FOREWORD

This manual covers the service procedures of the TOYOTA BATTERY

FORKLIFT 5FBE10-20 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of September 1998. Please
understand that disagreement can take place between the descriptions
i n the manual and actual vehicles due t o change i n design and specifi-
cations. Any change or modifications thereafter will be informed b y
Toyota Industrial Vehicles' Parts & Service News.

TOYOTA Material Handling Company

A Division of TOYOTA INWSRIES CORPORATION
 SECTION INDEX
NAME SECTION

GENERAL
BATTERY
OTHER THAN U.S.A.] (1993.1 - 1998.8)
CONTROL ClRCU IT [FOR
IFOR u.s.A.1 (1993.1 -1999.1 )
-

CONTROL CIRCUIT [FOR OTHER THAN U.S.A.] (1998.9

[FOR UL. U.S.A.. CANADA] (1999.2
-)
-)
A

-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8)
MULTI-DISPLAY FUNCTIONS [Fouu.s.A.j (1993.1 - )

-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8)
ELECTRICAL SYSTEM TROUBLESHOOTING [FoRu.s.A.1 (1993.1 -1

ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHERTHAN U.s.Ad(199889 -I A A

MOTOR
/ FRONT AXLE & TRANSMISSION (lgg3.1 - lgg8-l)
FRONT AXLE & DRIVE UNIT (1998-2-1
REAR AXLE (1993.1- 1998.1)
1 A

STEERING
-
-

BRAKE (1998.2- I
BODY & FRAME
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL ]
APPENDIX
 GENERAL
Page
EXTERIOR VIEWS ........................... 0-2
VEHICLE MODEL ........................... 0-3
FRAME NUMBER ........................... 0-3
HOW TO USE THIS MANUAL ................ 0-4
EXPLANATION METHOD .......................... 0-4
TERMINOLOGY .................................. 0-5
ABBREVIATIONS ................................. 0-5
LIST OF ABBREVIATIONS AND SYMBOLS .......... 0-6
OPERATIONAL TIPS ......................... 0-7
JACK-UP POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
CIRCUIT TESTER ............................ 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE ................................. 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ....................................... 0-11
TIGHTENING TORQUE TABLE ..................... 0-12
PRECOAT BOLTS ........................... 0-13
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ..................... 0-13
WIRE ROPE SUSPENSION ANGLE LIST ....... 0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ..................... 0-14
COMPONENTS WEIGHT ..................... 0-15
RECOMMENDED LUBRICANTS
AND CAPACITIES ......................... 0-15
LUBRICATION CHART ....................... 0-16
PERIODIC MAINTENANCE ................... 0-17
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................ 0-22
0-2

EXTERIOR VIEWS
VEHICLE MODEL
Battery capacity Voltage
Load capacity Model Control circuit
AH/5HR V
1.0 ton 5FBE10 280 *36 or 48 MCS-IIIA

1.25 ton 5FBE13 t t t

1.5 ton 5FBE15 390 t t
1.75 ton 5FBE18 t t t
1.815 ton 5FBE20 375 t t
*: 36 V is provided for UL specification.

FRAME NUMBER

Punching
position

Upper face of side member

of frame RH

Vehicle model Punching format

5FBE13-10011
5FBE10 5FBE13E10011 (EEC spec.)
1 ton
series
-
(1993.1 1993.9)
5FBE13
(1993.10 -
5FBE130 10011 (EEC spec.)
)
5FBE18-10011
5FBE15 5FBE18E10011 (EEC spec.)
1.5 ton
series
-
(1993.1 1993.9)
5FBE18010011 (EEC spec.)
5FBE18
(1993.10 -
)
2.0 ton 5FBE20-10011
5FBE20
series
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustra-
tion, followed by explanation of cautions and notes summarized as point operations.

Example of description in pattern B

DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T=N.m (kgf-cm)[ft-lbfl

--
T = 46.09 48.05
(470 490)
134.00- 35.451

Disassembly Procedure
1 Remove the cover. [Point 11

2 Remove the bush [Point 21 Operation explained later

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

[Point 11
Disassembly:
J
Put a match mark when removing the pump cover.

[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
2. How to read components figures (Example)
(1) The components figure use the illustra-

fl
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of FIG number in parts catalog
each components figure indicates the
Fig. number in the parts catalog.

3. Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removed parts as required
@ visual inspection (Partially described)

TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to observe them.

Note:
lmportant items of which negligence may cause accidents or matters in operation procedure
requiring special attention.

Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly RR Rear
Electrical hydraulic power Society of Automotive
EHPS SAE
steering Engineers (USA)
FR Front SST Special service Tool
I-/ Less STD Standard
LH Left hand T= Tightening torque
0PT Option OOT Number of teeth (00)
01s Oversize U/S Undersize
PS Power steering w/ With
RH Right hand
LIST OF ABBREVIATIONS AND SYMBOLS
Symbol Name Symbol Name Symbol Name
BATT Battery FRY Flasher Relay PBsN Snubber Print Board
BZ Buzzer H Horn PLw Working Pilot Lamp
CA Absorber Capacitor IWP Wheel Position Indicator RA Absorber Resistor
CADIP Drivelpump Absorber LBU-~ Back-up Lamp, LH RADIP Drivelpump Absorber
Capacitor LBU-~ Back-up Lamp, RH Resistor
CH Charger LC-L Clearance Lamp, LH PCKI I 2 Check Resistor No.112
CHIF Forward Chime LC-R Clearance Lamp, RH SA Surge Absorber
CHIR Reverse Chime LF-L Flasher Lamp, LH SLL Lequid Level Sensor
CSDIP DriveIPump Current L F - ~ ~Flasher Lamp, LH (Rear) SN1 Sunbber No.1
Sensor LF-R Flasher Lamp, RH SNCI 12 Snubber Capacitor 112
CSps Power Steering Current LF-RR Flasher Lamp, RH (Rear) SNR112 Snubber Resistor 112
Sensor LH-L Head Lamp, LH SSP Steering Pressure Sensor
DADIP Drivelpump Absorber LH-~ Head Lamp, RH SSL Speed Sensor, LH
Diode LR-F Rotaly Forward Lamp SSR Speed Sensor, RH
DCH Charger Diode LR-~ Rotaly Reverse Lamp STH Thermo Sensor
DC-SDD DC-DC Converter & LSAnI2
l Attachment Limit Switch SWAC Accel Switch
Source Drive (Drive) No.112 SWF Flasher Switch
DC-SDP DC-DC Converter & LSB Brake Limit Switch SWH Horn Switch
Source Drive (Pump) LSD Dead Man Limit Switch SWKy Key Switch
DF112 FLY-WHEEL Diode, LSL1/2 Lift Limit Switch No.112 SWL Light Switch
No.112 LSsT Stop lamp limit Switch SWPB Parking Brake Limit
DF314 FLY-WHEEL Diode No.314 L S T - ~ Stop Lamp, LH Switch
DlSP Display L s T - ~ Stop Lamp, RH SWsc Speed Control Switch
DMDlP DriveIPump Motor LST Tilt Limit Switch TF Transformer
DMps Power Steering Motor LT-~ Tail Lamp, LH THR Thermal Relay
DSBu Back-up Direction Switch LT-~ Tail Lamp, RH TM Main Transistor
DSF Forward Direction Switch Lw Working Lamp TMD Main Drive Transistor
DSFo Forward Optional MFL Forward Contactor, LH TMP Main Pump Transistor
Direction Switch MFR Forward Contactor, RH TMps Main Power Steering
DSR Reverse Direction Switch MP Pump Contactor Transistor
F1 Drive Fuse MPS Power Steering Contactor TU Timer Unit
F2 Pump Fuse MRL Reverse Contactor, LH VRAD Accel Drive Variable
F3 Power Steering Fuse MRR Reverse Contactor, RH resistor
F4 Lamp Fuse MScH Charger Magnet Switch VRSP Steering Position Variable
F5 Control Circuit Fuse PBcpu Computer Print Board resistor (Steering
FCH Charger Fuse PBEHPs EHPS Print Board potentiometer)
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks on rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve
in load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.

2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil
pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange
the parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean
tools and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassem-
bly. If no tightening torque is specified, tighten the bolt or nut according to the standard
tightening torque table.

3. Grasping the troule state

When a trouble occurs, du not attempt immediate disassembly or replacement but first check
if the trouble requires disassembly or replacement for remedying.

4. How to treat liquid waste

When draining liquid waste from a vehicle, use a pan or other suitable container to collect the
liquid.
Do not throw away oil, fuel, cooling water, oil filters, batteries, or other injurious materials since
these materials may adversely affect human health and the environment. Sort liquid waste into
different types and seek the service of experts for proper disposal.

Hoisting the vehicle

Loop wire ropes on the mast hook hole and the rear of the
head guard to hoist the vehicle.
JACK-UP POINTS
The vehicle often needs to be jacked up during assembly and reassembly.
Be sure to jack up the vehicle at the right positions. Placing a jack in the wrong position or jacking up
the vehicle in the wrong manner may cause an unexpected accident.

Front jack-up Rear jack-up

Front jack-up
If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with
a bearing plate at least 80 m m long.

Rear jack-up
When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the
weight on the opposite side.
The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle
maintains its balance during jack-up.
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively
according to the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the mea-
sured value should only be used for reference or rough judgement.

Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or
movement.

1. Difference in measurement results with the digital type and analog type
*The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual. Cautions when the polarities are
different between the analog type and digital type are described below.

(1) Analog circuit tester

I Measurement result example
Tester range:KR range
Forward direction Reverse direction
Analog type
Continuity
I Forward I shall exist I

No continuity
Reverse

(2) Digital circuit tester

Measurement result example
Tester range: 2 M Q range
Forward direction Reverse direction
Digital type

I Forward
I
I
NO continuity I
1
Continuity
Reverse shall exist
2 MR
2. Difference i n result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is
used. The resistance of a semiconductor such as a diode varies with the circuit tester power
supply voltage.
The diode characteristics are shown in the figure below.
(m~) The resistance values of the same semiconductor
5 measured with t w o types of circuit testers having
different power supply voltages are different.
Current 4
in This manual describes the results of measurement
forward
direction
with a circuit tester whose power supply voltage is
3.0 V.
2

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Voltage in forward direction lV)

3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement range switches over the internal
circuit to vary the circuit resistance. Even when the same diode is measured, the measure-
ment result varies with the measurement range.

Always use the range described in the repair manual

for measurement.

Variable resistor

Current
flow
I ,-
Resistor

Range: x 10
, (SW 1)
,,

Resistor
41 ,

TEwer
4
(SW2)
Range: x 1

source: 1.5 V

"0 Red 6@
Black
STANDARD BOLT AND NUT TIGHTENING TORQUE
How to judge tightening torque of a standard bolt or nut.

1. How to judge tightening torque of a standard bolt.

Find out the type of the bolt from the list below.
Then, find the bolt tightening torque from the table.

2. How to judge tightening torque of a standard nut.

The nut tightening torque can be judged from the bolt type. (See the item above.)

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.

Shape and class Class Hexagon head bolt I

4=4T

Hexagon
@- Bolt head No.
5 = 5T
6 = 6T
7 = 7T
8 = 8T
Part No.
91611-40625
T L e n g t h (mml
head bolt
Diameter (mm)

0 No mark 4T

Hexagon 4T iameter
No mark
flange bolt

Hexagon Two protruding 5T

head bolt lines

Stud bolt
Two protruding

Part No.
921 32-40614
Length (mm)
Four protruding Diameter (mm)
0-12

TIGHTENING TORQUE TABLE

I I I I

14 1.5 75 1 760 j 55 83 1850 161

16 1.5 113 j 1150 i 83 -
I
I _ I
I _

6 1 .O 6.4 1 65 i 56 in-lbf 7.5 1 75 j 65 in-lbf

8 1.25 16 j
I
160
I
12 18 j
I
175 j
I
13
10 1.25 32 j 330 j 24 36 j 360 j 26
5T
12 1.25 59 j
I
600 j
I
43 65 j
I
670 j
I
48
14 1.5 91 i
I
930 i
I
67 100 1 1050
I
1 76
16 1.5 137 1 1400 1 101 157 11600 ill6
6 1 .O 7.8 j
I
80 1
I
69 in-lbf 8.8 j
I
90 j
I
78 in-lbf
8 1.25 19 1 195 1 14 21 1 215 1 16
I I I I

10 1.25 38 j 400 29 43 1
1
440 j 32
6T I I I
12 1.25 72 1
I
730 1 53
I
79 1810 159
I I

14 1.5 110 j1100 i 8 0 123 1 1250 j 90

I I I I

16 1.5 170 11750 1127 191 11950 1141

6 1.O l1 I1 1 1 0 1
I
8 12 j
I
120 j
I
9
8 1.25 25 1260 119 28 1290 121
I I I I

7T
10 1.25 52 i
I
530 j
I
38 58 j
I
590 j
I
43
12 1.25 95 1
I
970 1 70
I
103 1 1050
I
:
I
76
14 1.5 147 j
I
1500 i 108
I
167 ,
11700 j123
16 1.5 226 1 2300
L
1 166 -
I
I
I
- I
I
I -
I

6 1.O 12 i
I
125 j
I
9 l4 1I 145
I
9
8 1.25 29 1
I
300 1 22
I
32 1 330 1I 24
10 1.25 61 j 620 j 45 68 1
I
690 j 50
8T I I I

12 1.25 108 11100 180 123 1 1250 1 90

14 1.5 172
I
1750 i 127
I
196 ,1 2000
I
j
I
145
16 1.5 265 1 2700 1 195 299 1 3050 1 221
 PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)

1. Do not use the precoat bolt as it is in either of the fol-

lowing cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or
tightened) by tightness check, etc.

I I Note:
For toraue check. use the lower limit of the allowable
tighteni;lg torque range. If the bolt moves, retighten it
according to the steps below.

2. Method for reuse of precoat bolts

(1) Wash the bolt and threaded hole. (The threaded
hole must be washed even for replacement of the
bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the 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 mating nipple contact sur-
faces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage
on the contact surfaces before installation.

2. When connecting a 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 Standard tightening torque N-m (kgf-cm) [ft-lbf] Hose inside
of screw diameter
Standard Tightening range m m (in)
7/16 - 20UNF 25 (250) [18.1 1 24-26 (240-270) [17.4-19.51 6 (0.24)
9/16 - 18UNF 49 (500) [36.2] 47-52(480-530) 134.7-38.31 9 (0.35)
314 - 16UNF 59 (600) [43.4] 56-62 (570-630) [41.2-45.61 12 (0.47)
718 - 14UNF 59 (600) [43.4] 56-62 (570-630) [41.2-45.61 12 (0.47)
718 - 14UNF 78 (800) [57.9] 74-82 (760-840) [55.0-60.81 15 (0.59)
1.1116 - 12UNF 118 (1200) [86.8] 112-123 (1140-1250) [82.5-90.41 19 (0.75)
1.5116 - 12UNF 137 (1400) [101.3] 130-144 (1330-1470) [96.2-106.41 25 (0.98)
PF1/4 25 (250) [18.1] 24-26 (240-270) [17.4-19.51 6 (0.24)
PF3/8 49 (500) [36.2] 47-52 (480-530) [34.7-38.31 9 (0.35)
PF1/2 59 (600) [43.4] 56-62 (570-630) 141.2-45.61 12 (0.47)
PF314 118 (1200) [86.8] 112-123 (1140-1250) [82.5-90.41 19 (0.75)
PF1 137 (1400) [101.3] 130-144 (1330-1470) [96.2-106.41 25 (0.98)
WlRE ROPE SUSPENSION ANGLE LIST
Lifting Compres- Suspension Lifting Compres- Suspension
~~~~i~~ Tension
angle sion method angle sion method

o0 1.00 time 0 time

-Ll
7
90" 1.41 time 1.00 time
by5
2' A
30' 1.04 time 0.27 time

h0
- 120' 2.00 time 1.73 time

60' 1.16 time 0.58 time

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [lbf]

Rope Cutting Single-rope Two-rope suspension Four-rope suspension

diameter load suspension
0" 0" 30' 60" 90° o0 30° 60' 90"
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[48071 [683.6] [I3671 [I3231 [ I 1691 [9701 [27341 [26461 [2337] [I9401
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [I9851 [I9181 [I7201 [I4111 [39691 [39371 [34401 [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 m m
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(Om4 in)
[ I1.691 L1565.61 [31531 [30211 [26461 [22051 L61741 [59541 152921 [44101
21280 18630 14710 43150 41190 37270 29420
12.5 m m 76880 10980 21570
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[173871 [2469.5] [4851] [4631] [4190] [33081 [97021 [9261I [83791 [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 m m
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[216751 [3087] [61741 [59541 [5292] [41901 [I23481 [ I19071 [I05841 [83791
COMPONENTS WEIGHT
Item Weight kg [Ibl
Drive motor
Approx. 41 1901
(One unit)
Pump motor Approx. 35 [771
5FBE10: Approx. 393 I8671
5FBE13: Approx. 556 112261
Counter weight 5FBE15: Approx. 620 [I3671
5FBE18: Approx. 785 11731I
5FBE20: Approx. 1070 I23601
Mast Wllift bracket
*Approx. 400 [8821
(with lift cylinder, less fork)
**Approx. 410 19041
[max. fork height = 3000 m m (118 in)]

RECOMMENDED LUBRICANTS AND CAPACITIES

Application Type Capacity
Transmission STD: Hypoid gear oil SAE85W-90 Right side: 1.7 t? (0.45 USgal)
(API GL-4) Left side: 1.8 (0.47 USgal)
(1993.1 - 1998.1)
45s: Hypoid gear oil SAE75W-80W 1.5 e (0.40 Usgal)
(API GL-4) (1.998.2 - )
Hydraulic (total) STD: Hydraulic oil IS0 VG32 *I6 e (4.2 USgal)
45s: MIL-H-5606-D **21 e (5.5 USgal)
Brake line STD: SAE J-1703 DOT-3
45s: SAE J-1703 DOT-3
Proper quantity
(1993.1 - 1998.1)
Brake fluid arctic S (1998.2 -
Chassis part STD: MP grease No.2
Proper quantity
45s: MIL-G-3278-A

45s: Refrigerator specification vehicle

*: For 3000 mm (118 in) maximum fork height
**: For 6000 mm (236 in) maximum fork height
LUBRICATION CHART

1. Chain I lnspect every 8 hours (daily)

2. Mast strip I1 lnspect every 40 hours (weekly)

3. Tilt cylinder front pin 111 lnspect every 170 hours (monthly)

4. Mast support bushing IV lnspect every 1000 hours (6 monthly)

5. Front axle hub V lnspect every 2000 hours (annually)

Transmission housing 0 lnspect and service

Reservoir tank Replace

Oil control valve link pin

Accelertor pedal link @ MP grease (STD)
Tilt steering locking mechanism MIL-G-3278-A (45s)

Brake pedal link @ Engine oil

Oil tank @ Hypoid gear oil

Rear wheel bearing @ Brake fluid

Rear axle bearing @ Hydraulic oil

Steering rack & pinion

Limit switch controller
(cold storage models only)
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment i f required.
T : Retightening C: Cleaning L: Lubrication
* : For n e w vehicle * 1: Flaw detector
Every Every Every Every
Inspection Period 1 month 3 months 6 months 12 months
Item Every Every Every Every
170 hours 500 hours 1000 hours 2000 hours

ELECTRICAL SYSTEM
Abnormal sound during revolution I t c t

Loose terminal T c +- t

Insulation resistance M t c
Motor
Brush wear and sliding contact status I c

Commutator fouling and damage I c

Brush spring fatigue M

Charge I +- c t

Battery fluid level I t c t

Battery fluid specific gravity M c +- c

Loose terminal I C +- C

Battery Abnormality at top of battery and

I C C t
battery case
Insulation resistance M c t

Cell voltage measurement after

M
charging
Timer operation I t c t

Terminal loosening I c c t

Charger Operating voltage measurement M t +-

Magnet switch function, contact

I
fouling and roughening
Loose contact, damage and wear I t t c

Auxiliary contact function, fouling and

I C t C
wear
Magnet I
Arc chute installation status
contactor
Timing and functioning I
Loose coil installation I
Loose main circuit lead installation I
Timing and operating function I t c c
Microswitch
Damage and loose installation I t t c
 Every Every Every Every
Inspection Period 1 month 3 months 6 months 12 months
Item Every Every Every Every
170 hours 500 hours 1000 hours 2000 hours
Direction lever Operating conditions and damage I c c c

Operation I c C +-

Controller Inside fouling and damage C c c t

Overcurrent limit valve M

Fuse Loosening I c C c

Damage of wiring harness and loose

I t C C

Wiring clamp
(including Loose connection and taping status I c c c

charging cord) Battery connector damage and

I C C C
connection status
Accelerator Operating and damage I c c t

POWER TRAIN
Oil leak I c c c

Transmission Oil level I c c c

Gear function and sound I c c c

TRAVELING EQUIPMENT
Tire air pressure M t c c

Tire cuts, damage and uneven wearing I t c c

Loose rim and hub nuts T t t t

Tire groove depth M t t c

Metal chips, pebbles and other foreign

I t C C
Wheels matter trapped in tire grooves
Rim and disc wheel damage I t @ C

Abnormal sound and looseness of

I C C C
front wheel bearing
Abnormal sound and looseness of rear
I C C C
wheel bearing
Cracks, damage and deformation of
Front axle I
case
Cracks, damage and deformation of
Rear axle I
rear axle
 Every Every Every Every
Inspection Period 1 month 3 months 6 months 12 months

Item Every Every Every Every

170 hours 500 hours 1000 hours 2000 hours

STEERING SYSTEM
Play and looseness I t t t
Steering wheel
Function I t t t

Hydraulic Oil leak I t t t

control valve Looseness of mounting T t t t

Oil leak I t t t

Power steering Mounting and linkage Looseness I t t t

Damage of power steering hose I

BRAKING SYSTEM
Play and reserve M t t t
Brake pedal
Braking effect I t t t

Pull margin I t t t

Braking effect I t t t
Parking brake
Rod and cable looseness and damage I t t t

Ratchet wear and damage I

Brake pipe and

Leakage, damage and mounting status I t t t
hose
Brake fluid Fluid level I t t t

Clearance between diskwheel and M t t t

lining
Pad wear and damage M
Disk brake wheel wear and damage M
Disk brake lever operating status I t t

Disk brake wheel set bolt loose T

Disk brake
Return spring fatigue M
Caliper body leak brake fluid I t t t

Master cylinder and wheel cylinder I

operation
Cylinder and piston cup wear and I
damage
 Every Every Every Every
Inspection Period 1 month 3 months 6 months 12 months
Item Every Every Every Every
1 70 hours 500 hours 1000 hours 2000 hours
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I c c c

Misalignment between left and right

Forks I c c 4-
fork fingers
Cracks at fork root and welded part I *'
Deformation and damage of each part
I 4- C t
and crack at welded part
Mast and lift bracket looseness I +- t +

Wear and damage of mast support

Mast and lift I
bush
bracket
Wear, damage and rotating condition
I C t t
of rollers
Wear and damage of roller pins I
Wear and damage of mast strip I c c c

Tension, deformation and damage of

I C t t
chain
Chain and Chain lubrication I t 4- C

chain wheel Abnormality of chain anchor bolt I t c c

Wear, damage and rotating condition

I t t C
of chain wheel
Various Abnormality and mounting condition
I 4- 4- 4-
attachments of each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
I C C C
mounting
Deformation and damage of rod, rod
I t C C
screw and rod end
Cylinder operation I c c c

Natural drop and natural forward tilt

Cylinder M c c C
(hydraulic drift)
Oil leak and damage I +- @ t

Wear and damage of pin and cylinder

I C 4- t
bearing
Lifting speed M +- t c

Uneven movement I t t t

Oil pump Oil leak and abnormal sound I t t c

Oil level and contamination I t 4- c

Hydraulic oil
Tank and oil strainer C t
tank
Oil leak I +- t 4-
 Every Every Every Every
Inspection Period 1 month 3 months 6 months 12 months
Item Every Every Every Every
170 hours 500 hours 1000 hours 2000 hours
Loose linkage I t c t
Control lever
Operation I c C +

Oil leak I t c t

Oil control Relief pressure measurement M

valve Relief valve and tilt lock valve
I C t t
functions
Oil leak I t c c

Hydraulic Deformation and damage I t c c

piping Loose joint T c t t

Hose tension and twisting I c c c

SAFETY DEVICES, ETC.

Cracks at welded portion I +- c c
Head guard
Deformation and damage I + t c

Loosening of mounting I +- c C
Back-rest
Deformation, crack and damage I t c t

Lighting
Function and mounting condition I t c c
system
Horn Function and mounting condition I t t c

Direction
Function and mounting condition I t t c
indicator
Instruments Functions I c c c

Back up buzzer Function and mounting condition I t c c

Rear-view Dirt, damage I c t c

mirror Rear reflection status I t c t

Seat Loosening and damage of mounting I t c t

Damage and cracks of frame, cross

I
Body members, etc.
Bolt looseness T
Other Grease up L c t t
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
Every Every Every Every
Inspection (operating hours or 1 month 3 months 6 months 12 months
months, whichever is earlier) Every Every Every Every
1 70 hours 500 hours 1000 hours 2000 hours
Brake fluid C

Hydraulic oil c

Hydraulic oil filter C

(New vehicle)

Transmission oil
Wheel bearing grease
Master cylinder rubber parts
Wheel cylinder rubber parts

Reserve tank tube

(Every 2 years)

Power steering hose

(Every 2 years)

Internal rubber parts of power steering system

(Every 2 years)

Material handling house

(Every 2 years)

Chain
(Every 3 years)
 BATTERY
Page
SERVICE STANDARDS ........................................ 1-2
DISPLAY INDICATION ........................................... 1-2
OVERDISCHARGE ALARM FUNCTION ..................... 1-2
BATTERY COMPARTMENT & MINIMUM
WEIGHT REQUIRED .......................................... 1-3
TROUBLESHOOTING ........................................... 1-4
BATTERY ASSY ................................................... 1-5

INSPECTION ..................................................... 1-6

SERVICE STANDARDS
Specific gravity in fully charged state (OC) [OF1 1.280 (20) [681
Specific gravity in fully discharged state (OC) [OF] 1.150 (20) I681
Discharge end voltage 3 6 V specification 32.0
V 4 8 V specification 42.5
Electrolyte Sulfuric acid diluted with distilled water
Fluid t o be spplied Distilled (deionized) Water
Insulation resistance Mfl I or more

DISPLAY INDICATION
1. The display indicates the remaining battery charge
level in 1 0 stages. When the remaining charge drops
to the set level or below, the indication flashes the
warn the timing for charging.

2. When the battery is discharged fully (100 %), the

overdischarge alarm function operates as follows:

OVERDISCHARGE ALARM FUNCTION

1. Material handling with traveling becomes impossible.
If simultaneous operation is attempted, priority is
given to traveling and material handling is not ef-
fected. (For prevention of battery from damage by
large current flow)

2. When material handling is attempted, all indicators on

the display flash and the buzzer sounds to alarm over-
discharge.

Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on, how-
ever, material handling operation can be performed.
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by re-
ferring to the table below. Always use a case allowing fixation of the battery stopper.

Compartment dimensions m m (in) Minimum required

Maximum battery
Vehicle battery weight
Front t o rear weight (with case)
model Width Y Height Z (with case)
length X N (kg) [Ibl
N (kg) [Ibl
451
5FBE 10 928 (36.54) 641 (25.24) 5099 (520) I 11471 6796 (693) 115301
(17.76)
5FBE13 t t t t t
5FBE15 551 (21.69) 997 (39.25) t 6865 (700) 115451 9591 (978) [21591
5FBE18 t t f t t
5FBE20 t t f t t

f
38 mm
(1.5 in)

4
Y
-
i
TROUBLESHOOTING

Pole plate corrosion Pole plate warping and

fallen acting substance

Insufficient charge

Shorting between

service

Deposition of fallen
- acting substance in Dirty terminal or plug-

Electrolyte leakage Loosened or corroded

and decrease connections
 1-5

BATTERY ASSY
REMOVAL-INSTALLATION

Removal Procedure
1 Disconnect the battery plug.

2 Remove the battery hood catch.

3 Open the battery hood.

4 Remove the battery stopper.

5 Remove the battery ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 INSPECTION
1. Electrolyte level inspection
GS battery:
Open the cap and add distilled water if the white line
on the red float is invisible. Add water until the white
line on the float appears and stop addition there be-
cause further addition until the contact between the
float and stopper results in overfilling.
YUASA battery:
Open the cap and add distilled water if the ring of the
red float is dropped. Add water until the float ring
comes into contact with the top portion.

As the level gauge is provided on the side surface of

the battery case, the electrolyte level can generally be
checked at a glance. However, periodically inspect the
level by opening the cap.
The green indicator of the level gauge is lit to indicate
activation of the level gauge sensor, and the red indi-
cator flashes to indicate the necessity of water addi-
tion.

Insufficient electrolyte
Flashing
level

Caution:
Never change the mounting position of the plug with
sensor.

Note:
The electrolyte consumption can be calculated by the following equation:
Consumption (CC) = 5 hour rating capacity x 0.0336 x number of cells x charging frequency

2. Electrolyte inspection
(1) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.
 3. Inspection of electrolyte specific gravity
(1) Use a hydrometer and measure the specific gravity
of the electrolyte

Specific gravity in fully charged state:

1.280 (at 20 O C )
Specific gravity in fully discharged state:
1.150 (at 20 OC)
The specific gravity of the electrolyte is expressed
by the value at 20 O C as the standard.
Specific gravity conversion equation
,S
, = St+ 0.0007 (t-20)
:S
,, Specific gravity at 2 0 OC
St : Specific gravity at t O C
t : Temperature at the time of measurement

"How to use the hydrometer

aInsert the nozzle of the hydrometer into the wa-
ter supply port and suck the electrolyte into the
outer cylinder.
@ Let the hydrometer in the outer cylinder float
correctly without contact with the top, bottom
and side wall of the outer cylinder, and read the
graduation at the electrolyte surface as shown
at left after disappearance of bubbles in the
sucked electrolyte.
@ After the measurement wash outside and in-
side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.

Nozzle

4. Insulation resistance inspection

Use an insulation resistance meter (megger) and mea-
sure the resistance between the battery and battery
case.

Insulation resistance: 1 MQor more

Note:
If the insulation resistance is less than 1 MQ, remove
the battery from the vehicle and wash it with water.
Dry the battery case roughly, and measure the insu-
lation resistance again. Install the battery on the ve-
hicle after checking that the insulation resistance is
1 MQor more.
* Battery control table
Prepare the control table for each battery to record and retain the inspection result.

Inspection Electrolyte
Specific Added wa-
date and Inspected cell No. tempera- Remarks Inspector
gravity ter volume
time ture
 CONTROL CIRCUIT
(1993.1 - 1998.8)
[FOR OTHER THAN U.S.A.]
[FOR U.S.A.] (1993.1 - 1999.1)

Page
MCS-IIIA CONTROLLER .....................
2-2
GENERAL ........................................ 2-2
SPECIFICATIONS ................................. 2-3
COMPONENTS ................................... 2-4
CONTROL PANEL REMOVAL. INSTALLATION ....... 2-9
CONTACTOR PANEL REMOVAL . INSTALLATION .... 2-10
INSPECTION .....................................2-11
DISASSEMBLY ................................... 2-29
REASSEMBLY .................................... 2-30
PANEL PARTS TIGHTENING TORQUE .............. 2-33
CONTINUITY CHECK WITH CIRCUIT TESTER ....... 2-34
OCL (OVERCURRENT LIMIT) VALUES .............. 2-35
ACCELERATION POTENTIOMETER
ADJUSTMENT ............................ 2-37
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT ............................ 2-38
PARKING BRAKE SWITCH ADJUSTMENT ..... 2-39
MATERIAL HANDLING SWITCH
ADJUSTMENT ............................ 2-40
DIRECTION SWITCH ........................ 2-41

DISASSEMBLY-INSPECTION-REASSEMBLY ........ 2-42

PS CONTROLLER ........................... 2-44
COMPONENTS ................................... 2-44
INSPECTION (STD) ............................... 2-45
REMOVAL.INSTALLATION(EHPS) ................. 2-46
EHPS CONTROLLER VOLTAGE MEASUREMENT .... 2-47
INSPECTION (EHPS) .............................. 2-48
REASSEMBLY (EHPS) ............................. 2-49
STEERING POTENT10 INSTALLATION
ADJUSTMENT ............................ 2-50
MCS-IIIA CONTROLLER
GENERAL
The 5FBE series is provided with the diagnostic (self-diagnosis) function for automatically detecting
any abnormality in the main traveling/material handling circuit, operating system such as the acceler-
ator and sensors t o sound the buzzer (bleep, bleep) and t o display the abnormal portion by the corre-
sponding error code on the multi-display.

A t the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken t o ensure safety.

When the display is set t o the analyzer (fault analysis) mode, defect detection and functional check of
the main drivelmaterial handling circuit, operating systems, and sensors are performed.

See the Multi-display section (page 3-21 for the diagnosis. See the Multi-display section (page 3-7) for
the analyzer.

Control Panel ASSY Contactor Panel ASSY

SPECIFICATIONS
Portion 5FBE10.13.15.18~20
F1 (Drive circuit) 225 A "'275 A
F2 (Pump circuit) 225 A "'275 A
Fuses F3 (PS circuit) 50 A
F4 (For lamps) 10 A
F5 (Control circuit) 10 A
T M (For drive motor) TSM003 (3 pcs.)
Transistors TMP (For material handling pump: OPT) TSM003 (2 pcs.)
TMps (For PS: OPT) ~~1MI1 0 0 ~ - 0 2 5
DAD (For drive motor) 30M F40
DAP (For material handling pump: OPT) 30M F40
DFI (DM flywheel) SR250L-6s
Diodes D F ~ (DM
R flywheel) 70M30
DF2L (PM flywheel) 70M30
DF3 (PM flywheel: OPT) 45M30
DF4 (PS flywheel) *21M1100H-025
CSD (For drive motor) HS800RT
Current
CSP (For material handling pump: OPT) HS800RT
sensor
CSps (For PS: OPT) MBP20A-10MJN
CAD (Absorber for drive motor) 60pF (2 pcs.)
Capacitors
CAP (Absorber for pump motor: OPT) 60pF (1 pcs.)
RAD (Absorber for drive motor) 1.5 R 120 W
Resistors
RAP (Absorber for pump motor) 1.5R 1 2 0 W
MFR.MFL(For forward drive) ME250
MRR.MRL(For reverse drive) ME250
Contactors
MP (For material handling) ME251
MPS(For PS) C48-A11 * 3 ~ 3 6 / 4 8 ~ 1

*' : 36V specification

**: The PS transistor and diode are integrated.
*3: UL specification (36VI48V)
COMPONENTS
Control panel
Resistor panel
Control panel Wlmaterial handling chopper (OPT)
 2-7

Contactor panel
2-8

MF-MR contactor

MP contactor
CONTROL PANEL REMOVAL-INSTALLATION

1 Battery plug 4
5 Connector
6 Wiring

Removal Procedure
1 Disconnect the battery plug.

2 Remove the side panel LH.

3 Remove the side panel under cover.

4 Remove the control panel cover.

5 Disconnect the connector.

6 Disconnect the wiring.

7 Remove the control panel.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose,
the control panel elements may be damaged.
CONTACTOR PANEL REMOVAL.lNSTALLATlON

1 Banery plug
2 Toe board
5 Wiring
-

Removal Procedure
1 Disconnect the battery plug.

2 Remove the toe board.

3 Remove the side panel LH.

4 Remove the side panel under cover.

5 Disconnect the wiring.

6 Remove the contactor panel.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug.
INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.

As the CPU board and DC-SD boards require battery voltage application, they must be inspected while
being mounted on the vehicle. (Use SST 09240-1 2240-71 .)

Inspection after control panel removal from the vehicle is mainly explained here.

1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1 Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.

Measurement terminals Controller side of battery plug - Body

The resistance should be as high as possible, but it varies greatly, depending on
Standard
the vehicle use status, place and weather. (Approx. 1 MQ)
2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor)
(OPT)
(1) lnspection method
Disconnect the wiring of CAD and CAP after discharging the CAD and CAP with a resistor of
about 1 0 0 Q.

Inspection point Measurement terminals Circuit tester range

CAD (Control panel) Both terminals of CAD (DAD side - TM side)
Q X ~ K
CAP (Control panel) Both terminals of CAP (DAP side - TMP side)

Standard

When circuit tester probes are brought into contact with both terminals of CAD or CAP, the pointer deflects
once to the 0 Q side and gradually deflects toward the oo Q side.

3. T M (drive circuit main transistor).TMP (pump circuit main transistor)

(1) lnspection method
Disconnect wiring from each of TM-TMP

Inspection point Measurement terminals Standard Clrcuit tester range

D: (-1 probe - S: ( + ) probe w Q
D-S
D: ( + ) probe - S: (-1 probe con

TM (control panel) D: (-1 probe - G: ( + ) probe 00 Q

D -G QXIK
TMP (control panel) D: ( + ) probe - G: (-1 probe (conduction)
G: (-) probe - S: ( + probe (conduction)
G-S
G: ( + ) probe - S: (-1 probe cx, Q

If any T M or TMP is found abnormal in inspection replace them (all TMs or all TMPs) as a set.
3- 1. DRD (Direction of Reverse Conductive Diode)
(1 lnspection method
Remove the DRD.

Inspection point Measurement terminals Standard Circuit tester range

Forward Anode: - probe - Cathode: + probe Approx. 1.6 k 0
DRD n x IK
Reverse Anode: + probe - Cathode: - probe 0352

u u
Conduction N o Conduction

4. DF1 (flywheel diode No.1)

(1) lnspection method
Disconnect the wiring from DF1

Inspection point Measurement terminals Standard Circuit tester range

(Forward)
DF1 Anode: (-) probe - Cathode: ( + probe Approx. 3 KQ
n x i ~
(control panel) (Reverse)
Anode: ( + ) probe - Cathode: (-1 probe co Q
5. DF2,-DF2, (flywheel diode No.2)
(1 ) lnspection method
Disconnect the wiring from DF2,-DF2,

Inspection point Measurement terminals Standard Circuit tester range

(Forward)
DF2,.DF2, Anode: (-) probe - Cathode: ( + ) probe Approx. 3 KQ
0 x 1 ~
(contactor panel) (Reverse)
+
Anode: ( ) probe - Cathode: (-1 probe co fl

6. DF3 (flywheel diode No.3 in panel with pump chopper)

( 1 ) lnspection method

Inspection point Measurement terminals Standard Circuit tester range

(Forward)
DF3 Anode: (-1 probe - Cathode: ( + 1 probe Approx. 3 Kn
n x l K
(control panel) (Reverse)
+
Anode: ( ) probe - Cathode: (-1 probe con
7. DAD (drive circuit absorber diode).DAP (pump circuit absorber diode)
(1) lnspection method
Disconnect the wiring from DAD-DAP.

Inspection point Measurement terminals Standard Circuit tester range

(Forward)
DAD
Anode: (-) probe - Cathode: ( + ) probe Approx. 6 KQ
DAP 62xIK
(Reverse)
(control panel)
Anode: ( + ) probe - Cathode: (-1 probe 00 Q

8. MFR.MFL (forward contactors).MR,.MR, (reverse contactors)-MP (material handling pump con-

tactor)
(1 Measure the coil resistance of each of MFR.MFL.MRR.MRL.MP.

Inspection point Measurement terminals Standard Circuit tester range

(In control panel)
MFRcoil , MFRcoil connector
MFL coil MFL coil connector Approx. 20 Q
Q x l
MRRcoil MRRcoil connector (at 20°C)
MRL coil MRL coil connector
MP coil MP coil connector
9. RAD (drive circuit absorber resistor)-RAP (pump circuit absorber resistor)
(1 ) lnsepction method
Battery removal
Disconnect the wiring from RAD-RAP (RAD: CN 1 18-RAP: CN 1 1 9).

Inspection point Measurement terminals Standard Circuit tester range

RAD
Both terminals of RAD-RAP Approx. 1.5 62 62x1
RAP

When inspecting with the battery installed, disconnect the CN1 17 connector.

Inspection point Measurement terminals Standard Circuit tester range

RAD: CN117-2- CN117-3
RAD
RAP: Approx. 1.5 62 62x1
RAP
CN 1 1 7-1 - Controller P I I terminal

CN 1 17 (Main harness side)

10. CPU board-DC-SD board
If the trouble cause is judged to be in the CPU board or DC-SD board, apply the battery voltage,
install SST09240-12240-71, and measure the applied voltage and resistance at each connector.

Caution:
Always disconnect the battery plug before removing or installing the CPU board or DC-SD board.

Note:
When replacing the CPU board or DC-SD board judged to be causing the trouble as a result of trou-
bleshooting, always measure the applied voltage and resistance at related portions before replace-
ment.
Use SST 09240-12240-71 for the measurement.

(1) SST connection method

@ Turn the key switch to OFF.
@ Disconnect the battery plug.
@ Disconnect the CPU board-DC-SD board connectors (CN101 to CN 107.CN11 1 .CN1 12).
@) Connect the SST.

Inspection side connector

CN107
 (2) Lists of measurement methods and standards
@ Explanation on list format

+
r Circuit tester ( probe

Circuit tester (-1 probe

Connector pin No.

1
Connector No.
CN102-1
- Connector No.
CN102-9
1
SWKy: ON
Conditions Standard Remarks

(43, K36 V) (N,,GND) SW

:, OFF
C
I A
Signal (part) name
C
-conditions for measurement

L ~ e v eNo.
l

@ Lists
C N 101 connector Basic conditions (battery plug ON.SWKy ON)

Connector No. * Connector No. Conditions Standard Remarks

CNIOI-I I Unused
CN101-2
CN101-3 I CN101-20
Approx. 18 3V
(15,+30V) I (N1,GND)
I
CN101-4 I CN101-20
Approx. 18 3V
(15,+30V) I (N1,GND)
Unused &

CN101-5 I CN101-20 SWKy ON Approx. 4 8 Vl36 V Voltage after

(10, C36 V) I (NI, GND) SW, OFF OV key switch
CN101-6 I
I
(32, CHOPD + ) I
CN101-20
(NI, GND)
5 * 0.25 V
CN101-7 I CN101-20
5 * 0.25 V
(30,VDD+) (N1,GND)
CN101-8 I CN101-20
Unused - 5V - -6 V
( ,- 5V) I (N1,GND)
CN101-9 I CN101-20 SWKy ON Approx. 4 8 Vl36 V Voltage after
(14, VBKY) I IN1, GND) SW, OFF OV key switch
CN101-11 CN101-20 SW, ON Approx. 4 8 Vl36 V Voltage after
(43, K36 V) I (N1, GND) SW, OFF 0V key switch
CN101-12
Unused
CN101-13 I
-
 Connector No. * Connector No. Conditions Standard Remarks
CN101-14 I CN101-20
I ov
(11, GND) I (NI, GND)
CN101-15 I Unused
CN101-16 CN101-20
(11,GND) I (N1,GND)
ov
CN101-17 I CN101-20
Traveling stop state 4 - 5 V
(33, CHOPD-) I (Nl, GND)
I

CN101-18 I CN101-20
(31, VDD-1 I (NI, GND)
Traveling stop state 4 - 5V

CN101-19 I Unused
CN101-20 Panel N1 Battery plug OFF
(N1, GND) I terminal SW, OFF
on
CN101-21 I CN101-20
Approx. 48 Vl36 V
(13,VBBT) I (N1,GND)
I

CN101-22 I CN101-20
(41, 836 V ) I ( N l , GND)
Approx. 48 Vl36 V Battery voltage

CN102 connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. * Connector No. Conditions Standard Remarks

CN102-1 j CN102-9 SWKy ON Approx. 4 8 V l 3 6 V Voltage after
(43, K36 V) I ( N l , GND) SW, OFF OV key switch
CN102-2 1 CN102-9
(41, 836 V I j (N1, GND)
Approx. 4 8 V l 3 6 V Battery voltage

CN102-3 1 Unused
I
I 4 8 V vehicle:
CN102-4 CN102-9 43f 5V
(P8,RCKl) I (N1,GND) 36 V vehicle:
I
I 32f 5V
CN102-5 I CN102-9
(P9,RCKl) I (N1,GND)
Approx. 48 Vl36 V

CN102-6 I CN102-9
ov
(N2, TMS) I (NI, GND)
I

CN102-7 I CN102-9
I Unused Approx. 48 Vl36 V Battery voltage
(41, B36 V ) I (N1, GND)
CN102-8 I CN102-9
(41, D36 V) I ( N l , GND)
Approx. 4 8 Vl36 V Battery voltage
 Connector No. o Connector No. Conditions Standard Remarks
CN102-9 Panel N1 Battery plug OFF
on
(NI, GND) terminal SW, OFF
CN102-10 Unused
I 48 V vehicle:
I
CN102-11 I CN102-9 43* 5V
(P8, TMD) (N1, GND) 3 6 V vehicle:
I
I
32 *
5V
CN102-12 I CN102-9
Traveling stop state -5 - - 6V
(92, TMG) I ( N l , GND)

CN103 connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. ++ Connector No. Conditions Standard Remarks

CN103-1 CN103-3
(35, VDP+) I (11, GND)
5 * 0.25 V

CN103-2 CN103-3
(37, CHOPP +) I (11, GND)
5 * 0.25 V + 5V
I

CN103-3 I Panel N1
(11, GND) I terminal
Battery plug OFF.SWKy OFF on
CN103-4 CN103-3 SW, ON Approx. 4 8 Vl36 V Voltage after
(10, C36V) I (11, GND) SW, OFF OV key switch
CN103-5 I CN103-3
Approx. 1 8 3 V
(15, +30V) I (11, GND)
I
CN103-6 I CN103-3
(30, VDD + 1 (11, GND)
5 * 0.25 V

CN103-7 I CN103-3
*
5 0.25 V
(32, CHOPD + ) 1, GND)
(I
CN103-8 I CN103-3
ov
(11, GND) I (11, GND)
I
CN103-9 I CN103-3
(36, VDP-) I (11, GND)
Material handling stop state 4- 5V

CN103-10 I CN103-3
4- 5v
(38, CHOPP-) I (11, GND)
CN103-11 I CN103-3
ov
(11, GND) I (11, GND)
CN103-12 CN103-3
(13, VBBT) I (1 1, GND)
Approx. 4 8 Vl36 V

CN103-13 CN103-3 SW, ON Approx. 48 Vl36 V

(14,VBKY) I (11,GND) SWKyOFF OV
CN103-14 CN103-3
Traveling stop state 4- 5V
(31, VDD-1 I (11, GND)
 Connector No. * Connector No. Conditions Standard Remarks
I
CN103-15 I CN103-3
(33, CHOPD-1 I (I
I,GND)
4- 5v
I
CN103-16 I
Unused
(11,GND) I

CN104 connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. * Connector No. Conditions Standard Remarks

I
Battery plug OFF.SWKy OFF
CN104-1 CN104-14 MFR
(41MFR) I (Ir+ )
Measure with the tester negative
probe connected to CN104-14.
Approx. 20 Q
contactor
I

CN104-1 I CN104-8 Measure with the tester positive

(4, MFR) 1 (74, CSD -1 probe connected to CN104-1.
Approx. 46 Vl35 V MFRcoil
I
CN104-2 I CN104-14
Battery plug OFF.SWKy OFF
Measure with the tester negative Approx. 20 Q MRR
15' MRR) j (I'
probe connected to CN104-1 4.
contactor
I
CN104-2 I CN104-8 Measure with the tester positive
(5, MRR) 1 (74, CSD -1 probe connected to CN104-2.
Approx. 46 Vl35 V MRRcoil
I
Battery plug OFF.SWKy OFF
CN104-3 CN104-14
Measure with the tester negative Approx. 20 Q MFLcontactor
(2' MFL) II (I
' + )
probe connected to CN104-1 4.
1
CN104-3 I CN104-8 Measure with the tester positive
(2, MFL) 1 (74, CSD-1 probe connected to CN104-3.
Approx. 46 Vl35 V MFL coil
I
CN104-4 I CN104-14
Battery plug OFF.SWKy OFF
Measure with the tester negative Approx. 20 Q MRL cotactor
13' MRL) I (I
' +)
probe connected to CN104-1 4.
CN104-4 CN104-8 Measure with the tester positive
(3, MRL) 1 (74, CSD-1 probe connected to CN104-4.
Approx. 46 Vl35 V MRL coil
I Battery plug OFF.SWKy OFF
CN104-5 CN104-15
Measure with the tester negative Approx. 20 Q MP contactor
(7,MP) I (I,M+)
7
I probe connected to CN104-1 5.
CN104-5 CN104-8 Measure with the tester positive
Approx. 46 Vl35 V MP coil
(7, MP) f (74, CSD-) probe connected to CN104-5.
CN104-6 CN104-8
(75, STH) 1 (74, CSD-)
5 f 0.25 V + 5V
 Connector No. * Connector No. Conditions Standard Remarks
CN104-8 I Panel N1
Battery plug OFF.SWKy OFF On
(74, CSD-) terminal
CN104-9 I CN104-8
Traveling stop state Approx. 1.2 V
(71, CSD) I (74, CSD - 1
I
CN104-10 I CN104-8
+12V
(73, CSD + I 1 (74, CSD -
1 2 f 0.6 V

CN104-11 I CN104-8
Approx. 4 8 V l 3 6 V
(P2, VBP2) 1 (74, CSD-)
I Battery plug OFF.SWKy OFF
~ ~ 1 0 4 - 1 I2 ~~104-13 Approx. I 10n
Measure with the tester negative Mps contactor
(6' Mps) (I (USA spec..: 68 n)
probe connected to N 104-13.
+

CN104-1 2 I CN104-8 Measure with the tester negative

Approx. 4 6 Vl35 V Mps coil
(6, Mps) 1 (74, CSD -) probe connected to CN104-1 2.
CNl04-13 I CN104-8
(I,M+) 1 (74,CSD-)
Approx. 4 6 Vl35 V

CN104-14 CN104-8
Approx. 4 6 V l 3 5 V
(1, M + ) 1 (74, CSD-)
CN104-15 I CN104-8
Approx. 4 6 V l 3 5 V
(1, M + ) I (74, CSD-)
I
CN104-16 I C N l 0 4 -8 Greater than 0 V and
(76, STHl 1 (74, CSD-) smaller than 5 V
CN1 04-1 7 I CN104-8 Traveling and material handling stop
Approx. 4 8 Vl36 V
(P9, VBP9) 1 (74, CSD-) state
CN104-18 I CN104-8
ov
(74, CSP-) 1 (74, CSD-)
CN104-19 I CN104-8
(72, CSP) 1 (74, CSD-)
Material handling stop state Approx. 1.2 V

CN104-20 I CN104-8
1.2* 0.6 V + 12 V
(73, CSP )+ 1 (74, CSD -)

CN105 Connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. * Connector No. Conditions Standard Remarks

CN105-1 CN105-10 LSLOFF *
5 0.25 V
(60, LS,) I (1 I,GND) LS, ON OV
5 *0.25 V
I
CN105-2 I CN105-10 LSL2OFF
(68, LSL21 I (1I,GND) LSL2ON OV
 Connector No.
CN105-3
-
I
I
Connector No.
CN105-10 LSTOFF
Conditions Standard
5 f 0.25 V
Remarks

(61, LS,) I (11, GND) LS, ON OV

CN105-4 I Unused
I
CN105-5 I Unused
CN105-6 I CN105-10 LSATTl ON 5 f 0.25 V
(63, LSATT1) ] (1 1, GND) LSArrl OFF OV
CN105-8 CN105-10
Approx. 5 V
(55, VRSP + I (1 1, GND)
CN105-9
(56, VRSP) I
CN105-10
(1 1, GND)
Approx. 0.9 - 3.9 V
CN105-10 Panel N 1 Battery plug OFF
on
(11, GND) I terminal SW, OFF
CN105-11 I Unused
CN105-12 I Unused

-
C N 1 0 6 Connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. Connector No. Conditions Standard Remarks

I

CN106-1 I CN106-2
I Traveling stop state OV
- (82, SSR) 1 (81, SSR)
CN106-2 CN106-1
Traveling stop state OV
(81, SSR) 1 (82, SS,)
CN106-3 CN106-4
Traveling stop state OV
(84, SSL) I (83, SSL)
I

CN106-4 I CN106-3
I Traveling stop state OV
(83. SSL) 1 (84, SSL)
CN106-5 CN106-13 DSFOFF 5 f 0.25V
(45, DSF) 1 (51, GND) DSF ON OV
CN106-6 CN106-13 DSROFF 5f0.25 V
(46, DSR) I (51, GND) DSRON OV
I
CN106-7 I CN106-13 SWAc OFF 550.25 V
(64, SWAc) 1 (51, GND) SWAc ON OV
CN106-8 I CN106-13
3 - 5 v
(53, VRAD + 1 (51, GND)
CN106-9 CN106-13
( , OPTl) 1 (51, GND)
 Connector No. * Connector No. Conditions Standard Remarks
I
I 4 8 V vehicle:
CN106-10 I CN106-1 3 Traveling and material handling stop 43 f 5V
(P6, VBP6) 1 (51, GND) state 36 V vehicle:
I
I 32 f 5V
I
I 4 8 V vehicle:
CN106-1 1 I CN106-1 3 Traveling and material handling stop 43f 5V
(P61,VBP61) 1 (51,GND) state 3 6 V vehicle:
I
I 32f 5V
CNlO6-12 I CNlO6-13 LSD OFF 5 * 0.25 V
(67, LSD) 1 (51, GND) LSD ON OV
CN106-13 Panel N1 Battery plug OFF
(51, GND) I terminal SW, OFF
on
CN106-14 CN106-13
(51, GND) (51, GNDl
ov
CN106-15 I CNlO6-13 SWscOFF 5 f 0.25 V
(77, SWsc) 1 (51, GND) SWsc ON OV
CN106-16 I CN106-13 SWpBOFF 5 f 0.25 V
I
(66, SWpB) 1 (51, GND) SWpB ON OV
CN106-17 CN106-13 LSB OFF OV
(65,LSs) 1 (51,GND) LSBON 5 f 0.25 V
CN106-18 I CN106-13 Shall vary smoothly according t o the
(52, VRAD) 1 (51, GND) traveling acceleration state.

CN107 connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. * Connector No. Conditions Standard Remarks

CN107-1 CN1 07-6
0 - 1 v
(141, SMTDA) (17, GND)
CN107-2 Cannot be measured with a circuit
(142, SDTMA) tester
CN107-3 CN107-6 Approx. 4 8 Vl36 V
Unused
( , VBKY) (17, GND) OV
CN107-4 CN107-6
(144, SMTDK)
ov
(17, GND)
CN107-5 Cannot be measured with a circuit
(143, SDTMK) tester
CN1 07-6 Panel N1 Battery plug OFF
(17, GND) terminal
ov
SW, OFF
CN107-7 Unused
CN107-8 CN107-6
(16, +30V) (17, GND)
18 *3V
2-26

-
CN 1 1 1 connector: Basic conditions (Battery plug ON.SWKyON)

Connector No. Connector No. Conditions Standard Remarks

CN111-1
Unused
- CN111-2 I
CNlll-3 I CN111-20
Unused Approx. 1 8 +3V
(15,+30V) I (N1,GND)
I
CN111-4 I CN111-20
(15, + 3 0 V) / (NI, GND)
Unused Approx. 1 8 & 3V

CNlll-5 I CNlll-20
Unused
Approx. 4 8 Vl36 V
(10, C36 V ) 1 (NI, GND) OV
CNlll-6 / CNlll-20
5 * 0.25 V
(37, CHOPP + I (N1, GND)
I

5 * 0.25 V
CN111-7 I CN111-20
(35,VDP+) (N1,GND)
CNlll-8 I CNlll-20
Unused - 5V - - 6V
(,-5V) I (N1,GND)
CN111-9 I CN111-20 Approx. 4 8 V l 3 6 V
Unused
(14, VBKY) / (NI, GND) ov
CN111-10 I Unused
CN111-11 CN111-20 SWKyON Approx. 4 8 Vl36 V
(43, K36 V) / (NI, GND) SW, OFF OV
CNIII-I2
CN111-13
/
I
Unused
I

CN111-14 I CN111-20
(11, GND) / ( N l , GND)
Unused OV

CN111-15 Unused
CNlll-16 CNlll-20
Unused OV
(11,GND) f (N1,GND)
CNlll-17 I CNlll-20
Material handling stop state 4 - 5 V
(38, CHOPP-) I (NI, GND)
CNlll-18 CN111-20
(36, VDP-1 I (NI, GND)
Material handling stop state 4 - 5 V

CNlll-19 Unused
Connector No. * Connector No. Conditions Standard Remarks
CN1 1 1-20 Panel N 1 Battery plug OFF
on
(N1, GND) 1 terminal SW,, OFF
CN111-21 I CNlll-20
Unused Approx. 48 Vl36 V
(13, VBBT) I (NI, GND)
I
CNlll-22 I CN111-20 Battery
Approx. 48 V136 V
(41, B36 V) I (N1, GND) voltage

CN112 connector: Basic conditions (Battery plug ON.SWKy ON)

Connector No. * Connector No. Conditions Standard Remarks

CN112-1 I CN112-9 Approx. 4 8 Vl36 V
(43, K36 V ) I (NI, GND)
Unused
ov
CN112-2 1 CN112-9
Unused Approx. 48 V l 3 6 V
(41, B36 V) I (N1, GND)
CN102-3 I Unused
I 4 8 V vehicle:
CN112-4 I CN112-9 27f 5V
IP14,RCKP) I IN1,GNDl 3 6 V vehicle:
I 20f 5V
II

CN112-5 I CN112-9
(PI 5, RCK2) I (Nl, GND)
Approx. 4 8 V136V

CN112-6 I CN112-9
ov
(N2, TMPS) (NI, GND)
CN112-7 I CN112-9
Unused Approx. 4 8 Vl36V
(41, 8 3 6 V) (N1, GND)
I
CN112-8 1 CN112-9
Approx. 4 8 Vl36V
(41, D36 V) 1 (NI, GND)
Unused

CN112-9 PanelN1
Unused Conduction
(NI, GND) I terminal
CN112-10 I Unused
CN112-11
(P14,TMPD) I
CN112-9
(N1,GND)
10 - 25V
- 5 - - 6V
CN 2-1 CN1 2-9
(93, TMPG) I (N1, GND)
Material handling stop state
11. Display
If the cause of a trouble is judged to exist in the display, apply the battery voltage and measure
the voltage at the connector.

CN 1 20 connector basic condition (battery plug ON)

Connector No. * Connector No. Conditions Standard Remarks

CN120-9 I CN 120-19
Approx. 18 =t3 V
(16, + 3 0 V ) 1 (17, GND)
CN 120-10 CN 120-20
Approx. 4 8 V
(104, BL) I ( N I , GND)
DISASSEMBLY
The control panel is overhauled infrequently. Defective part replacement according to the cause of the
trouble by inspection is performed in most cases. Please perform correct operation by referring to the
component parts drawing, assembly drawing and internal connection diagram.

Cautions for Parts Replacement

Tighten the bar and harness set nuts and screws to the specified torques.
Looseness or insufficient tightening will cause other troubles.
When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indi-
cating the mounting position. At the time of reassembly, prevent incorrect installation or wiring by
referring to the memo or tag. Incorrect installation or wrong wiring will cause other troubles.
Always coat silicone grease on parts which have been coated with silicone grease. Omission of
coating may cause overheating.
After reassembly, check no contact of the bars and cables at other than the contact portions. Before
installation on the vehicle, check continuity at points with a circuit tester. (See page 2-34 for the
inspection points with the circuit tester.)
2-30

REASSEMBLY
Control panel assembly drawing (STD)

DAD (B) CAD ( B )

(Y

P7
CSD
P2

DF 1

N1 TMD

DCISD b
Control panel assembly drawing (with pump chopper)

DAD (B) CAD (B) CAP (L) DF3

(Y)

P7

CSD

P2

DF 1

v
N1 TMD P I 3 P 1 2 CSP TMP D'AP

CNlOO CN1 15 CN1 17

T?!AiF?d
DClSD board

DCISD b
2-32

Contactor panel assembly drawing

PANEL PARTS TIGHTENING TORQUE
(Control panel)

ltem Tightening torque N.m (kgf-cm) [ft-lbfl

Main terminals
M5 2.16 - 2.75 (22 - 28) 11.59 - 2.031
TM-TMP M4 1.18 - 1.77 (12 - 18) 10.87 - 1.301
For installation M5 2.16 - 2.75 (22 - 28) [ I.59 - 2.031
Main terminals M6 3.14 - 3.73 (32 - 38) i2.32 - 2.751
5.10 - 5.69 (52 - 58) i3.76 - 4.201
DF1
For installation M6
Main terminals M6 2.1 6 - 2.75 (22 - 28) [ I.59 - 2.031
13.44 - 14.02 (137 - 143) 19.91 - 10.351
DF3
For installation MI2
DAD-DAP For installation M6 2.16 - 2.75 (22 - 28) f1.59 - 2.031
Heat sink For installation M5 2.13 - 2.75 (22 - 28) 11.59 - 2.031
Terminal set nuts for external connection M8 7.85 - 11.77 (80 - 120) l5.79 - 8.681

(Contactor panel)

ltem Tightening torque N.m (kgf-cm) [ft-lbfl

Main terminals M6 2.16 - 2.75 (22 - 28) [1.59 - 2.031
21.28 - 21.87 (217 - 223) [15.70 - 16.131
DF2,-DF2,
For installation M 20
MFL.MFR Main terminals M8 7.85 - 11.77 (80 - 120) 15.79 - 8.681
MRL.MRR
MP For installation M5 2.13 - 2.75 (22 - 28) l1.59 - 2.031

Heat sink For installation M5 2.13 - 2.75 (22 - 28) [1.59 - 2.031
Terminal set nuts for external connection M8 7.85 - 1 1.77 (80 - 120) [5.79 - 8.681

(For power steering)

Item Tightening torque N.m (kgf-cm) [ft-lbfl

Main terminals M5 1.96 - 2.94 (20 - 30) [ I.45 - 2.171
1.96 - 2.94 (20 - 30) 11.45 - 2.1 71
TMPS
For installation M5
CONTINUITY CHECK WITH CIRCUIT TESTER

Control panel (STD) Control panel (Wlchopper)

Contactor panel

Inspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe

Inspection points Standard Circuit tester

P2: + probe - N1: - probe Approx. 1 0 to 2 5 Q
Q xlK
Between P2 and N 1
P2: - probe - N1: + probe *an
P12: + probe - N l : - probe Approx. 1 0 t o 2 5 62
Q x 1K
Between P 1 2 and N 1
P I 2: - probe - N 1: + probe *an
Tester probes may be used in either
Between P2 and frame a0 Q ax IK
direction.
Between N1 and Tester probes may be used in either
a Q Q x 1K
frame direction.

* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects t o 0 Q and returns t o 00 Q then.
OCL (OVERCURRENT LIMIT) VALUES
1. Drive circuit OCL value measurement
(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Standard OCL value:
48 V vehicle: 460
3 6 V vehicle: 6 10
;+*: 6 0A A
Ammeter:
5 0 mV, 7 5 0 A
Shunt:
5 0 mV, 7 5 0 A

(2) Judgment method If the measured OCL value is not within the standard range, the current sen-
sor (CS) or CPU board may be defective. Make judgment as follows:
@ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
@ Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON.SWKy ON
Measurement terminals: CN104(9)71 @ - CN104(8) 74 @
Standard: Approx. 1.2V
* Use a digital voltmeter for measurement.
@ Operate the accelerator t o set the speed t o approx. 8 kmlh ( 5 milelh). Read the ammeter
and measure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN104(9)71 @ - CN 104(8)74 @
* Use a digital voltmeter for measurement.
@ Calculation
Measured value C - measured value B = D
Convert the calculated value D according t o the following equation. (Converted value: E)
1V = 100A
@ Judgment
Compare converted value E with measured value A in step @.
*
The current sensor can be judged normal if the result is within 5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.
Pump circuit OCL value measurement
The OCL value of the pump circuit cannot be measured because of the following reason:

In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.

The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.

As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.
 ACCELERATION POTENTIOMETER
ADJUSTMENT
Make adjustment in the state of acceleration potentiometer
wlfront toe board.

1. Operate the accelerator pedal and check if the acceler-

ation switch is turned ON and OFF.
Measurement terminals: 51 and 64
Standard
When the pedal is not depressed: co
When the pedal is depressed: 0 S2

2. Acceleration potentiometer installation adjustment

(1) Insert a 1.5 mm (0.06 in) thickness gauge between
the accelerator link stopper and accelerator bracket.
(2) Temporarily install the potentiometer so that the
switch (SW), is set to ON.
(3) Inspect the switch (SW), ON and OFF changeover
points.
When 1.0 mm (0.04 in) thickness gauge is inserted:
OFF
When 2.0 mm (0.08 in) thickness gauge is inserted:
T = 1.57-2.35 N.m
ON
Set screw (4) After the end of switch ONmOFF adjustment, fully
tighten the set screws.
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT
1. Adjust protrusion (A) of the brake switch (LS,) and
stop lamp switch (LS,).
A = 26 m m (1.02 in)

2 After installing LS, and L,S

,, check ON and OFF.
(1) Operate the brake pedal and check conduction at
each switch connector.

Standards

Switch Not operated Operated

LSS on n
00

LSST a0 n on

(2) Adjust each switch ONIOFF timing when the brake

pedal is operated. Make adjustment by turning the
adjusting bolt so that each switch is operated when
the brake pedal is depressed by dimension B in the
figure from the free state.

10 mm (0.39 in.)
Switch
on-an
an- on
 2-39

PARKING BRAKE SWITCH ADJUSTMENT

1. Inspect parking brake switch (SW,,) ONIOFF.

Standard

Lever state Returned Pulled

SWPB on con

Adjust the SW, installation state.

(1) Return the lever fully to the stroke end.
(2) With the limit switch pushed to its stroke end to-
ward the lever side, fix the switch by tightening the
switch bracket set bolts 1 and limit switch set
screws 2 .
 MATERIAL HANDLING SWITCH
ADJUSTMENT
1. Adjustment the switch (LS,,-LS,) ON timing when the
control lever is operated.
(1) Adjust LS, .LS, roller protrusion (A).
Dimension A is a reference value for reassembly.

A = 26 mm (1.02 in)

(2) The switch shall be turned ON at dimension A at the

tip end of the control lever.

Standard
B= 5 - 20 mm (0.20 - 0.79 in)
If the standard is not satisfied, make adjustment by
changing the roller protrusion and mounting position.

1 When pump chopper (OPT) is provided:

2. Adjust the pump chopper switch (LS,) ON timing.

(1) Adjust LS, roller protrusion (C).

C = 26 mm (1.02 in)

10-15mm (2) Adjust by turning the adjusting bolt so that the

switch (LS,) is turned on when the lift lever is
fulled to 1 0 - 15 mm (0.39 - 0.59 in) before its
stroke end.

Stroke end
DIRECTION SWITCH
REMOVAL-INSTALLATION

Removal Procedure
1 Remove the steering rear cover.

2 Disconnect the direction switch connector.

3 Remove the steering tilt lever.

4 Remove the steering front cover and display.

5 Remove the direction switch.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Disassembly Procedure
1 Remove the plate.

2 Remove the micro switch base.

3 Remove the microswitch Wlwire harness. [Point 11

4 Remove the cam roller and spring.

5 Remove the direction lever Wlknob.

6 Remove the cam.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operation
[Point 11
Reassembly: Install the microswitches in the correct posi-
tions.

Reassembly: When replacing a microswitch, connect the

cables according t o the cable colors in the fig-
ure.

Inspection: After assembling the direction switch, check

conduction of each microswitch before install-
ing the direction switch.
PS CONTROLLER
COMPONENTS
STD (Mpscontactor: The Mpscontactor is installed on the PS motor.)

EHPS
INSPECTION (STD)
1. P22-N 1 voltage measurement
Battery plug ON.SWKyON

Measurement terminals P22 - N1

Circuit tester range DC 5 0
Standard Battery voltage

As seen from the motor

2. Mps contactor coil conduction measurement

Battery plug OFF.SWKyOFF

Measurement terminals Both terminals of connector (CN42) of Mps Contactor

Circuit tester range Q x l
Standard Approx. 1 1 0 Q (at 20°C (68OF))
REMOVAL.INSTALLATION (EHPS)

1 Battery plug

Removal Procedure
1 Disconnect the battery plug.

2 Remove the side panel.

3 Remove the toe board.

4 Disconnect the wiring connectors.

5 Remove the PS controller.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
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