18
S 480 (95) 260 (51) 430 (85) 260 (51) 430 (85) 250 (49)
7FBEU20 I Lift j P j 540 (106) j 310 (61) i 490 (97) j 300 (59) j 490 (97) 300 (59) 1
OIL CONTROL VALVE
Page
OIL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . 15-5
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
OIL CONTROL VALVE ASSY . . . . . . . . . . . . . . . . . . . . 15-8
RELIEF PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . 15-11
LIFT LOCK UNLOCKING BOLT.................. 15-12
CONTROL VALVE LEVER ASSY ................. 15-13
OIL CONTROL VALVE(F0R MINI LEVER) ...... 15-14
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
HYDRAULIC CIRCUIT DIAGRAM ................. 15-17
SPECIFICATIONS.............................. 15-17
COMPONENTS................................ 15-18
OIL CONTROL VALVE ASSY (FOR MINI LEVER) .... 15-20
MATERIAL HANDLING OPERATION START TIMING
ADJUSTMENT ............................... 15-25
RELIEF PRESSURE ADJUSTMENT ............... 15-26
LIFT LOCK RELEASE BOLT ..................... 15-27
MINI LEVER BOX ............................. 15-28
GENERAL .................................... 15-28 rn
COMPONENTS................................ 15-29
OIL CONTROL VALVE
GENERAL
Oil Control Valve
Control Valve Sectional View
Lift Block Sectional View
Solenoid valve
\
Relief valve
- -
Tilt Block Sectional View
Solenoid valve
Relief valve
Tilt Limit Switch Section
Front t ard tilt switch

HYDRAULIC CIRCUIT DIAGRAM
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SPECIFICATIONS
All Models
TYpe Add-on type ( I .2spool mono block)

RELIEF PRESSURE Lift 17.2 (175) [2490]
MPa (kgf/cm2) [psi] Tilt 13.7 (140) [ISSO]
Spool outside diameter mm (in) 16.0 (0.63)
Stroke mm (in) 7.0 (0.28)
Others Built-in lift and tilt lock valves
15-6
COMPONENTS
OIL CONTROL VALVE ASSY
Note:
Operate the control lever to bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the material handling system before starting
removal.
-- -- - -
Removal Procedure
4 Remove the set pin for the oil control valve and lever.
5 Remove the oil control valve.
Note:
Adjust the limit switch after installing the oil control valve.
(See page 3-39.)
Apply MP grease to oil control valve lever linkage.
Check the hydraulic oil level, and add i f insufficient.
Note:
As parts are finished with high precision, carefully disassemble and reassemble to prevent any
damage.
Choose a clean location for the job.
T=N.m (kgfcm) [ft.lbfJ
1 Remove the limit switch. [Point I ]
2 Remove the limit switch holder and spring cover.
3 Remove the solenoid ASSY. [Point 21
4 Remove the solenoid valve.
5 Remove the lift spool ASSY.
6 Disassemble the lift spool ASSY. [Point 31
7 Remove the tilt spool ASSY.
8 Disassemble the tilt spool ASSY. [Point 31
9 Remove the additional spool ASSY.
10 Disassemble the additional spool ASSY. [Point 31
11 Remove the lift pilot relief valve set.
12 Remove the tilt pilot relief valve set.
13 Remove the check plunger.
14 Remove the valve seat.
15 Remove the lift lock check valve.
16 Remove the outlet housing.
Note:
Fully loosen the relief valve adjusting screw before reassembly.
Point Operations
[POINT I]
Disassembly* Reassembly:
SST 09610-10160-71
RELIEF PRESSURE ADJUSTMENT
Note:
Always follow the procedure below for adjustment.Careless adjustment may cause high-
pressure generation, resulting in damage t o hydraulic units such as the oil pump.
No adjustment is needed when the relief valve is not disassembled or is replaced with a new
one.
Tilt relief vzlve
1. Remove the plug (9116-18UNF-2B) from the top of the oil control valve and install a pressure gauge
there.
Pressure resistance of pressure gauge: 19600kPa (200 kgf/cm2) or more
2. Loosen the lift relief valve adjusting screw.
Loosen the lock nut (for better workability, remove the limit switch before) and loosen the adjusting
screw but to the extent it stays on the body.
3. Adjust the oil pressure as follows:
(2) Slowly operate the lift lever in the lifting direction, and gradually tighten the adjusting screw until the
fork starts to rise.
(3) Lift the fork fully and read the oil pressure at that position.Tighten the adjusting screw for the normal
pressure reading.
(4) Tighten the lock nut and re-check the oil pressure.
4. Adjust the tilt relief valve oil pressure.
The adjustment process is the same as for the lift relief valve, but tilt the mast fully backward when
measuring the oil pressure.
Relief Pressure Standards
Unit: MPa (kgflcm2) [psi]
All Models
Lift relief pressure 17.2 (175) [249]
Tilt relief pressure 13.7 (140) [I991
5. Remove the oil pressure gauge, and install the plug.

LIFT LOCK UNLOCKING BOLT
Action when the fork cannot be lowered due to solenoid valve failure
T=N.m (kgf-cm) [fi-lbfl
2 Loosen the lift lock unlocking bolt and operate the lift lever to manually lower the fork.
Note:
Always retighten the unlocking bolt after repair.lf the lift lock unlocking bolt is left loose, much
hydraulic oil is released from the oil pump and the lifting speed is significantly decreased,
resulting in difficulty in smooth operation.
15-13
CONTROL VALVE LEVER ASSY

Removal Procedure
2 Tilt lever: Disconnect wiring of the knob switch.
3 Remove the set bolt.
4 Disconnect the lever rod.
5 Remove the control valve lever. [Point I]
Note:
Apply grease (MP grease) to control valve lever link portions.
Point Operations
[POINT I]
Inspection:
Inspect the knob switch for continuity.
Standard: Switch ON: 0 R
Switch OFF: mR
OIL CONTROL VALVE(F0R MINI LEVER)
GENERAL
Oil Control Valve
15-15
Control Valve Sectional View
Unload valve
Relief valve
compensated
pressure reducing valve
Lift Block Sectional View
Lift lock check valve
Lift select valve
Proportional solenoid
15-16
Tilt Block Sectional View
ilt select valve
Attachment Block Section View

HYDRAULIC CIRCUIT DIAGRAM
Lift lock check valve Tilt lock check valve
Unload valve Relief valve Lift select valve Tilt select valve
Inlet Lift Tilt ATT
SPECIFICATIONS
All Model
TYpe Add-on type

RELIEF PRESSURE
17.2 (175) [249]
MPa (kgf/cm2) [psi]
Others With proportional solenoid valve
15-18
COMPONENTS
OIL CONTROL VALVE ASSY (FOR MINI LEVER)
Note:
Operate the control lever to bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the material handling system before starting
removal.
Removal Procedure
4 Remove the oil control valve.
Note:
Check the hydraulic oil level, and add if insufficient.
Caution:
Note:
As parts are finished with high precision, carefully disassemble and reassemble to prevent any
damage.
Choose a clean location for the job.
1 Remove the outlet housing. [Point I ]
2 Remove the ATT bock ASSY.
3 Remove the spring cover W1 adjusting screw. [Point 21
4 Remove the spring ASSY.
6 Remove the spring ASSY and ATT spool. [Point 31
7 Remove the solenoid valve ASSY. [Point 41
8 Remove the tilt block ASSY.
9 Remove the tilt sleeve ASSY. [Point 51
10 Remove the spring block W1 adjusting screw. [Point 21
I1 Remove the tilt lock check valve. [Point 61
14 Remove the spring ASSY and tilt spool. [Point 31
16 Remove the lift block ASSY.
17 Remove the release bolt from the lift block.
18 Remove the lift sleeve ASSY. [Point 51
19 Remove the spring block WI adjusting screw. [Point 21
20 Remove the lift lock check valve. [Point 61
22 Remove the spring cover WI adjusting screw. [Point 21
23 Remove the spring ASSY and lift spool. [Point 31
25 Remove the inlet block ASSY.
26 Remove the relief valve. [Point 73
27 Remove the unload valve. [Point 31
28 Disconnect the plug.
29 Remove the solenoid valve.
30 Pilot relief valve
Note:
Fully loosen the relief valve adjusting screw before reassembly.
Point Operations
[POINT I ]
Disassembly:
Put match marks and then remove the solenoid valve.
Reassembly:
Align the match marks and then reassemble the
solenoid valve.
[POINT 21
Reassembly:
Adjust the adjusting screw set dimension A to the
following value.
Standard: A = 1.8 mm (0.071 in)
After installing the oil control valve ASSY in the vehicle,

adjust the material handling operation start timing. (See
page 15-25.)
[POINT 31
Inspection:
Check to see if the orifice is clogged, and if it is, clean it
out.
[POINT 41
Inspection:
Check the solenoid valve continuity.
Between 4 and 8, 3 and 7 , 2 and 6, 1 and 5.
Standard: 7.3 i2
Inspection:
out.
[POINT 51
inspection:
out.
15-24
[POINT 61
Inspection:
out.
[POINT 71
Reassembly:
When the relief valve is disassembled, leave the
adjusting screw completely loosened.
[POINT 81
Inspection:
Check to see if the filter is clogged, and if it is, clean it
out.
Inspection:
Inspect the inlet sleeve solenoid valve continuity.
Standard: Continuity exists

Raise lift MATERIAL HANDLING OPERATION START
TIMING ADJUSTMENT
NOTE:
When the oil control valve is disassembled or a
component is replaced, check and adjust the material
handling operation start timing.
1. Slowly operate the lever, check each operation start
timing, and adjust the timing when it is off.
Lower lift ywTilf forward
2. Loosen the lock nuts on the end of each spool and turn
the adjusting screw to adjust the material handling
operation start timing.
Turn to the right (tightening side):
Delays the start timing.
Turn to the left (loosening side):
Advances the start timing.
NOTE:
For the screw turning angle, use + 4 5 O as a reference.
If the adjusting screw is tightened too much, material
handling speed will be slow with the lever full-stroke.
If the adjusting screw is loosened too much, jolt will
happen at the start of material handling operation.
3. Use the lock nut to lock the adjusting screw, and then
check the timing again.
RELIEF PRESSURE ADJUSTMENT
Note:
Always follow the procedure below for adjustment.Careless adjustment may cause high-
pressure generation, resulting in damage to hydraulic units such as the oil pump.
No adjustment is needed when the relief valve is not disassembled or is replaced with a new
one.
The tilt side relief pressure does not need to be adjusted.
1. Remove the plug (9116-18UNF-2B) from the top of the oil control valve and install a pressure gauge
there.
Pressure resistance of pressure gauge: 19600kPa (200 kgf/cm2) or more
1 Remove globe nut A, loosen lock nut B to just before the point where it comes off from the body, and
then loosen adjusting screw C.
2 Adjust the relief pressure.
(2) Move the lift lever upward while gradually tightening adjusting screw C, and then move the fork to
the top most position.
(3) Setting adjusting screw C so that the hydraulic pressure when the forks are in the top most position
(relief state) is within the standard.
(4) Tighten the lock nut and globe nut, and then recheck the relief pressure.
(5) Remove the oil pressure gauge and reinstall the plug.
Relief Pressure Standards
Unit: MPa (kgf/cm2) [psi]
All Models
Lift relief pressure 17.2 (175) [249]

LIFT LOCK RELEASE BOLT
T = N.m (kgf.cm) [ft.lbfl
\ m a r l
unlockina bolt
1 Loosen the lock nut.

2 Loosen the lift lock unlocking bolt and operate the lift lever to manually lower the fork.
Note:
Always retighten the unlocking bolt after repair.lf the lift lock unlocking bolt is left loose, much
hydraulic oil is released from the oil pump and the lifting speed is significantly decreased,
resulting in difficulty in smooth operation.
15-28
MINI LEVER BOX

GENERAL
Fork automatic leveling switch

15-29
COMPONENTS
15-30
Removal Procedure
2 Open the battery hood.
3 Remove the harness clamp and disconnect the wiring.
4 Close the battery hood and remove the knob, spacer, and slide adjusting bolt.
5 Remove the mini lever box. [Point I]
Point Operations
[Point I]
Removal~lnstallation:
Slide the mini lever box to the rear, lift up the rear side,
and remove the mini lever box.
15-31

T = N.m (kgf.cm) [ft.lbfl
1 Remove the lower box.
2 Remove the arm pad ASSY.
3 Disconnect the connector and remove the fork automatic leveling switch. [Point I ]
4 Disconnect the connector and remove the potentiometer. [Point 21
5 Disassemble the potentiometer. [Point 31
The reassembly procedure.is the reverse of the disassembly procedure.
Note:
Conduct matching when removing, reinstalling, or replacing the lift lever potentiometer, tilt lever
potentiometer, attachment lever 1 potentiometer, or attachment lever 2 potentiometer (OPT).
(See page 3-68.)
Point Operations
[POINT I]
Reassembly:
Orient the washer in the direction shown in the figure
and then install the washer.
Inspection:
Check the continuity of the fork automatic leveling
switch.
Standard ON : 0 i2
OFF: - R
ON
OFF
i 1
[POINT 21
Disassembly:
Attach a number to the connector that matches the
number of the upper box.
Reassembly:
Be certain to make the correct wiring connections and
connect the connectors to match the numbers.
Inspection:
A standalone inspection of the potentiometer cannot be
performed. Check the voltage on the display's analyzer
screen. (See page 3-34.)
[POINT 31
Reassembly:
1. Loosely connect the potentiometer to the position
shown in the figure.
2. Rotate the potentiometer all the way to the left and
tighten the screw.
3. Check to see if the lever operates normally.
Reassembly:
Align the plate A hole with the lever body pin point and
install the plate.
Reassembly:
Apply MP grease to the locations shown by arrows in the
figure and install the component.
SAS FUNCTIONS
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
FOR REPAIR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
TILT ANGLE SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . 16-7
LOAD SENSOR ............................... 16-8
.
MAST LIFTING HEIGHT SWITCH . . . . . . . . . . . . . . 16-10
.
MATCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-11
VEHICLE STANDARD STATE . . . . . . . . . . . . . . . . . . . . 16-12
CAUTIONS ON MODIFYING VEHICLES ........ 16-13
GENERAL
SAS (System of Active Stability) System
Sensors and switches installed at each portion o f the vehicle detect the vehicle movement and send
signals to the controllers. These signals are controlled with the controllers to drive each actuator for mast
control.
Functional part Mast tilting control
Functional part Mast tilting control

Lifting height switch 0
Tilt angle sensor 0 Oil control valve
SOL1 -2
0
Forward tilt switch 0
LCD display 0
Backward tilt switch 0
Diagnosis 0
Tilt knob switch 0
Load sensor 0
Combination meter
Tilt knob switch
Main controller
Oil control valve

Forward tilt switch
Backward tilt switch
16-3
COMPONENTS
Lifting height switch (V mast)
Lifting height switch (FV mast)

16-4
Lifting height switch (FSV mast)

5803
10
r"' -...?
: on
~
L...
5803-111
Tilt angle sensor

Load sensor (V, FV mast)
FOR REPAIR WORK
Caution:
Before starting SAS repair, make sure you fully understand the SAS functions.
1. Preparation for repair work
(1) Avoid washing the vehicle as much as possible; for cleaning, blow compressed air. If washing with
water is required, avoid water jet washing. Always blow compressed air to remove water after
washing.
( 2 ) Transport the controller in a packed state, and keep it packed until installation. Never transport it in
an exposed state. Be sure not to drop or apply impact to the controller.
(3) If matching is required after repair, park the vehicle on a flat surface in advance.
(4) Prepare necessary tools, testers (analog tester).
2. During repair work
(1) Don't turn the key switch to ON or OFF carelessly while the sensor wiring is disconnected. Key
switch ON in this state may cause an error and the error code will be stored in the controller. Error
codes cannot be cleared. When the stored error codes exceeds ten, the error codes are cleared
from the oldest one. Therefore necessary repair information becomes unavailable.
(2) Don't drive the vehicle during matching, as SAS function is disabled.
(3) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(4) When the oil control valve lift lock unlocking bolt is loosened, always tighten it to the specified
torque and return the bolt to the original state after the end of repair.
(5) Tighten the set bolts of respective functional parts to the specified torque.
(6) No adjustment is necessary for each sensor at the time of installation, but be sure to perform
matching after the installation.
( 7 ) When disconnecting a connector, don't pull it at the harness.
(8) When inspecting the harness, be sure to avoid taken not to damaging the connector terminals.
(9) Positioning of the low- and high-lifting heights described in the troubleshooting section are as
follows:
Classification How to distinguish
Fully lowered to height with lifting height switch MHI

Low lifting height
(Less than approx. 2 m)
High lifting height Height with lifting height switch MH2-1 (Approx. 2 m or more)
3. Emergency Action
If the mast cannot be lowered because of trouble when
the lift lever is operated to the down position, it can be
lowered as an emergency action as follows.
Loosen the lift unlock bolt and operate the lift lever to the
down position.
Lift unlock bolt
Note:
After repair, d o not forget t o retighten the lift lock
unlocking bolt. I f the lift lock unlocking bolt is loosened,
the lifting speed is remarkably decreased.
16-7
TILT ANGLE SENSOR

T=N.m (kgfzm) [ftdbfl
Removal Procedure
2 Remove the toe boards (front and rear).
3 Remove the right instrument panel.
4 Remove the tilt cylinder cover.
5 Disconnect the tilt angle sensor link.
7 Remove the tilt angle sensor.
Note:
Perform matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is
adjusted in length or replaced. (See page 16-11.)
For installation, apply MP grease on sliding section of the end.
LOAD SENSOR
T=N.m (kgfcm) [ft.lbfl
Removal Procedure
1 Hoist the inner mast. (See page 13-16.)
2 Remove the hose cover. (V mast)
3 Remove the insulator.
5 Remove the load sensor Wlhose.
6 Remove the load sensor.
Note:
Perform matching when the load sensor is removed, installed or replaced. (See P16-11.)
Point Operations
[POINT I]
Installation:
V, FV mast
When installing, make sure that rear face of the insulator
comes within around 5 mm (0.2 in) from the rear face of
the lift cylinder.
FSV mast
Make sure that the rear face of the lift cylinder and the
rear portion of the insulator is within the dimension A
below.
Vehicle model A
All models 11.4 to 15.5 mm (0.45 to 0.61 in)
Note:
For installation of the insulator, adjust the position so
that there is no interference between the tie wrap
connection and the front protector, inner mast (V, FV
mast), middle mast (FSV mast) and their piping.
MAST LIFTING HEIGHT SWITCH
FV*FSV mast
T=14.4-33.6
Removal Procedure
1 Remove the lower cover. (FV, FSV mast)
3 Remove the mast lifting height switch.
MATCHING
Of the sensors used for the SAS function, the tilt angle and load sensors are controlled based on the
signal voltage values for the mast vertical position, no-load state stored in the controller at the time of
shipment from the factory. When servicing these sensors or replacing related parts, matching (updating
the sensor signal voltage under the standard vehicle condition) is necessary.
Also, matching must be performed for the tilt angle sensor when the vehicle posture has changed greatly,
and for the load sensor when the load under no load condition is changed because of the addition or
removal of any attachment.
Matching is performed with the mask function of the display. Perform matching selecting "MATCHING" on
the mask function.
Matching items and examples of necessary operation
Forward tilt restric-
Automatic No-load
Content of matching tion
fork leveling standard load
position
Mast in vertical Mast in vertical
Matching condition No-load
position position *
Displayed code TILTL TlLTF LOAD
Object sensor Tilt angle sensor Tilt angle sensor Loadsensor
Maintenance operation examples:
1. When replacing main controller 0 0 0
2. When replacing tilt angle sensor 0 0 0
3. When changing the tilt angle sensor
0 0
rod length or replacing the sensor
4. When replacing load sensor 0
5. When changing attachment 0 0 0
6. When replacing mast 0 0 0

7. When replacing tilt cylinder 0 0
8. When adjusting tilt cylinder for uneven
0 0
lifting
*: In order to store the reference position for the controller to calculate the forward tilt restriction position,
perform matching by setting the mast to the vertical position.
Note:
The matching value for the tilt angle sensor determines the mast stop position in automatic fork
leveling. If the fork does not stop horizontally because of the site condition (such as an inclined
surface), perform matching with the mast in the vertical position. In this case, the mast stop angle
may differ from that on the level surface.
VEHICLE STANDARD STATE
Select a level surface without any irregularity for matching, as if the surface on which matching is to be
performed is slanted, error occurs in the standard state.
Note:
The finishing accuracy of floors for factories, warehouses and buildings in general calls for the
floor inclination to be 0.5" or under; therefore, matching on these floors is not affected--however,
don't perform matching on a floor that is inclined over 0.5" for draining purposes.
Fork stop position with automatic leveling and forward

tilting limit position
Set the vehicle to the following state in order to store the
signal voltage values of the tilt angle sensor when the mast is
perpendicular to the floor.
No-load standard load
Set the vehicle as follows so as to have the load sensor
signal voltage value stored under no-load conditions.
Standard: For V mast, raise the fork to 500 mm (19.7 in)
or for FV and FSV mast, raise the rear shaft
FV*FSV mast cylinder to 100 mm (3.9 in) and position a level
(angle gauge) at the height of I 2 0 0 to 1500 mm
(47.2 to 59.1 in) on the front or rear surface of
the outer mast with the mast in the vertical
position.
Note:
Set the mast in the vertical position from the backward
tilted position. (Do not set the mast in the vertical
position from the forward tilted position)
If there is a detachable attachment, keep the
attachment installed on the vehicle.
CAUTIONS ON MODIFYING VEHICLES
When replacing mast
When the mast is replaced, the mast harness has to be replaced with the one suitable for the
new lifting height.
When placing an order for a mast ASSY, check the need for sensors (lifting height switch, load
sensor, mast harness, and other SAS-related parts) and place an order accordingly.
Be sure to perform matching after replacement (See P3-68).
Other functional parts
See Section 15 for the oil control valve solenoid 1, 2, backward and forward tilt switch and tilt
lever knob button.
For the inspection of functional parts, see Section 4 TROUBLESHOOTING
APPENDIX
Page
SST LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
SERVICE STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . 17-6
CONNECTOR DRAWING . . . . . . . . . . . . . . . . . . . . . . 17-12
CONNECTING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 17-23
ELECTRIC WIRING DIAGRAM ................. 17-24
17-2
SST LIST
Section
lllust Part number Part name
1 2 3 4 5 6 7 8 9 1011 1 2 1 3 1 4 1 5 1 6
Puller B set
09140-10920-71 extension 0
tool
09150- 10920-71 Spacer 0
GENE0 B
09230-13130-71 controller 0
diagnosis kit
For CN20,
52, 55, 58,
(09232-13130-71) 0
86, and
94
CN25
(09238-13130-71) 0
09230-13700-71 IC check pin 0 0

/
0 0
Cylinder cap
09620-10100-71 remover B 0
replacer
09630-23600-71 Deep socket 0
t" - L-- --
09631-22000-71
Wear scale
0
,--- --nrV- j chain
Spring pin
09700-30200-71 0 0
tool remover
6 bp s 6~ 09950-76003-71
Puller set 0 0
(09950-50012)
-e %%
09950-76014-71
fil
Puller set 0 0 0 0
,
e&g%
B "' (09950-40011)
09950-76018-71
Replacer set 0 0 0 0
(09950-60010)
Section
1 2 3 4 5 6 7 8 910111213141516
oooo 09950-76019-71 Replacer

OOQO 0
(09950-60020) set No.2
&/ 09950-76020-71
(09950-70010)
Handle set 0 0 0 0
Battery
25009-13200-71
hanger
17-6
SERVICE STANDARDS
BATTETY
Item All models
Specific gravity upon
(at 20 "C) 1.280
perfect charging
Specific gravity upon end of
(at 20 "C) 1.150
discharge
Voltage upon end of 36V 32.0

discharge
v
48V 42.5
Insulation resistance MR 1 or more
CONTROLLER
ltem All models
F1 (fuse for drive and pump circuits) A 500
F4 (fuse for lamp circuit) A 10
F5 (fuse for control circuit) A 10
F6 (fuse for SAS and solenoid circuit) A 10
The higher the resistance the better, but it varies
Control panel insulation MR greatly with the vehicle operating condition, place,
environment and weather. (Approx. 1 MR or more)
MI3 (power supply contactor) coil resistance R Approx. 20 (at 20 "C)
Driver motor input voltage V 2 or less
Pump motor input voltage V 2 or less
Tightening torque: N-m (kgf-cm) [ft-lbfl
Pump and drive motor driver terminal Standard: 13 to 17 (133 to 173) [ I 0 to 131
Pump and drive motor terminal Standard: 11 to 15 (112 to 153) [8 to 111
ltem All models
Acceleration switch Pedal not operated Cu
R
(SWAC) Pedal operated Continuity
Accelerator potentiome- Not operating 0
R
ter resistance Operating a
DIRECTION SWITCH
Lever position
Forward Neutral Rear
DSF 0R -R -R
DSR WR -Q 0R
DSBU -R -R 08
BRAKE LIMIT SWITCH

ltem All models
Limit switch ON dimension See page 2-38.
DRIVE MOTOR
Item All models
Stator ASSY insulation resistance MR Standard: 1 or more
Motor cable continuity R Standard: 0
Thermo-sensor resistance R Standard: 540 to 620 (at 20°C)
PUMP MOTOR
Item All models
Clearance between the end mm 11.0 to 13.3
Standard:
frame and rpm sensor. (in) (0.4 to 0.5)
Stator ASSY insulation resistance MQ Standard: 1 or more
Motor cable continuity R Standard: 0
Thermo-sensor resistance R Standard: 540 to 620 (at 20°C)
-
DRIVE UNIT & FRONT AXLE
ltem All models
23.9 to 47.3 (2.4 to 4.8)
1.5 ton
[5.3 to 10.61
Hub starting force N (kgf) [Ibfj Standard:
27.2 to 53.9 (2.8 to 5.5)
1.8 , 2.0 ton
[6.2 to 12. I ]
Tightening torque N-m (kgfmcm) [ft-lbfl
Gear case set bolt Standard: 17.5 to 32.5 (179 to 332) [12.9 to 24.01
Hub nut Standard: See page 6-5.
17-8
REAR AXLE
Item All models
Rear axle ASSY
Rear axle ASSY starting force N (kgf) [Ibfl Standard: 100 to 171 (10.2 to 17.4) [22 to 371
Rear Wheel starting force N (kgf) [Ibfl Standard: 15 to 39 (1.5 to 4.0) [4 to 91
Rear axle cylinder
Standard: 70.00 (2.76)
Rear axle cylinder bore mm (in)
Limit 70.35 (2.77)
Tightening torque N-m (kgf-cm) [ft-lbfl
Rear axle ASSY lock nut Standard: 10 to 20 (102 to 204) [7 to 151
Rear axle cylinder set bolt Standard: 250 to 350 (2551 to 3571) [I85 to 2581
Tire angle sensor set bolt Standard: 1.6 to 2.0 (16.3 to 20.4) [I
.2 to 1.51
Tire angle sensor cover set bolt Standard: 10 to 16 (102.0 to 163.3) [7.4 to 11.81
STEERING
ltem All models
Steering wheel play mm (in) Standard: 20 to 50 (0.79 to 1.97)
Hydrostatic steering valve assy
MPa (kgfmcm2) 10.6 to 11.1 (108 to 113)
Relief set pressure Standard:
[Psi] [ I535.8 to 1606.91
Steering wheel set nut Standard: 25 to 45 (254.9 to 458.9) [18.4 to 33.21
BRAKE
Item All models
Foot brake
Standard: 6 (0.24)
Brake pad thickness mm (in)
Limit 3.5 (0.14)
Brake disc wheel thick- Standard: 9 (0.35)

mm (in)
ness Limit 8.0 (0.31)
Brake pedal
Brake pedal height (no
mm (in) Standard: 110 to 115 (4.3 to 4.5)
pad)
Brake pedal play mm (in) Standard: 35 (1.4)
Parking Brake
Number of operation notches of brake lever 3 to 4
Standard:
Operating force 150 N (15 kgf) [331 Ibfl
17-9
FRAME
Item All models
Counterweight
Tightening torque N-m (kgfscm) [ftmlbfl
Counterweight set bolt Standard: 10.8 to 24.5 (110 to 250) [8.0 to 18. I ]

ltem
Natural drop test
Natural drop mm (in) Limit 45 (1.77)
Natural forward tilt test
1 ton series Standard: 15 (0.59) or less
Natural forward tilt mm (in)
2 ton series Limit 20 (0.79) or less
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard: 8 (0.49) or less
Tilt cylinder oil leak amount
cm3 (in3) Standard: 16 (0.98) or less
(total for lift and tilt)
MAST
ltem
Mast adjustment (V MAST)
Inner mast roller clearance mm (in) Standard: 0 to 0.8 (0 to 0.031)
Mast rollers
Outer mast roller clearance mm (in) Standard: 0 to 0.5 (0 to 0.017)
Middle and lower lift roller
mm (in) Standard: 0 to 0.8 (0 to 0.031)
Lift bracket rollers clearance
Side roller clearance mm (in) Standard: 0 to 0.6 (0 to 0.024)
Mast strip to inner mast clearance mm (in) Standard: 0 to 0.8 (0 to 0.031)
Mast strip thickness mm (in) Limit 1.5 (0.059)
Fork
Fork front end misalignment mm (in) I Limit 10 (0.39)
60.0 to 140.0 (611.8 to 1427.6)
Mast support cap set bolt Standard:
[44.3 to 103.31
98.0 to 182.0 (999.0 to 1856.0)
Back rest set bolt Standard:
[72.3 to 134.31
49.0 to 78.0 (500 to 800)
Chain adjusting nut Standard:
[36.2 to 57.91
17-10
CYLINDER
Item
Lift cylinder (V. FSV)
Piston rod outside mm Standard: 34.93 (1.375)
diameter (in) Limit 34.85 (1.372)
mm Standard: 44.45 (1.750)
Cylinder bore
(in) Limit 44.65 (1.758)
Piston rod bend mm (in) Standard: 2.0 (0.08)
Lift cylinder (FV)
Piston rod outside mm Standard: 32 (1.2598)
mm Standard: 45 (1.7717)
Cylinder bore
(in) Limit 45.2 (1.7795)
Front cylinder (FV FSV)-
Piston rod outside mm Standard: 50.8 (2.0)
mm Standard: 70 (2.756)
Cylinder bore
(in) Limit 70.35 (2.7697)
Tilt cylinder
Standard: 30 (1.1811)
Piston rod outside diameter mm (in)
Limit 29.92 (1.1780)
Standard: 70 (2.7559)
Cylinder bore mm (in)
Limit 70.35 (2.7697)
Piston rod bend mm (in) Standard: I.O (0.039)
Tightening torque N.m (kgf-cm) [ft-lbfl
170 to 237 (1730 to 2419)
Lift cylinder cover Standard:
[ I25 to 1751
59.0 to 69.0 (601.6 to 703.6)
Flow regulator valve Standard:
[43.5 to 50.91
29.0 to 39.0 (295.7 to 397.7)
Safety down valve Standard:
[21.4 to 28.81
305 to 373 (3110 to 3801)
Front lift cylinder rod guide Standard:
[225 to 2751
410.0 to 462.0
Tilt cylinder piston castle nut Standard: (4180.8 to 4711.1)
[302.5 to 340.81
284.0 to 421.0
Tilt cylinder cover Standard: (2896.0 to 4293.0)
[209.5 to 310.61
17-11
OIL PUMP
ltem
Oil pump assy
0.15 (0.006) or less at LBC
Side plate thickness mm (in) Limit
surface
Gear shaft outside diameter mm (in) Limit 21.997 (0.87)
Body inside surface flaw depth mm (in) Limit 0.15 (0.006)
OIL CONTROL VALVE

Item
Oil control valve
Relief set pressure Lift Standard: 17200 (175) [2488.5]
kPa (kgf.cm2)[PSI] Tilt Standard: 13700 (140) [ I990.81
Oil control valve (For Mini Lever)
Relief set pressure
Lift Standard: 17200 (175) [2488.5]
kPa (kgf.cm2)[PSI]
SAS
ltem
10 to 16 (102.0 to 163.3)
Tilt angle sensor set bolt Standard:
[7.4 to 11.81
22 to 26 (224.5 to 265.3)
Loadsensor Standard:
[16.2 to 19.21
15.0 to 25.0 (153.0 to 255.1)
V Standard:
[11.1 to 18.51
Lifting height switch ASSY set bolt
14.4 to 33.6 (146.9 to 342.9)
FV . FSV Standard:
[10.6 to 24.81
CONNECTOR DRAWING
I' I
TAB REC
TAB REC
TAB REC
TAB REC
HO-
2 103 P CN132-7
3 120 Y CN132-8
CN130-3
CN130-2
CN5 STOP LAMP SW.
TAB
CN6 BRnKEsw.
TAB REC
NO P C J NO P C J
1 1
I
51 1 - I
I I
LS-
-
1 1I 51 1
I
B I J1
TAB REC -
2 120 DSFO 2 120 Y CN132-8
I
5 45 - DSF
6 43 - VBKY 6 43 Y J5
CN11 L I F T S W
ED TAB rnREC REC
CN 12 FLASHER RlLAY
TAB REC
NO P C J
TAB REC
TAB REC CN 19 STEERING SENSOR
TAB REC
TAB REC
CN 15 PARKING SW.
m & TAB REC
TAB REC
1 ;1 1 ; 1
; ;1 LH-L 1
IN~OII I
P
102
TAB
LH-R
J I lN10~ P
102
1 1
REC
J
CN13-3
1
2 N2 - LH-R 2 N2 W J51
CN27 F4.F5,F6 FUSE
-
TAB
a3REC
TAB REC
LS AT1
2 51 BR LS nil
CN22 SEAT SW.
ED
TAB rnREC
&
TAB REC
TAB
B
REC
2 N2 - CHI
SMART ALARM TAB REC
El
TAB
B
REC
TAB REC
TAB REC
TAB REC
TAB REC
STP
103 R BIU
4
TAB REC TAB REC
mi
CN38 RR UPR
CN96 <OPT> CMP LAMP sw
TAB
b q REC
TAB REC
NO P C J
1 43 L FB
2 111 SL 353
3 103 0 J56
4 104 G J55
5 108 BR CN34-5
6 109 G-Y CN31-3
7 107 V CN36-1
8 N2 W J54
TAB
rn
REC
TAB REC
TAB
mREC
TAB REC
TAB REC TAB REC
TAB REC
TAB
[m] REC
TAB REC
U
TAB REC
REC
12 SOL 12 CN132-I1
SOL P 2 13 LG CN130-8
TAB REC
TAB REC
VTA I
E2
TAB REC
CN84 TILT KN O B s w
TAB REC
TAB REC
TAB REC
TAB REC
CN70 DISPLAY REC

TAB REC
NO P C J
1 57 - VRAT
TAB 2 56 - VRAT
1
3 51 - VRAT
TAB REC
u
TAB REC
LS-
LSTR
LS-
TAB REC
CN 110 DRIVE CONT L H
1- TAB REC
REC
NO P C J 1
3 145 - CANH
4 / 146 - 1 CANL
5 CANTRD
6 1 147 / - I CANGND
7 42 - KEYSTART
8 1A - I CUDCN
w -
TAB REC
TAB REC
TAB REC
SWMHI
3 91 - SWMHI
w
TAB REC
TAB REC
31145 1 - I CANH 3 145 B J64
161147 1 - I CANGND 1161147 1 G 1 J66 I

7 42 - KEYSTART
8 CUDON
12 RESISTOR CN130 JOINT I - 1
pzQ TAB REC

TAB
NO P C J
1 2 3 4 5 6 7 8
1 145 - R REC
-
2 146 R 9 10 11 12 13 14 15 16 17 18
3
OOPT TAB REC I 1 OPT
TAB REC
2 39 B FAN EX(-)
F]
TAB REC
2 39 B FAN EX(-)
TAB REC
CN131 JOINT
TAB --
NO P C J
- 18 17 16 15 14 13 - 12 11 10
-
1
2 55 W CPR -
3 P2 W P2 1 2 3 - 4 5 6 7 - 89
REC
().OPT TAB REC ().OPT

11 21 31 4 1 1 1 51 61 71 8
9 /lo11111211311 4 ~ 1 5 ~ 1 6 ~ 1 7 ~ 1 8
TAB REC
1~01 P 1 C 1 J CN164 <OPT> MAIN CONT.
1 64 - SWAC
2 1 52 1 - 1 POTA TAB / 291

0 181
9 ~71
1 86~ 1/ 7 0
~1 1516~51
1 441
~ 131
3 121~11 1
2110/
3 56 - POTTA
4 59 - SPL 11 21 31 41 5 11 61 71 81 9
5 1 53 1 - I POTA+ 110111 112113114 1 5 / 1 6 / 1 7 ~ 1 8 1 9 ~ 2 0 ~
REC
CN163
( ):OPT TAB REC ( ):OPT
NO P C J
1 43 Y J39
VBBT 2 41 GR J29
B48V 3 18 0 J29
JOINT ()OPT
CN132-2 CN13-3
;;:;C
+N
;-5
4 @ CNl7-2
CN 13-6 CN45-4
CN46-1 CN13-2
CN46-2
SWR CN46-4 CN17-3
(41 GR) (N2.L)
CN130-18 CN23-1
c CNl32-7
CN24-2 CN38-8
N2 TERMINAL CN38-3
ELECTRIC WIRING DIAGRAM
-
(P2.G) CPR
F O R STD(MIN1 LEVER LESS)

FANEX IFAN, EXHAUST, CONTROL UNIT I I I MSCH STl SLL
1 ME ICONTACTOR, BAlTERY
VRAO I VARI-OHM ACCEL DRNE I I I SMTDK
VRAT I VARI-OHM. TILT DS F DIRECTION SWITCH. FORWARD SDTMK
VRAH ( VARCOHM, TIRE(HANDLE) DS R DIRECTIONSWITCH, REVERSE DlSP SDTMA
I
DS FO DIRECTION SWITCH, FORWARD OPTIONAL
VRALl I V A R I a M , LIFT, NO.l DS BU DIRECTION SWITCH. BACK-UP
VRAL7 I VARILCHM LlFT NO 2 LS L LIMIT SWITCH. LIFT NOTE)
VRATl VARI-OHM,TILT, NO.l LS F LIMIT SWITCH, TILT FR THIS DRAWING SHOWS
CASE OF FULL OPTION.
I
VRATZ VARI-OHM, TILT. N0.2 LS Ti7 LIMIT SWITCH. TILT RR
VRAATII VARI-OHM, ATTACHMENTl, NO.l LS AT1 I LlMlT SWITCH. AlTACHMENT NO1
VRAAT12 VARI-OHM, ATTACHMENTI, N0.2 LS AT2 I LIMIT SWITCH, ATrACHMENT NO2
VRAAT21 VARI-OHM, ATTACHMENTZ. NO.? LS ST 1 LlMlT SWITCH STOP 1 AMP
VRAAT22 VARI-OHM, ATTACHMENTZ, N0.2 LS B I LlMlT SWITCH, BRAKE LAMP, WORKING
LS PB I LIMIT SWITCH, PARKING BRAKE LAMP, FLASHER LH (REAR)
CUD1 CONTROL UNIT. DRIVE 1 LS D I LlMK SWITCH. DEADMAN L F.RR LAMP. FLASHER RH (REAR)
CUD? CONTROL UNIT, DRIVE 2 LAMP. FLASHER LH
CUP CONTROL UNIT. PUMP I I AMP FI ASHFR RH
PB CPU PRINT BOARD, COMPUTER LSTL ILAMP, STOP LH

SWITCH, LIGHT Lsr.~ ILAMP, STOP RH
TERMINATING RESISTANCE
SENSOR. PRESSURE LIFT
I)
LAMP, FLASH BEACON
n l 1 7 7 C R , < M A R T bl A R M \
SENSOR, SPEED, DRIVE 2

SOLAT& SOLENOID. ATTACHMENT,a4 SENSOR, SPEED, PUMP
SOLATM SOLENOID, ATTACHMENT, b4
FRY RELAY, FLASHER
I I I I I I 1 CHI R I CHIME, REVERSE

APPENDIX
Page
SST LIST ..................................... 17-2
CPU BOARD CONNECTOR. . . . . . . . . . . . . . . . . . . . 17-3
CONNECTOR DRAWING ...................... 17-4
CONNECTING DIAGRAM...................... 17-15
ELECTRIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . 17-16
17-2
SST LIST
Section
1 2 3 4 5 6 7 8 9 1011 1 2 1 3 1 4 1 5 1 6
GENE0 B
09230-13130-71 controller 0
diagnosis kit
For CN20,
52, 55, 58,
(09232-13130-71) 0
86, and
94
CN25
(09238-13130-71) 0
sub-.,arness
09234-13900-71
09950-76003-71
Puller set 0 0
(09950-50012)
CPU BOARD CONNECTOR
I
CNlOl CN102
-
CN103 CN104
1
u u
CN102
LEDTK
FAN-
LSATI+
POTL+
POTT+
POTATI+ 39 FAN-
POTAT2+
22 POT-
CNlOO
FAN7
CHKG
33 1
34 1 51 1 POT-
CONNECTOR DRAWING
HO- J6
21 103 1-1 DSBU 11 21 103 1 P I CN132-7

31 120 1-1 DSFO 11 31 120 1 Y I CN132-8
4 46 - DSR 4 46 G CN130-3
():OPT TAB REC ():OPT 5 45 - DSF 5 45 W CN130-2

6 51 - LS- 6 51 B J1
7 1 43 1-1 VBKY 11 7 1 43 1 Y I J5
1 (41) 1 (GR) 1 (CN29-I)
TAB REC
[rn]
CN9 <OPT> DIRECTIONAL PEDAL
REC
TAB REC
120 - DSFO 120 Y CN132-8
NO P C J NO P C J 103 - DSBU 103 P CN132-7
6 1 4 3 1 - I VBKY 6 1 4 3 1 Y I J5
REC
TAB FR COMB1 L H REC
CN 12 FLASHER RlLAY
TAB REC
TAB REC
2 43 - FRY
TAB REC CN19 STEERING SENSOR
TAB REC
CN14 FR COMBI RH
TAB
R
k
REC
N7 LC-R
4 104 - LC-R
TAB
&REC
TAB REC
2 N2 - LH-L
TAB REC
102 LH-R 102 CN13-3

LH-R
CN27 F4,F5.F6 FUSE
-
TAB
0 REC
TAB REC
LS AT1
LS ATT
TAB
0 REC
&
TAB REC
TAB REC
2 N2 - CHI pj
CN23-2 SMART ALARM TAB REC
Ell
TAB
B
REC
TAB REC
TAB REC
CN26 AccEL
TAB REC
TAB REC
TAB
0 REC TAB REC
TAB REC
TAB REC
NO P C J
1 43 L FB
2 111 SL J53
3 103 0 J56
4 104 G J55
5 108 BR CN34-5
6 109 G-Y CN31-3
7 107 V CN36-1
8 N2 W 354
TAB REC
TAB
rn
REC
CN46 TAIL LAMP RELAY
TAB
101
CN42 <OPT> MINI LEVER
lW
116 LG CN8-9
[ I ] CN52 DM TEMP RH
4 104 0 J10
TAB
NO P
REC
C J
@ @
1 26 V CN164-4 TAB REC
2 27 SL CN164-5
3 31 LG CN164-9
4 2 88 R T02+
5 70 BR CN161-I4
6
7 67 L CN161-5
8 51 B 321
TAB REC TAB REC
CN55 pM TEMP
@
TAB REC
TAB REC
TAB REC
TAB REC
13 - SOL P
1-
TAB REC
TAB REC NO P c J NO P c J
1 28 - VC 1 28 G CN41-3
2 20 - VTAl 2 20 R CN41-1
3 21 - VTA2 3 21 B CN41-2
SSD11
4 51 - E2 4 51 W J49
78 SSDI-
CN78 <OPT>
A
TILT LEVER
A
TAB REC
L ' - ' I I ! I
1
I
2 1' 22 1 - I VTAl II 1
I
2 1
!
22 1 0 1 CN41-4 I
I
TAB REC
TAB REC
CN80 <OPT> ATT2 LEVER
TAB REC
TAB REC
CN70 DISPLAY REC

TAB REC
TAB VRAT
14131211109 8 - 7 7 6 5 4 3 2 1 51 - VRAT
30 29 28 27 26 25 24 231 22 21 20 19 18 17 16 15 CN87 TILTSW
TAB REC
TAB REC
TAB REC
TAB REC
SOL T + CN163-6
--ww
TAB REC
REC
N O P C J
---
NO P
-C J
CUDIDO
-----------
1 91 GR CN130-6
2 CUDlDl
-2 51 B J1
- 3
----
3 59 Y CN130-10
4 CANL
- 4 58 BR CN130-I?
5 CANTRD
-
5
6 147 - CANGND
-
6 90 O CN130-7
7 42 - KEYSTART
-
7
8 CUDON
8 51 W J3
9 7 5 - SSDl+
-
-
10 78 SSDI-.TD1-
TAB REC
TAB REC
u
TAB REC
90 CN90-6 90 - SWMHI
3 91 - SWMHI
TAB
m
REC
lim 1145
:
-
TAB
CUDIDO
CUDlDl
CANH
1 145
REC
J64
6 1 147 1 - I CANGND
7 1 42 1 - I KEYSTART 11 7 1 42 1 L I
CN 112 RESISTOR
Wl TAB REC
TAB
RE.
2 146
().OPT TAB REC ( ).OPT
TAB REC
39 FAN EX(-)
TAB REC
-
~p
39 FAN EX(-)
17 63(7) V CN21-l(CN75-7) 17 63(7) V CN161-7(CN163-7)

18 N2 L J8 18 N2 L J31
CN131 JOINT
TAB REC
TAB
NO P C J
- 18 17 16 15 14 13 - 12 11 10
1
2 55 W CPR
3 P2 W P2
REC
().OPT TAB REC ():OPT
8 1 (9) ( (L) I (CN164-12)

9 (10) (BR) (CN164-13)
CN 1 32 JOINT
TAB
REC
( ).OPT TAB REC ( ):OPT
NO P C J
1 101 Y J9
2 104 0 J10
3 107 B SWR
4 111 R CN5-2
5 109 G J13
6 108 SL J14
(CN74-8) 15 (4) (B) (CN163-5)

(CN74-7) 16 (8) (p) (CN164-11)
17 (11) (GR) (CN74-6) 17 (11) (GR) (CN164-14)
(36) (w) (CN74-5) 18 (36) (w) (CN164-17)
CN161 M A I N C O N T 91817161-1514131211
TAB REC TAB 2 0 ~ 1 9 ~ 1 8 ~ 1 7 ~ 1 6 ~ 1 5 ~ 1 41101
~13~12~11
I1 2 1 3 1 4 1 5 1 1 1 6 1 7 1 8 1 9
110111 ~ 1 2 ~ 1 3 ~ 1 4 ~ 1 5 ~ 1 6 ~ 1 7 ~ 1 8 ~ 1 9 ~ 2 0 ~
( ):OPT TAB REC ():OPT
+
NOI P I C I J IINOI P I C I J
1 45 1 DSF 1 45 W CN130-2
2 1 46 ( - I DSR 1121 46 1 G 1 CN130-3
3 65 LSB 3 65 Y CN1304
4 66 LSPB 4 66 R CN130-5
I LSD 5 67 L CN22-l(CN42-7)
6 1 39 1 - 1 FAN- 1 / 6 1 39 1 B 1 J23
7 63(24) 1 V CN130-17(CN41-7)
8 1 3 1 4 1 - 1 STSC 1181 314 1 L 1 CN131-17
CN162 MAIN CONT
81 71 61 5 / 0 1 41 31 21 1
1 8 ~ 1 7 ~ 1 6 ~ 1 5 ~ 1 4 ~ 11101
3 ~ 192 ~ 1 1
TAB REC
CN164 <OPT> MAIN CONT.
TAB ~ 91
2 0 81
~ 1 71
9 ~61 81~ 1
1 71~ 51
1 641
~ 131
5 ~2141~ 1 3 ~ 1 2 ~ 1 1
11101
11 21 31 41 5 1 0 1 61 71 81 9
~10111~12~13~14~15~16~17~18~19~20~
TAB REC
1 ::1 1 1
18
14
144
143
GNDD
SMTDK
SDTMK
1 17
18
144
143 SL
CN131-4
CN131-5
CN163
( ):OPT TAB REC ( ).OPT
NO P C J
1 1 43 1 - I VBKY
2 1 41 1 - I VBBT I
7 1 7 1 - I SOLT-(SOLa2)
8 55 - CPR
9 44 - VBMB
101 1 I - I MB+
111 2 1 - I MB- I
1 1 2 1 N 2 1 W l N2 TERM I
13 317 - POTH
14 316 - POTH+
JOINT ():OPT
CN132-2 CN13-3
CN45-* :
;
-I2 CNl7-2 @
CN13-6 CN45-4
CN46-1 CN13-2
CN46-2
SWR CN46-4 CN17-3
N2 TERMINAL
b
cpn;!]
LAMP LAMP
FAN EXHACiST
WORKING ROTALY
w
CONTROL UNlT
BUZZER
CNi 3 i
CNll4
FAN EXHAUST
CONTROL UNlT
0
TIRE ANGEL SENSOR
LNY
ELECTRIC WIRING DIAGRAM
CPR
FANEX
VRAD
FAN EXHAUST. CONTROL UNIT
VARI-OHM ACCEL. DRIVE

MB CONTACTOR, BATTERY
F O R STD(MIN1 L E V E R LESS)
7
1 hilSCH STT SLL GNDD I
VRAT VARI-OHM, TILT DS F DIRECTION SWITCH. FORWARD
VRAH / VARI-OHM. TIRE(HANDLE) DS R DIRECTION SWITCH. REVERSE
BATT
1
/ BATTERY
VRALl
VRALP
II
/ VARI-OHM. LIFT NO 1
VARI-OHM LIFT NO 2
/
DS FG
DS Bu
LS L
I S TF
DIRECTION SWITCH. FORWARD OPTIONAL
DIRECTION SWITCH. BACK-UP
/ LlMlT SWITCH LlFT
I LIMIT SWITCH TILT FR
I
I
1
NOTE)
THIS DRAWING SHOWS
F4 FUSE. LAMP IS TR LIMIT SWITCH. TILT RR CASE OF FULL OPTION.
F5 FUSE. CONTROL CIRCUIT LS AT1 LIMIT SWITCH ATTACHMENT NO?
F6 FUSE FANISOLENOID LS AT2 LIMIT SWITCH ATTACHMENT NO2
FD FUSE DClDC CONVERTER I S ST LIMIT SWITCH STOP LAMP
LCD DlSP LCD DISPLAY 1 IS B I LIMIT SWITCH BRAKE I 1 L A I LAMP WORKING I
I ;:;
AMDl MOTOR DRIVE I
FOR DIRECTIONAL CONTROL
AM02 MOTOR DRIVE 2 CUD? CONTROL UNIT. DRIVE 1 PEDAL
-
AMP MOTOR PUMP
DC DC
SOLST
SOLL
SOLT
SOL-a1
SoL~hi
SOLTa2
DClDC CONVERTER
SOLENOID STEERING
SOLENOID LIFT
SOLENOID TILT
SOLENOID LIFT allDOWNl
SOLENOID LIFT bllUP)
SOLENOID TILT ~ZIFRONTJ
PB CPU
:z;;;L;u;; E
pr;;
PRINT BOARD COMPUTER
2
0
1 SWAC
SWK
SWMHl
SWITCH ACCEL
I SWITCH KEY
SWITCH TlLT KNOB

SWITCH. HEIGHT NO 1
L S TL
L ST.R
L BU R
HRy
TRY
I LAMP. STOP L H
I
I
LAMP. STOP R H
LAMP. BACK-UP R H
RELAY. HEAD LAMP
RELAY. TAIL LAMP
M a
SOL SOL
1031PI 1701Y) 45iVVI 46iGI
SOLTDZ SOLENOID TILT b2'REAR) SWCMP SWITCH. COMPARTMENT LFB LAMP. FLASH BEACON
SOLATa3 SOLENOID ATTACqMENT a3 SSDl SENSOR SPEED. DRIVE 1 L H L LAMP. HEAD L H Br BUZZER (SMART ALARM)
SOLATb3 SOLENOID ATTACHMENT b3 SSDP SENSOR SPEED DRIVE 2 L H R LAMP HEAD R H L~LIO LAMP COMPARTMENT
SOLATa4 SOLENOID ATTACHMENT 34 SSP SENSOR SPEED. PUMP L CL LAMP CLEARANCE LH SA SURGE ABSOBER
SOLATb4 SOLEWID ATTACHMENT b4 STMDl SENSOR. TEMPRETURE DRlVE I L CR LAMP CLEARANCE RH H HORN
SOLP SOLENOID PRESSUR STMDP SENSOR. TEMPRETURE DRlVE 2 L TL LAMP TAlL L H FRY RELAY, FLASHER
STMP SENSOR. TEMPRETURE PUMP LT R I LAMP. TAlL R H I I
/ CHI n / CHIME REVERSE I

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FOREWORD

This Manual contains specifications, maintenance, repair, diagnostic and

TOYOTA Material Handling Company

DRIVE UNIT & FRONT AXLE

VEHICLE EXTERIOR VIEW

omitted in some illustrations.

Abbreviation Meaning Abbreviation Meaning

Wooden block or stand

WlRE ROPE SUSPENSION ANGLE LIST

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

60" ''I6 0.58time

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE

Vehicle weight (without battery)

TOWING THE VEHICLE

2) Digital circuit tester

Hexagon Bolt with two

head bolt raised lines on 7T

No mark 4T minal diameter

TIGHTENING TORQUE TABLE

Nominal Hexagon Hexagon

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

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

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

Hydraulic oil level by lifting height

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

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

1. Mast strip 8. Steering rack and pinion gear

Inspection timing Every 6 Every 3 Every 6 Every 12

Motor Looseness in the connecting parts T t t t

Charging level (Display) I t t t

Electrolyte specific gravity M t t t

Looseness in the connecting parts I c t t

Voltage measurement of each battery cell M

Operating condition, contamination and I t t t

Motor input voltage M

Drive unit Oil level I 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

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

Looseness and abnormal noise of front I t t t

Wheelsfor Turning angle to left and right I

Power steering Looseness of the installation locations I t t t

Damage of power steering hose I

Operating force and pull margin I t t t

Looseness and damage I t t t

Clearance between disc and pad M t t t

Wear of sliding portion and pad I

Fork Fork deformation and wear I t t t

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

Mast and Mast and lift bracket looseness I c t t

Deformation, damage and slackness of I t t t

Natural drop and natural forward tilt M t c t

Oil leak and damage I t t t

Oil pump Oil leak and abnormal sound I t t t

Oil level and contamination I t t t

oil Filter clogging c

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

SAFETY DEVICES, ETC.

Lighting system Function and installation condition I t t t

Direction 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