8FBET15, 16, 18, 20

8FBEKT16, 18
8FBMT15, 16, 18, 20

Pub No. CE 345

8FBET15, 16, 18, 20
8FBEKT16, 18
8FBMT15, 16, 18, 20

Pub No. CE 345

8FBET15, 16, 18, 20
8FBEKT16, 18
8FBMT15, 16, 18, 20

Pub No. CE 345

 FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
8FBET15~20/8FBEKT16,18/8FBMT15~20 series. Please use this manual for
providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of December 2008. Please understand
that disagreement can take place between the descriptions in the manual 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.

(Reference)
Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 8FBET15~20/8FBEKT16,18/

8FBMT15-18 NEW MODEL FEATURES (No. PE318)
 SECTION INDEX
NAME

GENERAL
BATTERY
CONTROL SYSTEM
MULTI-FUNCTION DISPLAY
TROUBLESHOOTING
MOTOR
DRIVE UNIT & FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
SAS FUNCTIONS
MAIN OPTIONS
APPENDIX
 0-1

GENERAL
Page Page
VEHICLE EXTERIOR VIEW ....0-2 PERIODIC MAINTENANCE.. 0-22 I
VEHICLE MODELS............ ....0-4 PERIODIC REPLACEMENT
FRAME NUMBER............... ....0-4 OF PARTS AND
LUBRICANTS..................... 0-26
HOW TO USE THIS
MANUAL........................... ....0-5
EXPLANATION METHOD........ ....0-5
TERMINOLOGY....................... ....0-6
ABBREVIATIONS................ ....0-6
SI UNITS.................................... ....0-7
OPERATING TIPS............. ....0-8
JACK-UP POINT...................... ....0-9
HOISTING THE VEHICLE....... ..0-10
WIRE ROPE SUSPENSION
ANGLE LIST..................... ..0-11
SAFE LOAD FOR EACH
WIRE ROPE SUSPENSION
ANGLE................................. 0-11
COMPONENT WEIGHT.............. 0-12
TOWING THE VEHICLE............. 0-13
ELECTRICAL PARTS
INSPECTION............................. 0-14
STANDARD BOLT & NUT
TIGHTENING TORQUE.......0-15
BOLT STRENGTH CLASS
IDENTIFICATION METHOD ....0-15
PRECOAT BOLTS....................... 0-18
HIGH PRESSURE HOSE
FITTING TIGHTENING
TORQUE..............................0-18
RECOMMENDED LUBRICANT
QUANTITY AND TYPES.... 0-19
LUBRICATION CHART........ 0-20
0-2

VEHICLE EXTERIOR VIEW

8FBET15-20
8FBEKT16,18
 0-3

8FBMT15-20
0-4

VEHICLE MODELS
3-Wheel Models
Vehicle Model Load Capacity Control Method Voltage (V)
8FBET15 1.5 ton AC Microcomputer controller 48
8FBET16
1.6 ton T Î
8FBEKT16
8FBET18
1.8 ton Î Î
8FBEKT18
8FBET20 2.0 ton Î T

4-Wheel Models
Vehicle Model Load Capacity Control Method Voltage (V)
8FBMT15 1.5 ton AC Microcomputer controller 48
8FBMT16 1.6 ton T Î
8FBMT18 1.8 ton T T
8FBMT20 2.0 ton T Î

FRAME NUMBER
Vehicle model Punching format Punching position
8FBET15 8FBET15 © 10011

8FBEKT16 8FBEKT18© 10011

8FBEKT18

8FBET16 8FBET18 © 10011

8FBET18
8FBET20 8FBET20 ©10011
8FBMT15 8FBMT15 © 10011 Hu
8FBMT16 8FBMT18 © 10011
8FBMT18
Punching Position
8FBMT20 8FBMT20 © 10011
 0-5

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 illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by
explanation of cautions and notes summarized as point operations.

Example of description in pattern B

DISASSEMBLYINSPECTIONREASSEMBLY
Tightening torque unit T = N-m (kgf-cm) [ft-lbfj

Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2] €■ Operation explained later
3 Remove the gear.

Point Operations
[Point 1] Explanation of key point for operation with an illustration
Disassembly:
Put a match mark when removing the pump cover.

[Point 2]
Inspection:
Measure the bush inside diameter.
Limit: 19.12 mm (0.7528 in)
0-6

2. How to read component figures

(1) The component figures use the illustration in the parts catalog
3201
for the vehicle model. Please refer to the catalog to check the
part name.
Parts catalog
FIG number ZJ
3. Matters omitted from this manual
(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 SAE Society of Automotive Engineers (USA)
ATT Attachment SAS System of active stability
LH Left hand SST Special service tool
L/ Less STD Standard
OPT Option T= Tightening torque
O/S Oversize OOT Number of teeth (OOT)
PS Power steering U/S Undersize
RH Right hand w/ With
 0-7

SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify the various
systems of units used in the past for smoother international technical communication.

New Units Adopted in SI

Item New unit Conventional unit Conversion rate

* 1 (1 [conventional unit] = X [SI unit])

*
Force 2 N (newton) kgf 1 kgf = 9.80665 N
*
Torque 2
N-m kgf-cm 1 kgf-cm = 9.80665 N-m
(Moment)
*
Pressure 2 Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
T T mmHg 1 mmHg = 0.133322 kPa
Revolving speed rpm rpm 1 rpm = 1 r/min
*
Spring constant 2 N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Volume I cc 1 cc = 1 m/
Power W PS system 1 PS = 0.735499 kW
Heat quantity W-h cal 1 kcal = 1.16279 W-h
Specific fuel
g/W-h g/PS-h 1 g/PS-h = 1.3596 g/kW-h
consumption

<Reference>
* 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the
rate for conversion between conventional and SI units.
* 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which
should be used as the unit of force.

Conversion between Conventional and SI Units

Equation for conversion

Value in SI unit = Conversion rate x Value in conventional unit Conversion rate: Figure corresponding to X in the
Value in conventional unit = Value in SI unit -s- Conversion rate conversion rate column in the table above

When converting, change the unit of the value in conventional or SI units to the one in the conversion rate
column in the table above before calculation. For example, when converting 100 W to the value in
conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.
0-8

OPERATIING TIPS
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 terminal 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 they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.)
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.
3. Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble
requires disassembly or replacement for remedying.
4. Disposal of waste fluid, etc.
When draining waste fluid from the vehicle, receive it in a container.
If any oil, battery or other harmful substance is directly discharged or scrapped without permission, it will either
adversely affect human health or destroy the environment. Always sort waste fluids, etc. and treat them properly
by requesting disposal by specialized companies.
5. Greasing up each part
In addition to periodic grease-up according to the lubrication chart, apply MP grease (or molybdenum disulfide
grease) to each sliding contact face when repairing a portion (like pedal link) involving sliding contact.
6. Disconnect the battery plug
When unplugging the battery plug, use the grip. Do not pull up the cable.
 0-9

JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
Front Side
• Please carry out a jack up with the frame down side on the backside of a front tire.
• About a jack up point let the frame undersurface of 150 mm (5.9 in) range be a jack up point from a side
frame.
Rear Side
• When you carry out a jack up, please perform a jack up in the position shown in the following figure.

Front Side

<------- > 150 mm (5.9 in)

Rear Side

8FBET15-20 C D)
8FBEKT16-18

8FBEMT15-20
0-10

HOISTING THE VEHICLE

• When lifting the vehicle the front hangs by the mast and the rear by draw bar of counterweight.
• Before lifting the vehicle, tilt the mast to the most backward position.
• Please use ‘Protection pad’ at the roof end.

Note:
• Remove the rear combination lamp assy before installing the protection pad.
• This illustration is showing the STD mast.
• Be careful not to strain the head guard.

A: Use a fiber belt or wire rope.

B: Use a fiber belt.

m (in.)
8FBET 8FBMT
Model
Series Series
Approx. 2 Approx. 2
A
(78.7) (78.7)
Approx. 3 Approx. 3.5
B
(118) (137.8)

Before lifting the vehicle, check that the draw bar is not move upward. If the draw bar is moved
upward, be sure to push it down.
 0-11

WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension
Lifting angle Tension Compression Lifting angle Tension Compression
method method

0° 1.00 time 0 time 90° 1.41 time 1.00 time

90°
3=
Si pA
2t 2t

A
0’
30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
5b
120°
£

2t 2t

60° 1.16 time 0.58 time

0°
is
<o p

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (if) [Ibf]
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0° 0° 30° 60° 90° 0° 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)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
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] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1-43) (1-37) (1-2) (1-0) (2.8) (2-7) (2-4) (2-0)
(0.4 in)
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2-2) (2-1) (1.9) (1-5) (4.4) (4-2) (3-8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1-4) (2-8) (2-7) (2.4) (1-9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
0-12

COMPONENT WEIGHT
Unit: kg (lbs)
Component Vehicle model Weight
8FBET15 672 (1482)
8FBEKT16to 18 813(1792)
Battery 8FBET16 to 20 962(2121)
8FBMT15 672 (1482)
8FBMT16to20 962 (2121)
Front axle ASSY W/ drive motor ASSY All models 176 (388)
Pump motor ASSY All models 33 (73)
8FBET15to20 49(108)
Rear axle ASSY W/ rear axle cylinder ASSY
8FBMT15to20 76(168)
8FBET15 770 (1698)
8FBMT15 670 (1477)
8FBEKT16 655 (1444)
8FBET16 450 (992)
8FBMT16 380 (838)
Counterweight
8FBEKT18 805(1775)
8FBET18 620(1367)
8FBMT18 485(1069)
8FBET20 795(1753)
8FBMT20 650 (1433)
8FBET15
8FBMT15
8FBEKT16 365 (805)
8FBET16
Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork, Lifting height 8FBMT16
3000 mm (118 in), V mast) 8FBEKT18
8FBET18
8FBMT18 425 (937)
8FBET20
8FBMT20
 0-13

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.
0-14

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.

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.

Example of measurement result

Tester range: k£2 range
Analog type
Continuity
Forward
11 kQ
No continuity
Reverse
oo

Example of measurement result

Forward Reverse Tester range: 2 MQ range
kJ
* fl Digital type
No continuity
r~ -i I C2_J Forward
1
Continuity
Reverse
0 ® 2MQ
J ?I
?
I --
 0-15

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identify
bolt class based on the below chart and then determine using the tightening torque table.
2. For tightening torque of hexagon flange bolts, identify bolt class based on the below chart and then determine
using the tightening torque table.
3. For tightening torque of nuts, check the mating bolt and use the method 1.

BOLT STRENGTH CLASS IDENTIFICATION METHOD

Identification by Bolt Shape

■ -—-—— Shape and class Class
4 = 4T
5 = 5T
— Bolt head No. 6 = 6T
7 = 7T
8 = 8T

N° mafk 4T

Hexagon head bolt

1 ® | Two protruding lines 5T

Three protruding lines 7T

F°ur protruding lines 8T

Welded bolt 4T

No mark 4T

Stud bolt

Grooved 6T
0-16

Identification by Part No.

Part No.

91611-40625
Hexagon head bolt
Length (mm) I Bill Diameter
Diameter (mm) _J
Length
Class

92132-40614
Length (mm)
Diameter (mm)
Class

Tightening Torque Table

Diameter Pitch Specified torque

Class
mm mm N-m kgfcm ftlbf
6 1.0 5.4 55 4
8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 1.0 6.5 65 5
8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 1.5 265 2700 195
 0-17

Identification by Bolt Shape (Hexagon flange bolt)

Class 4.8T 6.8T 8.8T 10.9T 11.9T

/No mark
0 IG 0 0
I0 0
Hexagon flange bolt

0 G — —
0
Tightening Torque Table (Hexagon flange bolt)

Diameter Pitch Specified torque

Class
mm mm N-m kgf-cm ft-lbf
6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T
12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88
6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T
12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8.8T
12 1.25 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199
6 1.0 15.5 160 12
8 1.25 38 390 28
10 1.25 80 820 59
10.9T
12 1.25 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266
6 1.0 17.5 180 13
8 1.25 42 430 31
10 1.25 89 910 66
11.9T
12 1.25 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295
0-18

PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)

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

cases:

(1) After it is removed.

(2) When the precoat bolt is moved (loosened or tightened)

by tightness check, etc.

Note:
For torque check, use the lower limit of the allowable
tightening 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 surfaces 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 Nm (kgf cm) [ft-lbf] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16 —20UNF 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16—18UNF 34 (350) [25.3] 32 to 36 (330 to 370) [29.3 to 26.8] 9 (0.35)
3/4 — 16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8— 14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8 —14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15(0.59)
1-1/16 — 12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19(0.75)
1-5/16 — 12UNF 137(1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
PF3/8 34 (350) [25.3] 32 to 36 (330 to 370) [23.9 to 26.8] 9 (0.35)
PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12(0.47)
PF3/4 118(1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19(0.75)
PF1 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
 0-19

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Application Type Capacity
Drive unit 0.43 € (0.114 US gal)
TOYOTA genuine oil: ATF type T-4
Wet disc brake 0.21 t (0.055 US gal)
STD: AGIP ARICA 32 See “Hydraulic oil level by lifting
Hydraulic oil
Cold storage vehicle: AGIP ARNICA A15 height” below
MP grease
Chassis parts Molybdenum disulfide grease Appropriate amount
Esso beacon 32S
Battery Distilled water Appropriate amount

Hydraulic oil level by lifting height

Height Amount of oil fill Amount of oil inside tank

Mast
mm Litter (US gal) (Reference) Litter (US gal)
3000 to 4000 14 (3.7) 10.3 (2.72)
V to 5000 16 (4.2) 12.1 (3.20)
to 5500 17 (4.5) 13.0 (3.43)
to 4000 15(4.0) 10.7 (2.83)
to 5000 17(4.5) 12.6 (3.33)
FSW to 6000 19(5.0) 14.6 (3.86)
to 7000 19(5.0) 15.2 (4.02)
to 7500 20 (5.3) 16.2 (4.28)
FW 3000 to 4000 13 (3.4) 9.3 (2.46)
0-20

LUBRICATION CHART

8FBET15to 20

8FBEKT16, 18

1
2
3
4
5

10----- A

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

• : Replacement II. Inspection every 40 hours (weekly)
III. Inspection every 250 hours (6 weekly)
A: MP grease IV. Inspection every 1000 hours (6 monthly)
B: Motor oil V. Inspection 2000 hours (annual)
C: Gear oil VI: Inspection 3000 hours (1.5 years)
(TOYOTA genuine oil: ATF type T-IV)
D: Hydraulic oil (ISO VG32)
E: Molybdenum disulfide grease
F: TOYOTA genuine oil: ATF type T-IV

1. Mast pads 7. Steering rack and pinion gear

2. Tilt cylinder front pin 8. Oil tank
3. Mast support bushing 9. Tilt steering lock device
4. Lift chain 10. Rear wheel bearing
5. Drive unit 11. Rear axle bearing
6. Brake link 12. Wet disc brake
 0-21

8FBMT15 to 20

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

•: Replacement II. Inspection every 40 hours (weekly)
III. Inspection every 250 hours (6 weekly)
A: MP grease IV. Inspection every 1000 hours (6 monthly)
B: Motor oil V. Inspection 2000 hours (annual)
C: Gear oil VI: Inspection 3000 hours (1.5 years)
(TOYOTA genuine oil: ATF type T-IV)
D: Hydraulic oil (ISO VG32)
E: Molybdenum disulfide grease
F: TOYOTA genuine oil: ATF type T-IV

1. Mast pads 9. Tilt steering lock device

2. Tilt cylinder front pin 10. Swing lock cylinder crank and rod pin
3. Mast support bushing 11. Steering knuckle king pin
4. Lift chain 12. Rear wheel bearing
5. Drive unit 13. Tie rod end pin
6. Brake link 14. Rear axle cylinder end pin
7. Rear axle beam front pin 15. Rear axle beam rear pin
8. Oil tank 16. Wet disc brake
0-22

PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection-Repair or Replacement if required
M: Measurement-Repair or Adjustment if required
T: Retightening C: Cleaning L: Lubrication
*: For new vehicle *1 : Flaw detector
Every 6 Every 3 Every 6 Every 12
Inspection timing
weeks months months months
Every Every Every Every
Item —------------
250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound abnormality I* I <- <-
Motor Looseness in the connecting parts T <- <-
Insulation resistance M <- <-
Charging level (Display) I <- <-
Electrolyte level I <- <-
Electrolyte specific gravity M <- <-
Looseness in the connecting parts I <- <-
Battery
Abnormality in the upper portion of the battery and/or
I <- <—
the case
Insulation resistance M <- <-
Voltage measurement of each battery cell after
M
charging
Contact looseness, damage, abrasion I <- <-
Operating condition, contamination and abrasion of
I <- <-
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 main circuit
I
lead wire
Operating condition and timing I <- <-
Micro switch
Damage and looseness of installation locations I <- <—
Direction switch Operating condition, damage I <- <-
Operating condition I <- <-
Controller Interior contamination, damage C <- <-
OCL measurement M
Fuses Looseness of the installation locations I <- —
Harness deterioration, damage and looseness of the
I* I <- <—
Wiring clamp
(incl. charging Looseness of the connections, taping condition I* I <- <-
cable) Connecting condition and damage of the battery
I* I <- <-
connector
POWER TRANSMISSION SYSTEM
Oil leak I <- <-
Drive unit Oil level I <- <-
Bolt or nut looseness T
 0-23

Every 6 Every 3 Every 6 Every 12

_____ Inspection timing
weeks months months months
Every Every Every Every
Item
250 hours 500 hours 1000 hours 2000 hours
DRIVE SYSTEM
Front axle Damage and deformation I
Damage and deformation I

Rear axle Abnormal noise looseness of rear axle bearing I

Looseness of axle beam in vehicle longitudinal
M
* M
direction
Tire pressure (OPT) M <- <-
Tire crack, damage and abnormal wear I <-
Tire tread depth M
* M <- <-
Metal piece, stone and other foreign matter on tire I* I <- <r-
Wheels
Loosening of wheel nut and bolt T <— <-

Rim, side ring and disc wheel damage I* I <-

Looseness and abnormal noise of front wheel bearing I* I <- <-
Looseness and abnormal noise of rear wheel bearing I* I <- <-
STEERING SYSTEM
Play, loosening, looseness I* I <— «-
Steering wheel
Function I* I <- <-
Oil leak I* I <- <-
Steering valve
Looseness of the installation locations *
T T <-
Wheels for steering Turning angle to left and right I
Oil leak I <- <—

Power steering Looseness of the installation locations I <- <-

Damage of power steering hose I
BRAKING SYSTEM
Reserve M <- <—
Brake pedal
Braking performance I <- <-
Operating force and pull margin I <- <-
Parking brake
Braking performance I <- <-
Looseness and damage I* I <- <-
Rod and cable
Operating condition I* I <- <-
Oil leak I* I <- <—
Oil level I* I
Wear of sliding portion and pad ‘2

Wet disc brake Disc wear and damage *2

Pedal stroke *
M M
Operating condition I
Return spring fatigue *2

MATERIAL HANDLI MG SYSTEM

Damage or wear of fork or stopper pin I <- <-
Fork Misalignment between left and right fork fingers I <- <-
Cracks at fork root and welded part of tooth r?
*2 Inspection every 21,000 hours
0-24

Every 6 Every 3 Every 6 Every 12

weeks months months months
Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours

1 <- <—

1 <- <-
Mast and lift 1 <- <—
bracket Deformation and damage of each part and crack at
1 <- <-
welded part
1 <- <-
Wear, damage and rotating condition of roller
1 <- <-
Mast and lift bracket looseness
Chain lubrication 1 <- <—
Wear and damage of mast support bushing
Chain and chain Tension deformation, damage and slackness of chain 1* 1 <- <-
Wear and damage of roller pin
wheel Abnormality of chain anchor bolt and nut 1 <- <-
Wear and damage of mast pads
Wear, damage and revolution of chain wheel 1 <- <-
Various
Abnormality and installation condition of each part 1 <- <—
attachments
HYDRAULIC SYSTEM
Looseness, deformation and damage of rod and rod
1 <— <—
end
Cylinder operation 1 <- <-
Natural drop and natural forward tilt M <- <-

Cylinder Oil leak and damage 1 <- <—

Wear and damage of pin and cylinder bearing 1 <- <-
Loosening and damage of cylinder mounting T <— <—
Lifting speed M <- <-
Uneven movement 1 <— <-
Oil pump Oil leak and abnormal sound 1 <- <-
Oil level and contamination 1 <— <-
Hydraulic oil tank Oil leak 1 <- <-
Tank and oil strainer cleaning C <-
Hydraulic oil filter Filter clogging C
Control lever Operation 1 <- <-
Oil leak 1 <•— <-
Oil control valve Safety valve function 1 <- <-
Relief pressure measurement M
Hydraulic hose and Oil leakage, deformation and damage 1 <— <-
piping Looseness T <- <-
SAFETY DEVICES, ETC.
Looseness of the installation locations T <- <-
Head guard and
Deformation, crack and damage 1 <- <—
backrest
Crack at welded portion 1 <-
Lighting system Function and installation condition 1 <- <-
Direction
Function and installation condition 1 <- <—
indicator
Horn Function and installation condition 1 <- <-
 0-25

Every 6 Every 3 Every 6 Every 12

—Inspection timing
weeks months months months
Item " Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Backup buzzer Function and installation condition 1 <-
Rear view Rear reflection status 1 <- <-
mirror Dirt, damage 1 <— <-
Instruments Operation 1 <- <-
Loosening and damage of mounting 1 <-
Seat belt damage and function 1 <- <-
Seat
Deadman seat operation 1 <-
Seat switch function 1* 1 <-
OPS Function 1* 1 <-
Damage and cracks in frame, cross members, etc. I
Body
Bolts and nuts looseness T
Functions 1 <- <—
Loosening and damage at sensor mounting portion 1 <- <-
Damage, deformation, oil leakage and loosened
SAS 1 <r- <-
installation of functional parts
Loosening and damage of wire harnesses 1 <-
Rusting and corrosion of load sensor I
Others Grease up L <-
0-26

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

•: Replacement
Every Every Every Every
Replacement cycle
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item
250 hours 500 hours 1000 hours 2000 hours
Drive unit gear oil • <-
•Every
Wet disc brake oil
1.5 years
Hydraulic oil • <—
• New
Hydraulic oil filter vehicle initial • <-
replacement
Rear wheel bearing grease •
•Every
Power steering hose
2 years
•Every
Power steering rubber parts
2 years
•Every
Hydraulic hose
2 years
•Every
Mast pads
2 years
•Every
Mast support bushing
2 years
•Every
Lift chain and chain wheels
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
REMOVALINSTALLATION.............................................. 1 -5
INSPECTION...................................................................... 1-6
REPLACING BATTERY PLUG TERMINAL..................... 1-9
1-2

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.

Battery compartment dimensions [mm] Necessary

Vehicle type minimum/maximum Remarks
battery weight (with case) [Kg]
Depth X Width Y Height Z
8FBET15 522 830 627 672 / 790
8FBEKT16 630 T T 813/960
3 Wheel 8FBEKT18 630 T T 813/919
8FBET16-18 738 T T 962/1140
8FBET20 T T T 962/1064
8FBMT15 522 T T 672 / 790
4 Wheel
8FBMT16-20 738 T T 962/1140
 1-3

SERVICE STANDARDS
Specific gravity (Upon full charge) 1.280 [20 °C (68 °F)]
Specific gravity (Upon end of discharge) 1.150 [20 °C (68 °F)]
Discharge end voltage 48 V 40.8 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 1MQ or more

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

Indicate level Low Remaining Battery Charge Warning

Battery
When the battery charge becomes below the set level, the battery
discharged 10 9 8 7 6 5 4 3 2 1
charge indicator blinks and the alarm will sound for five seconds
state % F E
after the key switch is set to the ON position.
Oto 10
(exclusive)
O O O o O O O o o o
Battery Overdischarge Warning
10 to 20
(exclusive)
- O o o O O O o o o When the battery charge decreases further below the set level after
20 to 30 the remaining battery charge warning, any attempt at traveling or
(exclusive)
- - o o O O O o o o material handling operation will cause all charge indicator
30 to 40 segments to blink and the alarm to sound to warn the operator.
(exclusive)
- - - o O o O o 0 o
40 to 50
(exclusive)
- - - - o o O o o o
50 to 60
(exclusive)
o o o o o
60 to 70
(exclusive)
o o 0 o
70 to 80
(exclusive)
o o o
80 to 90
(exclusive)
o o
90 to 100
(exclusive)
o
100 or more
1-4

TROUBLESHOOTING
 1-5

BATTERY ASSY

Removal Procedure
1. Disconnect the battery plug.
2. Release the steering release lever.
3. Tilt up the steering column.
4. Open the battery hood and remove the side hood.
5. Remove the battery ASSY. [Point 1]

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

Point Operations
[Point]
Removal:
Using SST, remove the battery ASSY.
SST 25009-13201-71
1-6

INSPECTION
1. Electrolyte level inspection
Open the cap, and if the white line on the red float has
dropped, water should be added.
Add water until the white line appears.
Stop water addition when the white line appears, since
addition is excessive when the tip end of the float comes into
contact with the stopper.

As a level gauge is provided at the front of the battery case,

the electrolyte level can generally be checked at a glance, but
open the cap to check the level when making a periodic
inspection.
The green light of the level gauge lights up to indicate
activation of the level gauge sensor, and the red light flashes
to indicate the necessity of adding water.
Red light Green light
Normal level Off On
Insufficient level Blinking On

Note:
Never change the installation location of the sensor.

References:
The consumption of electrolyte can be calculated by the
following equation:
Consumption (cc) = 5 hour capacity x 0.0336 x number of cells
x number of charges
Battery voltage Battery capacity
Model
M [AH/5hr]
420
8FBET15
48 460
8FBMT15
500
525
8FBEKT16 48 575
625
630
8FBET16
48 690
8FBMT16
750
525
8FBEKT18 48 575
625
630
8FBET18
48 690
8FBMT18
750
630
8FBET20
48 690
8FBMT20
750
 1-7

2. Electrolyte inspection
The battery electrolyte is normal when it is transparent. Check
turbidity when inspecting the specific gravity. If it cannot be
checked clearly, put the electrolyte in a beaker for inspection.

3. Battery electrolyte specific gravity inspection

Use a hydrometer to measure the specific gravity of the
electrolyte.
Specific gravity upon complete charging ....
1.280 [20 °C (68 °F)]
Specific gravity upon end of discharge ....
1.150 [20 °C (68 °F)]

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

Equation for converting specific gravity

S20=St+0.0007 (t-20)
S20: 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.
1-8

4. 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 MO or more.

* Battery control table

Prepare a control table for each battery to record and maintain the inspection results.

Time and date Specific gravity Temperature Capacity

Inspection Inspected element Nr. Electrolyte Note Inspector
Electrolyte added water
 1-9

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.

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.
Terminal Screw driver

\ ir^

I.>; 7/7777'7771 Ip

Spring Spring

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.

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

tool.

5. Insert the terminal to the battery plug.

Check that the tip of the terminal goes over the tip of the spring
and securely set in the position.
 2-1

CONTROL SYSTEM
Page
GENERAL..................................................................2-2
SPECIFICATIONS.................................................... 2-3
COMPONENTS........................................................ 2-4
BEFORE REPAIR..................................................... 2-6
INSPECTION.....................................................................2-6
CONNECTOR INSPECTION................................... 2-7
TO USE SST...................................................................... 2-7
INSPECTION.....................................................................2-7
CONTROLLER....................................................... 2-22
REMOVALINSTALLATION........................................... 2-22
CONTACTOR PANEL ASSY................................. 2-24
REMOVAL-INSTALLATION........................................... 2-24
INSPECTION.................................................................. 2-25
OCL MEASUREMENT................................................... 2-26
REASSEMBLY................................................................ 2-29
DISPLAY................................................................. 2-30
LAMP SWITCH....................................................... 2-31
REMOVAL-INSTALLATION........................................... 2-31
DISASSEMBLY-INSPECTION-REASSEMBLY............ 2-33
ACCELERATOR SENSOR
(POTENTIOMETER).............................................2-34
BRAKE SENSOR (POTENTIOMETER)............... 2-36
MINI LEVER............................................................ 2-38
JOYSTICK....................................................................... 2-40
COMPONENTS...................................................... 2-42
REMOVAL-INSTALLATION........................................... 2-44
DISASSEMBLY-INSPECTION-REASSEMBLY............ 2-45
DISASSEMBLY-INSPECTION-REASSEMBLY.............2-47
2-2

GENERAL
8FBE series models are equipped with traveling/material handling controllers that control traveling and material
handling system. They are multi-functional controllers equipped with micro computers.
The traveling/material handling controller provides high performance in a wide range by means of inverter control of
AC motor drive system.
The main controller has a self-diagnosis function that automatically detects any abnormality of the main drive/pump
circuits, accelerator, brake, PS circuit, SAS/OPS 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
automatically taken to ensure safety.

In addition, setting the display to the analyzer (fault analysis) mode can identify the faulty portion and inspect the
main diver/pump circuits, each operating system and sensors.
SPECIFICATIONS
All models
F1 (for drive and pump circuit) 500A

F4 (for lights) 10A

Fuses F5 (for control circuit) 10A

F6 (for control circuit) 10A
F7 (for fan and solenoid) 10A
Contactor MB (for power supply) ME251
2-4

COMPONENTS
3 Wheel model 2401

2401-373
 2-5

2402

2403

EB—
CY—®

2403-089
2-6

BEFORE REPAIR
INSPECTION

1. Insulation resistance measurement

Note:
Always measure before inspecting the traveling/material
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 Mil or more)

Some components can be inspected after they are removed from the vehicle, some components can be inspected as
installed on the vehicle.
Main controller must be inspected as installed on the vehicle since the battery voltage must be applied.

Disassembly Procedure
• Overhauling the contactor 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 traveling/material handling controller and the main controller, as they 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.
• After installation, check that there is no interference of the bar and harness connection with other portion.
 2-7

CONNECTOR INSPECTION
TO USE SST
Use SSTs for quick and accurate measure on the 8FBET, 8FBEKT, 8FBMT series. The check will fail if the
connection method is wrong. Since boards may be damaged by incorrect connection, the operation is needed to be
careful.

Caution:
Always unplug the battery plug before SST connection and disconnection. If the battery plug is still
connected, various boards may be damaged.
Part No. Purpose Remarks
Measure the voltage or resistance for
09230-13240-71 For use CN101 toCN104
main controller.
09240-13240-71 Measure the voltage for AC driver. For use CN109 to CN111

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.

Measurement method and standard list

How to read the list

Tester Probe©

Tester Probe©

Connecror No. <-> Connector No. Conditions Standard Remarks

*
CN101-1 CN101-21 k
(51, LS-j Key switch OFF, DSF ON. Approx. 0V
(45, DSF)

Î
Terminal name Conditions for measurement

Electric Level No.

Connector pin No.

2-8

MAIN CONTROLLER
CPU board

CN101 CN102 CN103 CN104

n —-n ___ n L r
7 6 5 4 3 2 1 — 7 6 5 4 3 2 1 6 5 4 3 2 1

17 16 15 14 13 12 11 10 9 8 19 18 17|l6 15 14 13|12 1 1 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 2 3 22 21 20 27 26 25 24 23 2Î 21 20 19 18 17 25 24 23 22 21 20 19 18

34 33 32 31 30 29 28 3; 34 n
33 32 J L? 1 30 29 28 35 34 33 32 31 30 29 28 31 30
JL 29 28 27 26

CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN101-1 CN102-17 Unload solenoid ON Approx. 11V
(3, SOLLU+) (5, SLUL-) Unload solenoid OFF Approx. 0V
CN101-2 CN102-19 Tilt control solenoid ON Approx. 11V
(6, SLTFB+) (7, SLTFL-) Tilt control solenoid OFF Approx. 0V
CN101-3 CN102-1 Fan stop Approx. 1V
(97, FAN+) (98, FNDC1) Fan rotate Approx. 48V
CN101-4 CN 104-4
- Approx. 48V
(41.VBBT) (N2, N2)
CN101-5 CN101-16 Variation upon changeover from
Approx. 0V to 10V
(9, SLLA2+) (11, SLPS-) forward to backward lifting
CN101-6 CN101-12 Variation upon changeover from
Approx. 0V to 10V
(32, SLTA1+) (33, STPL-) forward to backward tilting
CN101-7 - Unused -
CN101-8 - Unused -
CN101-9 - Unused -
CN101-10 CN101-6 Resistance measurement with battery
Approx. 7Q *1
(36, SA1PL-) (32, SLTA1+) plug disconnected
CN101-11 CN101-6 Resistance measurement with battery
Approx. 7Q *1
(37, SA1PS-) (32, SLTA1+) plug disconnected
CN101-12 CN101-6 Resistance measurement with battery
Approx. 7Q
(33, STPL-) (32, SLTA1+) plug disconnected
CN101-13 CN101-6 Resistance measurement with battery
Approx. 7Q
(34, STPS-) (32, SLTA1+) plug disconnected
CN101-14 CN101-5 Resistance measurement with battery
Approx. 7Q *2
(39, SA2PL-) (9, SLLA2+) plug disconnected
 2-9

Connector No. <=> Connector No. Conditions Standard Remarks

CN101-15 CN101-5 Resistance measurement with battery
Approx. 70 *2
(40, SA2PS-) (9, SLLA2+) plug disconnected
CN101-16 CN101-5 Resistance measurement with battery
Approx. 70
(11.SLPS-) (9, SLLA2+) plug disconnected
CN101-17 CN101-5 Resistance measurement with battery
Approx. 70
(10, SLPL-) (9, SLLA2+) plug disconnected
CN101-18 - Unused -
CN101-19 CN 104-4 Key switch OFF Approx. 0V
(43, VBKY) (N2, N2) Key switch ON Approx. 48V
CN101-20 CN 102-26
- Approx. 5V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN 102-26
- Approx. 5V
(316, VRTRA+) (51, POT-)
CN101-24 CN 102-26
- Approx. 5V
(219, VRH+) (51, POT-)
CN101-25 CN 102-26
Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN 102-26
- Approx. 4.8V
(55, VRA2+) (51, POT-)
CN101-27 CN 102-26
Approx. 4.8V
(53, VRA1+) (51, POT-)
CN101-28 CN 102-26
- Approx. 4.6V
(29, VRT+) (51, POT-)
CN101-29 CN 102-26
- Approx. 4.6V *1
(30, VRAT1+) (51, POT-)
CN101-30 CN 102-26
- Approx. 4.6V *2
(31, VRAT2+) (51, POT-)
CN101-31 - Unused -
CN101-32
- - -
(51, POT-)
CN101-33 CN 102-26
- Approx. 4.8V
(74, VRB2+) (51, POT-)
CN101-34 CN 102-26
- Approx. 4.8V
(72, VRB1+) (51, POT-)

*1:STD
*2: OPT
2-10

CN102 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN102-1 CN 104-4 Fan stop More than 30V
(98, FNDC1) (N2, N2) Fan rotate Approx. 0V
CN102-2 CN104-4 Fan stop More than 30V
(99, FNDC2) (N2, N2) Fan rotate Approx. 0V
CN 102-3 CN 104-4 Key switch OFF Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Approx. 48V
CN 102-4 CN104-4 Key switch OFF Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Approx. 48V
CN 102-5 CN 104-4 Key switch OFF Approx. 0V
(17, SOLCOM) (N2, N2) Key switch ON Approx. 48V
CN 102-6 CN 104-4 Key switch OFF Approx. 0V
(17, SOLCOM) (N2, N2) Key switch ON Approx. 48V
Knob position correcting solenoid ON Approx. 11V
CN 102-7 CN 102-14
Knob position correcting solenoid Approx. 0V
(329, SLS+) (330, SLS-)
OFF
CN 102-8 - Unused -
Direction lever in the neutral Approx. 14V
CN 102-9 CN104-4 position
(332, OACC2) (N2, N2) Direction lever in the backward Approx. 0V
position
CN 102-10
- - -
(51, LS-)
CN 102-11 CN 104-4 Brake pedal is free Approx. 14V
(331.OACC1) (N2, N2) Brake pedal is depressed Approx. 0V
CN 102-12 - Unused -
CN 102-13 CN 104-4 Key switch OFF Approx. 48V
(335, RY1) (N2, N2) Key switch ON Approx. 36V
CN 102-14 CN 102-7 Resistance measurement with
Approx. 10Q
(330, SLS-) (329, SLS+) battery plug disconnected
CN 102-15 - Unused -
CN 102-16 CN101-1 Resistance measurement with battery
Approx. 10Q
(4, SLLL-) (3, SOLLU+) plug disconnected
CN102-17 CN101-1 Resistance measurement with battery
Approx. 10Q
(5, SLUL-) (3, SOLLU+) plug disconnected
CN 102-18 - Unused -
CN102-19 CN101-2 Resistance measurement with battery
Approx. 10il
(7, SLTFL-) (6, SLTFB+) plug disconnected
ATT1 lever in the neutral position Approx. 2.3V
CN 102-20 CN 102-26
ATT1 lever in the forward or Approx. 0.5 to 4V *1
(25, VRA12) (51, POT-)
backward position
ATT1 lever in the neutral position Approx. 2.3V
CN 102-21 CN 102-26
ATT 1 lever in the forward or Approx. 0.5 to 4V *1
(24, VRA11) (51, POT-)
backward position
Tilt lever in the neutral position Approx. 2.3V
CN 102-22 CN 102-26
Tilt lever in the forward or backward Approx. 0.5 to 4V
(23, VRT2) (51, POT-)
position
Tilt lever in the neutral position Approx. 2.3V
CN102-23 CN102-26
Tilt lever in the forward or backward Approx. 0.5 to 4V
(22, VRT1) (51, POT-)
position

*1: STD
 2-11

Connector No. <=> Connector No. Conditions Standard Remarks

CN102-24 CN 102-35
- Approx. 2.5V
(304, CSBAT) (305, CSBAT-)
CN 102-25 CN 102-26 Key switch OFF, brake pedal fully
Approx. 0.9 to 2.9V
(73, VRB2) (51, POT-) depressed
CN 102-26
- - -
(51, POT-)
CN 102-27 - Unused -
ATT2 lever in the neutral position Approx. 2.3V
CN 102-28 CN102-26
ATT2 lever in the forward or Approx. 0.5 to 4V *2
(27, VRA22) (51, POT-)
backward position
ATT2 lever in the neutral position Approx. 2.3V
CN 102-29 CN 102-26
ATT2 lever in the forward or Approx. 0.5 to 4V *2
(26, VRA21) (51, POT-)
backward position
CN 102-30 CN 102-26 Key switch OFF, accelerator pedal
Approx. 0.5 to 3.8V
(52, VRA1) (51, POT-) fully depressed
CN 102-31 CN 102-26
Tire position is neutral Approx. 2V
(317, VRTRA) (51, POT-)
CN 102-32 CN102-26 Key switch OFF, accelerator pedal
Approx. 0.9 to 4.1V
(54, VRA2) (51, POT-) fully depressed
CN 102-33 CN 102-26 Key switch OFF, brake pedal fully
Approx. 0.6 to 2.6V
(71, VRB1) (51, POT-) depressed
CN 102-34 - Unused -
CN 102-35
-■ - -
(305, CSBAT-)

*2: OPT

CN103 connector basic conditions (battery plug connected, key switch ON)
Connector No. Connector No. Conditions Standard Remarks
CN 103-1 CN 103-2 Swing SOL ON Approx. 9V
*3
(327, SLSW+) (328, SLSW-) Swing SOL OFF Approx. 0V
CN 103-2 CN103-1 Resistance measurement with battery
Approx. 60
(328, SLSW-) (327, SLSW+) plug disconnected
CN 103-3
- -
(14, DGND)
CN 103-4 CN 104-4 Key switch OFF Approx. 0V
(42, KYSAT) (N2, N2) Key switch ON Approx. 48V
CN 103-5
- - -
(N2, N2)
CN 103-6
- - -
(51, LS-)
CN 103-7 - Unused -
CN 103-8 CN 102-26
- Approx. 5V
(300, IPL+) (51, POT-)
CN 103-9
- Immeasurable -
(147, CAN2H)
CN 103-10
- Immeasurable -
(148, CAN2L)

*3: 8FBMT 15-20 vehicle only

2-12

Connector No. o Connector No. Conditions Standard Remarks

CN103-11
- Immeasurable -
(145, CAN 1H)
CN103-12
- Immeasurable -
(146, CAN1L)
CN 103-13 CN 103-6
- Approx. 14V
(311.SSTR+) (51, LS-)
CN 103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - Unused -
CN103-16 - Unused -
CN 103-17 CN 102-26 Variation upon changeover from
Approx. 1 to 4V
(56, VRTA) (51, POT-) forward to backward tilting
Lift lever in the neutral position Approx. 2.3V
CN 103-18 CN 102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(21, VRL2) (51, POT-)
position
CN 103-19 CN 102-26
- Approx. 2V
(302, IPL2) (51, POT-)
CN 103-20 - Unused -
CN 103-21 - Unused -
CN 103-22 - Unused -
CN 103-23 - Unused -
Key switch OFF, mast height switch Approx. 0V
CN 103-24 CN 103-6 ON
(91, SH2-1) (51.LS-) Key switch OFF, mast height switch Approx. 5V
OFF
Key switch OFF, height selector limit Approx. 0V
CN 103-25 CN103-6 switch ON
*2
(221, SHL) (51.LS-) Key switch OFF, height selector limit Approx. 5V
switch OFF
Lift lever in the neutral position Approx. 2.3V
CN 103-26 CN 102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(20, VRL1) (51, POT-)
position
CN 103-27 - Unused -
CN 103-28 CN 102-26 Variation upon changeover from
Approx. 0.5V to 4.3V *2
(220, VRH) (51, POT-) upward to downward lifting
Forks on the ground Approx. 1V
CN 103-29 CN 102-26
Amount of change between raising Approx. 0.5V to 4.5V
(59, SPLF) (51, POT-)
and lowering of the lift with a load
CN 103-30 CN 102-26
- Approx. 2V
(301, IPL1) (51, POT-)
CN 103-31 - Unused -
Key switch OFF, automatic lift leveling Approx. 0V
CN 103-32 CN103-6 switch ON
(70, STK) (51, LS-) Key switch OFF, automatic lift leveling Approx. 5V
switch OFF
CN 103-33 - Unused -
CN 103-34 - Unused -
CN 103-35 - Unused -

*2: OPT
 2-13

CN104 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN104-1 CN 104-4
- Approx. 48V
(41, B48V) (N2, N2)
CN 104-2 CN 104-4 Key switch OFF Approx. 0V
(44, VBMB) (N2, N2) Key switch ON Approx. 48V
CN 104-3 CN104-9 Key switch OFF Approx. 0V
(1, CBAT+) (2, CBAT-) Key switch ON Approx. 11V
CN 104-4
- -
(N2, N2)
CN 104-5
- - -
(N2, N2)
CN 104-6
- - -
(N2, N2)
CN 104-7 - Unused -
CN 104-8 - Unused -
CN 104-9 CN 104-3 Resistance measurement with battery
Approx. 200
(2, CBAT-) (1, CBAT+) plug disconnected
CN 104-10 CN 102-35
- Approx. 5V
(303, CSBAT+) (305, CSBAT-)
CN104-11 - Unused -
CN 104-12 CN 102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN 104-13 - Unused -
CN 104-14 CN 104-4
Approx. 14V
(334, PSACC+) (N2, N2)
CN 104-15 CN 104-4
- Approx. 14V
(60, PSSW+) (N2, N2)
CN104-16 - Unused -
CN 104-17 - Unused -
CN 104-18 CN103-6 Key switch OFF, seat switch ON Approx. 0V
(67, SDM) (51, LS-) Key switch OFF, seat switch OFF Approx. 5V
Key switch OFF, direction switch Approx. 0V
CN 104-19 CN 103-6 backward
(46, DSR) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
Key switch OFF, parking brake switch Approx. 0V
CN 104-20 CN 103-6 release
(66, SPB) (51, LS-) Key switch OFF, parking brake switch Approx. 5V
lock
CN 104-21 - Unused -
Key switch OFF, mast height switch Approx. 0V
CN 104-22 CN 103-6 ON
(90, SH1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN 104-23 - Unused -
CN 104-24 CN 103-6
Steering operation Approx. 0V to 5V
(314, SSTRC) (51, LS-)
CN 104-25 - Unused -
2-14

Connector No. <=> Connector No. Conditions Standard Remarks

Key switch OFF, direction switch Approx. 0V
CN104-26 CN 103-6 forward
(45, DSF) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
CN 104-27 - Unused -
CN 104-28 CN 103-6 Key switch OFF, load switch ON Approx. 0V
(68, SLM) (51, LS-) Key switch OFF, load switch OFF Approx. 5V
CN 104-29 - Unused -
CN 104-30 CN103-6
Steering operation Approx. 0V to 5V
(312, SSTR1) (51, LS-)
CN 104-31 CN 103-6
Steering operation Approx. 0V to 5V
(313, SSTR2) (51.LS-)

TRAVELING AC DRIVER 1 (LH)

CN109to CN111
J...
6 5 4 3 2 1
14 13 12 TOnFo 9 8 7

O O

CN109 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN 109-1 - Unused -
CN 109-2 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN 109-3 N1
Approx. 15V
(78, SSDL+) (N1, N1)
CN 109-4 N1 L: Approx. 0.5V or
-
(80, SSDL2) (N1, N1) H: Approx. 1.5V
CN 109-5 N1
- Approx. 5V
(86, STDML+) (N1, N1)
CN 109-6 N1
- Approx. 1V to 4V •
(87, STDML) (N1, N1)
 2-15

Connector No. <=> Connector No. Conditions Standard Remarks

CN 109-7 N1
- -
(151, SETLD2) (N1, N1)
CN 109-8 - Unused -
CN 109-9 N1
- -
(151, ISETLD) (N1,N1)
CN 109-10 N1 L: Approx. 0.5V or
-
(79, SSDL1) (N1,N1) H: Approx. 1.5V
CN 109-11 - Unused -
CN 109-12
- Immeasurable -
(145, CAN1H)
CN109-13
- Immeasurable -
(146, CAN1L)
CN109-14 - Unused -

TRAVELING AC DRIVER 2 (RH)

CN110 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN110-1 - Unused -
CN110-2 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN110-3 N1
- Approx. 15V
(75, SSDR+) (N1, N1)
CN110-4 N1 L: Approx. 0.5V or
-
(77, SSDR2) (N1, N1) H: Approx. 1.5V
CN110-5 N1
- Approx. 5V
(84, STDMR+) (N1.N1)
CN110-6 N1
- Approx. 1V to 4V
(85, STDMR) (N1, N1)
CN110-7 - Unused -
CN110-8 - Unused -
CN110-9 - Unused -
CN110-10 N1 L: Approx. 0.5V or
(76, SSDR1) (N1, N1) H: Approx. 1.5V
CN110-11 - Unused -
CN110-12
- Immeasurable -
(145, CAN1H)
CN110-13
- Immeasurable -
(146, CAN1L)
CN110-14 - Unused -
2-16

MATERIAL HANDLING AC DRIVER

CN111 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN111-1 * Unused -
CN111-2 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN111-3 N1
- Approx. 15V
(81.SSP+) (N1, N1)
CN111-4 - Unused -
CN111-5 N1
- Approx. 5V
(88, STPM+) (N1, N1)
CN111-6 N1
* Approx. 1V to 4V
(89, STPM) (N1, N1)
CN111-7 Unused -
CN111-8 N1
*- Approx. 5V
(152, SETP) (N1, N1)
CN111-9 N1
* Approx. 5V
(152, OSETP) (N1, N1)
CN111-10 N1 L: Approx. 0.5V or
-
(82, SSP1) (N1, N1) H: Approx. 1.5V
CN111-11 - Unused -
CN111-12
- Immeasurable -
(145, CAN1H)
CN111-13
- Immeasurable -
(146, CAN1L)
CN111-14 - Unused -
 2-17

CONTACTOR PANEL ASSY

CN27 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN27-1 CN27-2 Battery plug disconnected and CN27
Approx. 0Q
(P3, P3) (101, FLP) disconnection
CN27-2
- - -
(101, FLP)
CN27-3 CN27-4 Battery plug disconnected and CN27
Approx. 0Q
(P2, P2) (41.B48V) disconnection
CN27-4
- - -
(41, B48V)

CN28 connector basic conditions (battery plug connected, key switch ON)
Connector No. o Connector No. Conditions Standard Remarks
CN28-1 CN27-2 Battery plug disconnected and CN28
Approx. 0Q
(P3, P3) (101, FLP) disconnection
CN28-2
- - -■
(44, VBMB)
CN28-3 CN27-4 Battery plug disconnected and CN28
Approx. 0Q
(P3, P3) (41, B48V) disconnection
CN28-4
- - -
(19, VBMBSL)
2-18

CN136 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN 136-1 CN 136-2 Battery plug disconnected and
Approx. 20Q
(2, CBAT-) (1.CBAT+) CN136 disconnection
CN 136-2 CN136-1
- Approx. 11V
(1, CBAT+) (2, CBAT-)
CN 136-3 P1 terminal Battery plug disconnected and
Approx. OQ
(P2, P2) (P1,P1) CN136 disconnection
CN 136-4 - Unused -
CN 136-5 P4 terminal Battery plug disconnected and
Approx. OQ
(P3, P3) (P4, P4) CN136 disconnection
CN 136-6 P4 terminal Battery plug disconnected and
Approx. OQ
(P3, P3) (P4, P4) CN136 disconnection

CN137 connector basic conditions (battery plug connected, key switch ON)
Connector No. o Connector No. Conditions Standard Remarks
CN 137-1 CN 137-2
- Approx. 5V
(303, CSBAT+) (305, CSBAT-)
CN 137-2
- - -
(305, CSBAT-)
CN 137-3 CN 137-2
- Approx. 2.5V
(304, CSBAT) (305, CSBAT-)

CN223 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN223-1 - Unused -
CN223-2 CN223-4
- Approx. 12V
(97, FAN+) (335, RY1-)
CN223-3 - Unused -
CN223-4 CN223-2 Battery plug disconnected and
Approx. 180Q
(335, RY1) (97, FAN+) CN223 disconnection
CN223-5 - Unused -
CN223-6 N1 terminal
- Approx. 48V
(19, VBMBSL) (N1, N1)
CN223-7 - Unused -
CN223-8 N1 terminal
- Approx. 48V
(17, SOLCOM) (N1, N1)
 2-19

REVERSEZSTOP RELAY

Connector No. <=> Connector No. Conditions Standard Remarks

CN49-1 CN49-2 Brake pedal is free Approx. 0V
(334, PSACC+) (331, OACC1) Brake pedal is depressed Approx. 14V
CN49-1 CN49-3 Direction lever in the neutral Approx. 0V
(334, PSACC+) (332, OACC2) Direction lever in the backward Approx. 14V
CN49-2
- -
(331.OACC1)
CN49-3
- -
(332, OACC2)
CN49-4 CN49-6 Battery plug disconnected and CN49
00
(111, STL+) (101, B48V) disconnection
CN49-5 CN49-6 Battery plug disconnected and CN49
00
(198, LBU+) (101, B48V) disconnection
CN49-6 CN49-4 Brake pedal is depressed
Approx. OV
(101, B48V) (111.STL+)
CN49-6 CN49-5 Direction lever in the backward
Approx. OV
(101, B48V) (198, LBU+)

MULTI-FUNCITON DISPLAY

CN70

n_n_ r~y—i_ri_ _nn

|18|17|16|15|14 |13|12|11 |l0| 9 | 8 | 7 | 6 | 5 | 4 | 3 | 2 | 1 |
|36|35|34|33|32|3l|30|29|28|27|26|25|24|23|22|2l|20|l9|

CN70 connector basic conditions (battery plug connected, key switch ON)
Connector No. <=> Connector No. Conditions Standard Remarks
CN70-1 - Unused -

CN70-2 - Unused -

CN70-3
- - -
(169, TGND)
CN70-4
- - -
(14, DGND)
2-20

Connector No. o Connector No. Conditions Standard Remarks

CN70-5 CN70-4
- Approx. 6.3V
(16, D7V) (14, DGND)
CN70-6 CN70-3
- Approx. 5V *1
(162, ITKY3) (169, TGND)
CN70-7 - Unused -
CN70-8 CN70-3
- Approx. 5V *1
(160, ITKY1) (169, TGND)
CN70-9
- Immeasurable -
(166, OTKY3)
CN70-10
- Immeasurable -
(165, OTKY2)
CN70-11
- Immeasurable -
(164, OTKY1)
CN70-12 CN70-3
- Approx. 0V *1
(167, LEDTKY1) (169, TGND)
CN70-13 - Unused -
CN70-14 - Unused -
CN70-15
- Immeasurable -
(146, CAN1L)
CN70-16
- Immeasurable -
(145, CAN1H)
CN70-17 - Unused -
CN70-18 - Unused -
CN70-19 CN70-3
- Approx. 3V *1
(168, LEDTKY2) (169, TGND)
CN70-20 CN70-3
- Approx. 5V *1
(161, ITKY2) (169, TGND)
CN70-21 CN70-3
- Approx. 5V *1
(163, IPSTKY1) (169, TGND)
CN70-22 Unused
CN70-23 Unused
CN70-24 Unused
CN70-25 Unused
CN70-26 Unused
CN70-27 Unused
CN70-28 Unused
CN70-29 Unused
CN70-30 Unused

*1 : W/ PIN code entry system

 2-21

TEN-KEY (W/ PIN code entry system)

Connector No. <=> Connector No. Conditions Standard Remarks

CN33-1 CN33-7
- Approx. 5V
(160, ITKY1) (169, TGND)
CN33-2 CN33-7
- Approx. 5V
(161, ITKY2) (169, TGND)
CN33-3 CN33-7
- Approx. 5V
(162, ITKY3) (169, TGND)
CN33-4
- Immeasurable -
(165, OTKY2)
CN33-5 CN33-7
- Approx. 0V
(167, LEDTKY1) (169, TGND)
CN33-6 CN33-7
- Approx. 5V
(163, IPSTKY1) (169, TGND)
CN33-7
- - -
(169, TGND)
CN33-8
- Immeasurable -
(164, OTKY1)
CN33-9
- Immeasurable -
(166, OTKY3)
CN33-10 CN33-7
- Approx. 3V
(168, LEDTKY2) (169, TGND)
2-22

CONTROLLER

REMOVAL-INSTALLATION

Main Controller Assy

Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND; if there is
any voltage, insert a resistor at approx. 100Q between P4 and GND to discharge the capacitor.
N-m (kgf-cm) [ft-lbf]

T=5.5 (56.1) [4.06]

T=17.5 (178.5) [12.91]

Removal Procedure
1. Disconnect the battery plug.
2. Tilt up (or Release) the steering column ASSY.
3. Open the battery hood.

4. Remove the battery ASSY. (See page 1-5)

5. Remove the rear cover.

6. Remove the plastic rear cover.

7. Remove the battery guard.

8. Disconnect the wiring of the main controller.

9. Remove the main controller ASSY.

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 2-23

Traveling, Material Handling AC Driver

Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND; if there is
any voltage, insert a resistor at approx. 100Q between P4 and GND to discharge the capacitor.
N-m (kgf-cm) [ft-lbf]

Removal Procedure
1. Disconnect the battery plug.
2. Tilt up (or Release) the steering column ASSY.
3. Open the battery hood.
4. Remove the battery ASSY. (See page 1-5)
5. Remove the rear cover.
6. Remove the plastic rear cover.
7. Remove the battery guard.
8. Disconnect the wire harness from the main controller.
9. Remove the main controller ASSY.
10. Disconnect the power cables.
11. Remove the copper bar.
12. Remove the material handling AC driver RH.
13. Remove the traveling AC driver LH.
14. Remove the traveling AC driver.

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Before connecting the connectors or the cables, check the connector No. or the cable tags to ensure correct
connection.
2-24

CONTACTOR PANEL ASSY

REMOVALINSTALLATION
Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND; if there is
any voltage, insert a resistor at approx. 100Q between P4 and GND to discharge the capacitor.
N-m (kgf-cm) [ft-lbf]

Removal Procedure
1. Disconnect the battery plug.

2. Tilt up (or Release) the steering column ASSY.

3. Open the battery hood.

4. Remove the battery ASSY. (See page 1-5)

5. Remove the rear cover.

6. Remove the plastic rear cover.

7. Remove the battery guard.

8. Disconnect the wiring harness.

9. Remove the main controller ASSY.

10. Disconnect the power cables.

11. Remove the copper bar.

12. Remove the contactor panel ASSY.

 2-25

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Before connecting the connectors or the cables, check the connector No. or the cable tags to ensure correct
connection.

INSPECTION
1. MB (power supply contactor)
Inspection method
Disconnect CN136 connector, and measure the resistance of
the MB coil.
Portion to be Measurement Tester
Standard
inspected terminals range
Both terminals
of Approx. 20Q
MB coil Qx 1
CN 136-1(1) (at 20°C)
CN136-2 (2)

F4, F5 2. FUSES
Inspection method
Disconnect the fuse and measure the insulation resistance.
Portion to be Measurement Tester
Standard
inspected terminals range
Both terminals of
FUSES OQ 0x1
fuse

CN136
2-26

OCL MEASUREMENT
[For drive circuit]
1. Preparation before measurement
(1) Load the forklift so that it is within the rated capacity, and
position it so that the fork tip is facing a wall or steel pole.
Be sure to place a piece of wood between the fork tip and
the wall.

(2) Turn on the SST by pressing the POWER key on the unit
SST 09140-13130-71

(3) Press the MODE key twice to switch to the AC+DC A

measurement mode.
 2-27

(4) After pressing the SHIFT key, press the SAMPL key to set
SHIFT key enabled display the display update rate to “SLOW”.

Display update rate SHIFT key

SAMPL key

(5) After pressing the SHIFT key, press the CLEAR key to
start zero point adjustment. (Pressing the CLEAR key
makes the “ADJ” indicator flash and switches the unit to
zero point adjustment mode. When the “ADJ” indicator
stays on after flashing, zero point adjustment is
completed.)

2. Measurement work
(1) Set the clamp sensor of the SST on the motor cable.

Note:
Set the clamp sensor so that the cable is positioned in the
center of the clamp with the clamp sensor aligned
perpendicular to the cable.
2-28

(2) Turn on the key switch and set the direction switch to
“Forward”. Gradually depress the accelerator pedal to full
throttle and hold there. The SST will start measurement
automatically.
Note:
• The SST start measurement automatically as soon as
forward motion starts. Be sure to wait for approximately
20 seconds before reading the measurement value. “O.L.”
(Overflow alert) may be displayed during the first 10
seconds, or the displayed value may not be stable for a
while.
• If the measurement value is not stable after approximately
SHIFT key enabled display 20 seconds, retry measurement by pressing the SHIFT key
down then the PEAK/Hz key to enable filter setting as
shown in the illustration.
• Measurement can be done in this mode (AC+DC A mode,
Display update mode: SLOW) also. However, when using
other modes, motor current frequency in forward motion
is only 10 Hz or below and current measurement cannot
be obtained.

OCL Standard Value: 250 to 335A

[For pump circuit]

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.
 2-29

REASSEMBLY

Contactor Panel ASSY Reassembly Drawing

T=N-m (kgf-cm) [ft-lbf]

Caution:
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
2-30

DISPLAY
If the cause of trouble is judged to exist in the display, measure the voltage at the connector to which voltage is
applied.

n_n, , n__r~ÄJ-r-~i__n n n
|18|17|16|15|14|13|12|11|1O| 9|8|7|6|5|4[3|2|l|
|36|35|34|33|32|3i|30|29|28|27|26|25|24|23|22|2l|20|l9|

CN70 connector basic condition (Battery plug connected)

Connector No. o Connector No. Conditions Standard: Remarks
CN70-5 CN70-4
- Approx. 6.3V
(16, D7V) (14, DGND)
 2-31

LAMP SWITCH

REMOVALINSTALLATION
T=N m (kgf-cm) [ft-lbfj

Removal Procedure
1. Disconnect the battery plug.

2. Remove the steering wheel. [Point 1]

3. Remove the instrument panel.

4. Remove the direction cover.

5. Remove the column cover.

6. Disconnect the wiring of the lamp switch and remove it.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
2-32

Point Operations
[Point 1]

Disassembly:
Use the SST to remove the steering wheel.

SST 09604-76002-71
 2-33

DISASSEMBLYINSPECTIONREASSEMBLY

Disassembly Procedure
1. Remove the cam.

2. Remove the hom contact.

3. Remove the steering angle sensor.
4. Remove the light switch ASSY.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-34

ACCELERATOR SENSOR
(POTENTIOMETER)
1. Remove the accelerator potentiometer.

2. Check that the resistance between terminals.

Terminal 5-6 1.8 to 3.4 kQ
When the potentiometer is
rotated, the resistance must
Terminal 4-6
increase in proportion to its
angle.
Terminal 1-2 1.8 to 3.4 kil
When the potentiometer is
rotated, the resistance must
Terminal 2 - 3
increase in proportion to its
angle.

3. Temporarily install the accelerator potentiometer.

Note:
The accelerator potentiometer turns it for an installation hole
in about 10 degrees clockwise direction and install it.

4. Display the matching menu and check the output voltage of

the accelerator potentiometer.

Standard: VRA1 0.85 ± 0.1 V

If the voltage is within the standard range:
Press and hold down the switch (1) for more than 2 seconds to
perform matching.
If the voltage is outside the standard range;
(1) Loose the screw and adjust the voltage to the standard
value while checking the display and rotating the
accelerator potentiometer.
(2) Tighten the screw.

(3) Press and hold down the switch (1) for more than 2
seconds to perform matching.

5. Fully depress the accelerator pedal and check the voltage at

VRA1 Currently stored value that time.
Standard: VRA1 2.30 to 4.80 V
VRA2 2.75 to 4.80 V

Caution:
Before depressing the accelerator pedal, make sure that the
Spanner indicator on the display is blinking.
If the voltage is within the standard range:
Press and hold down the switch (1) for more than 2 seconds to
VRA2 perform matching.
If the voltage is outside the standard range:
Replace the accelerator potentiometer or accelerator pedal.
 2-35

Note:
For D2 pedal or DA pedal, take the pedal that has the lower
output voltages with the pedal fully stepped on, because them
of the forward pedal and reverse pedal may differ respectively.

6. Tighten the screw after adjustment and spread “I” mark by

yellow paint on the screw head.

Note:
• After performing the ACCEL OFF matching, be sure to
perform ACCEL ON matching.
• While the DRIVE is selected on the matching menu, the
spanner lamp blinks and driving is disabled.
• After entering and exiting the DRIVE on the matching
menu, Drive return to neutral is activated. Put the
direction lever in neutral and release the accelerator pedal
to cancel it.
2-36

BRAKE SENSOR (POTENTIOMETER)

1. Remove the brake potentiometer.
2. Check that the resistance between terminals.
Terminal 5-6 1.8 to 3.4 kil
When the potentiometer is
rotated, the resistance must
Terminal 4-6
increase in proportion to its
angle.
Terminal 1-2 1.8 to 3.4 kn
When the potentiometer is
rotated, the resistance must
Terminal 2-3
increase in proportion to its
angle.

3. Temporarily install the brake potentiometer.

Note:
The brake potentiometer turns it for an installation hole in
about 19 degrees clockwise direction and install it

4. Display the matching menu and check the output voltage of

the brake potentiometer.
Standard: VRA1 1.75 ± 0.1 V
If the voltage is outside the standard range:
Press and hold down the switch (1) for more than 2 seconds to
perform matching.
If the voltage is outside the standard range:
(1) Loose the screw and adjust the voltage to the standard
value while checking the display and rotating the brake
potentiometer.

(2) Tighten the screw.

(3) Press and hold down the switch (1) for more than 2
seconds to perform matching.

5. Perform matching of the wet disc brake activation point of the

brake potentiometer.
(1) Display the matching menu.
(2) Push the probe of a push-pull tester vertically into the
center of the brake pedal by applying a force of 162±8 N
(17±1 kg).
Note:
When performing the brake matching, be sure to release the
parking brake.
 2-37

(3) Using the matching menu, check the output voltage of the
VRB1 Currently stored value brake potentiometer.

:
BRAKE ACT Standard: VRB1 1.60 to 3.60 V
VRB2 2.05 to 4.50 V

Note:
The voltage must be 0.4 V or more higher than the voltage
checked in Step 4.
£ SEC
If the voltage is within the standard range:
.- ƒ Press and hold down the switch (1) for more than 2 seconds to
VRB2 perform matching.
If the voltage is outside the standard range:
Brake potentiometer or brake pedal mechanism faulty.

Note:
• After performing the BRAKE OFF matching, be sure to
perform BRAKE ACT matching.
• While the DRIVE is selected on the matching menu, the
spanner lamp blinks and driving is disabled.
• After entering and exiting the DRIVE on the matching
menu, Drive return to neutral is activated. Put the
direction lever in neutral and release the accelerator pedal
to cancel it.
2-38

MINI LEVER

Lift Lever-Attachment Lever

 2-39

Tilt Lever

Direction Switch

VBKY DSF DSR DSFo DSBu LS-

r\
F

N
r\
R

UI
< )

MARK TERMINAL
1 -
2 DSBu
3 DSFo
4 DSR
5 DSF
6 LS-
7 VBKY
8 VBKY
2-40

JOYSTICK

operation

Joystick for Lift and Tilt Operation

 2-41

Joystick for Attachment Operation

22.5 to 26°. 22.5 to 26° 22.5 to 26°. 22.5 to 26°

I_______________________________________________________ I

Direction Switch

VBKY DSF DSR DSFo DSBu LS-

F r\
N

MARK TERMINAL
1 -
2 DSBu
3 DSFo
4 DSR
5 DSF
6 LS-
7 VBKY
8 VBKY
2-42

COMPONENTS
6712

6712-043
 2-43

Mini Lever
6712

(LH LEVER,

AP—Û

67124)44

Joystick
6712

24

AP—i AQ
2-44

REMOVALINSTALLATION
T=N m (kgf-cm) [ft-lbf]

Removal Procedure
1. Open the battery hood and disconnect the connector.
2. Close the battery hood.

3. Remove the cover.

4. Remove the mini lever ASSY from the operator’s seat.

Removal Procedure
The installation procedure is the reverse of the removal procedure.
 2-45

DISASSEMBLYINSPECTIONREASSEMBLY
T=N-m (kgf-cm) [ft-lbf]

T= 2.0 to 4.0
(20.4 to 40.8)
[1.5 to 3.0]

Disassembly Procedure
1. Remove the lever for setting rotation. [Point 1]
2. Remove the rotary damper ASSY.

3. Remove the knob for fixing height and the lower bracket.

4. Remove the lever for setting forward and backward. [Point 2]

5. Remove the upper bracket.

6. Remove the armrest ASSY.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-46

Point Operations
[Point 1]
Installation:
Install the lever for setting rotation so that the dimension B
shown in the illustration on the left becomes 3 to 6 mm (0.118
to 0.236 in).
The B part moves 3.6 mm (0.142 in) with 1 notch of the
serration.

[Point 2]
Installation:
Align the hole in the clamp bracket with the lever shaft
protrusion to install, then turn as shown in the illustration on
the left.

Installation:
Follow the procedure below to install the forward-backward
adjustment lever.
(1 ) Move the armrest to the rearmost part.
(2) Tighten the flange nut until the operating force at the top of
the lever becomes 65 to 100 N (6.6 to 10.2 kgf) [14.6 to
22.5 Ibf].

(3) Press the armrest forward with the force of 100 N (10.2
kgf) [22.5 Ibf], and check that it doesn’t move. If it moves,
tighten the flange nut further.
(4) Tighten nut A to the specified torque.
T = 14 N m (142.8 kgfcm) [10.3 ft lbf]
 2-47

DISASSEMBLY’INSPECTION'REASSEMBLY

Disassembly Procedure
1. Remove the lever cover.
2. Disconnect the connector. [Point 1]
3. Remove each lever ASSY and guide. [Point 2]
4. Remove the direction switch ASSY.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Disassembly:
Always mark connectors with a tag etc. so that the connection
points can be found during reassembly.
Note:
Perform the matching when the mini lever/joystick is
disassembled.
 3-1

MULTI-FUNCTION DISPLAY
Page
GENERAL..................................................................... 3-2
GENERAL............................................................................. 3-2
GENERAL FUNCTIONS............................................. 3-3
GENERAL............................................................................. 3-3
ADMINISTRATOR FUNCTIONS........................................ 3-6
MASK FUNCTIONS.................................................. 3-21
GENERAL........................................................................... 3-21
PASSWORD....................................................................... 3-22
ANALYZER........................................................................ 3-24
TUNING............................................................................... 3-49
OPTION SET...................................................................... 3-58
MATCHING.......................................................................... 3-62
OTHERS MENU................................................................. 3-76
MULTI-FUNCTION DISPLAY ASSY....................... 3-88
COMPONENTS.................................................................. 3-88
REMOVAL • INSTALLATION........................................... 3-89
DISASSEMBLY * INSPECTION • REASSEMBLY........3-90
3-2

GENERAL
Multi-function display helps operators to identify various information easily by changing screens depending on the
vehicle conditions.

GENERAL

Display and Switches

Multi-function Multi-function
No. Description
Display Display Deluxe
(1) Switch (1): Low speed setting switch / Down switch O o
(2) Switch (2): Power select switch / Left switch O O
(3) Switch (3): Time or date selection switch / Right switch O O
(4) Switch (4): Meter mode selection switch / Enter switch O O
(5) Multiple screen display area O O
(6) OPS indicator O O
(7) Over load indicator X O
(8) Parking brake indicator O O
(9) Height limit indicator OPT OPT
(10) Low speed setting indicator O O
(11) Spanner indicator o O
(12) Overheat warning indicator o O
(13) Battery discharge indicator o O
(14) Power select indicator o O
(15) Direction indicator o O
(16) Mast tilt indicator X O
(17) Wheel indicator o O •

O: Standard x: Not available OPT: Option

 3-3

GENERAL FUNCTIONS
GENERAL

General Function List

O: Provided Not provided OPT: Option
Multi-function Multi-function
display Display Deluxe
O O
Indication that travel speed limiter is in active setting. O O
Indication that overspeed alarm is in active setting. O O
Indication that active mast front tilt control is in inactive
Initial display after key-ON O O
setting.
Indication that auto speed control is in active setting. - O
Indication that maximum height limiter is in active setting. OPT OPT
Indication that shock sensor is built in. OPT OPT
Calendar and clock O O
Battery discharge indicator 0 O
Digital speedometer O O
Low speed setting (turtle) indicator O O
Parking brake indicator O O
Power select (SPH) indicator O O
OPS indicator O O
Spanner time display
Date andindicator 0 O
Status display
Overheat warning indicator O O
Direction indicator O o
Wheel indicator O O
Mast tilt indicator - O
Load meter - O
Over load indicator - o
Height limit indicator OPT OPT
Indication of target height memory OPT OPT
Key switch on hour meter O O
Lap time meter O O
Drive motor service hour meter O O
Integrating meter
Pump motor service hour meter O O
Drive or pump motors service hour meter O O
Odometer O O
3-4

Multi-function Multi-function
display Display Deluxe
O O
Integrating meter
Planned maintenance hour meter O O
Battery over-discharge warning O O
Low battery capacity warning O O
Overheat warning O O
Low temperature warning O O
Parking brake ON warning O o
Parking brake OFF warning O 0
Trip meter
Return to neutral warning for travel OPS O o
Warning
Return to neutral warning for material handling OPS O o
OPS operation information O o
Return to neutral warning at starting O o
Diagnostic code display O o
Over speed alarm O o
Set load over alarm - o
Shock detection alarm OPT OPT
Power select (SPH) function (Operator Available) O o
Drive power control level setting (Operator Available) o o
Lift power control level setting (Operator Available) o o
Over speed alarm setting (Operator Available) o o
Low speed setting (Operator Available) o o
Maximum speed limitation setting
(Administrator Only)
o o
Level setting
Planned maintenance hour setting
(Administrator Only)
o o
Menu lock setting (Administrator Only) o o
Second password registration for administrator
(Administrator Only)
o o
Over load alarm setting
(Administrator Only)
- o
Maximum height limiter setting
OPT OPT
(Administrator Only)
Height limiter setting
Height position setting OPT OPT
(Operator Available)
Automatic height control setting
OPT OPT
(Operator Available)
 3-5

Multi-function Multi-function
------------- —---- ----------------------
display Display Deluxe
Display of shock detection memories OPT OPT
Support function for shock Setting of alarm values OPT OPT
sensor Shock detection level setting OPT OPT
Measurement of shock OPT OPT
Support function for PIN PIN code entry and setting OPT OPT
code entry Profile setting OPT OPT

* For an explanation of each function, see “New Model Features section.”

Initial screen after key-on

This screen is displayed for 2 seconds after the ignition key switch
is turned on. However, if the vehicle speed is detected 1 second or
more after that, the screen switches over to the TRAVELING
a screen.

30/ 9/2008 (TUE)

M a—

Display Description
30/ 9/2008 (TUE) Date display

Indication that travel speed limiter is in active setting.

o Indication that over speed alarm is in active setting.

Indication that auto speed control is in active setting.

♦J Indication that maximum height limiter is in active setting.

Indication that shock sensor is built in.

T-OFF Indication that active mast front tilt control is in inactive setting.
3-6

ADMINISTRATOR FUNCTIONS
Administrators can set the vehicle’s performance and each function.
Administrator functions are protected with password so that the general operators cannot change those functions.

Administrator Password
Note:
• Always operate switches displayed on the display with a finger tip. If a sharp pointed tool is used, the
switch may be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and reenter from the
beginning.

Password Entry Procedure

Step Display Operation Vehicle response

Q®]l10 Press switch (2) and switch (4) at

When pressing the switches, a
short beep sounds, and after 2
1 __ / the same time for more than 2
seconds another short beep
/ seconds.
sounds.
Switch (2) Switch (4)

Press switch (3) within 10

2 A short beep sounds.
seconds.

Press switch (3) within 10

3 A short beep sounds.
seconds.

When pressing the switches, a

Within 10 seconds, press switch
short beep sounds, and after 2
4 (2) and switch (4) at the same
seconds repeated short beeps
time for more than 2 seconds.
sound.
Switch (2) Switch (4)

When the second password has been set:

Second password screen is displayed. Enter the second
5 password.
Other:
This screen is skipped.

jSliTOmrzirrnrHi
sffl POWER MODE
6 ® DRIVE POWER Administrator menu screen is displayed automatically.
-I LIFT POWER
S3 (» I U CgZ
 3-7

Administrator MENU screen

W/0 PIN code entry W/ PIN code entry

(Ql r~D YTÌ iWì finì] ÎÎBimrTiiFnrïTL Ì

affi POWER MODE © REGISTRY
0 DRIVE POWER OPROFILE CHANGE
J LIFT POWER ffl DELETE
Ç3D ( <■ i ±J LtjJ, [Œ3 ( <■ I + j C>d

Icons
Icon Description Icon Description

This icon can set the drive and lift

■ ■
This icon can set the shock sensor
function. (Models with shock sensor
5 power control function.
■
only)

<S3>
u
This icon can set the travel control
function. 1 s This icon can set the PIN code entry
system function. (Models with PIN code
entry system only)

1 This icon can set the material handling

control function. (Models with height
selector or multi-function deluxe only)
Returning to general screen.

•m This icon can set the vehicle

management function.
3-8

Administrator Menu Screen (W/O PIN code entry)

General screen

Operating Procedure

□
I IM
□ 1. Input the password on the general screen to display the

□ ZZ
0 DRIVE POWER
J LIFT POWER
□ Administrator Menu screen.

I |q|Œ3 L<- î ■» ) Œ3
< /— —\ A
MENU

k
1
rj Qp0 <
y V —7 J È■1 B J

Switc 1(1) Switc 1(2) Swi Ich (3) Swi ch (4)

◄------- ►
r~ S
2. Press switch (2) or switch (3) to select the desired menu tab.
The selected tab is emphatically displayed and items that can
be set are displayed below.
iSiisirTimimra]

0 DRIVE POWER
J LIFT POWER
m l i
*
) ( t» )

3. Press switch (1) to select the item, and press switch (4) (enter)
to display the menu or setting screen for each function.

4 035 POWER MODE

0 DRIVE POWER
J LIFT POWER
( ♦ ) ( * I -LJ J

Note:
Select the return tab on the Administrator Menu screen, and
tor^irTimriTirsii press switch (4) (enter) to display the general screen.

END

ŒJ LfeL)
 3-9

Power control setting screen

• Power Mode Select

gl • Drive Power Select (Original Mode)

• Lift Power Select (Original Mode)
BsphI
0 DRIVE POWER
J LIFT POWER
( ♦ •)
V
( * i * ) (_jJjJ

Setting screen for drive function

• Speed Setting of Low Speed
• Speed Setting of Maximum Speed Limiter
• Speed Setting of Over speed Alarm
Emmmi SPEED
Jf^SPEED LIMIT
a SPEED ALARM
rrj nJi
Setting screen for material handling functions (OPT)
• Zero Point Setting of Load Meter *1
• Load Setting of Set Load Over Alarm *1
• Height Position Setting of Automatic Height Control *2

L • Height Position Setting of Height Limiter *2

• Height Position Setting of Maximum Height Limiter *2
*1: W/ Multi-function Display Deluxe
*2: W/ Height Selector

rm m itti itti
HE ]
ÏÂ HEIGHT LIM
+1 MAX HEIGHT LIM
J (_<■ ■ ■* ) LfeL)
I*
3-10

Vehicle management screen

• Setting of Planned Maintenance Hour Meter
• Setting of Auto Power Off
• Setting of Administrator’s Second Password
• Switching of Menu-Lock

Support screen for shock sensor (OPT)

• Checking Shock Memories

rtnsii • Reset of Shock Alarm

• Monitor and Setting of Shock Detection Level
I ® SHOCK MEWjliwfl • Clearing Shock Memories

4= ALARM RESET
hi MONITORZSET
( ♦ ) *
(
)
!■ (Tj?i

i r^ffi r^i m m igTi n=n

ffl MEMOR

¡23D ( > i J FP~)

Return to general screen

t (_
*• i -L_)
 3-11

1. Power Control Setting Menu Screen

This menu screen can set the drive and lift power control function.

BsphI
© DRIVE POWER
J LIFT POWER
CAJ l* » + ) U=U
(1) Power select screen
The power select mode (S, P, H or Original) can be selected by
( SSI POWER MODE pressing switch (2) or switch (3) on the power select screen by
shifting to the corresponding indicator position.
This is the same as the one in the operator functions.
H~pTh! Switch (2): S -> SPH -> H -> P
Switch (3): S -> P -> H -> SPH
Switch (4): Returning to power control setting menu
screen.
When the original mode is selected, all of S, P, and H are
inverted.

(2) Drive power control level setting

The drive power of the original mode can be set in five steps.
© DRIVE POWER Switch (2): Select the lower level.
Switch (3): Select the higher level.
Switch (4): Returning to power control setting menu
screen.
This is the same as the one in the operator functions.

(3) Lift power control level setting

The lift power of the original mode can be set in five steps.
J LIFT POWER Switch (2): Select the lower level.
Switch (3): Select the higher level.
4 5
rr 3 Switch (4): Returning to power control setting menu
screen.
This is the same as the one in the operator functions.
S P H
Œ3 C □d
3-12

2. Travel Setting Menu Screen

This menu screen can set the travel control function.

I SPEED I
Jf^SPEED LIMIT
A SPEED ALARM
nrr t * i * ) t j

(1) Low speed setting screen

The limit speed of the Low-speed setting function can be
[*^LOW ISPEED changed.
Switch (2): Setting traveling speed down.
1 Q km/h

r *
1 i ■+) r?n
Switch (3): Setting traveling speed up.
Switch (4): Returning to setting menu screen.
It is adjustable from 2 to 50 km/h with a step of 1 km/h.
If the operator set the speed to more than 50km/h, the low
speed function is disabled.
X_________ ___ _
In that case “OFF” is displayed.

(2) Maximum speed limit setting screen

The limit speed of the Maximum speed limiter can be changed.
Jft^SPEED LIMIT Switch (2): Setting traveling speed down.
Switch (3): Setting traveling speed up.
*| ^m/h Switch (4): Returning to setting menu screen
It is adjustable from 2 to 50 km/h with a step of 1 km/h.
If the operator set the speed to more than 50km/h, the
maximum speed limit function is disabled.
CSZ) In that case “OFF” is displayed.
 3-13

(3) Over speed alarm setting screen

The speed to activate the over speed alarm function can be
a SPEED ALARM
2
changed.
Switch (2): Setting traveling speed down.
Switch (3): Setting traveling speed up.
Switch (4): Returning to setting menu screen
It is adjustable from 5 to 50 km/h with a step of 1 km/h.
If the operator set the speed to more than 50km/h, the over
speed alarm function is disabled
In that case “OFF” is displayed.

3. Material Handling Setting Menu Screen

This menu screen can set the Material Handling control function.
(TTi m iwi n=ri
■JBWTiiiEHiaawMai
LOAD ALARM SET
1aJ HEIGHT SET
i. ♦ J C> i ■* ) L*- )

fj|
HE]
Ria HEIGHT LIM
+J MAX HEIGHT LIM
t<■ i j )
3-14

(1) Load meter zero point adjustment screen (Multi-function

display deluxe only)
i ZERO SET Zero point of the load meter is adjusted.
V mast

(OSET)
0.0 Ot (NEXT)
At low lift height (ZERO SET):
Set the mast approximately vertical, and raise forks at height
of approximately 500mm from the ground.
Pressing switch (1) for more than 2 seconds will reset the
indicated value to 0. In that case “OK” is displayed.
Switch (4): Return to menu screen

( ZERO SET

ÎSEC 0.0
(OSET) H3
0 1
(NEXT)

FW and FSW mast

At low lift height (ZERO SET1):
( ZERO SET 1 1 Set the mast approximately vertical, and raise forks at height of
approximately 500mm from the ground.

d c1.0 0t
Pressing switch (1) for more than 2 seconds will reset the indicated
value to 0.
In that case “OK” is displayed.
2SEC Switch (4): Next screen
(OSET)
lEl (NEXT)

FW and FSW mast

At high lift height (ZERO SET2):
i ZERO SET 2 1 Set the mast approximately vertical, and raise the rear lift cylinders
to a height of approximately 100mm.

^1 c10 0t
Pressing switch (1) for more than 2 seconds will reset the indicated
value to 0.
In that case “OK” is displayed.
2 SEC Switch (4): Return to menu screen
(OSET) INEXTI
X______ _____ ________ j

(2) Set load over alarm setting screen (Multi-function display

r deluxe only)
The load to over set load alarm is set.
Switch (2): Setting load down.
Switch (3): Setting load up.
Switch (4): Return to menu screen

x.
 3-15

(3) Automatic height control setting screen (W/ Height Selector)

R

Hil HEIGHT SET

let I

2 SEC
I SET ) [ 1 1 ( t3 )

(4) Clear all memories screen (W/ Height Selector)

1UJ HEIGHT SET CLFn

. ~Jl rJ|
HfflALL CLEAR?|
2 SEC"
rCLR-j rsi

(5) Height limiter setting screen (W/ Height Selector)

RS HEIGHT LIN
ga / CLR
a sec ____ ____
rsËT) i ■» :i ran

(6) Maximum height limiter setting screen (W/ Height Selector)

tJ MAX HEIGHT LIM

§9 / CLR
a sec ____ ____
|j~sm i j»J C5~)l
3-16

4. Vehicle Management Setting Menu Screen

-s This menu screen can set the vehicle management function.
(sai rgn rji fZi rgriAgi
eX MAINT raeraeWîlM

*7i
rwhi^im fÂl rrnr

*~)
C~ ( * l * ) çgj

(1) Planned maintenance hour meter setting screen

Time for planned maintenance hour meter can be set from 10
[ ÈLX MAINTENANCE HR Ì to 2000 hours by 10-hour increments between 10 and 200

CURRENT S Oh hours, while 50-hour increments between 200 and 2000 hours.
Switch (2): Decreasing set time
SETTING 2000 h Switch (3): Increasing set time
Switch (4): Returning to menu screen
2 SEC
(RESET) ( * I cæl Pressing switch (1) for more than 2 seconds will reset the
current value to 0.

(2) Auto power off time setting

X

The time to activate the auto power off function can be

POWER OFF '
01
—

changed.
Switch (2): Decreasing set time

5 Switch (3): Increasing set time

Switch (4): Returning to menu screen
.....

Vm 1 n It is adjustable from 2 to 60 minutes with a step of 1 minute.

Auto power off function is disabled by selecting “OFF” which is
next to “60 min”.
 3-17

'3) Administrator’s second password setting screen

The administrator can register the second password.
The second password can be registered by continuing to press switch (1) for 2 seconds after entering it by using
switch (1) to (4). If press the switch (4) for 2 seconds or more, the screen returns to the menu screen without
memorizing it.
Administrator should manage the second password so that it doesn’t get unknown.
Even if it has got unknown, the technician can clear it on the masked menu.

■
□
□□ '
□□□ irtWi f7TirTiiyiiT?ii4=ri
eX MAINTENANCE HR
<3D AUTO POWER OFF
PASSWORD
□
r l* « u LtJ i

[ >J©
isi>1h1[<
HhJ
Switch (1) Switch (2) Switch (3) Switch (4)

(4) Delete of password

Pressing switch (1) for more than 2 seconds can clear the password on the administrator’s second password
setting screen.
If press the switch (4) for 2 seconds or more, the screen returns to the menu screen.
□□ '

□□
□□□ ■

îssi iwi nn îjü rFn r+ri •“PASSWORD

ex MAINTENANCE HR
CO AUTO POWER OFF
PASSWORD 2&EC
■
2 SEC
ï ♦J U- i O U-»1 I CLRJ erto
A
r f----- Ï (-----
SÉ0 <
<
> ®
'----- J
(^)b
Switch (1) Switch (2) Switch (3) Switch (4)

t I
3-18

(5) Menu lock screen

Change in the setting values by an operator can be limited.
Setting to “Yes” will cancel displaying the setting menu and
power control setting screen for an operator.
When “menu lock” is effective, operators cannot change the
power mode and operator’s menu is not displayed.
Switch (2): Selecting “Yes”
Switch (3): Selecting “No”
Switch (4): Returning to menu screen

5. Shock Sensor Setting Menu Screen (OPT)

This menu screen can set the Shock Sensor function.

4= ALARM RESET
Li MONITOR/SET
*±j
m r lPjJ

ffl MEMORY CLL

6. End Menu Screen

Switch (4): Returning to general screen
r^i r~n m im FBI
END

( i ) rP~)
 3-19

Administrator Menu Screen (W/ PIN code entry)

General screen
• Entering Administrator Password

1. PIN Code Entry System Setting Menu Screen

This menu screen can set the PIN Code Entry System function.
• Registry of PINs
m r~n m cftiÌ • Change of Profile Assignment
• Delete of PINs for operators
REGISTRY • Profile Data Setting
(BOPROFILE CHANGE • Change of Initial PIN

ffl DELETE

fBl
'PROFILE SETTING
fTffl
•-INITIAL PIN
[ ♦ 1 I +■ I * ) ( 4-1 )

2. Material Handling Setting Menu Screen (W/ Height Selector or

Multi-function display deluxe)
■x
This menu screen can set the Material Handling control function.
For details, refer to “Material Handling Setting Menu Screen” (W/O
SET PIN code entry).
• Zero Point Setting of Load Meter *1
E3) LOAD ALARM SET • Load Setting of Set Load Over Alarm *1
• Height Position Setting of Automatic Height Control *2
1UI HEIGHT SET • Height Position Setting of Height Limiter *2
J I
(. * * i ) U=!J. • Height Position Setting of Maximum Height Limiter *2
*1: W/ Multi-function Display Deluxe
*2: W/ Height Selector

Rd HEIGHT LIM
ÏJ MAX HEIGHT LIM
3-20

3. Vehicle Management Setting Menu Screen

This menu screen can set the track management function.
For details, refer to “Vehicle Management Setting Menu Screen”
(W/O PIN code entry).
a ma] • Setting of Planned Maintenance Hour Meter
• Setting of Auto Power Off
• Setting of Administrator’s Second Password
• Switching of Menu-Lock

( *
Ç i + ) C
*F)

4. Shock Sensor Setting Menu Screen (VW Shock Sensor)

This menu screen can set the Shock Sensor function.
• Checking Shock Memories
rwirriCETitTirïn • Reset of Shock Alarm
|i ■ lilililïà il [¡KM • Monitor and Setting of Shock Detection Level
• Clearing Shock Memories
4= ALARM RESET
hiMONITOR/SET
r
*
3 t > » n
*

irmr~nmi^fHT
■maiianiiawiirfil

( > I tJ ŒJ

5. End Menu Screen

Switch (4): Returning to general screen
 3-21

MASK FUNCTIONS
GENERAL
n the multifunction display, aside from the general functions that an operator or an administrator normally use, the
ollowing mask functions for use by the service staff for vehicle maintenance and specification setting are also
>rovided. The service functions are protected by the password so that the important internal data will not be
iamaged by wrong use of service functions by users by mistake.

Mask Function List

When used
Function Description Board
Vehicle delivery Others
replacement
Displays the electrical system
status and reads the error Upon vehicle
Analyzer - -
information detected by abnormality
controllers.
Makes fine adjustment of
Tuning O As requested
traveling and material handling -
*2 by customer
functions.
Specification Sets each vehicle option and O
- -
setting other specifications. *1 *2,
*3
Option setting Each control
Enables or disables each control O
function enable/ - -
function. *2,
*3
disable
Drive
Updates voltage values of
SAS O
sensor signals under the - -
Mini lever *2,
*3
Matching standard vehicle condition.
Load meter
Makes the speedometer reading O
Tire data -
appropriate. *2
Starts counting the hour meter,
Meter start O
odometer, trip meter and O -
*3
maintenance hour meter.
Enables simultaneous operation
Demo mode Before starting
of traveling and material handling - -
before starting the hour meter. the hour meter

Initialize a set value with the O When it is

To default set -
Others menu default value. *2,
*3 necessary
Mask second O When it is
Sets the mask second password. -
password setting *3 necessary
Administrator’s
Delete the administrator’s O As requested
second password -
second password. *3 by customer
clear
Adjusts the contrast of the O As requested
Contrast -
display screen. *3 by customer
*1: The option set function is used to fit the specifications of the controller and the multi-function display for the
options actually equipped on the vehicle. Functions are not available for the vehicle where they are not mounted,
even if the OPTION SET enables them.
*2: Board: Main controller control board
*3: Board: Control board for the multi-function display
3-22

PASSWORD
Note:
• Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch may be
damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning. If the MASK MENU cannot be displayed after several attempts, the system may be faulty.

Password Entry Procedure

Step Display Operation Vehicle response

1
0 Press switch (2), switch (3) and
switch (4) at the same time for
When pressing the switches, a
short beep sounds, and after 2
_J seconds another short beep
more than 2 seconds.
sounds.
Switch (2) Switch (3) Swi,Ch <4>

^Pfîl <
Press switch (4) within 10
2 A short beep sounds.
seconds.
Switch (4)

(----- /---------

< >
3
J X.______ J Press switch (1) within 10
A short beep sounds.
seconds.
Switch (1)

When pressing the switches, a

Within 10 seconds, press switch
short beep sounds, and after 2
4 (2) and switch (3) at the same
seconds repeated short beeps
time for more than 2 seconds.
sound.

MASK PASSWORD When the mask second password has been set:

5 ■ ¡■■a
/ ! \ 2SEC
Second password screen is displayed. Input the second
password.
Other:
This screen is skipped.
IËXÎTI

6
VER 1.00 Mask function initial screen is displayed for 5 seconds.

BUILT IN ANALYZER

ÎKl ffîifîl ÎÎÏPTl ÌMflTl l’FtvTll'lTÌ

1 .DIAG MEMORY
7 2.1/0 TEMP/VOLT ANALYZER MENU screen is automatically displayed.
3.1/0 TRAVELING
*Z)
c qjt
 3-23

MASK MENU Screen

Operating Procedure

1. Enter the password on the general screen (See page 3-22) to

(gwCignai iSFi display the MASK MENU screen.

1.DIAG MEMORY
2.1/0 TEMP/VOLT
3.1/0 TRAVELING
F»3 ( » I C^Fj

2. Select a desired function using the switch (2) or (3). Then

press the switch (4) to display the function screen or setting
screen of the selected function.

Reads out information about the error detected by a controller

læl ANALYZER MENU screen and indicates the operating state of the electric system of the
vehicle.

[tlìR| TUNING MENU screen

Fine adjusts the settings fortraveling control, material handling
control, etc.

fm’l OPTION SET MENU screen

Adjusts the display and the controllers according to the
specifications of each vehicle or the control conditions set for it.

[Mini MATCHING MENU screen

Updates the sensor output voltages and the set values stored
in the memories of the display and each controller.

This allows you to:

• Start each meter
*.
• Switch demo mode*.
|eto| OTHERS MENU screen • Initialize the settings.
• Set a mask second password.
• Clear the administrator second password.
• Adjust the contrast of the LCD display.

I5Ì END of MASK MENU From this screen, you can move to a normal screen.

After completing the hour meter start setting, “METER START” and “DEMO MODE” will not displayed on the
OTHERS MENU screen.
3-24

ANALYZER
GENERAL
Analyzer function supports operations for inspection/investigating faulty section by displaying the condition of the
control system, using communication between each controller and the multifunction display.
By switching the multifunction display to analyzer mode, operative conditions of the sensors and actuators which are
used for traveling, material handling and SAS/OPS functions, or the error information detected by the controller can
be read.
This is very useful for checking operative condition of each function and saving time for repairing when there is a
detect. Full utilization of the analyzer functions helps quick, easy servicing.

The analyzer has the following functions:

1. Diagnosis memory function (DIAG MEMORY)

The controller stores up to 10 error codes (diagnosis codes) detected in the electrical system in the past. The
diagnosis function reads these error codes and indicates them on the display.
Each error code is displayed with its detection time as the key ON hour meter reading.

2. In/Out monitor function (I/O MONITOR)

This function displays switch ON/OFF state and the analog input values from individual sensors and switches in
the traveling, material handling, and SAS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(1) I/O TEMP/VOLT
Displays the temperature of each electrical functional part and the analog input voltage detected by each
controller.
(2) I/O TRAVELING
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
(3) I/O MATERIAL HANDLING
Displays the material handling and mast control switch ON/OFF states and analog input voltages from
material handling and mast control sensors.

(4) I/O STEERING

Displays the ON/OFF states of knob position correction control and the analog input voltages from
respective sensors.
(5) I/O OTHERS
Displays the analog input voltages from battery current sensor and shock sensor.
3. Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected
item in order to permit operation check of that function.

4. Program version display (VERSION)

Displays program version of each controller
Note:
The error code indication:
One error code is displayed in the upper right-hand portion on the I/O MONITOR or ACTIVE
TEST screen, when an error is detected.
 3-25

ANALYZER SCREEN ITEM LIST

Analyzer menu screen Screen No. Display item Description
1. DIAG MEMORY 1/2 1.-5.
Indications of errors occurred
2/2 6. ~ 10.
2. I/O TEMP/VOLT TDM Drive motors temperature: °C
1/4 TDMDH Drive motor drivers heat sink temperature: °C
TDMDB Drive motor drivers board temperature: °C
TMCB Main controller board temperature: °C
TPM Pump motor temperature: °C
2/4
TPMDH Pump motor driver heat sink temperature: °C
TPMDB Pump motor driver board temperature: °C
B48V Battery voltage: V
VBKY Voltage after key switch: V
3/4
VBMBSL Solenoid power source voltage: V
VBMB Voltage after MB contactor: V
VDMDL Drive motor driver L main circuit voltage: V
4/4 VDMDR Drive motor driver R main circuit voltage: V
VPMD Pump motor driver main circuit voltage: V
3. I/O TRAVELING SPEED Traveling speed: km/h or mph
1/5 VRA Accelerator sensors voltage: V
VRB Brake sensors voltage: V
SDM Seat switch
DSF Forward switch
2/5
DSR Reverse switch
SPB Parking brake switch
SYR (Not used)
SLSW *1
Swing lock solenoid
3/5 SH Lifting height switch
SPLF Load sensor voltage: V (MPa)
SPEED Traveling speed: km/h or mph
SPDDML Drive motor L rpm: rpm [Target rpm: rpm]
4/5
SPDDMR Drive motor R rpm: rpm [Target rpm: rpm]
SSDL Drive motor L rotation sensors voltage: V
SSDR Drive motor R rotation sensors voltage: V
5/5
CSDL Drive motor L current sensors voltage: V
CSDR Drive motor R current sensors voltage: V
4. I/O M.HANDLING SLUL Unload solenoid
SLLL Lift lowering lock solenoid
SLTFL Tilt lock solenoid
1/8 SLM Load display switch
STK Automatic fork leveling control switch
SDM Seat switch
SHL Height limiter switch
3-26

Analyzer menu screen Screen No. Display item Description

4. I/O M.HANDLING VRTA Tilt angle sensor voltage: V
SPLF Load sensor voltage: V (MPa)
2/8
SH Lifting height switch
VRH Height reel sensor voltage: V
3/8 SPDPM Pump motor rpm: rpm [Target rpm: rpm]
SSP Pump motor driver rotation sensor voltage: V
4/8
CSPM Pump motor driver current sensors voltage: V
SLUL Unload solenoid
SLLL Lift lowering lock solenoid
5/8
CSL Lift proportional valve solenoid current: A
VRL Lift lever angle sensors voltage: V
SLUL Unload solenoid
SLTFL Tilt lock solenoid
6/8
CST Tilt proportional valve solenoid current: A
VRT Tilt lever angle sensors voltage: V
SLUL Unload solenoid
7/8 CSA1 Attachment (1) proportional valve solenoid current: A
VRA1 Attachment (1) lever angle sensors voltage: V
SLUL Unload solenoid
8/8 CSA2 Attachment (2) proportional valve solenoid current: A
VRA2 Attachment (2) lever angle sensors voltage: V
5. I/O STEERING VRTRA Tire angle sensor voltage: V
SPEED Traveling speed: km/h or mph
1/1 Steering angle knob position actual value (target
K-POS
value), Steering synchronizer solenoid
STS Steering angle sensor signal
6. I/O OTHERS CSBAT Battery current sensor voltage: V
1/1 IPL Shock sensor voltage: V
DOPT (Not used)
7. ACTIVE TEST SWING SOL *1
Swing lock solenoid forced operation
STEERING SOL Steering synchronizer solenoid forced operation
1/3
LIFT LWR SOL Lift lowering lock solenoid forced operation
TILT SOL Tilt solenoid forced operation
UNLOAD SOL Unload solenoid forced operation
FAN Cooling fan for controller forced operation
2/3
ACC OUT1 Accessory outputl forced operation
ACC OUT2 Accessory output2 forced operation
3/3 SWG TEST LMP Swing lock operation check
8. VERSION DISPLAY Display program version
1/2
MAIN C/R Main controller program version
DM DRIVER L Drive motor driver L program version
2/2 DM DRIVER R Drive motor driver R program version
PM DRIVER Pump motor driver program version

1: 8FBMT15 - 20 models only

 3-27

XNALYZER MENU screen

Operating Procedure
Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

VER 1.00

BUILT IH ANALYZER

“1. DIAG MEMORY”

Switch (1): Switching selection to next item
i ÌfiNLl iTTiFJl fnpTÌ (moti Ip+?i FK? Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
1.DIAG MEMORY Switch (4): To “DIAG MEMORY” screen

2.1/0 TEMPZVOLT “2. I/O TEMP/VOLT”

3.1/0 TRAVELING Switch (1): Switching selection to next item

Switch (2): Selecting MASK MENU
ZEJ [ * I ) C.+J ) Switch (3): Selecting MASK MENU
Switch (4): To “I/O TEMP/VOLT” screen

“3. I/O TRAVELING”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “I/O TRAVELING” screen

“4. I/O M.HANDLING”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “I/O M.HANDLING” screen

5.1/0 STEERING “5. I/O STEERING”

6.1/0 OTHERS Switch (1):

Switch (2):
Switching selection to next item
Selecting MASK MENU
( > i -U CJTi Switch (3): Selecting MASK MENU
Switch (4): To “I/O STEERING” screen

“6. I/O OTHERS”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “I/O OTHERS” screen
3-28

“7. ACTIVE TEST”

Switch (1): Switching selection to next item
iWLffiWnpTl iHgFl fpRl l^? Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
7.ACTIVE TEST Switch (4): To “ACTIVE TEST” screen

8.VERSION “8. VERSION”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
i~F2ì i > I -U OT Switch (3): Selecting MASK MENU
Switch (4): To “VERSION” screen

Diagnosis Memory Function (DIAG MEMORY)

The controller stores up to 10 most recent errors. The DIAG MEMORY screen displays these diagnosis codes with
their detection time information (in key ON hour meter reading).
The most recent diagnosis code is displayed as 1, followed by 2, 3 and so on to 10.

Operating Procedure

1. Enter the password on the general screen (See page 3-22) to

display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

V.
BUILT IN ANALYZER

2. Check the “1. DIAG MEMORY” is selected on the screen, and

press switch (4) to display “DIAG MEMORY 1/2” screen.
[jAtiül fîiïï?) fnPTl fMfffl
1.DIAG MEMORY
2.1/0 TEMP/VOLT
3.1/0 TRAVELING
LÀ ) OI4J Ln-» )
 3-29

3. Press switch (4) on “DIAG MEMORY 2/2” screen to return to

the ANALYZER MENU screen.
Note:
• When no diagnosis code is displayed on the screen and
the hour meter time is O.Oh, it indicates that no errors
occurred in the past after that row.
• It is impossible to directly jump from the DIAG MEMORY
screen to other function screen. Return to the ANALYZER
MENU screen.
• For details of diagnosis code, refer to section 4, Diagnosis
Code List.

“DIAG MEMORY 1/2”

Displays diagnosis codes 1 to 5.
Switch (4): To “DIAG MEMORY 2/2” screen

“DIAG MEMORY 1/2”

Displays diagnosis codes 6 to 10.
DIAG MEMORY 2/2 Switch (4): Returning to the ANALYZER MENU screen.
6. 72-4 400.Oh
7. 67-1 30. Oh
8. 64-1 2. Oh
9. 61-1 0. lh
10. 0.0h CSzJ
3-30

In/Out Monitor Function (I/O MONITOR)

This function displays the analog input voltage from each of traveling, material handling, SAS and OPS switches,
sensors and actuators.
The circuit or their quality can be judged by monitoring the displayed value.

In/Out Monitor (1) (I/O TEMP/VOLT)

Displays the temperature of each electrical functional part and the analog input voltage detected by each controller.

Operating Procedure
1. Display the ANALYZER MENU screen. (See page 3-27)
QrnlI ifHül inpTl ffigfl iStrD fTTI
1.DIAG MEMORY
2.1/0 TEMP/VOLT
3.1/0 TRAVELING
r»p ( >1-0 OT|
2. Press the switch (1) to select the “2. I/O TEMP/VOLT” and
press the switch (4) to display “I/O TEMP/VOLT 1/4” screen.
ffiüö rfiü?i inF?i iPtDirn 3. After it, “I/O TEMP/VOLT 2/4” to “I/O TEMP/VOLT 4/4” is

1.DIAG MEMORY displayed sequential every time switch (4) is pressed. Press
switch (4) on “I/O TEMP/VOLT 4/4” screen to return to the
ANALYZER MENU screen.

3.1/0 TRAVELING Note:

I ♦J i._> i j up ) You cannot move directly from I/O TEMP/VOLT screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each time.

“I/O TEMP/VOLT 1/4”

TDM: Drive motor temperature: °C
1/0 TEMR/UOLT 1/d] Temperatures of the drive motor L/R are displayed.

TDM: 25/ 251___ TDMDH: Drive motor driver heat sink temperature: °C
Temperatures of the drive motor driver heat sink L/R are
TDMDH: 25/ 25 displayed.
TDMDB: Drive motor driver board temperature: °C
TDMDB: 25/ 25 Temperatures of the drive motor driver board L/R are
displayed.
< - ■ ■
(NEXT Switch (4): To “I/O TEMP/VOLT 2/4” screen
 3-31

“I/O TEMP/VOLT 2/4”

TMCB: Main controller board temperature: °C
' I/O TEMPZUOLT 2/4l Temperature of main controller board is displayed.
TMCB : 25 TPM: Pump motor temperature: °C
Temperature of pump motor is displayed.
TPM : 25 TPMDH: Pump motor driver heat sink temperature: °C
Temperature of the pump motor driver heat sink is displayed.
TPMDH: 25 TPMDB: Pump motor driver board temperature: °C
Temperature of the pump motor driver board is displayed.
[TPMDB: 25 IRËXT)
Switch (4): To “I/O TEMP/VOLT 3/4” screen

“I/O TEMP/VOLT 3/4”

B48V: Battery voltage: V
i 1x0 TEMPxUOLT 3x41 Battery voltage is displayed.
B48V :50.0 Standard: 48 V
VBKY: Voltage after key switch: V
VBKY :50.0 Voltage after key switch is displayed.
VBMBSL: Solenoid power source voltage: V
VBMBSUSO.O Voltage of solenoid power source is displayed.
VBMB: Voltage after MB contactor: V
VBMB :50.0 (ÜËXTl
Voltage of after MB contactor is displayed.
Switch (4): To “I/O TEMP/VOLT 4/4” screen

“I/O TEMP/VOLT 4/4”

VDMDL: Drive motor driver L main circuit voltage: V
[ 1x0 TEMPxUOLT 4x41 Voltage of drive motor driver L main circuit is displayed.
VDMDUSO.O VDMDR: Drive motor driver R main circuit voltage: V
Voltage of drive motor driver R main circuit is displayed.
VDMDR:50.0 VPMD: Pump motor driver main circuit voltage: V
Voltage of pump motor driver main circuit is displayed.
VPMD :50.0 Switch (4): Returning to the ANALYZER MENU screen
3-32

In/Out Monitor (2) (I/O TRAVELING)

Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.

Operating Procedure
1. Display the ANALYZER MENU screen. (See page 3-27)

2.1/0 TEMP/VOLT
3.1/0 TRAVELING
(3D (> I m L *- J

2. Press the switch (1) to select the “3. I/O TRAVELING” and
press the switch (4) to display the “I/O TRAVELING 1/5”
IfiNp ffüffl ifiFTl IptFl screen.

1.DIAG MEMORY Note:

You cannot move directly from I/O TRAVELING screen to the
2.1/0 TEMP/VOLT screen of the other items. Return to ANALYZER MENU screen
.1/0 TRAVELING once, then move to screen of each time.

DEJ ( * i CPI
“I/O TRAVELING 1/5”
SPEED: Traveling speed: km/h or mph
Displays the traveling speed.
VRA: Accelerator sensor 1/2 voltage: V
Displays input voltage from the accelerator sensor to the
controller.

Standard:
Accelerator sensor 1
When accelerator is not operated: 0.40 to 1.25 V
When accelerator pedal is fully depressed: 2.25 to 4.80 V
Accelerator sensor 2
When accelerator is not operated: 0.65 to 2.32 V
When accelerator pedal is fully depressed: 2.70 to 4.80 V
VRB: Brake sensor 1/2 voltage: V
Displays input voltage from the brake sensor to the controller.
Standard:
Brake sensor 1
When brake is not operated: 1.30 to 2.25 V
Wet disc brake operating point 1.60 to 3.70 V
Brake sensor 2
When brake is not operated: 1.35 to 3.30 V
Wet disc brake operating point 2.05 to 4.50 V
Switch (4): To “I/O TRAVELING 2/5” screen
 3-33

“I/O TRAVELING 2/5”

SDM: Seat switch
( I/O TROUELING 2/5l Switch ON/OFF quality judgment by sitting on and leaving the
operator’s seat
SDM :1 1 SDM: 1 = ON when sitting on the seat
DSF :o DSR :0 SDM: 0 = OFF when leaving the seat
DSF: Forward switch
SPB :0 DSR: Reverse switch
Switch ON/OFF quality judgment by operating the direction
(NEXT) lever
STD or D2 pedal models

Display
Direction lever
DSF: DSR:
Forward 1 (= ON) 0 (= OFF)
Neutral 0 (= OFF) 0 (= OFF)
Reverse 0 (= OFF) 1 (= ON)

Double accelerator pedal models

Display
Forward/backward pedal
DSF: DSR:
Forward 1 (= ON) 0 (= OFF)
Neutral/Operated simultaneously
* 0 (= OFF) 0 (= OFF)
Backward 0 (= OFF) 1 (= ON)

SPB: Parking brake switch

Switch ON/OFF quality judgment by operating the parking
brake lever.
SPB: 0 = OFF (in a state of parking brake being operated)
SPB: 1 = ON (in a state of parking brake being released)
*: If these operations are performed simultaneously, both DSF
and DSR may be ON in some cases.
Switch (4): To "I/O TRAVELING 3/5” screen
3-34

“I/O TRAVELING 3/5”

SYR: Not used
r I/O TRRUELING 3/5Ì SLSW: Swing lock solenoid (4-Wheel models only)
SYR Judges the quality of the switch ON/OFF by operating the
swing lock solenoid
SLSW 1 SH:1OO SLSW: 1 = ON Energized (swing lock released) state
SLSW: 0 = OFF Non-energized (swing lock) state
SPLF 0.70( 0.3) SH: Lifting height switch

XSPEED
Judges the quality of the switch ON/OFF by raising and
_ _ _ _ 12.0 (NEXT)
lowering the fork.

SH:100
SH1

SH1 SH2-1 SH2-2

Height Display
Switch Switch Switch
Low lifting
100 1 (=ON) 0 (=OFF) 0 (=OFF)
height
High lifting
010 0 (=OFF) 1 (=ON) 0 (=OFF)
height

SPLF: Load sensor voltage: V (MPa)

Displays input voltage from the load sensor to the controller,
and detected pressure.
Standard at no load: 0.5 to 4.5 V
Voltage increases as load increases.
SPEED: Traveling speed: km/h or mph
Displays the traveling speed.
Switch (4): To “I/O TRAVELING 4/5” screen

“I/O TRAVELING 4/5”

SPDDML: Drive motor L revolution: rpm
IZQ TRRUËLÏNG 4z5Ì SPDDMR: Drive motor R revolution: rpm
This screen indicates the measured and target numbers of
revolutions of the drive motor.
SPDDML:3000C30001 The rotation sensor is checked by actually running the vehicle.
The number of revolutions of the drive motor increases with an
SPDDMR:3000C30001 increase in the traveling speed.
(NEXT) Switch (4): To "I/O TRAVELING 5/5” screen
 3-35

“I/O TRAVELING 5/5”

SSDL: Drive motor L rotation sensor 1/2 voltage: V
IzQ TRRUELING 5x5 SSDR: Drive motor R rotation sensor 1/2 voltage: V

SSDL: 1.20/1.201____I This screen indicates the voltages of the drive motor rotation
sensors.
SSDR:1.20/1.20 Standard:
When motor is stopped:
CSDL:2.50/2.50 Constant, either approx. 0.50 V or approx. 1.20 V
When motor is rotating:
CSDR: 2.50/2.50 C5^ Variable between approx. 0.50 V and 1.20 V
CSDL: Drive motor LH current sensor 1/2 voltage: V
CSDR: Drive motor RH current sensor 1/2 voltage: V
This screen indicates the voltages of the drive motor current
sensors.
Standard:
Standard value when vehicle is stopped: Approx. 2.50 V
Standard value when vehicle is running: 0.50 to 4.50 V
Switch (4): Returning to the ANALYZER MENU screen

In/Out Monitor (3) (I/O M.HANDLING)

Displays the material handling and mast control switch ON/OFF states and analog input voltages from material
landling and mast control sensors.

Operating Procedure

[ffiNp fTliffl iTip?) 1. Display the ANALYZER MENU screen. (See page 3-27)

1.
DIAG MEMORY
2.1/0 TEMP/VOLT
3.1/0 TRAVELING

2. Press the switch (1) to select the “4. I/O M. HANDLING” and
press the switch (4) to display the “I/O M.HANDLING 1/8”
screen.

5.1/0 STEERING
6.1/0 OTHERS
( O i ■» ) CSD,
3-36

“I/O M.HANDLING 1/8”

SLUL: Unload solenoid
IzQ M.HANDLING 1x8 Displays output signal to the unload solenoid.

SLUL :o SLLL:01 I SLLL: Lift lock solenoid

Displays output signal to the lift lock solenoid.
SLTFLZO SLTFL: Tilt lock solenoid
Displays output signal to the tilt lock solenoid.
SLM : 0 STK :0
SDM :i SHL :0(FiË>m

Seat
Sitting on seat Leaving seat
condition
Lift lever Tilt lever
Lever Not Backward tilt
-
condition operated Raising Lowering Forward tilt Low lifting High lifting
height height
SLUL 0 (=OFF) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF)
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) *1
0 (=OFF) 0 (=OFF)
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)

*1: If backward tilting operation and lift raising operation are performed simultaneously, these Os may temporarily turn
into 1s (= ON).
SLM: Load display switch
Switch ON/OFF quality judgment by operating the lift knob
switch.
STK: Automatic fork leveling control switch
Switch ON/OFF quality judgment by operating the tilt knob
switch.
SDM: Seat switch
Switch ON/OFF quality judgment by operating the seat switch.
SHL: Height limiter switch
Switch ON/OFF quality judgment by operating the height limit
switch.
Switch (4): To “I/O M.HANDLING 2/8” screen
 3-37

“I/O M.HANDLING 2/8”

VRTA: Tilt angle sensor voltage: V
I/O M.HANDLING 2x8 Displays input voltage from the tilt angle sensor to the
VRTA:2.50 □ controller.
Standard with mast in the vertical position: 0.85 to 4.00 V
SPLF:0.70( 0.9) Mast vertical -> forward tilt: Input voltage decreases
Mast vertical -> backward tilt: Input voltage increases
SH :100 SPLF: Load sensor voltage: V (MPa)
See “I/O TRAVELING 3/5”
VRH :2.50
\1
(NextV) SH: Lifting height switch
See “I/O TRAVELING 3/5”
VRH: Height reel sensor voltage: V
Displays input voltage from the height reel sensor to the
controller.
Standard: 0.20 to 4.80 V
Mast raising -> Input voltage increases
Mast lowering -> Input voltage decreases
Switch (4): To "I/O M.HANDLING 3/8” screen

“I/O M.HANDLING 3/8”

SPDPM: Pump motor revolution: rpm
I/O M.HANDLING 3/8 This screen indicates the measured and target numbers of
revolutions of the pump motor.
The number of revolutions of the pump motor increases with
SPDPM:2000C2000] an increase in the material handling speed.
Switch (4): To “I/O M.HANDLING 4/8” screen

(NEXT)

“I/O M.HANDLING 4/8”

SSP: Pump motor driver rotation sensor voltage: V
I/O M.HANDLING 4/8 Displays the voltage from the pump motor driver rotation
sensor.
SSP :1.2O □ Standard:
CSPM:2.50/2.50 When motor is stopped: Constant, either approx. 0.50 V or
approx. 1.20 V
When motor is rotating: Variable between approx. 0.50 V
and 1.20 V
(NEXT) CSPM: Pump motor driver current sensor 1 / 2 voltage: V
Displays the voltage from the pump motor driver current
sensor 1/2.
Standard:
Standard value when vehicle is stopped: Approx. 2.5 V
(When material handling lever, steering wheel, and
forward/backward switch are in neutral)
Other than the above: 0.5 to 4.5 V
Switch (4): To “I/O M.HANDLING 5/8” screen
3-38

“I/O M.HANDLING 5/8”

SLUL: Unload solenoid
IxQ M,HANDLING 5x8 See “I/O M.HANDLING 1/8”
slul:o slll:o I I SLLL: Lift lowering lock solenoid
See “I/O M.HANDLING 1/8”
CSL :0.00 CSL: Lift proportional solenoid current: A
Displays the current from the lift proportional solenoid.
VRL :2.40/2.40 Standard:
During uppermost raising operation: 0.60 to 0.90 A
,_ _ _ _ _ _ _ _ _ _ _ _ _ _ SS! During lowermost lowering operation: 0.60 to 0.90 A
When motor is stopped: 0.00 A
The current increases according to the amount of operation of
the lift lever
VRL: Lift lever angle sensor 1/2 voltage: V
Displays input voltage from lift lever angle sensor 1 / 2 to the
controller.
Standard:
Lift lever angle sensor 1
During uppermost raising operation: 2.82 to 4.50 V
During lowermost lowering operation: 0.30 to 1.72 V
When lever is in neutral: 1.80 to 2.80 V
The voltage increases during raising operation, while it
decreases during lowering operation.
Standard:
Lift lever angle sensor 2
During uppermost raising operation: 0.30 to 1.72 V
During lowermost lowering operation: 2.82 to 4.50 V
When lever is in neutral: 1.80 to 2.80 V
The voltage decreases during raising operation, while it
increases during lowering operation.
Switch (4): To “I/O M.HANDLING 6/8” screen
 3-39

“I/O M.HANDLING 6/8”

SLUL: Unload solenoid
I/O M.HANDLING 6/8 See “I/O M.HANDLING 1/8”
:
SLUL:0 sltfl 01 I SLTFL: Tilt lock solenoid
See “I/O M.HANDLING 1/8”
CST :0.00 CST: Tilt proportional valve solenoid current: A
Displays the current from the tilt proportional solenoid.
VRT :2.40/2.40 Standard:
I'NEXTI During backwardmost tilting operation: 0.60 to 0.90 A
During forwardmost tilting operation: 0.60 to 0.90 A
When motor is stopped: 0.00 A
The current increases according to the amount of operation of
the tilt lever.
VRT: Tilt lever angle sensor 1/2 voltage: V
Displays input voltage from tilt lever angle sensor 1/2 to the
controller.
Standard:
Tilt lever angle sensor 1
During backwardmost tilting operation: 2.82 to 4.50 V
During forwardmost tilting operation: 0.30 to 1.72 V
When lever is in neutral: 1.80 to 2.80 V
The voltage increases during backward tilting operation, while
it decreases during forward tilting operation.
Standard:
Tilt lever angle sensor 2
During backwardmost tilting operation: 0.30 to 1.72 V
During forwardmost tilting operation: 2.82 to 4.50 V
When lever is in neutral: 1.80 to 2.80 V
The input voltage decreases during backward tilting operation,
while it increases during forward tilting operation.
Switch (4): To “I/O M.HANDLING 7/8” screen
3-40

“I/O M.HANDLING 7/8”

SLUL: Unload solenoid
( I/O M.HANDLING See “I/O M.HANDLING 1/8”
CSA1: Attachment (1) proportional valve solenoid current: A
SLULIO Displays the current from the attachment (1) proportional
CSA1:0.00 solenoid.
Standard:
VRA1:2.40/2.40 During backwardmost tilting operation: 0.60 to 0.90 A
During forwardmost tilting operation: 0.60 to 0.90 A
s_____________________________________
(NEXT) When motor is stopped: 0.00 A
The current increases according to the amount of operation of
the tilt lever.
VRA1: Attachment (1) lever angle sensor 1/2 voltage: V
Displays input voltage from the attachment 1 lever angle
sensor 1 / 2 to the controller.
Standard:
Attachment 1 lever angle sensor 1
During backwardmost tilting operation: 2.82 to 4.50 V
During forwardmost tilting operation: 0.30 to 1.72 V
When lever is in neutral: 1.80 to 2.80 V
The voltage increases during backward tilting operation, while
it decreases during forward tilting operation.
Standard:
Attachment 1 lever angle sensor 2
During backwardmost tilting operation: 0.30 to 1.72 V
During forwardmost tilting operation: 2.82 to 4.50 V
When lever is in neutral: 1.80 to 2.80 V
The input voltage decreases during backward tilting operation,
while it increases during forward tilting operation.
Switch (4): To “I/O M.HANDLING 8/8” screen
 3-41

“I/O M.HANDLING 8/8”

SLUL: Unload solenoid
I/O M.HANDLING 8/8 See “I/O M.HANDLING 1/8”
CSA2: Attachment (2) proportional valve solenoid current: A
SLUL:O □ Displays the current from the attachment (2) proportional
CSA2:0.00 solenoid.
Standard:
VRA2:2.40/2.40 During backwardmost tilting operation: 0.60 to 0.90 A
During forwardmost tilting operation: 0.60 to 0.90 A
When motor is stopped: 0.00 A
The current increases according to the amount of operation of
the tilt lever.
VRA2: Attachment (2) lever angle sensor 1/2 voltage: V
Displays input voltage from the attachment (2) lever angle
sensor 1 / 2 to the controller.
Standard:
Attachment 2 lever angle sensor 1
During backwardmost tilting operation: 2.82 to 4.50 V
During forwardmost tilting operation: 0.30 to 1.72 V
When lever is in neutral: 1.80 to 2.80 V
The voltage increases during backward tilting operation, while
it decreases during forward tilting operation.
Standard:
Attachment 2 lever angle sensor 2
During backwardmost tilting operation: 0.30 to 1.72 V
During forwardmost tilting operation: 2.82 to 4.50 V
When lever is in neutral: 1.80 to 2.80 V
The input voltage decreases during backward tilting operation,
while it increases during forward tilting operation.
Switch (4): Returning to the ANALYZER MENU screen
3-42

In/Out Monitor (4) (I/O STEERING)

Displays the ON/OFF states of knob position and the analog input voltages from respective sensors.

Operating Procedure
1. Display the ANALYZER MENU screen. (See page 3-27)

2. Press the switch (1 ) to select the “5. I/O STEERING” and press
the switch (4) to display the “I/O STEERING 1/1” screen.

“I/O STEERING 1/1”

VRTRA: Tire angle sensor voltage: V
Displays input voltage from the tire angle sensor to the
controller.
Standard when tires are in straight ahead position:
2.10 to 2.80 V (3 wheel models)
1.80 to 2.50 V (4 wheel models)
SPEED: Traveling speed: km/h or mph
Displays the traveling speed.
K-POS: Steering angle knob position actual value
This screen indicates the actual (target) position of the steering
knob and the ON/OFF status of the knob position
compensation solenoid
Actual value:
The knob position calculated and recognized by the controller
from the steering angle sensor signal
Target value:
The knob position calculated and recognized by the controller
from the tire angle sensor signal
Steering synchronizer solenoid:
0 = OFF non-energized state (Position compensation
disabled)
1 = ON energized state (Position compensation enabled)
 3-43

One rotation (360°) of the steering wheel is divided by 160, and the
value is set to “80” when the knob is in the position as indicated in
the illustration.
Clockwise turn of the steering wheel: Increase in value
Counterclockwise turn of the steering wheel: Decrease in value
STS: Steering angle sensor signal

STS :000
STS1 JT— STSC
STS2

1 = ON
0 = OFF
When the steering wheel is rotated once, STS1 and STS2 repeat
ON and OFF. STSC only turns on when the knob is in the standard
position.

n/Out Monitor (5) (I/O OTHERS)

)isplays the analog input voltages from battery current sensor and shock sensor.

Operating Procedure
1. Display the ANALYZER MENU screen. (See page 3-27)
[jRHL] (fiihil frjpll IfifffllptnrgL
1.DIAG MEMORY
2.1/0 TEMP/VOLT
3.1/0 TRAVELING
CSJ ( > i ) L» )

2. Press the switch (1) to select the “6. I/O OTHERS” and press
the switch (4) to display the “I/O OTHERS 1/1” screen.
iRNLl rriiffl IoptI Ififlfi
4.1/0 M.HANDLING
5.1/0 STEERING
6.1/0 OTHERS
( <frj L
* i ■» ) L«-Ml
3-44

“I/O OTHERS 1/1”

CSBAT: Battery current sensor voltage: V
i I/O OTHERS 1/11 Displays input voltage from the battery current sensor to the

CSBAT:2.50 controller.
Standard value when vehicle is stopped: Approx. 2.50 V
IPL :1.95/1.95 IPL: Shock sensor voltage: V
Displays input voltage from the shock sensor to the controller.
DOPT :0 Standard value when vehicle is stopped: Approx. 2.0 V
DOPT: Not used
C53 Switch (4): Returning to the ANALYZER MENU screen
 3-45

Active Test (ACTIVE TEST)

In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected item in
Drder to permit operation check of that function.

Active Test Item List

Selection Item
Item Description
Signal Content of operation Signal Content of operation
SWING SOL Swing lock solenoid forced operation OFF Lock ON Unlock
STEERING SOL Knob position correcting solenoid forced By-pass close By-pass open
OFF ON
operation
LIFT LWR SOL Lift lock solenoid forced operation OFF Lowering not possible ON Lowering possible
TILT SOL Tilt control solenoid forced operation Forward tilt not Forward tilt possible
OFF ON
possible
UNLOAD SOL Unload solenoid forced operation Material handling not Material handling
OFF ON
*possible possible
FAN Cooling fan for controller forced Fan stops Fan rotates
OFF ON
operation
ACC OUT1 Accessory output 1 (brake auxiliary Stop lamp does not Stop lamp operates
OFF ON
equipment output) forced operation operate
ACC OUT2 Accessory output 2 (back-up auxiliary Back buzzer and Back buzzer and
equipment output) forced operation OFF back-up lamp do not ON back-up lamp operate
operate
SWG TEST LMP Swing lock solenoid operation display OFF No indication ON Indication

*: The lift may lower depending on the load.

• On the ACTIVE TEST screen, an ON or an OFF is always displayed next to each item.
• If the selected item is forcibly turned off or on by pressing the switch (2) or (3) and it is switched over to another
item by pressing the switch (1), forced operation is canceled (and switches over to normal operation).
• The operation guidance in connection with the switches (2) and (3) indicates whether an item is forcibly operated
or not.
(Refer to below)

Operation guidance Condition

( ♦ ) (>!■►) (NEXTI Selected item not forcibly operated

( ♦ ) ( 4- I (NEXT) Selected item forcibly turned ON

( ♦ ) I ■+ ) (NEXTI Selected items forcibly turned OFF

( ♦ ) (Next) Applicable function not provided or its state signal not received
3-46

Operating procedure
1. Display the ANALYZER MENU screen. (See page 3-27)

2.1/0 TEMP/VOLT
3.1/0 TRAVELING
( i -» ) (_P )

2. Press the switch (1 ) to select the “7. ACTIVE TEST” and press
the switch (4) to display the “ACTIVE TEST” 1/3 screen.
ffïïïîl fnpfl ÎMfffl IpÏt?I (Tnì
7.ACTIVE TEST
8.VERSION
(7ÿ~) ( > I ] ppg

“ACTIVE TEST 1/3”

SWING SOL: Swing lock solenoid
ACTIVE TEST 1_ _ >Z3I Jack up the rear axle, and check that the rear axle swings.

SWING SOL I off /inn ON (Solenoid ON): Unlock

OFF (Solenoid OFF): Lock
STEERING SOL OFF z ON STEERING SOL: Knob position correcting solenoid
LIFT LWR SOL OFF z ON Slowly turn the steering wheel, and check the difference of the
TILT SOL OFF z ON rear tire movement.
(“♦“) ( * 1 * ) (NEXT) ON (By-pass open): Tires do not move match
OFF (By-pass close): Tires move (normal operation)
LIFT LWR SOL: Lift lock solenoid
Check the quality of lowering action by lift lowering operation.
ON (Solenoid ON): Lowering possible (normal operation)
OFF (Solenoid OFF): Lowering not possible
TILT SOL: Tilt control solenoid
Check the quality of mast forward tilt operation by forward tilt
operation.
ON (Solenoid ON): Forward tilt possible
OFF (Solenoid OFF): Forward tilt not possible
Switch (1): Selecting the next item on the “ACTIVE TEST
1/3” screen
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
Switch (4): To “ACTIVE TEST 2/3” screen
 3-47

“ACTIVE TEST 2/3”

UNLOAD SOL: Unload valve solenoid
ACTIVE TEST 1 2/3 Check the quality by material handling operation.
ON (Solenoid ON):
¡UNLOAD SOL f sax on Material handling operation possible
FAN |x ON OFF (Solenoid OFF):
ACC 0UT1 jx ON Material handling operation not possible (It may slowly lower
ACC 0UT2 Effix ON according to load condition, but this is not a fault).
*
□
(- ( * 1 * J (NEXTI FAN: Cooling fan for controller
Forcibly output the ON/OFF signal to check the fan operation
ON: Fan rotates
OFF: Fan stops
ACC OUT1: Accessory output 1 (brake auxiliary equipment output)
forced operation.
Used to check if the stop lamp works normally.
ON: Stop lamp operates
OFF: Stop lamp does not operate
ACC OUT2: Accessory output 2 (back-up auxiliary equipment
output) forced operation.
Used to check if the backup buzzer and the backup lamp work
normally.
ON: Buzzer sound and back-up lamp operates
OFF: Buzzer stop and back-up lamp do not operate
Switch (1): Selecting the next item on the “ACTIVE TEST
2/3” screen
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
Switch (4): To “ACTIVE TEST 3/3” screen

“ACTIVE TEST 3/3”

SWG TEST LMP:
ACTIVE TESTI l3z3 Check the swing lock operation states by OPS light.
ON (Indicated):
SWG TEST LHP |OFF Operation situation is indicated with OPS light
OPS light ON: Swing lock operated
OPS light OFF: Swing lock released
OFF (not indicated):

ino r>~r^3 csi OPS light operates as OPS light (normal operation)
Switch (1 ): Not used
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
Switch (4): Returning to the ANALYZER MENU screen
3-48

VERSION (Program Version)

Displays program version of each controller.

Operating Procedure

1. Display the ANALYZER MENU screen. (See page 3-27)

IWbSìfli inni Impti
1.DIAG MEMORY
2.1/0 TEMP/VOLT
3.1/0 TRAVELING
r~E~i~HQ cp~)
2. Press the switch (1) to select the “8. VERSION” and press the
switch (4) to display the “VERSION 1/2” screen.
3. Press the switch (4) to display the VERSION 2/2 screen, and
7.ACTIVE TEST press switch (4) again to return from the VERSION 2/2 screen

8.VERSION to the ANALYZER MENU screen.

Note;
You cannot move directly from a VERSION screen to another
V
m !>!■►) t +J
1
)
J
screen. To do so, first return to the ANALYZER MENU screen, and
then move from it to the screen where the desired items is
displayed.

“VERSION 1/2”
DISPLAY: Program version of the multi-function display
VERSION 1/2 MAIN C/R: Program version of the main controller
Switch (4): To “VERSION 2/2” screen
DISPLRV : 1.00
MRIH C/R : 1.00

(NEXT)

“VERSION 2/2”
DM DRIVER L: Program version of the drive motor driver LH
VERSION 2/2 DM DRIVER R: Program version of the drive motor driver RH
PM DRIVER: Program version of the pump motor driver
DM DRIUER L: 1.00 Switch (4): Returning to the ANALYZER MENU screen
DM DRIUER R: 1.00
PM DRIUER : 1.00

C5j
 3-49

TUNING

GENERAL
This feature performs fine adjustment of traveling and material handling controls. When receiving requests from
jsers, such as the request to weaken the acceleration off regenerative braking force, various settings levels can be
changed on the tuning screens.
Tuning functions has 70 items (included spare items)

Tuning Item List

Level (•: Initial setting value)

Menu No. Item
1 2 3 4 5 6 7 8
Activation timing of low battery capacity
Slow
1 warning and battery over-discharge Fast Disabled
•
warning
Slow Fast
2 Battery charge indicator calibration No.1 •
decrease decrease
3 Battery charge indicator calibration No.2 Sensitive • Insensitive
Motor torque when the battery discharge
4 Down • Keep
has proceeded.
5 Not used •
6 Accelerator pedal sensitivity Insensitive • Sensitive
7 Accelerator pedal torque Weak • Strong
8 Accelerator soft-start Slow • Quick
Regenerative braking torque at
9 Weak • Strong
accelerator-off
Regenerative braking soft-start at
10 Slow • Quick
accelerator-off
TUNE 11 Acceleration torque at switch-back Weak • Strong
GEN
12 Acceleration soft start at switch-back Slow • Quick
Regenerative braking torque at switch-
13 Weak • Strong
back
Regenerative braking soft-start at
14 Slow • Quick
switch-back
Regenerative braking soft-stop at
15 Slow • Quick
switch-back
16 Accelerator traction torque Weak • Strong
Strong
17 Accelerator and brake traction torque Weak
•
Rollback speed when the traveling
Slow
18 direction is opposite to the direction Fast
•
lever.
Rollback speed when the traveling
Slow
19 direction is the same as the direction Fast
•
lever.
20 Not used •
3-50

Level (•: Initial setting value)

Menu No. Item
1 2 3 4 5 6 7 8
21 Traction speed limitation at turning Slow • Fast
Same
Maximum speed limitation during
22 Slow Forward
backward traveling
•
Same
Low-speed setting during backward
23 Slow Forward
traveling
•
24 Not used •
25 Not used •
TUNE Pump motor output during lift up Fast
GEN 26 Slow
operation •
Pump motor output during tilt forward
27 Slow • Fast
and backward operation
Pump motor output during the
28 attachment (1) lever push and pull Slow • Fast
operation
Pump motor output during the
29 attachment (2) lever push and pull Slow • Fast
operation
30 Not used •
Neutral range of lift lever for lift down
START Small • Wide
operation
INCH Inching speed during lift down operation Slow • Fast
Maximum speed during lift down
LIFT MAX Slow • Fast
operation
DOWN
Acceleration speed during lift down
ACC Weak • Strong
operation
Deceleration speed during lift down
DEC Weak • Strong
operation
Neutral range of lift lever for lift up
START Small • Wide
operation
INCH Inching speed during lift up operation Slow • Fast
LIFT MAX Maximum speed during lift up operation Slow • Fast
UP Acceleration speed during lift up
ACC Weak • Strong
operation
Deceleration speed during lift up
DEC Weak • Strong
operation
Neutral range of tilt lever for tilt forward
START Small • Wide
operation
Inching speed during tilt forward
INCH Slow • Fast
operation
TILT Maximum speed during tilt forward
MAX Slow • Fast
FWD operation
Acceleration speed during tilt forward
ACC Weak • Strong
operation
Deceleration speed during tilt forward
DEC Weak • Strong
operation
 3-51

Level (•: Initial setting value)

Menu No. Item
1 2 3 4 5 6 7 8
Neutral range of tilt lever for tilt
START Small • Wide
backward operation
Inching speed during tilt backward Fast
INCH Slow •
operation
TILT Maximum speed during tilt backward
MAX Slow • Fast
BWD operation
Acceleration speed during tilt backward
ACC Weak • Strong
operation
Deceleration speed during tilt backward
DEC Weak • Strong
operation
Neutral range of attachment (1) lever for
START Small • Wide
the attachment (1) lever push operation
Inching speed during attachment (1)
INCH Slow • Fast
lever push operation
ATT1 Maximum speed during the attachment
MAX Slow • Fast
PUSH (1) lever push operation
Acceleration speed during the
ACC Weak • Strong
attachment (1) lever push operation
Deceleration speed during the
DEC Weak • Strong
attachment (1) lever push operation
Neutral range of attachment (1) for the
START Small • Wide
attachment (1) lever pull operation
Inching speed during attachment (1)
INCH Slow • Fast
lever pull operation
ATT1 Maximum speed during the attachment Fast
MAX Slow •
PULL (1) lever pull operation
Acceleration speed during the
ACC Weak • Strong
attachment (1) lever pull operation
Deceleration speed during the
DEC Weak • Strong
attachment (1) lever pull operation
Neutral range of attachment (2) lever for
START Small • Wide
the attachment (2) lever push operation
Inching speed during attachment (2)
INCH Slow • Fast
lever push operation
ATT2 Maximum speed during the attachment
MAX Slow • Fast
PUSH (2) lever push operation
Acceleration speed during the
ACC Weak • Strong
attachment (2) lever push operation
Deceleration speed during the
DEC Weak • Strong
attachment (2) lever push operation
Neutral range of attachment (2) lever for
START Small • Wide
the attachment (2) lever pull operation
Inching speed during attachment (2)
INCH Slow • Fast
lever pull operation
ATT2 Maximum speed during the attachment
MAX Slow • Fast
PULL (2) lever pull operation
Acceleration speed during the
ACC Weak • Strong
attachment (2) lever pull operation
Deceleration speed during the Strong
DEC Weak •
attachment (2) lever pull operation
3-52

TUNING MENU Screen

Operating Procedure

1. Enter the password on the general screen (See page 3-23) to

display the mask function initial screen. After 5 seconds, the

1ft
ANALYZER MENU screen is automatically displayed.
YER 1.00

BUILT IN ANALYZER

2. By default, the MASK MENU screen is displayed with the

[ANL] tab selected. On this screen, press the switch (3) and
select the [TUN] tab.
Note:
The number of tuning menu items displayed varies according
to the number of spools of the mini-lever.

“1. GENERAL”
Switch (1): Switching selection to next item.
ÌùnTi lïîiïil iTìftÌ ÎmûtI gfFI f*
Tl Switch (2): Selecting MASK MENU. (See page 3-23)
Switch (3): Selecting MASK MENU. (See page 3-23)
1. GENERAL Switch (4): To TUNING LEVEL setting screen

2. LIFT LEVER “2. LIFT LEVER”

3. TILT LEVER Switch (1):

Switch (2):
Switching selection to next item.
Selecting MASK MENU. (See page 3-23)
[ * i ca Switch (3): Selecting MASK MENU. (See page 3-23)
Switch (4): To TUNING LEVEL setting screen

“3. TILT LEVER”

Switch (1): Switching selection to next item.
iWiîtUnIiWiimîZiîFZî^ Switch (2): Selecting MASK MENU. (See page 3-23)
Switch (3): Selecting MASK MENU. (See page 3-23)
4.ATT1 LEVER Switch (4): To TUNING LEVEL setting screen

5.ATT2 LEVER “4. ATT1 LEVER”

Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-23)
ŒJ i * i *
J Çgl Switch (3): Selecting MASK MENU. (See page 3-23)
Switch (4): To TUNING LEVEL setting screen

“5. ATT2 LEVER”

Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-23)
Switch (3): Selecting MASK MENU. (See page 3-23)
Switch (4): To TUNING LEVEL setting screen
 3-53

GENERAL
Sets tuning levels for standard functions.

Operating Procedure

1. Display the TUNING MENU screen.

i îqnTi fTütii ifjp?) fMfffi
1.GENERAL
2. LIFT LEVER
3. TILT LEVER
( * j ( * i + ) (V)

2. Check that “1. GENERAL” is selected, and press the switch (4)
to display TUNING LEVEL setting screen.

“TUNE GEN.”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to next screen

Switch (1): Switching selection to next item

Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning TUNING MENU screen
3-54

LIFT LEVER (TUNING LIFT LEVER)

Sets tuning levels for the lift lever of mini lever and joystick.

Operating Procedure

1. Display the TUNING MENU screen and press the switch (1),
ifiïïîi früti] inp?) (FA (in select the "2. LIFT LEVER”.

1.GENERAL
2.LIFT LEVER
3.TILT LEVER
l ( * I * ) ( «-» jJ

2. Press the switch (4) to display TUNING LEVEL setting screen.

“LIFT DOWN”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to next screen

“LIFT UP”
Switch (1): Switching selection to next Item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
 3-55

□LT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever of mini lever and joystick.

Operating Procedure
1. Display the TUNING MENU screen and press the switch (1),
fflND ffÜNl iTipTl iFifffl select the “3. TILT LEVER”.

1. GENERAL
2. LIFT LEVER
.TILT LEVER
nrj (>!■►_) qj~)|

2. Press the switch (4) to display TUNING LEVEL setting screen.

“TILT FWD”
Switch (1 ): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to next screen

“TILT BWD”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
3-56

ATTI LEVER (TUNING ATTI LEVER)

Sets tuning levels for the ATT1 lever of mini lever and joystick.

Operating Procedure

1. Display the TUNING MENU screen and press the switch (1),
select the “4. ATT1 LEVER”.
4.
ATT1 LEVER
ATT2
5. LEVER
£30 QjJ

2. Press the switch (4) to display TUNING LEVEL setting screen.

“ATTI PUSH”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to next screen

“ATT1 PULL”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
 3-57

\TT2 LEVER (TUNING ATT2 LEVER)

Bets tuning levels for the ATT2 lever of mini lever and joystick.

Operating Procedure
1. Display the TUNING MENU screen and press the switch (1),
ÆnTi fïÜNl select the “5. ATT2 LEVER”.

4.ATT1 LEVER
5.ATT2 LEVER
¡□ED ( > i Gg

2. Press the switch (4) to display TUNING LEVEL setting screen.

“ATT2 PUSH”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to next screen

“ATT2 PULL”
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
3-58

OPTION SET
Note:
• The option set function is used to fit the specifications of the controller and the multi-function display
for the options actually equipped on the vehicle. Functions are not available for the vehicle where they
are not mounted, even if the OPTION SET enables them.
• If main controller or multi-function display is replaced, it is necessary to reset it according to the vehicle
specification.

Option Set item List

Switching settings
Indication Description Setting Setting
Indication Indication
content content
*
MPH 1 Setting the traveling speed display unit YES MPH NO km/h
DATE TYPE
* 1 Setting the calendar format D/M/Y (E) / Y/M/D (J) / M/D/Y (U)
Setting to enable/disable wheel indicator
WHEEL IND and tilt angle indicator YES Enabled NO Disabled
(Multi-function display deluxe only)
Alarm while
Setting to Over Set Load Alarm Alarm to
LOAD ALM A displaying the B
(Multi-function display deluxe only) activate always
load meter
Setting to enable/disable over speed
SPD ALM2 YES Enabled NO Disabled
alarm 2
Setting to enable/disable all the buzzer
*
OPS BUZZER 1 YES Enabled NO Disabled
sounds related to OPS function
Setting to enable/disable buzzer sound
SEAT BUZZER YES Enabled NO Disabled
when seat switch is off
Setting to enable/disable parking brake
PKB BUZZER YES Enabled NO Disabled
off warning
*
B-TYPE 1 Adjust the charge indicator calculation A1 /A2/B1 /B2
Turn on while
regenerative Turn on while
STOP LAMP Setting mode of stop lamp operation A braking or B brake pedal
brake pedal operating
operating
Operate while
the vehicle
Operate while
moves to
Setting mode of back-up buzzer and operating the
BACK BUZZER A backward or B
back-up lamp operation direction lever
operating the
to backcward
direction lever
to backward
SHOCK
Setting to enable/disable shock-sensor YES Enabled NO Disabled
SENSOR
* 1
Setting traction limitation mode when
Accelerator
ACCEL & BRK operating the accelerator and the brake A B Brake priority
priority
simultaneously
Setting to enable/disable auto speed
ASC W/LOAD YES Enabled NO Disabled
control
Setting to enable/disable traveling speed
MODE S Enabled A Disabled
limit of auto speed control
Setting to enable/disable turning speed
TURN SPEED
* 2 YES Enabled NO Disabled
limitation
 3-59

Switching settings
Indication Description Setting Setting
Indication Indication
content content
Traction Traction
Setting traction limitation mode at over­ restrictions restrictions
D-LIM MODE
* 1 A B
discharge warning regardless of according to
discharge level discharge level
Setting pump limitation mode at over­ Lift interrupt
*
P-LIM MODE 1 A Lift interrupt B
discharge warning while traveling
Setting to enable/disable active mast
T FWD LIMIT YES Enabled NO Disabled
front tilt angle control
Setting to enable/disable backward tilt
T BWD LEVEL YES Enabled NO Disabled
automatic leveling control
Setting to enable/disable forward tilt
T F-SPD LIM YES Enabled NO Disabled
speed limit control
Setting number of ways for oil control
OCV WAY
* 1 2/3/4/Ö
valve
*
H-SELECTOR 1 Setting to enable/disable height selector YES Enabled NO Disabled
'1 : These are set according to the vehicle specification at the time of shipment.
"2 : 3-wheel vehicle only

OPTIONSET Screen
Operating Procedure
1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

BUILT IN ANALYZER

2. By default, the MASK MENU screen is displayed with the

[ANL] tab selected. On this screen, press the switch (3) to
select the [OPT] tab.

Switch (2) Switch (3)

3-60

3. Check that “1. OPTION SET” is selected, and press switch (4)
to display OPTION SET screen.
ÍQHÍ1 ÎTÏÎt?l füpfl liioTi Ip+FÎ ílñl
Note:
1.OPT IONSET You cannot move directly from the OPTION SET screen to
another screen. To do so, first return to the OPTION SET
MENU screen, and then move from it to the screen where the
desired items are displayed.
Switch (1): Switching selection to next item
£3D ( <■ i *_J ca. Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “OPTION SET” screen

“OPTION SET” Screen 1

Switch (1): Switching selection to next item
MPH Switch (2): Setting from NO to YES
DATE TYPE Switch (3): Setting from YES to NO
Switch (4): Switching to next screen
WHEEL IND
LOAD ALM
SPD ALM2
(♦)(>! (RËXT^

“OPTION SET” Screen 2

Switch (1): Switching selection to next item
x NO Switch (2): Setting from NO to YES
x NO Switch (3): Setting from YES to NO
SEAT BUZZER
Switch (4): Switching to next screen
PKB BUZZER x NO
B-TYPE < AZ >
STOP LAMP A x B

“OPTION SET” Screen 3

Switch (1): Switching selection to next item
BACK BUZZER Switch (2): Setting from NO to YES
SHOCK SENSOR Switch (3): Setting from YES to NO
Switch (4): Switching to next screen
ACCEL & BRK
ASC WxLOAD
MODE
pF") I j ÍNEXTj
 3-61

"OPTION SET” Screen 4

Switch (1): Switching selection to next item
Itijrn SPEED I YES z NO Switch (2): Setting from NO to YES
D-LIM MODE A / B Switch (3): Setting from YES to NO
Switch (4): Switching to next screen
P-LIM MODE A / B
T FWD LIMIT urc
I tz.--' / NO
T BUD LEUEL ucc
1 IZ--' / NO
( ♦J 1 J (NEXTI
C------

“OPTION SET” Screen 5

r Switch (1): Switching selection to next item
T F-SF'D LIM W^z NO Switch (2): Setting from NO to YES
OCU WAV 0Z3Z4Z5 Switch (3): Setting from YES to NO
Switch (4): Returning to OPTION SET MENU screen
H-SELECTOR YES/ NO

* J Ljp csj
3-62

MATCHING

GENERAL
Each function is controlled by using the sensors and each signal voltage at standard vehicle condition stored in the
controller at the time of shipment.
Therefore, a matching (updating of the signal voltage of a sensor at standard vehicle condition) is required when
performing maintenance on a section or replacing parts related to the sensor.

For the accelerator sensor and brake sensor used for drive functions, the signal voltage values at accelerator fully
released, accelerator fully closed, brake fully released and brake operation starting positions are stored, respectively,
in the controller to control based on these values. When servicing these sensors or replacing related parts,
MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary.

For the tilt angle, load and tire angle sensors used for SAS functions, the signal voltage values at standard vehicle
condition are stored respectively, in the controller to control based on these values. When servicing or replacing
these sensors, matching (updating the sensor signal voltage value in the standard vehicle condition) is necessary.
Also, matching is needed for the tilt angle sensor when the vehicle posture has changed excessively, and for the load
sensor when the load under no load condition (no load on fork) is changed because of addition or removal of any
attachment or fork, replacement of mast or change of fork length. On the other hand, matching is needed for the tire
angle sensor when the tire angle sensor or related part is replaced.

Each lever angle sensor for mini lever or joystick function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment. When servicing these sensors or replacing
related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary.

Load meter stores mast specification information and signal voltage values during no-load of the load sensor to the
multi-function display, and indicates based on these. When servicing the mast or load sensor, or replacing related
parts, matching (updating the sensor signal voltage value and mast specification information in the standard vehicle
condition) is necessary.

It is necessary to input the tire data to the controller according to the tire size, for optimizing the speedometer
reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the tire size
or type is changed according to "TIRE DATA List”.

Matching Items and Prerequisite for Implementation

1. DRIVE

Prerequisite for
No. Indication Description
implementation
Accelerator sensor output value with fully released accelerator position
1 ACCEL OFF *2
*1,
to the controller.
Accelerator sensor output value with fully stepped accelerator position to
2 ACCEL ON *2
*1,
the controller.
Brake sensor output value with fully released brake position to the
3 BRAKE OFF *3
*1,
controller.
Brake sensor output value at the operation starting position of brake to
4 BRAKE ACT *3
*1,
the controller.
 3-63

>. SAS

Prerequisite for
No. Indication Description
implementation
Tilt angle sensor output value with fork in the horizontal position to the *4
*1,, *5, *9
8,
1 TILT LEVEL
controller. *10
Tilt angle sensor output value at the forward tilt limit position and the load *4
*1,
, *5, *6, *8, *9,
2 TILT FWD LIMIT
sensor output value without load to the controller. *10
Tire angle sensor output value while the vehicle is traveling straight to
3 TIRE POSITION *1,
*7
the controller.

J. MINI LEVER (or joystick)

Prerequisite for
No. Indication Description
implementation
Lift lever angle sensor output value in the lift lever neutral position is
1 LEVER 1 *1,
*11
stored in the controller.
Tilt lever angle sensor output value in the tilt lever neutral position is
2 LEVER 2 *1,
*12
stored in the controller.
Attachment (1 ) lever angle sensor output value in the attachment (1 )
3 LEVER 3 *1, *13
lever neutral position is stored in the controller.
Attachment (2) lever angle sensor output value in the attachment (2)
4 LEVER 4 *1, *14
lever neutral position is stored in the controller.

I. LOAD METER (Vehicle with multi-function display deluxe model only)

Prerequisite for
No. Indication Description
implementation
The mast type is stored.
1 MAST TYPE *9, *15
[V-»FSW->FW->FSV->FV-> “ - ” (N/A)]
CYL. SIZE Diameter of the lift cylinder is stored. (V mast only) *9, *15
2 CYL. SIZE 1 Diameter of the lift cylinder is stored. (Except V mast) *9, *15
CYL. SIZE 2 Diameter of the lift cylinder is stored. (Except V mast) *9, *15
ZERO SET Zero point of the load meter is stored. (V mast only) *6, *8, *9, *15
3 ZERO SET 1 Zero point of the load meter is stored. (Except V mast) *6, *8, *9, *15
ZERO SET 2 Zero point of the load meter is stored. (Except V mast) *6, *8, *9, *15
As requested by
4 COMPENSATION The value of load meter compensation data is stored. customer to adjust
the accuracy

5. TIRE DATA

Prerequisite for
No. Indication Description
implementation
1 TIRE DATA The tire data according to the tire size is stored. *16
*1,
Prerequisite content for implementation
'1 : When replacing main controller
'2: When removing/installing or replacing accelerator sensor
'3: When removing/installing or replacing break sensor
'4: When removing/installing or replacement tilt angle sensor
'5: When replacement of tilt angle sensor rod
'6: When removing/installing or replacing load sensor
'7: When removing/installing or replacing tire angle sensor or sensor cover
'8: When installing or changing attachment or fork
'9: When removing/installing or replacing mast
3-64

*10: When removing/installing or replacing tilt cylinder

*11: When replacing lift lever angle sensor
*12: When replacing tilt lever angle sensor
*13: When replacing attachment (1) lever angle sensor
*14: When replacing attachment (2) lever angle sensor
*15: When replacing multifunction display
*16: When the tire size or type is changed.

Before Starting Matching

Before performing matching, you must set the vehicle to “standard condition”. For “standard vehicle condition”, refer
to Section 16, “SAS/OPS”.
 3-65

MATCHING MENU Screen

Operating Procedure
------------------------------------------------------------------------------------------------------ >
1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

X
BUILT IN ANALYZER

2. By default, the MASK MENU screen is displayed with the

[ANL] tab selected. On this screen, press the switch (3) and
select the [MAT] tab.

Note:
The menu item “4. LOAD METER” is not displayed on
vehicles other than multi-function deluxe model.

“1. DRIVE”
Switch (1): Switching selection to next item.
foNÌÌ ffiifll ffiPT5! iHfff] IS1 Switch (2): Selecting MASK MENU. (See page 3-23)
Switch (3): Selecting MASK MENU. (See page 3-23)
1. DRIVE Switch (4): To MATCHING DRIVE screen

2.SAS “2. SAS”

Switch (1): Switching selection to next item.
3.MINI LEVER Switch (2): Selecting MASK MENU. (See page 3-23)
( 1 ) U->J Switch
Switch
(3):
(4):
Selecting MASK MENU. (See page 3-23)
To MATCHING SAS screen

“3. MINI LEVER”

Switch (1): Switching selection to next item.
röïïTi ffiïïfi ÌÀFflJiiml iFhTirKi Switch (2): Selecting MASK MENU. (See page 3-23)
Switch (3): Selecting MASK MENU. (See page 3-23)
4.LOAD METER Switch (4): To MATCHING MINI LEVER screen

5.TIRE DATA “4. LOAD METER”

Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-23)
LS r*~T~Q CT Switch (3): Selecting MASK MENU. (See page 3-23)
Switch (4): To MATCHING LOAD METER screen

“5. TIRE DATA”

Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-23)
Switch (3): Selecting MASK MENU. (See page 3-23)
Switch (4): To TIRE DATA screen

Note:
“4. LOAD METER” will not be displayed on vehicles other than
multi-function deluxe model.
3-66

DRIVE (MATCHING DRIVE)

Matching is performed for drive function.

Note:
• After performing the ACCEL OFF matching, be sure to perform ACCEL ON matching.
• After performing the BRAKE OFF matching, be sure to perform BRAKE ACT matching.
Operating Procedure
1. Display the MATCHING MENU screen and press the switch
(qnH friüül iTìpBWI Iptiïl fSL (1), select the “1. DRIVE”.
1.DRIVE
2 SAS
3’mINI LEVER
(~T3 OT

2. Press the switch (4) to display MATCHING screen.

Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.

Note:
In standard vehicle condition, if the value in the bracket ( ) and
the value outside the bracket ( ) are different, matching is
required.

3. Make sure that the Spanner indicator on the display is blinking.

Caution:
During drive matching, the Spanner indicator blinks, informing
that the vehicle does not run even if the accelerator pedal
depressed.

“ACCEL OFF” Screen

If matching is performed (press switch (1)), "OK” is indicated on the
ACCEL OFF_ _ _ _ _ _ _ display. (See page 2-34)
Switch (1): Pressing this for more than 2 seconds will
0.85 (0.85) perform matching.
Switch (4): To “ACCEL ON” screen
1.45 (1.45)
( set 1 Ifla iheRTi
 3-67

“ACCEL ON” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
ACCEL 0 N display. (See page 2-34)
Switch (1): Pressing this for more than 2 seconds will
3.25 (3.25) perform matching.
Switch (4): To “BRAKE OFF” screen
3.70 (3.70)
2SEC
( SETJ EE3 HEXT)

“BRAKE OFF” Screen

X If matching is performed (press switch (1)), “OK” is indicated on the
BRAKE OFF display. (See page 2-36)
Switch (1): Pressing this for more than 2 seconds will
1.75 (1.75) perform matching.
Switch (4): To “BRAKE ACT” screen
2.30 (2.30)
2 SEC
"SËT7I OK
X_____________________________________________ _ __________/

“BRAKE ACT” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
i BRAKE ACT display. (See page 2-37)
Switch (1): Pressing this for more than 2 seconds will
2.85 (2.85) perform matching.
Switch (4): Returning to MATCHING MENU screen.
3.30 30) ■

2 SEC
( SETJ

SAS (MATCHING SAS)

hatching is performed for SAS function.
Operating Procedure
1. Display the MATCHING MENU screen and press the switch
iWlfTHNllTiAlWliFAl^
(1), select the "2. SAS”.

3.MINI LEVER
I ♦_) O I ) C-
*=LJ,
2. Press the switch (4) to display MATCHING screen.
Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.

Note:
In standard vehicle condition, if the value in the bracket ( ) and
the value outside the bracket ( ) are different, matching is
required.
3-68

“TILT LEVEL” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
TILT LEVEL display
Switch (1): Pressing this for more than 2 seconds will
perform matching.
2.50 (2.50) Switch (4): To “TILT FWD LIMIT” screen

g SEC
( SET ) 03 ihexT)

“TILT FWD LIMIT” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
TILT FWD LIMIT display
Switch (1): Pressing this for more than 2 seconds will
2.50 (2.50) perform matching.
Switch (4): To “TIRE POSITION” screen
0.70 (0.70)
2 SEC
( SET j 03 (NEXT)

“TIRE POSITION” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
TIRE POSITION display
Switch (1): Pressing this for more than 2 seconds will
perform matching.
2.30 (2.30) Switch (4): Returning to MATCHING MENU screen.

MINI LEVER (MATCHING MINI LEVER or JOYSTICK)

Matching is performed for mini lever or joystick functions.

Operating Procedure
1. Display the MATCHING MENU screen and press the switch
iflNii (Tii^ ÎûFtI m (1), select the “3. MINI LEVER” menu.

1.DRIVE
2.SAS
3.MINI LEVER
r*
~i ( * i +j
 3-69

2. Press the switch (4) to display MATCHING SET screen.

Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.
Note:
In standard vehicle condition, if the value in the bracket ( ) and
the value outside the bracket ( ) are different, matching is
required.

“LEVER1” Screen
If matching is performed (press switch (1)), “OK” is indicated on the
LEVER1 display
Switch (1): Pressing this for more than 2 seconds will
2.40 (2.40) perform matching.
Switch (4): To “LEVER2” screen
2.40 (2.40)
a sec
( SET )

“LEVER2” Screen
If matching is performed (press switch (1)), “OK” is indicated on the
LEVER2 display
Switch (1): Pressing this for more than 2 seconds will
2.40 (2.40) perform matching.
Switch (4): To “LEVER3” screen
2.40 (2.40)
a sec
( SET -I INEXTIJ

“LEVER3” Screen
If matching is performed (press switch (1)), “OK” is indicated on the
LEVER3 display
Switch (1): Pressing this for more than 2 seconds will
2.40 (2.40) perform matching.
Switch (4): To “LEVER4” screen
2.40 (2.40) Note:
2 SEC r “Lever3” screen will be displayed according to the number of
( SETJ 019 (NExn ways being set.

“LEVER4” Screen
If matching is performed (press switch (1)), “OK” is indicated on the
LEVER4 display
Switch (1): Pressing this for more than 2 seconds will
2.40 (2.40) perform matching.
Switch (4): Returning to MATCHING MENU screen.
2.40 (2.40) Note:

I! 13 ( tj
zsec n
( SET )
j “Lever4” screen will be displayed according to the number of
ways being set.
3-70

LOAD METER (MATCHING LOAD METER)

In order to optimize the load meter, it is necessary to input each value of the "mast type”, “cylinder data”, “0 point
adjustment” and “accuracy adjustment” according to the mast attached, on the display.
These values are already set at the time of shipment, but when replacing the mast or readjustment is required for the
accuracy of the load meter, set these values again.

Operating Procedure
1. Display the MATCHING MENU screen and press the switch
i^nTi fîiÎNl iripfl liiffTl iSiFliTn (1), select the “4. LOAD METER”.

4.LOAD METER
5.TIRE DATA
£30 t > I o cjn

2. Press the switch (4) to display MATCHING SET screen.

Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.

Note:
In standard vehicle condition, if the value in the bracket ( ) and
the value outside the bracket ( ) are different, matching is
required.

“MAST TYPE” Screen

Switch (2): V<—FSW<-FW<-FSV<—FV<-“ - ” (NA)
Switch (3): V- >FSW->FW^FSV->FV-> “ - ” (NA)
Switch (4): To “CYL. SIZE” screen

“CYL. SIZE” Screen (V mast only)

Switch (2): Setting cylinder diameter smaller
CYL. SIZE Switch (3): Setting cylinder diameter larger
Switch (4): To “ZERO SET” screen

Note:
If the “ - ” (not available) option is selected on the MAST TYPE
screen, the load meter function and the overload alarm
function become disabled, and the administrator menu setting
C
* I ■» j (NEXT) screen does not appear.
 3-71

“CYL. SIZE 1” Screen (Except V mast)

Switch (2): Setting cylinder diameter 1 smaller
CYL. SIZE 1 Switch (3): Setting cylinder diameter 1 larger
Switch (4): To "CYL. SIZE 2” screen

■)
*
(>! [NEXTI

“CYL. SIZE 2” Screen (Except V mast)

Switch (2): Setting cylinder diameter 2 smaller
CYL. SIZE 2 1 Switch (3): Setting cylinder diameter 2 larger
Switch (4): To “ZERO SET 1” screen

55«
\L
* __l ) (HEXT)
Cylinder Diameter List
Mast type Applied models Cylinder diameter No.1 *1 Cylinder diameter No.2 *2
8FBET15, 16, 18
8FBEKT16, 18 45 -
V 8FBMT15, 16, 18
8FBET20
48 -
8FBMT20
8FBET15, 16, 18
8FBEKT16, 18 48 45
FSW 8FBMT15, 16, 18
8FBET20
52 48
8FBMT20
8FBET15, 16, 18
8FBEKT16, 18 48 32
FW 8FBMT15, 16, 18
8FBET20
52 35
8FBMT20

*1: Lift cylinder bore (V), Front lift cylinder bore (FSW, FW)
*2: Rear lift cylinder bore (FSW), Piston rod outside diameter of rear lift cylinder (FW)
3-72

“ZERO SET” Screen (V mast only)

If matching is performed “OK” (or “NG”) is indicated on the display.
i ZERO SET I OK: Matching completed
NG: Signal voltage value is out of the matching range.

cI.OOt
When "NG” is indicated, check the vehicle condition, abnormalities
of load sensor, disconnection and short circuit of the harness.
Note:
2 SEC Make sure to perform matching with the vehicle set to
(ÜSET) (NEXT) “standard vehicle condition”.

Standard vehicle condition:

Set the mast approximately vertical, and raise the forks at
height of approximately 500 mm (19.7 in) from ground.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): TO “COMPENSATION” screen

500 mm
(19.7 in)
/
; li
“ZERO SET 1” Screen (Except V mast)
If matching is performed “OK” (or “NG”) is indicated on the display.
( ZERO SET 1 1 OK: Matching completed

M (10 Ot
NG: Signal voltage value is out of the matching range.
When “NG” is indicated, check the vehicle condition, abnormalities
of load sensor or height switch, disconnection and short circuit of
the harness.
MSEC
Note:
_________ (NEXT!
_____ ✓ Make sure to perform matching with the vehicle set to
“standard vehicle condition”.

Standard vehicle condition:

Set the mast approximately vertical, and raise the forks at
height of approximately 500 mm (19.7 in) from ground.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): TO “ZERO SET 2” screen

500 mm 3
(19.7 in)
 3-73

“ZERO SET 2” Screen (Except V mast)

If matching is performed “OK” (or “NG”) is indicated on the display.
ƒ\ 1 y iRO SET 2 OK: Matching completed
NG: Signal voltage value is out of the matching range.

2 SI
;0.00t
(os ET) IHEXTJ
When “NG” is indicated, check the vehicle condition, abnormalities
of load sensor or height switch, disconnection and short circuit of
the harness.
Note:
Make sure to perform matching with the vehicle set to
“standard vehicle condition”.

Standard vehicle condition:

Set the mast approximately vertical, and raise the rear lift
cylinder to a height of approximately 100 mm (3.9 in).
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): TO “COMPENSATION” screen

“COMPENSATION” Screen
x This function corrects values indication on the display according to
COMPENSATION actual live load.
When performing correction, set the mast vertically and take on
( 0.00) loading object (object with its accurate weight is known), then while
t raising the fork for approx. 500 mm (19.7 in), adjust the value
indicated on the top right hand corner of the screen to the laden
weight by operating the switch.
Switch (2): Minus correction
Switch (3): Plus correction
Switch (4): Returning to MATCHING MENU screen
3-74

TIRE DATA
It is necessary to input the tire data to the controller according to the tire radius, for optimizing the speedometer
reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the tire size
or type is changed according to “Tire Data List”.

Operating Procedure

1. Display the MATCHING MENU screen and select the “5. TIRE
füNii ffÜNl ÌriFrl liîflTl DATA”.

4.LOAD METER
5.TIRE DATA
( ittvj rm

2. Press the switch (4) to display “TIRE DATA” screen.

“TIRE DATA” Screen

Switch (2): Setting tire data smaller
TIRE DATA_ _ _ _ _ _ _ Switch (3): Setting tire data larger
Switch (4): Returning to MASK MENU screen.

238
(_> I :i CSZ)

Tire Data List

Vehicle model Tire size Tire type Tire constant
Non-puncture / Marangoni E3 238
Non-puncture / Continental SC15 238
18x7-8/4.33 Non-puncture Non-mark / Marangoni V3 235
8FBET15
Non-puncture Non-mark / Continental SC15 Super
235
Clean
18x7-8 16PR Pneumatic / Marangoni SW 239
Non-puncture / Marangoni E3 237
Non-puncture / Continental SC 15 237
8FBET16 18x7-8/4.33 Non-puncture Non-mark / Marangoni V3 235
8FBEKT16 Non-puncture Non-mark / Continental SC15 Super
235 •
Clean
18x7-8 16PR Pneumatic / Marangoni SW 238
 3-75

Vehicle model Tire size Tire type Tire constant

Non-puncture / Marangoni E3 236
Non-puncture / Continental SC15 236
8FBET18
18x7-8/4.33 Non-puncture Non-mark / Marangoni V3 234
8FBEKT18
Non-puncture Non-mark / Continental SC15 Super
234
Clean
Non-puncture / Marangoni E3 242
Non-puncture / Continental SC15 242
8FBET20 200/50-10/6.50 Non-puncture Non-mark / Marangoni V3 239
Non-puncture Non-mark / Continental SC15 Super
239
Clean
Non-puncture / Marangoni E3 238
Non-puncture / Continental SC15 238
18x7-8/4.33 Non-puncture Non-mark / Marangoni V3 235
8FBMT15 Non-puncture Non-mark / Continental SC15 Super
235
Clean
Pneumatic / Marangoni SW 241
18x7-8 16PR
Pneumatic / Continental C12 241
Non-puncture / Marangoni E3 237
Non-puncture / Continental SC15 237
18x7-8/4.33 Non-puncture Non-mark / Marangoni V3 234
8FBMT16 Non-puncture Non-mark / Continental SC15 Super
234
Clean
Pneumatic / Marangoni SW 240
18x7-8 16PR
Pneumatic / Continental C12 240
Non-puncture / Marangoni E3 236
Non-puncture / Continental SC15 236
18x7-8/4.33 Non-puncture Non-mark / Marangoni V3 234
8FBMT18 Non-puncture Non-mark / Continental SC15 Super
234
Clean
Pneumatic / Marangoni SW 240
18x7-8 16PR
Pneumatic / Continental C12 240
Non-puncture / Marangoni E3 242
Non-puncture / Continental SC15 242
8FBET20 200/50-10/6.50 Non-puncture Non-mark / Marangoni V3 239
Non-puncture Non-mark / Continental SC15 Super
239
Clean
3-76

OTHERS MENU
Note:
After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be displayed on
the “OTHERS MENU”.

Before hour meter start After hour meter start

ÍqñD ifiiril fopTl fMoTlIeElilTi

1.METER START 1.TO DEFAULT SET

2. DEMO MODE 2. MASK PASSWORD
3. TO DEFAULT SET 3. MANAGER PASS CLR
£3D t > i GD i > i ■» ) CSDJ

íflÑii ffiifll iiïp?l Íííút) ÌetcìfKÌ ÍQÑii fTÏiril ííiFrl Iñffñletcif^D

4.MASK PASSWORD 4.CONTRAST
5. MANAGER PASS CLR
6. CONTRAST
<
*
( ♦ )___ (
!
>
-►) cm ( ♦ ) ( » i 4 ) ( w)

Operating Procedure
f------------------------------------------------------------------- X Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

VER 1.00

BUILT IN ANALYZER

“1. METER START”

Switch (1): Switching selection to next item
fäwTl ffiiiJl ÍtípTí líiffñletclAñi Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
1.METER START Switch (4): To “METER START' screen

2. DEMO MODE “2. DEMO MODE”

Switch (1): Switching selection to next item
3. TO DEFAULT SET Switch (2): Selecting MASK MENU
( ♦j ívtv) cm Switch (3): Selecting MASK MENU
Switch (4): To “DEMO MODE” screen
“3. TO DEFAULT SET”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “TO DEFAULT SET” screen
 3-77

“4. MASK PASSWORD”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “TO DEFAULT SET’ screen

5. MANAGER PASS CLR “5. MANAGER PASS CLR”

Switch (1): Switching selection to next item
6. CONTRAST Switch (2): Selecting MASK MENU
tTD ( > i -*_J CTj Switch (3): Selecting MASK MENU
Switch (4): To “MANAGER PASS CLR” screen
“6. CONTRAST”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “CONTRAST” screen

VIETER START (HOUR METER START)

This menu item is used to make the following meters start counting: hour meters, odometer, trip meter and
naintenance hour meter.
/Vith this menu option, you can also enable the following functions or operations regardless of whether the demo
node is enabled or disabled.
• Enables the material handling operation during traveling.
• Enables the parking brake reminder function.
• Enables the detection, warning and recording function, while clearing the data on damage detected by the
simplified damage detection system (option).
• Enables all functions of the PIN code entry system (option).
Mote:
• This option does not the clear the PIN code authentication data or the simplified damage detection level
that was set when the demo mode was enabled.
• Once the hour meter has started, it cannot be returned to the state where it was before it starts.
Operating Procedure
/-------------------------------------------------------------------------------------- k
1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

BUILT IN ANALYZER

2. Press the switch (2) or (3) to check the "OTHERS MENU” is

selected.

Switch (2) Switch (3)

3-78

3. Press the switch (4) to display METER START screen.

iWliWiTTTllWli^iTTl
1.METER START
2. DEMO MODE
3. TO DEFAULT SET
CT3 ( > ! ■»_) Qgj
“METER START” Screen
Hour meter start procedure
METER START 1. Press the switch (2) for more than 2 seconds to display the
right arrow (guidance) on the screen.

YES / ffl
gl CS3
2. While pressing the switch (2), if you press the switch (3),
inverted NO on the screen turns to inverted YES, and the
METER START setting is completed.

YES / B
r~r
*p csi
3. Press the switch (4) to return to MASK MENU screen.

METER START
/ NO
 3-79

)EMO MODE
'his menu item is used to enable or disable the demo mode.
iefore starting the hour meter, you can enable the following functions temporarily in the demo mode.
Demo mode Yes (enabled) No (disabled)
Material handling during traveling Allowed Not allowed
Parking brake OFF warning Enabled Disabled
Shock sensor (OPT) Detection, warning, recording Enabled Disabled
Authentication possible Authentication possible
Authentication function only for registered by simply pressing the
PIN code entry system (OPT) authentication numbers log-in switch
Registration, change or deletion
Enabled Disabled
of authentication number

<lote:
Even after the demo mode has been disabled, the data recorded and the settings made during the demo
node are all retained.

Operating Procedure
■X
1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.0Q

BUILT IN ANALYZER -X

2. Press the switch (2) or (3) to check the “OTHERS MENU” is

selected.

3. Display thè OTHERS MENU screen and press thè switch (1),
selectthe “2. DEMO MODE”.
ÆÜTI ffîïïü fiTfl ifjffñ letcl I1A
4. Press thè switch (4) to display DEMO MODE screen.
1.METER START
2.DEMO MODE
3.TO DEFAULT SET
£33 £g)
3-80

“DEMO MODE” screen

--------------------- \ Switch (2): Setting from YES
DEMO MODE Switch (3): Setting from NO
Switch (4): Return to OTHERS MENU screen
Note:
After the start of the hour meter, no settings can be made in
the demo mode.
 3-81

TO DEFAULT SET
This menu item is used to initialize the tuning values or the settings of items with default values.
Setting items applied:
• Menu lock
• Power select mode (SPH)
• Drive power control setting, material handling power control setting
• Low speed setting
• Maximum speed setting
• Over speed alarm setting
• Tuning level
• Auto power OFF time

Operating Procedure
---------------------------------------------------------------------------------------------------------------------------------------------------------
1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

BUILT IN ANALYZER
CT

2. Press the switch (2) or (3) to check the “OTHERS MENU” is

selected.

Switch (2) Switch (3)

Before hour meter start

Before hour meter start
3. Press the switch (1) to check if “3. TO DEFAULT SET” is
ÍOÑTl ffiiiìl ffÌFTÌ ÌMfffì letclrFTi selected.

4. Press the switch (4) to display TO DEFAULT SET screen.

1. METER START
2. DEMO MODE After hour meter start

3. Display the OTHERS MENU screen and press the switch (1),
.TO DEFAULT SET select the “1. TO DEFAULT SET’.
*_í
l_ ( 4- i j eg)] 4. Press the switch (4) to display TO DEFAULT SET screen.

After hour meter start

íflÑD ffiB írÍFÍi líiñii leteliTTì

1.
T0 DEFAULT SET
2. MASK PASSWORD
3. MANAGER PASS CLR
L 4»_j iCTTCTJ ICT )
3-82

“TO DEFAULT SET” Screen

1. Press the switch (2) and select the “YES”.
TO DEFAULT SET
YES /
( +■ i

2. To initialize the settings, press and hold down the switch (1) for
more than 2 seconds.
TO DEFAULT SET Note:
• When the Default Set operation is in progress, do not turn
/ NO off the ignition key switch or disconnect the battery plug.
• You can return to another mask function menu by
2 SEC pressing the switch (4), except when the Default Set
operation is in progress.
SET ) L_4J CSJ

TO DEFAULT SET

■■■■■■■■■I
OK
 3-83

l/IASK SECOND PASSWORD SETTING (MASK PASSWORD)

"his menu item is used to set or clear a mask second password.
fou can enter any four-digit number as a mask second password, using the 4 switches on the multifunction display.
F you set a mask second password, you will be prompted to enter the second password after you enter the ordinary
jassword necessary to display the MASK FUNCTION screen, and you can move to the MASK FUNCTION screen
)nly when the passwords you entered coincide with the registered ones.
«Jo mask second password has been set by default.
<lote:
)o not forget the password you set. In the event you forget it, consult your dealer.

Operating Procedure
(----------------------------------------------------------------------------------'
1. Enter the password on the general screen (See page 3-22) to
display the mask function. After 5 seconds, the ANALYZER
MENU screen is automatically displayed.
VER 1.00

V
BUILT IN ANALYZER

2. Press the switch (2) or (3) to check the “OTHERS MENU” is

selected.

Switch (2) Switch (3)

Before hour meter start

Before hour meter start
3. Press the switch (1) to check that “4. MASK PASSWORD” is
rñÑTl ífiiii) fnFñ líifffl ietelCKÌ selected.

4. Press the switch (4) to display MASK SECOND PASSWORD

screen.
5. MANAGER PASS CLR After hour meter start
6. CONTRAST 3. Display the OTHERS MENU screen and press the switch (1),
□EJ ( <■ I ) Çgi select the “2. MASK PASSWORD” menu.
4. Press the switch (4) to display MASK SECOND PASSWORD
After hour meter start setting screen.

í5Ñii ffîïïil Iíípií ffifffl letc)lT=n

1 ULt;l'Em
■ i

3.MANAGER PASS CLR

-- FP~i>
ví * ) (<■!■►)
3-84

Mask second password set

MASK PASSWORD 1. When you enter a four-digit number, “SET” appears in the
lower left corner of the screen, informing that you are ready to
\ I/
■M■■ 2 SEC
2.
save it as a password.
Press and hold down the switch (1) for more than 2 seconds to
save the password. After the password has been saved, “OK”
appears.
(CLR) (exiti Note:
• A 4-digit number needs to be entered in order for it to be
accepted as a password.
1 • If you press and hold down the switch (4) for more than 2
seconds, the number you entered becomes invalid and
MASK PASSWORD I the screen switches over to another mask function menu
screen.

El El El El
2 SEC 2 SEC
( SET ) (EXITJ

MASK PASSWORD 1

El El El El
OK
X______________________________________________ " ................. J

Mask second password clear

If you press and hold down the switch (1) for more than 2 seconds
without entering any digit on the MASK PASSWORD screen, the
registered password is deleted and "OK” appears on the
completion of its deletion.

Note:
The mask second password can be cleared only when no digit
has been entered (when every box is [ ■ ]).

I
MASK PASSWORD
□ □□□
OK Cg
 3-85

ADMINISTRATOR SECOND PASSWORD CLEAR (MANAGER PASS CLR)

This menu item is used to clear the administrator second password.
f so requested by the customer, you can clear the administrator second password on the mask function screen.

Operating Procedure
f-------------------------------------------------------------------- \ 1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

BUILT IN ANALYZER

2. Press the switch (2) or (3) to check the “OTHERS MENU” is

selected.

Before hour meter start

Before hour meter start
3. Press the switch (1) to check that “5. MASK PASSWORD” is
selected.
íSÑTl ffiìiìl friPTl líiffñ
4. Press the switch (4) to display MANAGER PASS CLR screen.
4.MASK PASSWORD
After hour meter start
5.MANAGER PASS CLR 3. Display the OTHERS MENU screen and press the switch (1),
6.CONTRAST select the “3. MANAGER PASS CLR”.
L±J t <- I LfeLj 4. Press the switch (4) to display MANAGER PASS CLR screen.

After hour meter start

íflÑii ffiïïî) ffÌPTÌ IñaTl letcliKÌ

1.T0 DEFAULT SET
3.MANAGER PASS CLR
3-86

“ADMINISTRATOR SECOND PASSWORD CLEAR”

(MANAGER PASS CLR) Screen
f MANAGER PASS CLR 1 If you press and hold down the switch (1) for more than 2 seconds,
the administrator second password is deleted and “OK” appears on
the completion of its deletion.
[¡©ALL CLEAR? Switch (1): Clears the password if pressed and held
down for more than 2 seconds.
2 SEC Switch (4): Returning to OTHERS MENU screen

<
CLR
____ J
1
i MANAGER PASS CLR
d , J r l
L KALIL CLEAR?
2 SEC
( CLR ) 03
LCD CONTRAST ADJUSTMENT
This menu item is used to adjust the contrast of the multifunction LCD display.

Operating Procedure

(---------------------------------------------- T 1. Enter the password on the general screen (See page 3-22) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
VER 1.00

BUILT IN ANALYZER
-J

2. Press the switch (2) or (3) to check the "OTHERS MENU” is

selected.

Switch (2) Switch (3)

 3-87

Before hour meter start

Before hour meter start
3. Press the switch (1 ) to check that “6. CONTRAST” is selected.
Press the switch (4) to display CONTRAST screen.
íflÑii ffiiBl (np?l letclfKi
After hour meter start
4. MASK PASSWORD 3. Display the OTHERS MENU screen and press the switch (1),
5. MANAGER PASS CLR select the “4. CONTRAST”.
6.CONTRAST 4. Press the switch (4) to display contrast setting screen.
irrp itti
After hour meter start

“CONTRAST” Screen
Switch (2): Contrast level down
Switch (3): Contrast level up
Switch (4): Returning to OTHERS MENU screen
3-88

MULTI-FUNCTION DISPLAY ASSY

 3-89

REMOVAL • INSTALLATION

Removal Procedure
I. Remove the battery plug.
’. Remove the column cover (front).

J. Remove the instrument panel RH.

I. Remove the multi-function display from the instrument panel RH.

Installation Procedure
fhe installation procedure is the reverse of the removal procedure.
3-90

DISASSEMBLY • INSPECTION • REASSEMBLY

Disassembly Procedure
1. Remove the rear cover.
2. Remove the circuit plate.
3. Remove the display ASSY.
4. Remove the switch plate.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 4-1

TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING............................. 4-2
CONNECTOR HANDLING................................................ 4-2
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE.................................................................. 4-2
TROUBLESHOOTING METHOD............................ 4-4

DIAGNOSIS CODE LIST..........................................4-6 “

WHEN AN ERROR CODE IS DISPLAYED.......... 4-18

WHEN NO ERROR CODE IS DISPLAYED........4-181
4-2

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: 10 W or less

Note:
Measure while lightly shaking the wire harness up and down
and sideways.
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.
 4-3

Short circuit check

1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between the corresponding connector
terminal and N1. Always inspect the connectors at both ends.
Standard: 1 MQ or above

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: 1 MQ or above

The wiring may short-circuit due to pinching by the body or

defective clamping.

Visual and contact pressure checks

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

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

connector and check the extracting force.
Defective contact may exist at a terminal where the extracting
force is less than that of other terminals.
Note:
Even if there is rust or foreign matter trapped at the terminal,
or the contact pressure between male and female terminals is
low, abnormal contact condition may be changed to normal by
disconnecting and reconnecting the connector. In that case,
repeat connector connection and disconnection several times.
If defect is perceived even once, terminal contact may be
defective.
4-4

TROUBLESHOOTING METHOD

Main controller defect

Explanation of Frames

1. Disconnect the battery plug, disconnect the CN43

connector, and visually check inside the connector
and the caulked portion of its wire for defects.
A single frame indicates measurement with a tester or an
(Refer to BEFORE BLESHOOTING.)
ordinary step.
2. Connect the CN43 connector, connect the battery
plug, and then turn on the key switch without sitting in
the seat.

Inspection: Check of seat switch condition

A double frame indicates inspection by an analyzer
Check the value of SDM, using the Analyzer menu.
function.
fANLl I/O TRAVELING 2/5

Test item.
 4-5

TO USE SST
Use SSTs for quick, accurate electrical troubleshooting on the 8FBET, 8FBMT 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. SST name remarks

09230-13240-71 Main controller check harness

(for power source check)
C8-1 to 4
09240-13240-71 AC driver check harness
E8-1,2
09230-13700-71 CN76 short harness 61-1,2
C2-2, 3
C4-1 to 6
C5-1 to 6
C8-1 to 4
E2-2
09232-13130-71 Each short harness E8-1.2
FB-1, 2
62-1,2
71- 1 to 3
72- 1 to 4
G5-1 to 6
09238-13130-71 CN99 check harness 68-1 to 3

Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
connected, various boards may be damaged.
DIAGNOSIS CODE LIST
Indication : Information can be checked on the display when vehicle trouble occurs.
Memory : Use indication information that can be checked when the mask function DIAG MEMORY is used.
Lamp : Spanner

Indication Memory Lamp Error mode Phenomenon on vehicle See page

O/H
DCR AO-1 Drive motor power-circuit overheating abnormality. Drive motor output restricted or traveling stop. 4-18
lighting
O/H Pump motor output restricted or material handling and
PCR AO-2 Pump motor drive power-circuit overheating abnormality. 4-21
lighting Power steering stop.
Spanner Traveling stop.
A1-1 A1-1 Main controller high voltage. 4-24
blinking Material handling stop.
Spanner
A1-2 A1-2 Drive motor drive circuit LH high voltage. 4-25
blinking
Drive motor output restricted.
Spanner
A1-3 A1-3 Drive motor drive circuit RH high voltage. 4-26
blinking
Spanner Material handling stop.
A1-4 A1-4 Pump motor drive circuit high voltage. 4-27
blinking Power steering stop.
O/H Traveling stop.
C/R A2-1 Main controller overheating abnormality. 4-28
lighting Material handling stop.
O/H
DCR A2-2 Drive motor drive circuit board overheating abnormality. Drive motor output restricted or traveling stop. 4-29
lighting
O/H Pump motor output restricted or material handling and
PCR A2-3 Pump motor drive circuit board overheating abnormality. 4-32
lighting Power steering stop.
Spanner Battery voltage in the B48V line after the F5 fuse the
A3-1 A3-1 Battery connection incorrect. 4-35
blinking set voltage
Traveling and material handling possible even after
Spanner
A5-1 A5-1 Seat switch GND short abnormality. leaving seat. 4-36
blinking
Parking brake reminder alarm partially disabled.
Spanner Traveling stop.
A8-1 A8-1 F1 fuse abnormality (Open).
blinking Material handling stop.
4-38
Spanner Traveling stop.
A8-2 A8-2 F6 fuse abnormality (Open).
blinking Material handling stop.
Spanner
A9-2 A9-2 F7 fuse abnormality (Open). Material handling stop. 4-42
blinking
Spanner Traveling stop.
AA-1- AA-1 Main controller temperature sensor abnormality. 4-44
blinking Material handling stop.
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
AA-2 AA-2 Drive motor drive board temperature sensor abnormality (LH). 4-45
blinking
Drive motor output restricted.
Spanner
AA-3 AA-3 Drive motor drive board temperature sensor abnormality (RH). 4-46
blinking
Spanner
AA-4 AA-4 Pump motor drive board temperature sensor abnormality. Pump motor output restricted. 4-47
blinking
Spanner Cooling fan stop.
AB-1 AB-1 Cooling fan drive circuit abnormality. 4-48
blinking Drive motor output restricted.
Spanner Traveling stop.
AC-1 AC-1 Semiconductor switch abnormality. 4-50
blinking Material handling stop.
Spanner
AD-1 AD-1 Drive motor (LH) - Main controller communication abnormality. Traveling stop.
blinking
Spanner Drive motor (LH) - Main controller communication abnormality
AD-2 AD-2 Traveling stop.
blinking ( on start up ).
Spanner
AD-3 AD-3 Drive motor (RH) - Main controller communication abnormality. Traveling stop.
blinking
4-52
Spanner Drive motor (RH) - Main controller communication abnormality
AD-4 AD-4 Traveling stop.
blinking ( on start up ).
Spanner Material handling stop.
AD-5 AD-5 Pump motor driver - Main controller communication abnormality.
blinking Power steering stop.
Spanner Pump motor driver - Main controller communication abnormality Material handling stop.
AD-6 AD-6
blinking ( on start up ). Power steering stop.
Spanner
AF-1 - CPU error. System stop.
blinking
Spanner
AF-2 — CPU error. System stop.
blinking
Spanner
AF-3 - CPU error. System stop.
blinking
Spanner
AF-4 AF-4 CPU error. System stop.
blinking
4-55
Spanner
AF-5 AF-5 CPU error. Display only.
blinking
Spanner
AF-6 AF-6 CPU error. Some control operations not stable.
blinking
Spanner
AF-7 AF-7 CPU error. Some control operations not stable.
blinking
Spanner
AF-8 AF-8 CPU error. Some control operations not stable.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
CO-2 CO-2 Drive motor power-circuit short (LH). 4-56
blinking
Drive motor output restricted.
Spanner
CO-4 CO-4 Drive motor power-circuit short (RH). 4-58
blinking
Spanner
C1-1 C1-1 Drive motor current sensor neutral voltage error (LH). 4-60
blinking
Spanner
C1-2 C1-2 Drive motor current sensor over current (LH). 4-61
blinking
Drive motor output restricted.
Spanner
C1-3 C1-3 Drive motor current sensor neutral voltage error (RH). 4-62
blinking
Spanner
C1-4 C1-4 Drive motor current sensor over current (RH). 4-63
blinking
O/H
DM C2-1 Drive motor temperature sensor abnormality. 4-64
lighting
Spanner
C2-2 C2-2 Drive motor temperature sensor abnormality (LH). Drive motor output restricted. 4-65
blinking
Spanner
C2-3 C2-3 Drive motor temperature sensor abnormality (RH). 4-67
blinking
Spanner
C3-1 C3-1 Drive motor power-circuit temperature sensor abnormality (LH). 4-69
blinking
Drive motor output restricted.
Spanner
C3-2 C3-2 Drive motor power-circuit temperature sensor abnormality (RH). 4-70
blinking
Spanner
C4-1 C4-1 Accelerator sensor 1 open.
blinking
Spanner
C4-2 C4-2 Accelerator sensor 2 open.
blinking
Spanner
C4-3 C4-3 Accelerator sensor 1 VCC short.
blinking
Drive motor output restricted. 4-71
Spanner
C4-4 C4-4 Accelerator sensor 2 VCC short.
blinking
Spanner
C4-5 C4-5 Accelerator sensor offset abnormality.
blinking
Spanner
C4-6 C4-6 Accelerator sensor matching value error.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
C5-1 C5-1 Brake sensor 1 open.
blinking
Spanner
C5-2 C5-2 Brake sensor 2 open.
blinking
Spanner
C5-3 C5-3 Brake sensor 1 VCC short.
blinking
Drive motor output restricted. 4-74
Spanner
C5-4 C5-4 Brake sensor 2 VCC short.
blinking
Spanner
C5-5 C5-5 Brake sensor offset abnormality.
blinking
Spanner
C5-6 C5-6 Brake sensor matching value error.
blinking
Spanner
C8-1 C8-1 Drive motor speed sensor open (LH). 4-77
blinking
Spanner
C8-2 C8-2 Drive motor speed sensor short (LH). 4-80
blinking
Drive motor output restricted.
Spanner
C8-3 C8-3 Drive motor speed sensor open (RH). 4-83
blinking
Spanner
C8-4 C8-4 Drive motor speed sensor short (RH). 4-86
blinking
Spanner Traveling stop.
CB-1 CB-1 MB contactor open.
blinking Material handling stop.
Spanner
CB-2 CB-2 MB contactor short. Discharge after Key switch-off is impossible.
blinking
Spanner Traveling stop.
CB-3 CB-3 MB contactor drive circuit open. 4-89
blinking Material handling stop.
Spanner
CB-4 CB-4 MB contactor drive circuit short. Display only.
blinking
Spanner Traveling stop.
CB-5 CB-5 MB contactor drive circuit short.
blinking Material handling stop.
Spanner
CC-1 CC-1 Drive motor CPU error(LH). Drive motor output restricted.
blinking
Spanner
CC-2 CC-2 Drive motor CPU error(LH). Drive motor output restricted.
blinking
4-94
Spanner
CC-3 CC-3 Drive motor CPU error(LH). Drive motor output restricted.
blinking
Spanner
CC-4 CC-4 Drive motor CPU error(LH). Drive motor output restricted.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
CC-5 CC-5 Drive motor CPU error(LH). Display only.
blinking
Spanner
CC-6 CC-6 Drive motor CPU error(LH). Display only.
blinking
4-94
Spanner
CC-7 CC-7 Drive motor CPU error(LH). Display only.
blinking
Spanner
CC-8 CC-8 Drive motor CPU error(LH). Display only.
blinking
Spanner
CD-1 CD-1 Drive motor CPU error(RH). Drive motor output restricted.
blinking
Spanner
CD-2 CD-2 Drive motor CPU error(RH). Drive motor output restricted.
blinking
Spanner
CD-3 CD-3 Drive motor CPU error(RH). Drive motor output restricted.
blinking
Spanner
CD-4 CD-4 Drive motor CPU error(RH). Drive motor output restricted.
blinking
4-95
Spanner
CD-5 CD-5 Drive motor CPU error(RH). Display only.
blinking
Spanner
CD-6 CD-6 Drive motor CPU error(RH). Display only.
blinking
Spanner
CD-7 CD-7 Drive motor CPU error(RH). Display only.
blinking
Spanner
CD-8 CD-8 Drive motor CPU error(RH). Display only.
blinking
Spanner Material handling stop.
EO-2 EO-2 Pump motor drive power-circuit short. 4-96
blinking Power steering stop.
Spanner
E1-1 E1-1 Pump motor current sensor neutral voltage error. 4-98
blinking Material handling stop.
Spanner Power steering stop.
E1-2 E1-2 Pump motor current sensor over current. 4-99
blinking
O/H
PM E2-1 Pump motor temperature increase abnormality. 4-100
lighting
Pump motor output restricted.
Spanner
E2-2 E2-2 Pump motor temperature sensor abnormality. 4-101
blinking
Spanner
E3-1 E3-1 Pump motor drive power-circuit temperature sensor abnormality. Pump motor output restricted. 4-103
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
E8-1 E8-1 Pump motor speed sensor open. 4-104
blinking Material handling stop.
Spanner Power steering stop.
E8-2 E8-2 Pump motor speed sensor short. 4-106
blinking
Spanner Material handling stop.
EC-1 EC-1 Pump motor drive CPU error.
blinking Power steering stop.
Spanner Material handling stop.
EC-2 EC-2 Pump motor drive CPU error.
blinking Power steering stop.
Spanner Material handling stop.
EC-3 EC-3 Pump motor drive CPU error.
blinking Power steering stop.
Spanner Material handling stop.
EC-4 EC-4 Pump motor drive CPU error.
blinking Power steering stop.
4-108
Spanner
EC-5 EC-5 Pump motor drive CPU error. Display only.
blinking
Spanner
EC-6 EC-6 Pump motor drive CPU error. Display only.
blinking
Spanner
EC-7 EC-7 Pump motor drive CPU error. Display only.
blinking
Spanner
EC-8 EC-8 Pump motor drive CPU error. Display only.
blinking
Spanner
EE-1 EE-1 Display -> Main controller communication error. PIN Code Entry System disable.
blinking
4-109
Spanner
EE-2 EE-2 Display -> Main controller communication error ( on start up ). PIN Code Entry System disable.
blinking
With PIN CODE ENTRY: PIN Code Entry System
Spanner
F1-1 F1-1 Main controller -» Display communication error. disable.
blinking
Without PIN CODE ENTRY:Display only.
4-110
With PIN CODE ENTRY: PIN Code Entry System
Spanner
F1-2 F1-2 Main controller -> Display communication error ( on start up ). disable.
blinking
Without PIN CODE ENTRY:Display only.
Spanner
F4-1 F4-1 Display CPU error. Display only.
blinking
Spanner
F4-2 F4-2 Display CPU error. Display only.
blinking
4-111
Spanner
F4-3 F4-3 Display CPU error. Display only.
blinking
Spanner
F4-4. F4-4 Display CPU error. Display only.
blinking
 4-12
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
F4-5 F4-5 Display CPU error. Display only.
blinking
With PIN CODE ENTRY: PIN Code Entry System
Spanner
F4-6 F4-6 Display CPU error. disable.
blinking
Without PIN CODE ENTRYrDisplay only.
With PIN CODE ENTRY: PIN Code Entry System 4-111
Spanner
F4-7 F4-7 CDisplay CPU error. disable.
blinking
Without PIN CODE ENTRY:Display only.
With PIN CODE ENTRY: PIN Code Entry System
Spanner
F4-8 F4-8 Display CPU error. disable.
blinking
Without PIN CODE ENTRYDisplay only.
Spanner
FB-1 FB-1 Battery current sensor neutral voltage error.
blinking
Display only. 4-112
Spanner
FB-2 FB-2 Battery current sensor abnormality.
blinking
Spanner
FF-1 FF-1 D7V power supply circuit over current. Display turns OFF.
blinking
4-114
Spanner Knob position correcting stop.
FF-2 FF-2 SSTR+ power supply circuit over current.
blinking Steering becomes stiff.
COLD
- - Drive motor driver low temperature. Drive motor output restricted.
DCR
COLD
- Pump motor driver low temperature. Pump motor output restricted.
PCR
Spanner
32-1 32-1 Drive motor drive circuit LH EEPROM abnormality. Display only. 4-116
blinking
Spanner
32-2 32-2 Drive motor drive circuit RH EEPROM abnormality. Display only. 4-117
blinking
Spanner
32-3 32-3 Pump motor drive circuit EEPROM abnormality. Display only. 4-118
blinking
Spanner
54-1 54-1 Swing lock solenoid open.
blinking
Spanner
54-2 54-2 Swing lock solenoid short.
blinking Partial limitation of the rear wheel swing control
4-119
Spanner function (4W only).
54-3 54-3 Swing lock solenoid drive circuit abnormality.
blinking
Spanner
54-4 54-4 Swing lock solenoid its continuity.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner Partial limitation of the rear wheel swing control
61-1 61-1 Load sensor open.
blinking function (4W only).
4-122
Spanner Partial limitation of mast control function.
61-2 61-2 Load sensor VCC short. Load indicator cannot display.
blinking
Spanner
62-1 62-1 Tilt angle sensor open.
blinking
Partial limitation of mast control function. 4-124
Spanner
62-2 62-2 Tilt angle sensor VCC short.
blinking
Spanner
64-1 64-1 Lift lower lock solenoid open.
blinking
Spanner
64-2 64-2 Lift lower lock solenoid short.
blinking
Lift lower may stop. 4-126
Spanner
64-3 64-3 Lift lower lock solenoid drive circuit abnormality.
blinking
Spanner
64-4 64-4 Lift lower lock solenoid its continuity.
blinking
Spanner
65-1 65-1 Tilt control solenoid open.
blinking
Spanner
65-2 65-2 Tilt control solenoid short.
blinking
Forward tilt may stop, backward tilt may go fully back. 4-129
Spanner
65-3 65-3 Tilt control solenoid drive circuit abnormality.
blinking
Spanner
65-4 65-4 Tilt control solenoid its continuity.
blinking
Spanner
66-1 66-1 Outside matching value range for tilt angle error. Partial limitation of mast control function. 4-132
blinking
Partial limitation of the rear wheel swing control
Spanner function (4W only).
67-1 67-1 Lifting height switch open. 4-133
blinking Partial limitation of mast control function.
Load indicator display is unsteady.
Spanner
68-1 68-1 Lifting height sensor open.
blinking
Spanner Height selector disable.
68-2 68-2 Lifting height sensor VDC short. 4-136
blinking Lift speed limited.
Spanner
68-3 68-3 Lifting height sensor abnormality.
blinking
Indication Memory Lamp Error mode

4-14
Phenomenon on vehicle See page
Spanner
71-1 71-1 Tire angle sensor open.
blinking
Spanner Knob position correcting stop.
71-2 71-2 Tire angle sensor VCC short. 4-139
blinking Drive motor output restricted.
Spanner
71-3 71-3 Tire angle sensor fixing.
blinking
Spanner
72-1 72-1 Steering-wheel angle sensor SS1 open.
blinking
Spanner
72-2 72-2 Steering-wheel angle sensor SS2 open.
blinking Knob position correcting stop.
4-141
Spanner Steering becomes stiff.
72-3 72-3 Steering-wheel angle sensor SSC open.
blinking
Spanner
72-4 72-4 Steering-wheel angle sensor SSIand SS2 open.
blinking
Spanner
73-1 73-1 Knob position synchronizer solenoid open.
blinking
Spanner
73-2 73-2 Knob position synchronizer solenoid short.
blinking
Knob position correcting stop. 4-147
Spanner
73-3 73-3 Knob position synchronizer solenoid drive circuit abnormality.
blinking
Spanner
73-4 73-4 Knob position synchronizer solenoid its continuity.
blinking
Spanner Knob position correcting stop.
74-1 74-1 Outside matching value range for tire angle error. 4-150
blinking Partial limitation of traveling motor control function.
Spanner
H1-1 H1-1 Lift lever potentiometer open.
blinking
Spanner
H1-2 H1-2 Lift lever potentiometer VCC short. Lift stop.
blinking
Spanner
H1-3 H1-3 Lift lever potentiometer assembly error. 4-151
blinking
Spanner
H1-4 H1-4 Lift lever potentiometer neutral error. Material handling stop.
blinking
Spanner
H1-5 H1-5 Lift lever potentiometer matching value error. Lift stop.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
H2-1 H2-1 Tilt lever potentiometer open.
blinking
Spanner
H2-2 H2-2 Tilt lever potentiometer VCC short. Tilt stop.
blinking
Spanner
H2-3 H2-3 Tilt lever potentiometer assembly error. 4-153
blinking
Spanner
H2-4 H2-4 Tilt lever potentiometer neutral error. Material handling stop.
blinking
Spanner
H2-5 H2-5 Tilt lever potentiometer matching value error. Tilt stop.
blinking
Spanner
H3-1 H3-1 Attachment 1 lever potentiometer open.
blinking
Spanner
H3-2 H3-2 Attachment 1 lever potentiometer VCC short. Attachment 1 stop.
blinking
Spanner
H3-3 H3-3 Attachment 1 lever potentiometer assembly error. 4-155
blinking
Spanner
H3-4 H3-4 Attachment 1 lever potentiometer neutral error. Material handling stop.
blinking
Spanner
H3-5 H3-5 Attachment 1 lever potentiometer matching value error. Attachment 1 stop.
blinking
Spanner
H4-1 H4-1 Attachment 2 lever potentiometer open.
blinking
Spanner
H4-2 H4-2 Attachment 2 lever potentiometer VCC short. Attachment 2 stop.
blinking
Spanner
H4-3 H4-3 Attachment 2 lever potentiometer assembly error. 4-157
blinking
Spanner
H4-4 H4-4 Attachment 2 lever potentiometer neutral error. Material handling stop.
blinking
Spanner
H4-5 H4-5 Attachment 2 lever potentiometer matching value error. Attachment 2 stop.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
H5-1 H5-1 Lift PULL solenoid open. Lift stop.
blinking
Spanner
H5-2 H5-2 Lift PULL solenoid short. Material handling may stop.
blinking
Spanner
H5-3 H5-3 Lift PUSH solenoid open. Lift stop.
blinking
4-159
Spanner
H5-4 H5-4 Lift PUSH solenoid short.
blinking
Spanner
H5-5 H5-5 Lift PUSH/PULL solenoid drive circuit abnormality. Material handling may stop.
blinking
Spanner
H5-6 H5-6 Lift PUSH/PULL solenoid its continuity.
blinking
Spanner
H6-1 H6-1 Tilt PULL solenoid open. Tilt stop.
blinking
Spanner
H6-2 H6-2 Tilt PULL solenoid short. Material handling may stop.
blinking
Spanner
H6-3 H6-3 Tilt PUSH solenoid open. Tilt may stop.
blinking
4-162
Spanner
H6-4 H6-4 Tilt PUSH solenoid short.
blinking
Material handling stop.
Spanner
H6-5 H6-5 Tilt PUSH/PULL solenoid drive circuit abnormality.
blinking
Spanner
H6-6 H6-6 Tilt PUSH/PULL solenoid its continuity. Tilt may stop.
blinking
Spanner
H7-1 H7-1 Attachment 1 PULL solenoid open. Attachment 1 stop.
blinking
Spanner
H7-2 H7-2 Attachment 1 PULL solenoid short. Material handling may stop.
blinking
Spanner
H7-3 H7-3 Attachment 1 PUSH solenoid open. Attachment 1 stop.
blinking
4-165
Spanner
H7-4 H7-4 Attachment 1 PUSH solenoid short.
blinking
Material handling may stop.
Spanner
H7-5 H7-5 Attachment 1 PUSH/PULL solenoid drive circuit abnormality.
blinking
Spanner
H7-6 H7-6 Attachment 1 PUSH/PULL solenoid its continuity. Attachment 1 may stop.
blinking
Indication Memory Lamp Error mode Phenomenon on vehicle See page
Spanner
H8-1 H8-1 Attachment 2 PULL solenoid open. Attachment 2 stop.
blinking
Spanner
H8-2 H8-2 Attachment 2 PULL solenoid short. Material handling may stop.
blinking
Spanner
H8-3 H8-3 Attachment 2 PUSH solenoid open. Attachment 2 stop.
blinking
4-168
Spanner
H8-4 H8-4 Attachment 2 PUSH solenoid short.
blinking
Material handling may stop.
Spanner
H8-5 H8-5 Attachment 2 PUSH/PULL solenoid drive circuit abnormality.
blinking
Spanner
H8-6 H8-6 Attachment 2 PUSH/PULL solenoid its continuity. Attachment 2 may stop.
blinking
Spanner Traveling stop.
HB-1 HB-1 Solenoid power supply circuit open.
blinking Material handling stop.
Spanner
HB-2 HB-2 Solenoid power supply circuit short. 4-171
blinking
Material handling stop.
Spanner
HB-3 HB-3 Solenoid power supply circuit over current.
blinking
Spanner
HC-1 HC-1 Unload valve solenoid open.
blinking
Spanner
HC-2 HC-2 Unload valve solenoid short.
blinking
Material handling may stop. 4-175
Spanner
HC-3 HC-3 Unload valve solenoid drive circuit abnormality.
blinking
Spanner
HC-4 HC-4 Unload valve solenoid its continuity.
blinking
Spanner
G5-1 G5-1 Shock sensor 1 open.
blinking
Spanner
G5-2 G5-2 Shock sensor 1 VCC short.
blinking
Spanner
G5-3 G5-3 Shock sensor 1 neutral voltage error.
blinking
Shock senser disabled. 4-178
Spanner
G5-4 G5-4 Shock sensor 2 open.
blinking
Spanner
G5-5 G5-5 Shock sensor 2 VCC short.
blinking
Spanner
G5-6 G5-6 Shock sensor 2 neutral voltage error.

4-17
blinking
4-18

WHEN AN ERROR CODE IS DISPLAYED

• Error Code AO-1 (Drive motor power-circuit overheating abnormality)

Related portion

CN101-4
(41, VBBT)

Drive motor drive circuit Drive motor drive circuit

LH RH
Temperature sensor Temperature sensor

Probable cause:
® Connector contact defect ® Overheating (continuous overload operation)
® Harness defect ® Drive motor drive circuit defect
® Cooling fan clogging ® Main controller defect
© Cooling fan defect

If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Do not leave the vehicle standing in a hot place.

Error code AO-1

Inspection: Operation check of cooling fans 1 and 2

Forcibly turn on the cooling fans, using Active Test. The fans do
-------------- not rotate.
— —>Q
FANLI ACTIVE TEST 2/3

The fans rotate.

_____________________ y_____________________
Inspection: Temperature check
Turn on the key switch and check the value of TDMDH
using the Analyzer menu.

IANU.l/Q TEMP/VQLT 1/4

Record the value of
TDMDH.
 4-19

Check the following and take necessary action, and the device as it is.
* Whether exhaust vent is blocked by paper etc.
* Whether operation was performed under overload conditions

Main controller defect

4-20

Inspection 1: Continuity check

Disconnect the CN113 and CN114 connectors from cooling fans 1 and 2, and check if there is continuity
between CN113-2 and N1 and between CN114-2 and N1.

When using an analog tester

Portions to be checked Standard
CN113-2(-) to N1(+) Continuity
CN114-2(-) toN1(+) Continuity

Inspection 2: Harness check

Check each harness for its continuity.

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,
and visually check inside the connector and the caulked portion of its wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Note: Perform this check with SST disconnected.

Portions to be checked Standard
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN 102-1 to CN113-2 Continuity
CN 102-2 to CN 114-2 Continuity
 4-21

• Error Code AO-2 (Pump motor drive power-circuit overheating abnormality)

Related portion

CN101-4
(41.VBBT)

Pump motor drive circuit

Temperature sensor
—I I-

Probable cause:
© Connector contact defect ® Overheating (continuous overload operation)
® Harness defect ® Pump motor drive circuit defect
® Cooling fan clogging © Main controller defect
© Cooling fan defect

If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Do not leave the vehicle standing in a hot place.

Error code AO-2

Inspection: Operation check of cooling fans 1 and 2

Forcibly turn on the cooling fans, using Active Test.

fANLl ACTIVE TEST 2/3

---
The fans do not rotate, ,0
z—x

FAN OFF -> ON

The fans rotate.

v
Temperature check
Turn on the key switch and check the value of TPMDH
using the Analyzer menu.

fANLl I/O TEMP/VOLT 2/4______________________

Record the value of
TPMDH.
4-22

The TDMDH temperature is 78° C or more and

it has lowered by 5° C or more compared to the
TDMDH temperature previously checked.

Check the following and take necessary action, and the device as it is.
* Whether exhaust vent is blocked by paper etc.
* Whether operation was performed under overload conditions.

Main controller defect

 4-23

nspection 1: Continuity check

Disconnect the CN113 and CN114 connectors from cooling fans 1 and 2 and check if there is continuity between
CN113-2 and N1 and between CN114-2 and N1.
When using an analog tester
Portions to be checked Standard
CN113-2(+) to N1(-) Continuity
CN114-2(+) to N1(-) Continuity

nspection 2: Harness check

Check each harness for its continuity.

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,
and visually check inside the connector and the caulked portion of its wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Note: Perform this check with SST disconnected.

Portions to be checked Standard
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN 102-1 to CN 113-2 Continuity
CN102-2 to CN 114-2 Continuity
4-24

• Error Code A1-1 (Main controller high voltage)

Related portion

CN28-4 (19, VBMBSL) i^7 CN28-3

CN28-3(19, VBMBSL)
J----------------- ------------------- ------------------ O

Main
controller
CN28-4(19, VBMBSL)

Probable cause:
© Battery defect © Battery plug defect
© MB contactor defect © Battery overvoltage
© F7 fuse open ® The battery plug was disconnected during traveling.
(After the key switch is turned on and off,
A9-2 will be displayed.)

Error code A1-1

* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.

Check the battery plug.

Check the battery electrolyte.
 4-25

• Error Code A1-2 (Drive motor drive circuit LH high voltage)

Related portion

Probable cause:
© Battery defect @ Battery plug defect
® MB contactor defect ® Drive motor drive circuit LH defect
(D F1 fuse open ® The battery plug was disconnected during traveling.

If CB-1 is also displayed, perform troubleshooting with priority given to CB-1.

If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.
If A1-1 is also displayed, perform troubleshooting with priority given to A1-1.

* Check the battery electrolyte.

4-26

• Error Code A1-3 (Drive motor drive circuit RH high voltage)

Related portion

Probable cause:
© Battery defect © Battery plug defect
© MB contactor defect ® Drive motor drive circuit RH defect
© F1 fuse open ® The battery plug was disconnected during traveling.

If CB-1 is also displayed, perform troubleshooting with priority given to CB-1.

If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.
If A1-1 is also displayed, perform troubleshooting with priority given to A1-1.

* Check the battery plug.

* Check the battery electrolyte.
 4-27

• Error Code A1-4 (Pump motor drive circuit high voltage)

Related portion

Probable cause:
© Battery defect @ Battery plug defect
©MB contactor defect ® Pump motor drive circuit defect
® F1 fuse open © The battery plug was disconnected during traveling.

If CB-1 is also displayed, perform troubleshooting with priority given to CB-1.

If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.
If A1-1 is also displayed, perform troubleshooting with priority given to A1-1.

* Check the battery plug.

* Check the battery electrolyte.
4-28

• Error Code A2-1 (Main controller overheating abnormality)

Related portion

Main controller

Temperature sensor

TH101

Probable cause:
® The ambient temperature around the Main controller is high. ® Temperature sensor defect (Main controller defect)
@ Overheating (continuous overload operation)

Do not leave the vehicle standing in a hot place.

Check the following and take necessary action, and the device as it is.
(The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
 4-29

• Error Code A2-2 (Drive motor drive circuit board overheating abnormality)

Related portion

CN101-4
(41.VBBT)

Drive motor circuit Drive motor circuit

LH RH
Temperature sensor Temperature sensor

Probable cause:
© Connector contact defect ® Overheating (continuous overload operation)
@ Harness defect ® Drive motor drive circuit defect
® Cooling fan clogging ® Main controller defect
© Cooling fan defect

If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Do not leave the vehicle standing in a hot place.

4-30

cp
/
Turn off the key switch and eave the vehicle standing The TDMDB temperature is 81 °C or more for
for a while (about 30 minute s). both cooling fans 1 and 2 and it has lowered by
5°C or more compared to the TDMDBH
temperature previously checked.
•

Inspection: Temperature check

Turn on the key switch and check the value of TDMDB,
using the Analyzer menu.

fANLl I/O TEMP/VOLT 1/4

TDMDB: The TDMDB (L) temperature is The TDMDB (R) temperature is
Less than 81 °C or more and it has not 81°C or more and it has not
81°C lowered by 5°C or more compared lowered by 5°C or more compared
to the TDMDB (L) temperature to the TDMDB (R) temperature
f previously checked. , previously checked.
Drive motor drive circuit LH defect Drive motor drive circuit RH defect
v
Check the following and take necessary action, and the device as it is.
* Whether exhaust vent is blocked by paper etc.
* Whether operation was performed under overload conditions.

Main controller defect

 4-31

Inspection 1: Continuity check

Disconnect CN113 and CN114 and check if there is continuity between CN113-2 and N1 and between CN114-2
and N1.

When using an analog tester

Portions to be checked Standard
CN113-2 (-) to N1 (+) Continuity
CN114-2 (-) to N1 (+) Continuity

Inspection 2: Harness check

Check each harness for its continuity.

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Note: Perform this check with SST disconnected.

Portions to be checked Standard
CN101-3 to CN113-1 Continuity
CN101-3to CN114-1 Continuity
CN 102-1 to CN 113-2 Continuity
CN 102-2 to CN 114-2 Continuity
4-32

• Error Code A2-3 (Pump motor drive circuit board overheating abnormality)

Related portion

CN101-4
(41, VBBT)

Pump motor drive circuit

PCB Temperature sensor

Probable cause:
© Connector contact defect ® Overheating (continuous overload operation)
© Harness defect ® Pump motor drive circuit defect
© Cooling fan clogging © Main controller defect
® Cooling fan defect

If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Do not leave the vehicle standing in a hot place.

 4-33

Check the following and take necessary action, and the device as it is.
* Whether exhaust vent is blocked by paper etc.
* Whether operation was performed under overload conditions.

Main controller defect

4-34

Inspection 1: Continuity check

Disconnect the CN113 and CN114 connectors from cooling fans 1 and 2, and check if there is continuity
between CN113-2 and N1 and between CN114-2 and N1.
When using an analog tester
Portions to be checked Standard
CN113-2 (-) to N1 (+) Continuity
CN114-2 (-) to N1 (+) Continuity

Inspection 2: Harness check

Check each harness for its continuity.

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
Note: Perform this check with SST disconnected.
Portions to be checked Standard
CN101-3 to CN113-1 Continuity
CN101-3to CN114-1 Continuity
CN 102-1 to CN 113-2 Continuity
CN 102-2 to CN 114-2 Continuity
 4-35

• Error Code A3-1 (Battery connection incorrect )

Related portion

Probable cause:
CD The voltage in the B48V line after the F5 fuse is above the set voltage.

Plug contact defect or incorrect

connection of battery

Main controller defect

Mmain controller defect

Check the battery,

and replace it with a regular battery if necessary.
4-36

• Error Code A5-1 (Seat switch GND short abnormality)

Related portion

Probable cause:
© Connector contact defect ® Harness defect
@ Seat switch defect © Main controller defect

Connector contact defect

Seat switch defect

Harness defect

Main controller defect

 4-37

inspection 1: Check each harness for its continuity.

Before this check, disconnect the battery plug, disconnect the CN103, CN104 and CN43 connectors, visually
check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN 103-6 to CN43-1 Continuity
CN103-18 to CN43-2 Continuity
CN43-1 to CN43-2 No continuity
4-38

• Error Code A8-1, -2 (F1 and F6 fuse abnormality (Open))

Related portion

MB F1
P3 P4
O---------Q
O O-
CN 136-5
CN

F6
Battery CN28-1 ------ CN28-2 CN 104-2 (44, VBMB)

—
Drive motor

b
Main
drive circuit LH controller

Drive motor

—
©

b
drive circuit RH

o Pump motor drive

circuit
©

Probable cause:
® Cable or connector contact defect @ F6 fuse box defect
® Improper installation of F1 or F6 fuse ® Hamess or cable defect
® F1 or F6 fuse open © Main controller defect
 4-39

Error code A8-1

* If CB-1, CB-3, CB-5, A8-2 or A9-2 occurs, perform troubleshooting with priority given to CB-1, CB-3, CB-5, A8-2 or
A9-2.

Improper fastening of terminals

Drive motor drive circuit LH defect

Drive motor drive circuit RH defect
Pump motor drive circuit defect

F1 fuse installation defect

F1 fuse open

Motor drive circuit defect (*)

Motor drive circuit defect (*)

Disconnect the battery plug and remove the cupper bar for connection to the motor drive circuit positive terminal.
Measure the resistance between the positive and negative terminals of the motor drive circuit.
When using an analog tester
Positive terminal: [-] probe \
> Motor drivers are defective if their resistance measured is 10 Q or less.
Negative terminal: [+] probe J
4-40

Error code A8-2

* If CB-1, CB-3 or CB-5 occurs, Perform troubleshooting with priority given to CB-1, CB-3 or CB-5.

Connector contact defect

F6 fuse installation defect

Identify the causes of CB1 to CB5.

F6 fuse open

F6 fuse box defect

Harness defect

Main controller defect

 4-41

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN28, CN104 and CN136 (P3) connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN104-2 to CN28-2 Continuity
CN28-1 to CN136-5(P3) Continuity
CN 104-2 to N1 No continuity
CN28-1 to N1 No continuity
4-42

• Error Code A9-2 (F7 fuse abnormality (Open))

Related portion

CN 102-3 (19, VBMBSL)^ CN28-4(19, VBMBSL) | CN28-3

J o
Main
controller
CN102-4 (19, VBMBSL)

Probable cause:
© Connector contact defect ® F7 fuse box defect
©MB contactor defect © Harness defect
© F7 fuse installation defect © Main controller defect
© F7 fuse open

Error code A9-2

* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.

Connector contact defect

F7 fuse installation defect

Identify the causes of CB1 to CB5.

 4-43

F7 fuse open

F7 fuse box defect

Harness defect

Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN28, CN102 and CN136 (P3) connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN102-3 to CN28-4 Continuity
CN102-4 to CN28-4 Continuity
CN28-3 to CN136-5 (P3) Continuity
CN 102-3 to N1 No continuity
CN102-4toN1 No continuity
CN28-3 to N1 No continuity
4-44

• Error Code AA-1 (Main controller temperature sensor abnormality)

Related portion

Main controller

Temperature sensor

TH101

Probable cause:
Main controller defect

Error code AA-1

* If AA-1 is displayed, the Main controller is defective, so replace it.

 4-45

• Error Code AA-2 (Drive motor drive board temperature sensor abnormality
LH)
Related portion

Drive motor drive circuit LH

Temperature sensor

Probable cause:
Drive motor drive circuit LH defect

Error code AA-2

* If AA-2 is displayed, the drive motor drive circuit LH is defective, so replace it.
4-46

• Error Code AA-3 (Drive motor drive board temperature sensor abnormality
RH)
Related portion

Drive motor drive circuit RH

Temperature sensor

Probable cause:
Drive motor drive circuit RH defect

Error code AA-3

* If AA-3 is displayed, the drive motor drive circuit RH is defective, so replace it.
 4-47

• Error Code AA-4 (Pump motor drive board temperature sensor

abnormality)
Related portion

Pump motor drive circuit

Temperature sensor

Probable cause:
Pump motor drive circuit defect

Error code AA-4

* If AA-4 is displayed, the pump motor drive circuit is defective, so replace it.
4-48

• Error Code AB-1 (Cooling fan drive circuit abnormality)

Related portion

CN101-3 (97,FAN+) CN113-1

Cooling fan 1
CN102-1 (98.FNDC1) CN113-2
Main
controller CN114-1

Cooling fan 2
CN 102-2 (99.FNDC1) CN114-2

Probable cause:
(D Connector contact defect ® Harness defect
© Cooling fan defect © Main controller defect
 4-49

Cooling fan 2 defect

Cooling fan 1, Cooling fan 2 defect

Harness defect

Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN101-3to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN 102-1 to CN 113-2 Continuity
CN 102-2 to CN 114-2 Continuity
CN101-3 to CN102-1 No continuity
CN101-3 to CN102-2 No continuity
CN 102-1 to CN 102-2 No continuity
4-50

• Error Code AC-1 (Semiconductor switch abnormality)

Related portion

Probable cause:
© Drive motor drive circuit RH harness defect ® Drive motor drive circuit LH defect
@ Drive motor drive circuit LH harness defect ® Pump motor drive circuit defect
® Pump motor drive circuit harness defect ® Main controller defect
© Drive motor drive circuit RH defect
 4-51

Error code AC-1

* Portion where the AC-1 error occurs when the pump motor drive circuit or the drive motor drive circuit RH or LH is
checked

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN103, CN111, CN110 and CN109 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN103-4toN1 No continuity
CN103-4 to CN111-2 Continuity
CN 103-4 to CN 110-2 Continuity
CN 103-4 to CN109-2 Continuity
4-52

• Error Code AD-1, -2, -3, -4, -5, -6 (Main controller (CAN) communication
abnormality)

Related portion

Probable cause:
® Connector contact defect ® Motor drive circuit defect
® Harness defect

* if AC-1 occurs, perform troubleshooting with priority given to AC-1.

 4-53

Connector contact defect

Harness defect

Main controller defect

Motor drive circuit defect

Error that was recorded in *1

AD-2: Drive motor drive circuit LH defect
AD-4: Drive motor drive circuit RH defect
AD-6: Pump motor drive circuit defect
4-54

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN103, CN104, CN109, CN110 and CN111 connectors
disconnected, visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 109-7 to CN109-9 Continuity AD-1,2
CN 109-8 to CN 109-9 No continuity AD-1,2
CN 103-4 to CN 109-2 Continuity AD-1,2
CN 103-11 to CN 109-12 Continuity AD-1,2
CN103-12to CN109-13 Continuity AD-1,2
CN 109-2 to CN 109-12 No continuity AD-1,2
CN 109-2 to CN 109-13 No continuity AD-1,2
CN109-12to CN109-13 No continuity AD-1,2
CN110-7 to CN110-9 No continuity AD-3.4
CN110-8 to CN110-9 No continuity AD-3.4
CN 103-4 to CN110-2 Continuity AD-3.4
CN103-11 toCN110-12 Continuity AD-3.4
CN103-12to CN110-13 Continuity AD-3.4
CN110-2 to CN110-12 No continuity AD-3.4
CN110-2 to CN110-13 No continuity AD-3.4
CN110-12 to CN110-13 No continuity AD-3.4
CN111-7 to CN111-9 No continuity AD-5.6
CN111-8 to CN111-9 Continuity AD-5.6
CN103-4 to CN111-2 Continuity AD-5.6
CN103-11 to CN111-12 Continuity AD-5.6
CN103-12 to CN111-13 Continuity AD-5.6
CN111-2 to CN111-12 No continuity AD-5.6
CN111-2 to CN111-13 No continuity AD-5.6
CN111-12 to CN111-13 No continuity AD-5.6
CN 103-4 to CN 103-5 No continuity AD-2,4,6
CN 103-11 to CN 103-5 No continuity AD-2,4,6
CN 103-12 to CN 103-5 No continuity AD-2,4,6
 4-55

• Error Code AF-1, -2, -3 , -4, -5, -6, -7, -8 (CPU error)
Related portion

Main controller

Probable cause:
Main controller defect

Error code AF-1, -2, -3, -4, -5, -6, -7, -8

* If AF is displayed, the Main controller is defective, so replace it.

4-56

• Error Code CO-2 (Drive motor power-circuit short LH)

Related portion

Probable cause:
(D Drive motor LH defect ® Drive motor drive circuit LH defect
© Motor cable defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.

Drive motor drive circuit LH defect

(Note: Drive circuit that is originally the drive motor drive circuit LH before replacement)
 4-57

*1 If the error codes CO-2, CO-4 and EO-2 are displayed all at once, perform the following
checks without checking the motor drive circuits.

Drive motor drive circuit LH defect

inspection 1 : Continuity check of motor cables

Check the cables for its continuity.

Disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked
portion of each cable for defects, and then check the P7, P8 and P9 cables.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

Both ends of P7 cable Continuity
Both ends of P8 cable Continuity
Both ends of P9 cable Continuity
P7 cable and P8 cable No continuity
P8 cable and P9 cable No continuity
P9 cable and P7 cable No continuity
4-58

• Error Code CO-4 (Drive motor power-circuit short RH)

Related portion

Probable cause:
© Drive motor RH defect ® Drive motor drive circuit RH defect
® Motor cable defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.

Drive motor drive circuit RH defect

(Note: Drive circuit that is originally the drive motor drive circuit RH before replacement)
 4-59

*1 If the error codes CO-2, CO-4 and EO-2 are displayed all at once, perform the following
checks without checking the motor drive circuits.

Inspection: (Motor check)

NG
1. Turn off the key switch and disconnect the battery plug. » Drive motor RH defect
2. Check the drive motor RH. (See page 5-5)

OK
v
Drive motor drive circuit RH defect

Inspection 1: Continuity check of motor cables

Check the cables for its continuity.
Disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked
portion of each cable for defects, and then check the P71, P81 and P91 cables.
Refer to BEFORE TROUBLESHOOTING.

Portions to be checked Standard

Both ends of P71 cable Continuity
Both ends of P81 cable Continuity
Both ends of P91 cable Continuity
P71 cable and P81 cable No continuity
P81 cable and P91 cable No continuity
P91 cable and P71 cable No continuity
4-60

• Error Code C1-1 (Drive motor current sensor neutral voltage error LH)
Related portion

Drive motor drive circuit LH

Current sensor

Probable cause:
Drive motor drive circuit LH defect

Error code C1-1

* If C1-1 is displayed, the drive motor drive circuit LH is defective, so replace it.
 4-61

• Error Code C1-2 (Drive motor current sensor over current LH)
Related portion

Probable cause:
0 Drive motor LH cable defect ® Drive motor LH defect
® Drive motor drive circuit LH defect

Error code C1-2

Turn the key switch from OFF to ON, No error occurs. * Check the drive motor LH cable.
to check for errors. * Check the drive motor LH for continuity.
CO-2 error C1-1 error
occurs. occurs.
X V

Proceed to identify the cause of CO-2. Proceed to identify the cause of C1-1.
4-62

• Error Code C1-3 (Drive motor current sensor neutral voltage error RH)
Related portion

Drive motor drive circuit RH

Current sensor

Probable cause:
Drive motor drive circuit RH defect

Error code C1-3

* If C1-3 is displayed, the drive motor drive circuit RH is defective, so replace it.
 4-63

• Error Code C1-4 (Drive motor current sensor over current RH)
Related portion

Probable cause:
© Drive motor RH cable defect ® Drive motor RH defect
@ Drive motor drive circuit RH defect

Error code C1-4

Turn the key switch from OFF to ON, No error occurs. * Check the drive motor RH cable.
to check for errors. * Check the drive motor RH for continuity.

CO-4 error occurs. C1-3 error occurs.

v V
Proceed to identify the cause of CO-4. Proceed to identify the cause of C1-3.
4-64

• Error Code C2-1 (Drive motor temperature sensor abnormality)

Related portion

Probable cause:
Overheating (continuous overload operation)

Do not leave the vehicle standing in a hot place.

Check the following and take necessary action, and the device as it is.
(The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
 4-65

• Error Code C2-2 (Drive motor temperature sensor abnormality LH)

Related portion

Probable cause:
© Connector contact defect ® Drive motor LH temperature sensor harness defect
© Drive motor LH temperature sensor defect ® Drive motor drive circuit LH defect

Error code C2-2

Connector contact defect

Temperature sensor defect

Harness defect

Drive motor drive circuit LH defect

4-66

Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN58-2 and CN58-1)
Standard value: Approx. 245 Q and 600 kO

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug and the CN109 and CN58 connectors and with SST disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN 109-5 to CN58-2 Continuity
CN 109-6 to CN58-1 Continuity
CN58-1 to CN58-2 No continuity

*1: Connect CN58-1 and CN58-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN 109-5 and CN 109-6.
 4-67

• Error Code C2-3 (Drive motor temperature sensor abnormality RH)

Related portion

Probable cause:
© Connector contact defect ® Drive motor RH temperature sensor harness defect
® Drive motor RH temperature sensor defect ® Drive motor drive circuit RH defect

Connector contact defect

Temperature sensor defect

Harness defect

Drive motor drive circuit RH defect

4-68

Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN52-2 and CN52-1)
Standard value: Approx. 245 Q and 600 kQ

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug and the CN110 and CN52 connectors and with SST disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN110-5 to CN52-2 Continuity
CN110-6 to CN52-1 Continuity
CN52-1 to CN52-2 No continuity

*1: Connect CN52-1 and CN52-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN110-5 and CN110-6.
 4-69

• Error Code C3-1 (Drive motor power circuit temperature sensor

abnormality LH)
Related portion

Drive motor drive circuit LH

Temperature sensor

TH101

Probable cause:
Drive motor drive circuit LH defect

Error code C3-1

' If C3-1 is displayed, the drive motor LH is defective, so replace it.

4-70

• Error Code C3-2 (Drive motor power circuit temperature sensor

abnormality RH)
Related portion

Drive motor drive circuit RH

Temperature sensor

TH101

Probable cause:
Drive motor drive circuit RH

Error code AA-1

* If AA-1 is displayed, the drive motor RH is defective, so replace it.

 4-71

• Error Code C4-1, -2, -3, -4, -5, -6 (Accelerator sensor abnormality)

Related portion

Probable cause:
© Connector contact defect © Main controller defect
® Accelerator sensor defect ® Accelerator fully open/fully closed matching error
® Accelerator sensor harness defect

Improper installation of acceleration sensor

Connector contact defect

Accelerator sensor defect

Harness defect

Main controller defect

No error code must be displayed when the accelerator is operated.

4-72

Error code C4-6

After the completion of matching,

Inspection 3: Matching
C4-6 error does not occur.
Perform matching between the fully closed and fully Use the device as it is.
open states of the accelerator.

After the completion of matching,

C4-6 error occurs.
Main controller defect

Inspection 1: Check the accelerator sensor as a single unit.

Perform this check with the battery plug and CN26 disconnected and CN101 and CN102 connected.

(1) Measuring the resistance of the accelerator sensor

Standard (on sensor side):
CN26-5 to CN26-6 1.8 to 3.5 kQ
CN26-1 to CN26-2 (Open state)

(2) Measuring the resistance of the accelerator sensor output circuit

Standard (on sensor side):
CN26-4 to CN26-6 The resistance must increase as the
CN26-3 to CN26-2 potentiometer is rotated.

Inspection 2: Check each harness for its continuity.

Perform this check with the battery plug, CN26, CN101 and CN102 disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.
O : Items to be checked
C4
Portions to be checked Standard
1 2 3 4 5 6
CN101-27 to CN26-5 Continuity O - - - O -
CN 102-30 to CN26-4 Continuity O - - - - -
CN101-22 to CN26-6 Continuity - - o - o -
CN101-26 to CN26-1 Continuity - o - - o -
CN 102-32 to CN26-3 Continuity - o - - - -
CN101-32 to CN26-2 Continuity - - - o o -
CN26-5 to CN26-6 No continuity O - - - - -
CN26-5 to CN26-2 No continuity o - - - - -
CN26-4 to CN26-6 No continuity o - - - o -
CN26-4 to CN26-2 No continuity o - - - o -
CN26-4 to CN26-5 No continuity - - o - o -
CN26-4 to CN26-1 No continuity - - o - o -
CN26-1 to CN26-6 No continuity - o - - - -
CN26-1 to CN26-2 No continuity - o - - - -
CN26-3 to CN26-6 No continuity - o - - o -
CN26-3 to CN26-2 No continuity - o - - o -
CN26-3 to CN26-5 No continuity - - - o o -
CN26-3 to CN26-1 No continuity - - - o o -
CN 102-30 to CN 102-32 No continuity - - - - o -
 4-73

*1: Connect CN26-5 and CN26-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN 101-27 and CN 102-30.
*2: Connect CN26-1 and CN26-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-26 and CN102-32.
*3: Connect CN26-6 and CN26-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-22 and CN102-30.
*4: Connect CN26-2 and CN26-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-32 and CN102-32.

nspection 3: Perform matching.

(See page 3-62)
4-74

• Error Code C5-1, -2, -3, -4, -5, -6 (Brake sensor abnormality)

Related portion

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4

CN101-22 (50, VRA-) CN6-6

Main Brake
controller CN101-33 (74, VRB1+) CN6-1 sensor

CN 102-25 (73, VRB2) CN6-3

CN101-32 (51, POT-) CN6-2

Probable cause:
© Connector contact defect © Main controller defect
® Brake sensor defect ® Brake fully closed/fully open matching error
® Brake sensor harness defect

Improper installation of brake sensor

Connector contact defect

Brake sensor defect

Harness defect

Main controller defect

No error code must be displayed when the brake is operated.

 4-75

Error code C5-6

After the completion of matching,

Inspection 3: Matching
C5-6 error does not occur.
Perform matching between the fully closed and fully X Use the device as it is.
open states of the brake.

After the completion of matching,

C5-6 error occurs.
r
Main controller defect

Inspection 1: Check the brake sensor as a single unit.

Perform this check with the battery plug and CN6 disconnected and CN101 and CN102 connected.

(1) Measuring the resistance of the brake sensor

Standard (on sensor side):
CN6-5 to CN6-6 1.8 to 3.5 kD
CN6-5 to CN6-2 (Open state)

(2) Measuring the resistance of the brake sensor output circuit

Standard (on sensor side):
CN6-5 to CN6-6 The resistance must increase as the
CN6-5 to CN6-2 potentiometer is rotated.

Inspection 2: Check each harness for its continuity.

Perform this check with the battery plug, CN6, CN101 and CN102 disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.
O: Items to be checked
C5
Portions to be checked Standard
1 2 3 4 5 6
CN101-34 to CN6-5 Continuity O - - - O -
CN102-33 to CN6-4 Continuity O - - - - -
CN101-22 to CN6-6 Continuity - - o - 0 -
CN101-33 to CN6-1 Continuity - o - - o -
CN 102-25 to CN6-3 Continuity - o - - - -
CN101-32 to CN6-2 Continuity - - - o 0 -
CN6-5 to CN6-6 No continuity O - - - - -
CN6-5 to CN6-2 No continuity o - - - - -
CN6-5 to CN6-6 No continuity o - - - 0 -
CN6-5 to CN6-2 No continuity o - - - 0 -
CN6-5 to CN6-5 No continuity - - o - 0 -
CN6-5 to CN6-1 No continuity - - o - o -
CN6-5 to CN6-6 No continuity - o - - - -
CN6-5 to CN6-2 No continuity - o - - - -
CN6-5 to CN6-6 No continuity - o - - 0 -
CN6-5 to CN6-2 No continuity - o - - 0 -
CN6-5 to CN6-5 No continuity - - - o 0 -
CN6-5 to CN6-1 No continuity - - - o o -
CN 102-33 to CN 102-25 No continuity - - - - 0 -
4-76

*1: Connect CN6-5 and CN6-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-34 and CN102-33.
*2: Connect CN6-1 and CN6-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-33 and CN102-25.
*3: Connect CN6-6 and CN6-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-22 and CN102-33.
*4: Connect CN6-2 and CN6-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-32 and CN102-25.

Inspection 3: Perform matching.

(See page 3-62)
 4-77

• Error Code C8-1 (Drive motor speed (rotation) sensor open LH)

Related portion

Probable cause:
© Connector contact defect © Rotation sensor 2 defect
® Rotation sensor harness defect ® Drive motor drive circuit LH defect
® Rotation sensor 1 defect

‘ Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
4-78

Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Disconnect the battery plug, disconnect CN109 and CN53, visually check inside each connector and the caulked
portion of each wire for defects and then check the CN109 and CN53 harnesses.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN 109-3 to CN53-8 Continuity
CN 109-3 to CN53-4 Continuity
CN 109-10 to CN53-7 Continuity
CN 109-4 to CN53-3 Continuity
CN 109-3 to CN 109-4 No continuity
CN 109-3 to CN 109-10 No continuity
CN109-4 to CN 109-10 No continuity

*1: Connect CN53-7 to CN53-8 on the CN109 side through 09232-13130-71 and check if there is continuity
between CN 109-3 and CN109-10.
*2: Connect CN53-3 to CN53-4 on the CN109 side through 09232-13130-71 and check if there is continuity
between CN109-3 and CN109-4.
 4-79

nspection 2: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN53, CN61 and CN51, visually check inside each connector and the
caulked portion of each wire for defects and then check the CN53 and CN61 harnesses and the CN53 and CN62
harnesses. (Refer to BEFORE TROUBLESHOOTING)

Portions to be checked Standard

CN53-8 to CN61-2 Continuity
CN53-7 to CN61-1 Continuity
CN53-4 to CN62-2 Continuity
CN53-3 to CN62-1 Continuity
CN53-3 to CN53-4 No continuity
CN53-3 to CN53-7 No continuity
CN53-3 to CN53-8 No continuity
CN53-4 to CN53-7 No continuity
CN53-4 to CN53-8 No continuity
CN53-7 to CN53-8 No continuity

*3: Connect CN61-1 and CN61-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-8 and CN53-7.
*4: Connect CN62-1 and CN62-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-4 and CN53-3.
4-80

• Error Code C8-2 (Drive motor speed (rotation) sensor short LH)

Related portion

Probable cause:
© Connector contact defect © Rotation sensor 2 defect
© Rotation sensor harness defect ® Drive motor drive circuit LH defect
© Rotation sensor 1 defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
 4-81

Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN109 and CN53, visually check inside each connector and the caulked
portion of each wire for defects and then check the CN109 and CN53 harnesses.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN109-3 to CN53-8 Continuity
CN 109-3 to CN53-4 Continuity
CN 109-1 Oto CN53-7 Continuity
CN 109-4 to CN53-3 Continuity
CN 109-3 to CN 109-4 No continuity
CN 109-3 to CN 109-10 No continuity
CN 109-4 to CN 109-10 No continuity

*1: Connect CN53-7 to CN53-8 on the CN109 side through 09232-13130-71 and check if there is continuity
between CN 109-3 and CN 109-10.
*2: Connect CN53-3 to CN53-4 on the CN109 side through 09232-13130-71 and check if there is continuity
between CN109-3 and CN109-4.
4-82

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN53, CN61 and CN51, visually check inside each connector and the
caulked portion of each wire for defects and then check the CN53 and CN61 harnesses and the CN53 and CN62
harnesses. (Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN53-8 to CN61-2 Continuity
CN53-7 to CN61-1 Continuity
CN53-4 to CN62-2 Continuity
CN53-3 to CN62-1 Continuity
CN53-3 to CN53-4 No continuity
CN53-3 to CN53-7 No continuity
CN53-3 to CN53-8 No continuity
CN53-4 to CN53-7 No continuity
CN53-4 to CN53-8 No continuity
CN53-7 to CN53-8 No continuity

*3: Connect CN61-1 and CN61-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-8 and CN53-7.
*4: Connect CN62-1 and CN62-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-4 and CN53-3.
 4-83

• Error Code C8-3 (Drive motor speed (rotation) sensor open RH)

Related portion

Probable cause:
© Connector contact defect © Rotation sensor 2 defect
® Rotation sensor harness defect ® Drive motor drive circuit LH defect
® Rotation sensor 1 defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
4-84

Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN110 and CN53, visually check inside each connector and the caulked
portion of each wire for defects and then check the CN110 and CN53 harnesses.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN110-3 to CN53-2 Continuity
CN 110-3 to CN53-6 Continuity
CN 110-10 to CN53-1 Continuity
CN110-4 to CN53-5 Continuity
CN110-3to CN110-4 No continuity
CN110-3 to CN110-10 No continuity
CN110-4 to CN110-10 No continuity

*1: Connect CN53-1 to CN53-2 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-3 and CN110-10.
*2: Connect CN53-5 to CN53-6 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-3 and CN110-4.
 4-85

nspection 2: Hamess continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN53, CN59 and CN60, visually check inside each connector and the
caulked portion of each wire for defects and then check the CN53 and CN61 harnesses and the CN53 and CN60
harnesses. (Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN53-2 to CN59-2 Continuity
CN53-1 to CN59-1 Continuity
CN53-6 to CN60-2 Continuity
CN53-5 to CN60-1 Continuity
CN53-1 to CN53-2 No continuity
CN53-1 to CN53-5 No continuity
CN53-1 to CN53-6 No continuity
CN53-2 to CN53-5 No continuity
CN53-2 to CN53-6 No continuity
CN53-5 to CN53-6 No continuity

*3: Connect CN59-1 and CN59-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-2 and CN53-1.
*4: Connect CN60-1 and CN60-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-6 and CN53-5.
4-86

• Error Code C8-4 (Drive motor speed (rotation) sensor short RH)

Related portion

Probable cause:
© Connector contact defect © Rotation sensor 2 defect
@ Rotation sensor harness defect © Drive motor drive circuit LH defect
© Rotation sensor 1 defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
 4-87

Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Disconnect the battery plug, disconnect CN110 and CN53, visually check inside each connector and the caulked
portion of each wire for defects and then check the CN110 and CN53 harnesses.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN 110-3 to CN53-2 Continuity
CN110-3 to CN53-6 Continuity
CN 110-10 to CN53-1 Continuity
CN 110-4 to CN53-5 Continuity
CN110-3 to CN110-4 No continuity
CN110-3 to CN110-10 No continuity
CN110-4 to CN110-10 No continuity

*1: Connect CN53-1 to CN53-2 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-3 and CN 110-10.
*2: Connect CN53-5 to CN53-6 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-3 and CN110-4.
4-88

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN53, CN59 and CN60, visually check inside each connector and the
caulked portion of each wire for defects and then check the CN53 and CN61 harnesses and the CN53 and CN62
harnesses. (Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN53-2 to CN59-2 Continuity
CN53-1 to CN59-1 Continuity
CN53-6 to CN60-2 Continuity
CN53-5 to CN60-1 Continuity
CN53-1 to CN53-2 No continuity
CN53-1 to CN53-5 No continuity
CN53-1 to CN53-6 No continuity
CN53-2 to CN53-5 No continuity
CN53-2 to CN53-6 No continuity
CN53-5 to CN53-6 No continuity

*3: Connect CN59-1 and CN59-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-2 and CN53-1.
*4: Connect CN60-1 and CN60-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN53-6 and CN53-5.
 4-89

• Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality)

Related portion

© Connector contact defect © Fuse defect

©MB contactor defect ® Main controller defect
© Harness defect
4-90

Error code CB-1

If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

Check the state of the battery.

Identify the cause of CB-3.

F6 fuse defect
F7 fuse defect

F6 fuse box defect

F7 fuse box defect

Harness defect

MB contactor defect

Main controller defect

 4-91

Error code CB-2

If the error codes AD-5 and -6, E1-1 and -2, EO-2, E8-1 and -2, EC-1, -2, -3 and -4 are displayed all at once, perform
troubleshooting with priority given to AD-5 and -6, E1-1 and -2, EO-2, ,E8-1 and -2, and EC-1,-2, -3 and -4.
If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is disconnected, so
measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.

Identify the cause of CB-3.

________________________________ x_______________________________
Inspection: Check of voltage
1. Disconnect and then connect the battery plug again, turn on the
Less than 15 V
key switch. > Main controller defect
2. Turn off the key switch and 5 seconds or more after that, measure
the voltage between P4 and N1 of the contactor.

15 Vor more
v
Pump motor drive circuit defect
4-92

CB-3, -5
No error occurs.
---------------------- > Connector contact defect

NG
--------------- > MB contactor defect

NG
--------------- > Harness defect

Main controller defect

 4-93

Error code CB-4

Disconnect the battery plug and visually check inside the CN136
connector and the caulked portions of their wires for defects. (Refer to
BEFORE TROUBLESHOOTING.)

___________________________ ____________________________
Inspection: Check of MB contactor coil
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN136 connector and measure the resistance of
the MB contactor coil (resistance between CN136-1 and CN136-2).
Standard value: 15 to 30 Q (Approx. 20 Q: 20°C)

___________________________ y___________________________
Inspection 1: Hamess check
Disconnect the CN104 and CN136 connectors and check the
harnesses for their continuities.

Defective portion: Portion where a problem was found during a check of the MB contactor coil or harness.
Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN28, CN102, CN104 and CN136 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.

Portions to be checked Standard Point

CN28-4 to CN 102-3 Continuity CB-1
CN28-4 to CN 102-4 Continuity CB-1
CN28-2 to CN 104-2 Continuity CB-1
CN28-3 to CN 136-5 (P3) Continuity CB-1
CN28-1 to CN 136-5 (P3) Continuity CB-1
CN28-1 to N1 No continuity CB-1
CN28-2 to N1 No continuity CB-1
CN28-3 to N1 No continuity CB-1
CN28-4toN1 No continuity CB-1

Inspection 2: Check each harness for its continuity.

Before this check, disconnect the battery plug, disconnect the CN104 and CN136 connectors,
visually check inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.

Portions to be checked Standard Point

CN 136-1 to CN104-9 Continuity CB-3
CN 136-2 to CN 104-3 Continuity CB-3
CN136-1 to CN 136-2 No continuity CB-4, 5
CN 136-1 to N1 No continuity CB-3
CN136-2toN1 No continuity CB-3
CN136-1 toP1 No continuity CB-4
CN 136-1 toP4 No continuity CB-4
4-94

• Error Code CC-1,-2,-3,-4,-5,-6,-7,-8 (CPU error LH)

Related portion

Drive motor
drive circuit LH

Probable cause:
Drive motor drive circuit LH defect

Error code CC-1,-2,-3,-4,-5,-6,-7,-8

* If CC is displayed, the drive motor drive circuit LH is defective, so replace it

 4-95

• Error Code CD-1,-2,-3,-4,-5,-6,-7,-8 (CPU error RH)

Related portion

Drive motor
drive circuit RH

Probable cause:
Drive motor drive circuit RH defect

Error code CC-1,-2,-3,-4,-5,-6,-7,-8

* If CD is displayed, the drive motor drive circuit RH is defective, so replace it.

4-96

• Error Code EO-2 (Pump motor drive power circuit short)

Related portion

Probable cause:
(D Pump motor drive circuit defect ® Pump motor drive circuit defect
® Motor cable defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
*lf this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is
disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.

Pump motor drive circuit defect

(Note: Drive circuit that is originally the drive motor drive circuit before replacement)
 4-97

'1 If the error codes CO-2, CO-4 and EO-2 are displayed all at once, perform the following checks without checking the motor drive
circuits.

nspection: (Motor check)

I. Turn off the key switch and disconnect the battery plug. > Pump motor drive circuit defect
>. Check the pump motor. (See page 5-15)

OK
v
Pump motor drive circuit defect

nspection 1: Continuity check of motor cables

Check the cables for its continuity.
Disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked
portion of each cable for defects, and then check the P14, P15 and P16 cables.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

Both ends of P14 cable Continuity
Both ends of P15 cable Continuity
Both ends of P16 cable Continuity
P14 cable and P15 cable No continuity
P15 cable and P16 cable No continuity
P16 cable and P14 cable No continuity
4-98

• Error Code E1-1 (Pump motor current sensor neutral voltage error)
Related portion

Pump motor drive circuit

Current sensor

Probable cause:
Pump motor drive circuit defect

Error code E1-1

* If E1-1 is displayed, the pump motor drive circuit is defective, so replace it

 4-99

• Error Code E1-2 (Pump motor current sensor over current)

Related portion

Pump P15 / \
motor ƒ Pump \
drive "Ì motor I
circuit P16 \ /

Probable cause:
® Pump motor cable defect ® Pump motor defect
® Pump motor drive circuit defect

Error code E1-2

No error occurs. * Check of pump motor cable

Turn the key switch from OFF to ON to check for errors.
* Check the pump motor for continuity.

EO-2 error occurs. E1-1 error occurs.

v v
Proceed to identify the cause of EO-2. Proceed to identify the cause of E1-1.
4-100

• Error Code E2-1 (Pump motor temperature sensor increase abnormality)

Related portion

Probable cause:
Overheating (continuous overload operation)

Do not leave the vehicle standing in a hot place.

The TPM temperature is 126°C or more and it has

lowered by 5°C or more compared to the TPM
temperature previously checked.

Check the following and take necessary action, and the device as it is.
(The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
 4-101

• Error Code E2-2 (Pump motor temperature sensor abnormality)

Related portion

Probable cause:
© Connector contact defect ® Pump motor temperature sensor harness defect
® Pump motor temperature sensor defect @ Pump motor drive circuit defect

Connector contact defect

Temperature sensor defect

Harness defect

Pump motor drive circuit defect

4-102

Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN55-2 and CN55-1)
Standard value Approx. 245 Q and 600 kQ

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.
Disconnect the battery plug and the CN111 and CN55 connectors and with SST disconnected visually check
inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.

Portions to be checked Standard

CN111-5 to CN55-2 Continuity
CN111-6 to CN55-1 Continuity
CN55-1 to CN55-2 No continuity

*1: Connect CN55-1 and CN55-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN111-5 and CN111-6.
 4-103

» Error Code E3-1 (Pump motor drive power circuit temperature sensor
abnormality)
delated portion

Pump motor
drive circuit

Temperature sensor

3robable cause:
Pump motor drive circuit defect

Error code E3-1

' If E3-1 is displayed, the pump motor drive circuit is defective, so replace it.
4-104

• Error Code E8-1 (Pump motor speed (rotation) sensor open)

Related portion

CN111-3 (81, SSP+) CN56-2

Pump motor Rotation

drive circuit sensor
CN111-10(82, SSP1) CN56-1

Probable cause:
© Connector contact defect @ Rotation sensor defect
® Rotation sensor harness defect @ Pump motor drive circuit defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
*lf this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is
disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.

Connector contact defect

Hamess defect

Pump motor drive circuit

defect

Pump motor drive circuit

defect

Pump motor drive circuit

defect

^Approx. 100 Q
Rotation sensor defect
 4-105

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Disconnect the battery plug, disconnect CN111 and CN56, and visually check inside each connector and the
caulked portion of each wire for defects and then check each harness.
Refer to BEFORE TROUBLESHOOTING.

Portions to be checked Standard

CN111-3 to CN56-2 Continuity
CN111-10 to CN56-1 Continuity
CN111-3 to CN111-10 No continuity

*1: Connect CN56-1 and CN56-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN111-3 and CN111-10.
4-106

• Error Code E8-2 (Pump motor speed (rotation) sensor short)

Related portion

CN111-3 (81, SSP+) CN56-2

Pump motor Rotation

drive circuit sensor
CN111-10(82, SSP1) CN56-1

Probable cause:
(D Connector contact defect @ Rotation sensor defect
® Rotation sensor harness defect © Pump motor drive circuit defect

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
*lf this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is
disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.

Connector contact defect

Harness defect

Pump motor drive circuit

defect

Pump motor drive circuit

defect

x ,E8-2 error occurs.

Inspection: (Check of motor drive circuits) Approx.
1. Turn off the key switch and disconnect the battery plug. 100 Q
2. Disconnect 09232-13130-71 from the CN56 connector (on the wire harness side). Other than Pump motor drive circuit
---------------- >
3. Insert 09240-13240-71 in the CN111 connector and connect it to the pump motor defect
drive circuit.
4. Measure the resistance between CN111-10 and N1 on the SST side.
^Approx. 100 Q
Rotation sensor defect
 4-107

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Disconnect the battery plug, disconnect CN111 and CN56, and visually check inside each connector and the
caulked portion of each wire for defects and then check each harness.
Refer to BEFORE TROUBLESHOOTING.

Portions to be checked Standard

CN111-3 to CN56-2 Continuity
CN111-10 to CN56-1 Continuity
CN111-3 to CN111-10 No continuity

*1: Connect CN56-1 and CN56-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN111-3 and CN111-10.
4-108

• Error Code EC-1, -2, -3, -4, -5, -6, -7, -8 (CPU error)
Related portion

Pump motor drive

circuit

Probable cause:
Pump motor drive circuit defect

Error code EC-1, -2, -3, -4,- 5, -6, -7, -8

* If EC is displayed, the pump motor drive circuit is defective, so replace it.

 4-109

» Error Code EE-1, -2 (Display Main controller communication error)

delated portion

CN 103-3 (14, DGND) CN70-4

CN 103-14 (16, D7V) CN70-5

Main
Display
controller CN103-11 (145, CAN1H) CN70-16

CN103-12 (146, CAN1L) CN70-15

Probable cause:
© Connector contact defect © Display defect
© Harness defect © Main controller defect

Error code EE-1, 2

' Identify the cause of F1-1 or F1-2.

4-110

• Error Code F1-1, -2 (Main controller -> Display communication error)

Related portion

CN103-11 (145.CAN1H) CN70-16(145, CAN1H)

Main
Multi-display
controller
CN103-12 (146.CAN1L) CN70-15 (146, CAN1L)

Probable cause:
© Connector contact defect ® Main controller defect
© Harness defect ® Display defect

*1 If the symptom persists after replacement of the display, there should be any other problems, so replace the Main controller.

Inspection 2: Check harnesses for its continuity.

Disconnect the battery plug, disconnect the CN70 and CN103 connectors and check the harnesses for their
continuities.

Portions to be checked Standard

CN103-11 to CN70-16 Continuity (Approx. 0 Q)
CN 103-12 to CN70-15 Continuity (Approx. 0 Q)
CN70-15to CN70-16 No continuity (Not 0 Q)
 4-111

• Error Code F4-1,-2,-3,-4,-5,-6,-7,-8 (Display CPU error)

Related portion

Multi-display

Probable cause:
Display defect

Error code F4-1, -2, -3, -4, -5, -6, -7, -8

* If F4 is displayed, the display is defective, so replace it.

4-112

• Error Code FB-1, -2 (Battery current sensor neutral voltage error)

Related portion

CN104-10 (303, CSBAT+) CN 137-1

CN 102-24 (304, CSBAT) CN 137-3 Battery

Main
sensor
controller
CN 102-35 (305, CSBAT-) CN 137-2

Probable cause:
© Connector contact defect ® Battery current sensor defect
® Harness defect © Main controller defect

Main controller defect

*1 If the symptom persists after replacement of the Current sensor, there should be any other problems, so replace the Main
controller.
 4-113

nspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN137, CN102 and CN104, and visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
Note: Perform this check with SST disconnected.

Portions to be checked Standard

CN 104-10 to CN 137-1 Continuity
CN 102-24 to CN 137-3 Continuity
CN 102-35 to CN 137-2 Continuity
CN 137-1 to CN 137-2 No continuity
CN 137-3 to CN 137-1 No continuity
CN 137-3 to CN 137-2 No continuity

*1: Connect CN137-1 and CN137-3 on the harness side through 09232-13130-71 and check if there is
continuity between CN104-10 and CN102-24.
*2: Connect CN137-2 and CN137-3 on the harness side through 09232-13130-71 and check if there is
continuity between CN102-24 and CN102-35.
4-114

• Error Code FF-1, -2 (Power supply circuit over current)

Related portion

CN103-14 (16,D7V) CN70-5

DISPLAY
CN103-3(14, DGND) CN70-4
Main
controller CN103-13 (311, SSTR+) CN19-1

Steering-wheel
angle sensor
CN103-6 (51, LS-) CN19-2

Probable cause:
© Connector contact defect ® Harness defect
@ Display or steering angle sensor defect © Main controller defect

Main controller defect

 4-115

nspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN70 and CN103 connectors, and visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN 103-14 to CN70-5 Continuity
CN103-3 to CN70-4 Continuity
CN70-5 to CN70-4 No continuity

Error code FF-2

Main controller defect

Inspection 2: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN19 and CN103 connectors, and visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN103-13 to CN19-1 Continuity
CN 103-6 to CN 19-2 Continuity
CN19-1 to CN 19-2 No continuity
4-116

• Error Code 32-1 (Drive motor drive circuit LH EEPROM abnormality)

Related portion

CN109-7 (151, SETLD2)

Drive motor drive circuit

LH CN109-8 NC

CN109-9 (151, OSETLD)

Probable cause:
© Connector contact defect © Drive motor drive circuit LH defect
© Drive motor drive circuit LH harness defect

*: When a new motor drive circuit is installedc on the vehicle, the 32-1 error always occurs (which does not mean that
the new drive circuit is defective).
Turn off and then back on the key switch.

If AD-3, 4, 5 or 6 is also displayed, perform troubleshooting with priority given to AD-3, 4, 5 or 6.

Error code 32-1

1. Disconnect the battery plug, disconnect the CN109 connector, and

32-1
visually check inside the connector and the caulked portion of its
error does not occur. Drive motor drive circuit LH
wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
connector contact defect
2. Connect the CN109 connector, connect the battery plug, and then
turn on the key switch to check for errors.
32-1
error occurs.
V
Drive motor drive circuit LH defect
 4-117

> Error Code 32-2 (Drive motor drive circuit RH EEPROM abnormality)

delated portion

CN110-7 NC

Drive motor drive circuit CN110-8 NC

RH
CN110-9 NC

’robable cause:
© Connector contact defect © Drive motor drive circuit RH defect
© Drive motor drive circuit RH harness defect

: When a new drive motor drive circuit is installedc on the vehicle, the 32-2 error always occurs (which does not
mean that the new drive motor drive circuit is defective).
Turn off and then back on the key switch.

f AD-1, 2, 5 or 6 is also displayed, perform troubleshooting with priority given to AD-1, 2, 5 or 6.

Error code 32-2

1. Disconnect the battery plug, disconnect the CN110 connector, and

32-2
visually check inside the connector and the caulked portion of its
error occurs. Drive motor drive circuit LH
wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
connector contact defect
2. Connect the CN110 connector, connect the battery plug, and then
turn on the key switch to check for errors.
32-2
error occurs.
V
Drive motor drive circuit RH defect
4-118

• Error Code 32-3 (Pump motor drive circuit EEPROM abnormality)

Related portion

CN111-7 NC

Pump motor drive circuit CN111-8 (152, SETP)

CN111-9 (152, OSETP)

Probable cause:
© Connector contact defect ® Pump motor drive circuit defect
® Pump motor drive circuit harness defect

If AD-1, 2, 3 or 4 is also displayed, perform troubleshooting with priority given to AD-1, 2, 3 or 4.

Error code 32-3

1. Disconnect the battery plug, disconnect the CN111 connector, and

32-3
visually check inside the connector and the caulked portion of its
error does not occur. Pump motor drive circuit
wire for defects. (Refer to BEFORE TROUBLESHOOTING) s connector contact defect
2. Connect the CN111 connector, connect the battery plug, and then
turn on the key switch to check for errors.
32-3 error occurs.
Pump motor drive circuit defect
 4-119

• Error Code 54-1,-2,-3,-4 (Swing lock solenoid abnormality)

Related portion

CN 103-1 (327, SLSW+) CN95-1

CN 103-2 (328, SLSW-) CN95-2

CN103-5 (N2, N2)

Main Swing lock
controll CN104-4 (N2, N2) solenoid

CN 104-5 (N2, N2)

CN 104-6 (N2, N2)

55 5?

Probable cause:
© Connector contact defect © Swing lock solenoid defect
© Swing lock solenoid harness defect @ Main controller defect

If the 54-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code 54-1

Connector contact defect

Track down the

cause of the 54-4 error.

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
Main controller defect
4-120

Connector contact defect

Track down the

cause of the 54-3 error.

Swing lock solenoid defect

Hamess defect

Main controller defect

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
Main controller defect
 4-121

Error code 54-4

Connector contact defect

Swing lock solenoid defect

Harness defect

Main controller defect

nspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN95, CN103 and CN104 connectors, visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN103-1 to CN95-1 Continuity 54-4
CN 103-2 to CN95-2 Continuity 54-4
CN 103-1 to CN 104-4 No continuity 54-4
CN 103-2 to CN 104-4 No continuity 54-4
CN95-1 to CN95-2 No continuity 54-1,2,3,4
CN95-2 to P1 No continuity 54-1,2,3,4
CN95-2 to P4 No continuity 54-1,2,3,4

* Connect the CN95 connector and measure the resistance between CN 103-1 and CN 103-2, to see if it falls
between 4 and 11 Q (approx. 6 Q at 20°C )
4-122

• Error Code 61 -1,-2 (Load sensor abnormality)

Related portion

CN 104-12 (58, SPLF+) CN76-1

CN103-29 (59, SPLF) CN76-2

Main Load sensor
controller
CN101-32 (51, POT-) CN76-3

Probable cause:
® Connector contact defect ® Load sensor harness defect
© Load sensor defect ® Main controller defect

Connector contact defect

Load sensor defect

Hamess defect

Main controller defect

 4-123

Error code 61-2

Connector contact defect

Lord sensor defect

Harness defect

Main controller defect

nspection 1,2: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN76, CN101, CN103 and CN104 connectors, and with SST
disconnected, visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN104-12 to CN76-1 Continuity 61-1
CN103-29 to CN76-2 Continuity 61-1
CN101-32 to CN76-3 Continuity 61-2
CN76-3 to CN76-2 No continuity 61-1
CN76-3 to CN76-1 No continuity 61-1
CN76-2 to CN76-1 No continuity 61-2

*1: Connect CN76-1 and CN76-2 on the harness side through 09230-13700-71 and check
if there is continuity between CN104-12 and CN103-29.
*2: Connect CN76-2 and CN76-3 on the harness side through 09230-13700-71 and check
if there is continuity between CN103-29 and CN101-32.
4-124

• Error Code 62-1 ,-2 (Tilt angle sensor abnormality)

Related portion

CN101-20 (57, VRTA+) CN86-1

CN 103-17 (56, VRTA) CN86-2

Main Tilt angle
controller sensor
CN101-32 (51, POT-) CN86-3

Probable cause:
© Connector contact defect © Tilt angle sensor harness defect
© Tilt angle sensor defect © Main controller defect

Connector contact defect

Tilt angle sensor defect

Harness defect

Main controller defect

 4-125

Error code 62-2

Connector contact defect

Tilt angle sensor defect

Harness defect

Main controller defect

Inspection 1, 2: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN86, CN101, and CN103 connectors, and with SST disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 101-20 to CN86-1 Continuity 62-1
CN 103-17 to CN86-2 Continuity 62-1
CN101-32 to CN86-3 Continuity 62-2
CN86-3 to CN86-2 No continuity 62-1
CN86-3 to CN86-1 No continuity 62-1
CN86-2 to CN86-1 No continuity 62-2

*1: Connect CN86-1 and CN86-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN 101-20 and CN 103-17
*2: Connect CN86-2 and CN86-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-17 and CN101-32
4-126

• Error Code 64-1 ,-2,-3,-4 (Lift lower lock solenoid abnormality)

Related portion

CN 101-1 (3, SOLLU+) CN88-2

CN 102-16 (4, SLLL-) CN88-1

CN103-5 (N2, N2)

Main Lift lock
controller CN104-4(N2, N2) solenoid

CN 104-5 (N2, N2)

CN104-6 (N2, N2)

77

Probable cause:
© Connector contact defect ® Lift lock solenoid defect
® Lift lock solenoid harness defect © Main controller defect

If the 64-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Track down the cause of the

64-4 error.

Connector contact defect

Portion where a problem was found during a check of the lift lock solenoid or its harness.
Main controller defect
 4-127

Error code 64-2

Track down the cause of the

64-3 error.

Connector contact defect

Lift lock solenoid defect

Harness defect

Main controller defect

Error code 64-3

Portion where a problem was found during a check of the lift lock solenoid or its harness.
Main controller defect
4-128

Connector contact defect

Lift lock solenoid defect

Harness defect

Main controller defect

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN88, CN101, CN102, CN103 and CN104 connectors, and
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-1 to CN88-2 Continuity 64-4
CN 102-16 to CN88-1 Continuity 64-4
CN 101-1 to CN 104-4 No continuity 64-4
CN 102-16 to CN 104-4 No continuity 64-4
CN88-1 to CN88-2 No continuity 64-1,2,3,4
CN88-1 to P1 No continuity 64-1,2,3,4
CN88-1 to P4 No continuity 64-1,2,3,4

* Connect the CN88 connector and measure the resistance between CN101-1 and CN102-16 to see if it falls
between 7 and 17 Q (approx. 10 Q at 20°C )
 4-129

» Error Code 65-1 ,-2,-3,-4 (Tilt control solenoid abnormality)

delated portion

CN101-2 (6, SLTFB+) CN89-2

CN102-19 (7, SLTFL-) CN89-1

CN103-5(N2, N2)
Main
Tilt solenoid
controller CN104-4 (N2, N2)

CN 104-5 (N2, N2)

CN 104-6 (N2, N2)

Probable cause:
© Connector contact defect ® Tilt control solenoid harness defect
® Tilt control solenoid defect ©Main controller defect

f the 65-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code 65-1

Track down the cause of the

65-4 error.

Connector contact defect

Portion where a problem was found during a check of the tilt control solenoid or its harness.
Main controller defect
4-130

Track down the cause of the

65-3

Connector contact defect

Tilt control solenoid defect

Harness defect

Main controller defect

Portion where a problem was found during a check of the tilt control solenoid or its harness.
Main controller defect
 4-131

Error code 65-4

Connector contact defect

Tilt control solenoid defect

Hamess defect

Main controller defect

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN89, CN101, CN102, CN103 and CN104 connectors, and
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-2to CN89-2 Continuity 65-4
CN 102-19 to CN89-1 Continuity 65-4
CN101-2 to CN104-4 No continuity 65-4
CN 102-19 to CN 104-4 No continuity 65-4
CN89-1 to CN89-2 No continuity 65-1,2,3,4
CN89-1 to P1 No continuity 65-1,2,3,4
CN89-1 to P4 No continuity 65-1,2,3,4

* Connect the CN89 connector and measure the resistance between CN101-2 and CN102-19 to see if it falls
between 7 and 17 Q (approx. 10 Q at 20°C)
4-132

• Error Code 66-1 (Outside matching value range for tilt angle error)

Related portion

Main
controller

Probable cause:
© The tilt horizontal angle matching value is outside the specified matching range.
© The forward tilt angle matching value is outside the specified matching range.
© The load sensor matching value is outside the specified matching range.

Matching After the completion of matching,

Perform matching of the tilt horizontal angle, the forward tilt angle, and 66-1 error does not occur.
the load sensor.
----------------------------- > Use the device as it is.
Refer to MULTI-DISPLAY FUNCTIONS / MUSK FUCTION I
MACHING
After the completion of
matching,
66-1 error occurs.
v
Main controller defect
 4-133

• Error Code 67-1 (Lifting height switch open)

Related portion

Lifting height
CN102-10 (51, LS-) CN92-1 switch

CN 104-22 (90, SH1) CN92-2

Main
controller
CN103-24 (91.SH2-1) CN92-3
—o

Probable cause:
® Connector contact defect ® Lifting height switch defect
® Harness defect © Main controller defect

Error code 67-1

Connector contact defect

Lifting height switch defect

4-134

____________________________ y___________________________
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
» Harness defect
2. Disconnect the CN102, CN103 and CN104 connectors and check
the harnesses for their continuities.
OK
v
Main controller defect

Main controller defect

 4-135

Main controller defect

nspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN92, CN102.CN103 and CN104 connectors disconnected.
Visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN102-10 to CN92-1 Continuity
CN 104-22 to CN92-2 Continuity
CN103-24 to CN92-3 Continuity
CN92-1 to CN92-2 No continuity
CN92-1 to CN92-3 No continuity
CN92-2 to CN92-3 No continuity
4-136

• Error Code 68-1,-2,-3 (Lifting height sensor abnormality)

Related portion

Probable cause:
© Lifting height sensor defect ® Lifting height sensor harness defect
@ Connector contact defect @ Main controller defect

Connector contact defect

Lifting height sensor defect

Harness defect

Main controller defect

 4-137

Error code 68-2

1. Disconnect the battery plug, disconnect the CN99 connector, and

visually check inside the connector and the caulked portion of its 68-2
wire for defects. (Refer to BEFORE TROUBLESHOOTING) error does not occur.
Connector contact defect
2. Connect the CN99 connector, connect the battery plug, and then
turn on the key switch to check how the vehicle operates and if an
error occurs.
68-2 error occurs. t
Inspection: Check of lifting height sensor as a single unit
1. Turn off the key switch and disconnect the battery plug.
68-1 error occurs.
2. Disconnect the CN99 connector. Lifting height sensor defect
3. Connect the battery plug and turn on the key switch.
Check the error code.
68-2 error occurs.
______________________________ _ ___ ¥_____________________________
Inspection 1: Continuity and short check of harness
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101 and CN103 connectors and check the
harnesses for their continuities.
oir^;
Main controller defect

Error code 68-3

NG
Lifting height sensor defect

Change in VRH value:

0.5 or more Normal
(Connector contact defect)

NG
Harness defect

Main controller defect

4-138

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.

Disconnect the battery plug, disconnect CN99, CN101 and CN103 and perform the check without connecting
SST.

Portions to be checked Standard Point

CN101-24 to CN99-2 Continuity 68-1, 3
CN 103-28 to CN99-3 Continuity 68-1, 3
CN 101-32 to CN99-1 Continuity 68-2, 3
CN99-1 to CN99-3 No continuity 68-1,3
CN99-2 to CN99-1 No continuity 68-1,3
CN99-3 to CN99-2 No continuity 68-2, 3

*1: Connect CN99-2 and CN99-3 on the harness side through 09238-13130-71 and check if there is continuity
between CN101-24 and CN103-28.
*2: Connect CN99-3 and CN99-1 on the harness side through 09238-13130-71 and check if there is continuity
between CN 103-28 and CN101-32.
 4-139

• Error Code 71-1,-2,-3 (Tire angle sensor abnormality)

Related portion

CN101-23 (316, VRTRA+) CN32-3

CN102-31 (317, VRTRA) CN32-2

Main Tire angle
controller sensor
CN102-26 (51, POT-) CN32-1

Probable cause:
© Connector contact defect © Tire angle sensor joint, rear axle link system defect
© Tire angle sensor harness defect © Main controller defect
© Tire angle sensor defect

Error code 71-1

71-1 error occurs.

Tire angle sensor defect

Harness defect

Main controller defect

4-140

Connector contact defect

Tire angle sensor defect

Tire angle sensor installation
portion defect.

Harness defect

Main controller defect

Inspection 1,2: Check each harness for its continuity.

Disconnect the battery plug and the CN32, CN101 and CN102 connectors and with SST disconnected
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-23 to CN32-3 Continuity 72-1
CN 102-31 to CN32-2 Continuity 72-1
CN 102-26 to CN32-1 Continuity 72-2
CN32-1 to CN32-2 Continuity 72-1
CN32-1 to CN32-3 Continuity 72-1
CN32-2 to CN32-3 Continuity 72-2

*1: Connect CN32-3 and CN32-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-23 and CN102-31.
*2: Connect CN32-1 and CN32-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN110-26 and CN110-31.
 4-141

• Error Code 72-1,-2,-3,-4 (Steering-wheel angle sensor abnormality)

Related portion

CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3

Main CN 104-31 (313, SSTR2) CN19-4 Steering

controller angle sensor
CN 104-24 (314, SSTRC) CN19-5

CN102-10 (51, LS-) CN19-2

Probable cause:
© Connector contact defect ® Steering angle sensor defect
@ Steering angle sensor harness defect © Main controller defect

The error code 72-4 may be displayed if only the tire angle sensor, but not the steering wheel, is rotated.

Error code 72-1

1. Disconnect the battery plug, disconnect the CN19 connector, and

visually check inside the connector and the caulked portion of its 72-1
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) error does not occur. Connector contact defect
2. Connect the CN19 connector, connect the battery plug, turn on the
key switch, and turn the steering wheel to see if an error occurs.
72-1 error occurs.
v
Inspection: Checking the state, turning the steering wheel
Turn on the key switch and check the value of STS using the Analyzer STS: 1
* ‘
menu. *
( represents either 0 or 1.)
fANLl I/O STEERING 1/1
STS: 0**
(* represents either 0 or 1.) v
Disconnect the battery plug and disconnect the CN19 connector. After
that, connect CN19-2 to CN19-3 (on the main harness side) through
09232-13130-71 to short them, and then connect the battery plug and
turn on the key switch.
4-142

Steering angle sensor

defect

Main harness defect

Main controller defect

Disconnect the CN104 connector and disconnect the CN19 connector.

Connect the battery plug and turn on the key switch.

Xf
STS: 0“
Inspection: Checking the state, turning the steering wheel
(* represents either 0
or 1.)
Turn on the key switch and check the value of STS using the Analyzer -------------------------------- » Steering angle sensor defect
menu.
FANLi i/q gTE^RiNQ 1/1

STS: 1**
(* represents either 0 or 1.) f

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
-------------------------------- > Main harness defect
2. Disconnect the CN104 connectors and check the harnesses for
their continuities.
0K X

Main controller defect

 4-143

Error code 72-2

Main controller defect

Steering angle sensor

defect

Main harness defect

Main controller defect

4-144

Main controller defect

 4-145

Main controller defect

Error code 72-4

Track down the cause of 72-1 (SSTR1).

Proceed to identify the cause of 72-2 (SSTR2).
4-146

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect CN19, CN102, CN103 and CN104 and perform the check without
connecting SST.
Visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 104-30 to CN19-3 Continuity 72-1
CN 104-31 to CN19-4 Continuity 72-2
CN 104-24 to CN19-5 Continuity 72-3
CN 103-13 to CN19-1 Continuity 72-4
CN 102-1 Oto CN19-2 Continuity 72-4
CN19-1 to CN 19-3 No continuity 72-1
CN19-1 to CN 19-4 No continuity 72-2
CN19-1 to CN19-5 No continuity 72-3
CN 19-2 to CN19-3 No continuity 72-1
CN 19-2 to CN19-4 No continuity 72-2
CN 19-2 to CN19-5 No continuity 72-3
CN19-1 to CN 19-2 No continuity 72-1,2,3,4

*1: Connect CN19-1 and CN19-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-13 and CN104-30.
*2: Connect CN19-1 and CN19-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN 103-13 and CN 104-31.
*3: Connect CN19-1 and CN19-5 on the harness side through 09232-13130-71 and check if there is continuity
between CN 103-13 and CN 104-24.
*4: Connect CN19-1 and CN19-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN 103-13 and CN 102-10.
 4-147

• Error Code 73-1 ,-2,-3,-4 (Steering knob synchronizer solenoid abnormality)

delated portion

CN102-7 (329, SLS+) CN98-1

CN102-14 (330, SLS-) CN98-2

CN103-5 (N2, N2)

Main Steering knob
controller CN104-4(N2, N2) synchronizer
solenoid
CN104-5 (N2, N2)

CN 104-6 (N2, N2)

7T

3robable cause:
© Connector contact defect © Knob position compensation solenoid defect
® Knob position compensation solenoid harness defect © Main controller defect

f the 73-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code 73-1

1. Disconnect the battery plug, disconnect the CN98 connector, and

73-4
visually check inside the connector and the caulked portion of its
error occurs. Track down the cause of the
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) ----------------------------- >
73-4 error.
Connect the CN98 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.

Connector contact defect

Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
Main controller defect
4-148

Track down the cause of

the 73-3 error.

Connector contact
defect

Knob position
compensation solenoid
defect

Harness defect

Main controller defect

Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
Main controller defect
 4-149

Error code 73-4

Connector contact defect

Knob position compensation

solenoid defect

Harness defect

Main controller defect

nspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN98, CN102, CN103 and CN104 connectors, Visually check inside
each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 102-7 to CN98-1 Continuity 73-4
CN102-14 to CN98-2 Continuity 73-4
CN 102-7 to CN 104-4 No continuity 73-4
CN 102-14 to CN 104-4 No continuity 73-4
CN98-1 to CN98-2 No continuity 73-1,2,3,4
CN98-2 to P1 No continuity 73-1,2,3,4
CN98-2 to P4 No continuity 73-1,2,3,4

Connect the CN98 connector and measure the resistance between CN102-7 and CN102-14 to see if it falls
between 7 and 17 Q (approx. 10 Q at 20°C).
4-150

• Error Code 74-1 (Outside matching value range for tire angle error)

Related portion

Steering knob synchronizer

solenoid

Probable cause:
©Tire straight running matching value is outside the specified matching range.

If the 71-1, 71-2 or 71-3 error occurs, identify the cause of it first, and then perform the following.

After the completion of

matching, 74-1 error
Matching has been made
Perform tire straight running matching. Refer to MULTI-DISPLAY does not occur.
correctly.
FUNCTIONS / MUSK FUCTION / MACHING
Use the device as it is.
After the completion of matching,
74-1 error occurs.
V
Main controller defect
 4-151

• Error Code H1-1, -2, -3, -4, -5 (Lift iever potentiometer abnormality)

Related portion

CN101-25 (28, VRL+) CN77-4

CN 103-26 (20, VRL1) CN77-3

Main Lift lever
controller CN 103-18 (21, VRL2) CN77-2 potentiometer

CN 102-26 (51, POT-) CN77-1

If the lever was removed for a check, be sure to perform matching after installing it.
The H1-4 error may occur if the key switch is turned on while the lift lever is being operated.

Probable cause:
© Connector contact defect © Lift lever potentiometer defect
® Lift lever potentiometer harness defect © Main controller defect

Connector contact defect

Lift lever potentiometer defect

Harness defect

Main controller defect

4-152

Lift lever potentiometer defect

Error code H1-5

Matching of the lift lever potentiometer After the completion of matching,

Refer to MULTI-DISPLAY FUNCTIONS MUSK I H1-5 error does not occur. Matching has been made correctly.
FUCTION / MACHING Use the device as it is.
After the completion of
matching, H1-5 error
occurs.
v
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN77, CN101, CN102 and CN103 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
O : Items to be checked
H1
Portions to be checked Standard
1 2 3 4 5
CN101-25 to CN77-4 Continuity O - - - -
CN 103-26 to CN77-3 Continuity O - - - -
CN 103-18 to CN77-2 Continuity O - - - -
CN 102-26 to CN77-1 Continuity - o - - -
CN77-2 to CN77-1 No continuity O - o - -
CN77-3 to CN77-1 No continuity o - o - -
CN77-2 to CN77-4 No continuity - 0 o - -
CN77-3 to CN77-4 No continuity - o o - -
CN77-4 to CN77-1 No continuity o - o - -
CN77-2 to CN77-3 No continuity - - o - -
 4-153

» Error Code H2-1, -2, -3, -4, -5 (Tilt lever potentiometer abnormality)

delated portion

CN101-28 (29, VRT+) CN78-4

CN 102-23 (22, VRT1) CN78-3

Main Tilt lever
controller CN 102-22 (23, VRT2) CN78-2 potentiometer

CN 102-26 (51, POT-) CN78-1

f the lever was removed for a check, be sure to perform matching after installing it.
rhe H2-4 error may occur if the key switch is turned on while the tilt lever is being operated.

’robable cause:
© Connector contact defect © Tilt lever potentiometer defect
© Tilt lever potentiometer harness defect © Main controller defect

Error code H2-1, -2, -3

1. Disconnect the battery plug, disconnect the CN78 connector, and

H2-1.-2, -3
visually check inside the connector and the caulked portion of its
error does not occur. ~ . . . , ,
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) ---------------------------- > Connector contact defect
2. Connect the CN78 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
H2-1, -2 or-3 error
One of these errors occurs.
_______________________ v___________________________
Inspection: Check of tilt lever potentiometer H1-1, -2 or -3 error
1. Turn off the key switch and disconnect the battery plug. One of these errors
2. Replace the tilt lever potentiometer connector (CN78) with the lift occurs.
> Tilt lever potentiometer defect
lever potentiometer connector (CN77).
3. Connect the battery plug and turn on the key switch.
Check the error code. H1-4, H2-4
can be ignored.
H2-1, -2 or-3 error
One of these errors occurs. x
Inspection 1: Harness check
1. Turn off the key switch and disccinnect the battery plug. NG
> Harness defect
2. Disconnect the CN101 and CN1 02 connectors and check the
harnesses for their continuities.

OK
v
Main controller defect
4-154

Tilt lever potentiometer defect

Error code H2-5

Matching of the tilt lever potentiometer After the completion of matching,

Matching has been made
Refer to MULTI-DISPLAY FUNCTIONS / MUSK H2-5 error does not occur.
-------------------------------- > correctly.
FUCTION / MACHING
Use the device as it is.
After the completion of
matching, H2-5 error
occurs. f
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN78, CN101, CN102 and CN103 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

H2
Portions to be checked Standard
1 2 3 4 5
CN101-28 to CN78-4 Continuity O - - - -
CN 102-23 to CN78-3 Continuity O - - - -
CN 102-22 to CN78-2 Continuity O - - - -
CN 102-26 to CN78-1 Continuity - o - - -
CN78-2 to CN78-1 No continuity o - o - -
CN78-3 to CN78-1 No continuity o - o - -
CN78-2 to CN78-4 No continuity - o o - -
CN78-3 to CN78-4 No continuity - o o - -
CN78-4 to CN78-1 No continuity o - o - -
CN78-2 to CN78-3 No continuity - - o - -
 4-155

• Error Code H3-1, -2, -3, -4, -5 (Attachment 1 lever potentiometer

abnormality)

Related portion

CN101-29 (30, VRAT1+) CN79-4

CN 102-21 (24, VRA11) CN79-3

Main Attachment 1
controller CN102-20 (25, VRA12) CN79-2 lever
potentiometer
CN 102-26 (51, POT-) CN79-1

f the lever was removed for a check, be sure to perform matching after installing it.
fhe H3-4 error may occur if the key switch is turned on while the attachment 1 lever is being operated.

Probable cause:
® Connector contact defect ® Attachment 1 lever potentiometer defect
® Attachment 1 lever potentiometer harness defect © Main controller defect

Error code H3-1, -2, -3

Connector contact defect

Attachment 1 lever
potentiometer defect

Harness defect

Main controller defect

4-156

Attachment 1 lever potentiometer defect

Error code H3-5

After the completion of matching, .....

Matching of the attachment 1 lever potentiometer. ■ ,o c . . 55 Matching has been made
Refer to MULTI-DISPLAY FUNCTIONS MUSK 1 H3-5 error does not occur. ..a
-------------------------------------------- > correctly.
FUCTION / MACHING Use the device as it is.

After the completion of

matching, H3-5 error
occurs.
v
Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN79, CN101 and CN102 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
O : Items to be checked
H3
Portions to be checked Standard
1 2 3 4 5
CN101-29 to CN79-4 Continuity O - - - -
CN 102-21 to CN79-3 Continuity O - - - -
CN 102-20 to CN79-2 Continuity O - - - -
CN 102-26 to CN79-1 Continuity - o - - -
CN79-2 to CN79-1 No continuity O - o - -
CN79-3 to CN79-1 No continuity o - 0 - -
CN79-2 to CN79-4 No continuity - o o - -
CN79-3 to CN79-4 No continuity - o o - -
CN79-4 to CN79-1 No continuity o - o - -
CN79-2 to CN79-3 No continuity - - o - -
 4-157

> Error Code H4-1, -2, -3, -4, -5 (Attachment 2 lever potentiometer
abnormality)

delated portion

CN101-30 (31,VRAT2+) CN80-4

CN102-29 (26, VRA21) CN80-3

Main Attachment 2
controller CN 102-28 (27, VRA22) CN80-2 lever
potentiometer
CN 102-26 (51, POT-) CN80-1

f the lever was removed for a check, be sure to perform matching after installing it.
'he H4-4 error may occur if the key switch is turned on while the attachment 2 lever is being operated.

’robable cause:
© Connector contact defect © Attachment 2 lever potentiometer defect
® Attachment 2 lever potentiometer harness defect @ Main controller defect

Error code H4-1, -2, -3

1. Disconnect the battery plug, disconnect the CN80 connector, and

H4-1, -2, -3 error
visually check inside the connector and the caulked portion of its
does not occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) ----------------------------> Connector contact defect
2. Connect the CN80 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
H4-1, -2 or-3 error
One of these errors occurs.
Inspection: Check of attachment 2 ever potentiometer H2-1, -2 or -3 error
1. Turn off the key switch and discc>nnect the battery plug, One of these errors
2. Replace the attachment 2 lever jotentiometer connector (CN80) occurs. Attachment 2 lever
with the tilt lever potentiometer connector (CN78). potentiometer defect
3. Connect the battery plug and tur n on the key switch. H2-4, H4-4 can be
Check the error code. ignored.
H4-1, -2 or -3 error
One of these errors occurs. x f

Inspection 1: Harness check

1. Turn off the key switch and discc»nnect the battery plug. NG
----------------------------> Hamess defect
2. Disconnect the CN101 and CN1 02 connectors and check the
harnesses for their continuities.

OK
v
Main controller defect
4-158

Attachment 2 lever potentiometer defect

Error code H4-5

Matching of the attachment 2 lever potentiometer. After the completion of matching,

Refer to MULTI-DISPLAY FUNCTIONS / MUSK H4-5 error does not occur. Matching has been made correctly.
FUCTION / MACHING Use the device as it is.
After the completion of
matching, H4-5 error
occurs. 5f
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN80, CN101 and CN102 connectors disconnected, visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
O : Items to be checked
H4
Portions to be checked Standard
1 2 3 4 5
CN101-30 to CN80-4 Continuity O - - - -
CN 102-29 to CN80-3 Continuity O - - - -
CN 102-28 to CN80-2 Continuity O - - - -
CN102-26 to CN80-1 Continuity - o - - -
CN80-2 to CN80-1 No continuity O - o - -
CN80-3 to CN80-1 No continuity o - o - -
CN80-2 to CN80-4 No continuity - o o - -
CN80-3 to CN80-4 No continuity - o o - -
CN80-4 to CN80-1 No continuity o - o - -
CN80-2 to CN80-3 No continuity - - o - -
 4-159

• Error Code H5-1, -2, -3, -4, -5, -6 (Lift PUSH/PULL solenoid abnormality)

Related portion

CN 101-5 (9, SLLA2+) CN75-5

Lift push
CN101-16 (11, SLPS-) CN75-1 solenoid

CN74-5
Lift pull
Main CN101-17 (10, SLPL-) CN74-1 solenoid
controller
CN 103-5 (N2, N2)

CN 104-4 (N2, N2)

CN 104-5 (N2, N2)

CN 104-6 (N2, N2)

/✓

Probable cause:
© Connector contact defect © Lift pull solenoid harness defect
© Lift push solenoid harness defect ® Lift pull solenoid defect
® Lift push solenoid defect ® Main controller defect

If the H5-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code H5-1, -3

Track down the cause of the

H5-6 error.

Connector contact defect

Portion where a problem was found during a check of the lift solenoid or its harness.
Main controller defect
4-160

Track down the cause of the

H5-5 error.

Connector contact defect

Lift solenoid defect

Harness defect

Main controller defect

Portion where a problem was found during a check of the lift solenoid or its harness.
Main controller defect
 4-161

Error code H5-6

1. Disconnect the battery plug, disconnect the CN74 and CN75

connectors, and visually check inside the connector and the H5-6 error does not
caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING.)
2. Connect the CN74 and CN75 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

H5-6 error occurs.

V
HB-2 error occurs. Track down the cause of the
Check if the HB-2 error has also occurred. ------------------------------- > HB-2 error.

HB-2 error does not occur.

v
Inspection: Check of lift solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN74 and CN75 connectors and measure the NG
J Lift solenoid defect
resistance of the lift solenoid.
(CN74-5 to CN74-1, CN75-5 to CN75-1).
Standard value: 6 to 12 Q (approx. 7 Q at 20°C )

OK
V
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG X
s Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK
V
Main controller defect

inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN74, CN75, CN101, CN103 and CN104 connectors, and
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-5 to CN74-5 Continuity H5-6
CN101-17 to CN74-1 Continuity H5-6
CN101-5 to CN75-5 Continuity H5-6
CN101-16 to CN75-1 Continuity H5-6
CN101-5 to CN 104-4 No continuity H5-6
CN 101-17 to CN 104-4 No continuity H5-6
CN 101-16 to CN 104-4 No continuity H5-6
CN74-5 to CN74-1 No continuity H5-1.2, 3, 4, 5,6
CN75-5 to CN75-1 No continuity H5-1.2, 3, 4, 5,6
CN74-1 to P1 No continuity H5-1.2, 3, 4, 5, 6
CN74-1 to P4 No continuity H5-1.2, 3, 4, 5,6
CN75-1 to P1 No continuity H5-1.2, 3, 4, 5,6
CN75-1 to P4 No continuity H5-1.2, 3, 4, 5,6

*1: Connect CN74 to the solenoid and measure the resistance between CN101-5 and CN101-17
to see if it falls between 6 and 12 Q (approx. 7 Q at 20°C ).
*2: Connect CN75 to the solenoid and measure the resistance between CN101-5 and CN101-16
to see if it falls between 6 and 12 Q (approx. 7 Q at 20°C ).
4-162

• Error Code H6-1, -2, -3, -4, -5, -6 (Tilt PUSH/PULL solenoid abnormality)

Related portion

CN101-6 (32, SLTA1+) CN75-6

Tilt push
CN 101-13 (34, STPS-) CN75-2 solenoid

CN101-12 (33, STPL-) CN74-6

Tilt pull
Main CN 103-5 (N2, N2) CN74-2 solenoid
controller
CN 104-4 (N2, N2)

CN104-5(N2, N2)

CN104-6 (N2, N2)

77 “7

Probable cause:
© Connector contact defect © Tilt pull solenoid harness defect
® Tilt push solenoid harness defect ® Tilt pull solenoid defect
® Tilt push solenoid defect ® Main controller defect

If the H6-5 error occurs, disconnect the battery plug immediately and track down the cause of it.

Track down the cause of the

H6-6 error.

Connector contact defect

Portion where a problem was found during a check of the tilt solenoid or its harness.
Main controller defect
 4-163

Error code H6-2, -4

Track down the cause of the

H6-5 error.

Connector contact defect

Tilt solenoid defect

Hamess defect

Main controller defect

Error code H6-5

Portion where a problem was found during a check of the tilt solenoid or its harness.
Main controller defect
4-164

Connector contact defect

Track down the cause of the

HB-2 error.

Tilt solenoid defect

Harness defect

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN74, CN75, CN101, CN103 and CN104 connectors, and
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-6 to CN74-6 Continuity H6-6
CN101-12 to CN74-2 Continuity H6-6
CN101-6 to CN75-6 Continuity H6-6
CN101-13 to CN75-2 Continuity H6-6
CN101-6 to CN 104-4 No continuity H6-6
CN101-12 to CN 104-4 No continuity H6-6
CN101-13 to CN104-4 No continuity H6-6
CN74-6 to CN74-2 No continuity H6-1,2, 3, 4, 5,6
CN75-6 to CN75-2 No continuity H6-1.2, 3, 4, 5,6
CN74-2 to P1 No continuity H6-1.2, 3, 4, 5,6
CN74-2 to P4 No continuity H6-1, 2, 3, 4, 5, 6
CN75-2 to P1 No continuity H6-1.2, 3, 4, 5,6
CN75-2 to P4 No continuity H6-1.2, 3, 4, 5,6

*1: Connect CN74 to the solenoid and measure the resistance between CN101-6 and CN101-12
to see if it falls between 6 and 12 Q (approx. 7 Q at 20°C ).
*2: Connect CN75 to the solenoid and measure the resistance between CN101-6 and CN101-13
to see if it falls between 6 and 12 Q (approx. 7 Q at 20°C ).
 4-165

» Error Code H7-1, -2, -3, -4, -5, -6 (Attachment 1 PUSH/PULL solenoid
abnormality)

Related portion

CN101-6 (32, SLTA1+)

CN101-11 (37, SA1PS-)

CN 101-10 (36, SA1PL-)

Main
controller CN 103-5 (N2, N2)

CN 104-4 (N2, N2)

CN 104-5 (N2, N2)

CN 104-6 (N2, N2)

77 7r

’robable cause:
© Connector contact defect © Attachment 1 pull solenoid harness defect
® Attachment 1 push solenoid harness defect ® Attachment 1 pull solenoid defect
® Attachment 1 push solenoid defect ® Main controller defect

f the H7-5 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code H7-1, -3

Track down the cause of the

H7-6 error.

Connector contact defect

Portion where a problem was found during a check of the attachment 1 solenoid or its harness.
Main controller defect
4-166

Track down the cause of the

H7-5 error.

Connector contact defect

Attachment 1
solenoid defect

Hamess defect

Main controller defect

Portion where a problem was found during a check of the attachment 1 solenoid or its harness.
Main controller defect
 4-167

Error code H7-6

1. Disconnect the battery plug, disconnect the CN74 and CN75

connectors, and visually check inside the connector and the H7-6 error does not
caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN74 and CN75 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

H7-6 error occurs.

v
HB-2 error occurs. Track down the cause of the
Check if the HB-2 error has also occurred. ------------------------------- >
HB-2 error.

HB-2 error does not occur.

V
Inspection: Check of attachment 1 solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN74 and CN75 connectors. NG Attachment 1
Measure the resistance of attachment 1 solenoid solenoid defect
(CN74-7 to CN74-3, CN75-7 to CN75-3).
Standard value: 6 to 12 Q (approx. 7 Q at 20°C )

OK
V
Inspection 1: Hamess check
1. Turn off the key switch and disconnect the battery plug. NG
Hamess defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK
V
Main controller defect

nspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN74, CN75, CN101, CN103 and CN104 connectors, and
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-6 to CN74-7 Continuity H7-6
CN101-10 to CN74-3 Continuity H7-6
CN101-6 to CN75-7 Continuity H7-6
CN 101-11 to CN75-3 Continuity H7-6
CN101-6 to CN104-4 No continuity H7-6
CN 101-10 to CN 104-4 No continuity H7-6
CN101-11 toCN104-4 No continuity H7-6
CN74-7 to CN74-3 No continuity H7-1.2, 3, 4, 5,6
CN75-7 to CN75-3 No continuity H7-1.2, 3, 4, 5,6
CN74-3 to P1 No continuity H7-1.2, 3, 4, 5,6
CN74-3 to P4 No continuity H7-1,2, 3, 4, 5,6
CN75-3 to P1 No continuity H7-1.2, 3, 4, 5,6
CN75-3 to P4 No continuity H7-1.2, 3, 4, 5,6

*1: Connect CN74 to the solenoid and measure the resistance between CN101-6 and CN101-10
to see if it falls between 6 and 12 Q (approx. 7 Q at 20°C ).
*2: Connect CN75 to the solenoid and measure the resistance between CN101-6 and CN101-11
to see if it falls between 6 and 12 Q (approx. 7 Q at 20°C ).
4-168

• Error Code H8-1, -2, -3, -4, -5, -6 (Attachment 2 PUSH/PULL solenoid
abnormality)

Related portion

CN101-5 (9, SLLA2+) CN75-8

Attachment 2
CN101-15(40, SA2PS-) CN75-4 push solenoid

CN74-8
Attachment 2
CN 101-14 (39, SA2PL-) CN74-4 pull solenoid
Main
controller CN103-5 (N2, N2)

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN 104-6 (N2, N2)

7/^7

Probable cause:
© Connector contact defect © Attachment 2 pull solenoid harness defect
@ Attachment 2 push solenoid harness defect ® Attachment 2 pull solenoid defect
® Attachment 2 push solenoid defect ® Main controller defect

If the H8-5 error occurs, disconnect the battery plug immediately and track down the cause of it.

Track down the

cause of the H8-6
error.

Connector contact
defect

Portion where a problem was found during a check of the attachment 2 solenoid or its harness.
Main controller defect
 4-169

Error code H8-2, -4

Track down the cause of the

H8-5 error.

Connector contact defect

Attachment 2 solenoid defect

Harness defect

Main controller defect

Error code H8-5

Portion where a problem was found during a check of the attachment 2 solenoid or its harness.
Main controller defect
4-170

Connector contact defect

Track down the cause of the

HB-2 error.

Attachment 2
solenoid defect

Harness defect

Main controller defect

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN74, CN75, CN101, CN103 and CN104 connectors, and visually
check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN101-5 to CN74-8 Continuity H8-6
CN101-14 to CN74-4 Continuity H8-6
CN101-5 to CN75-8 Continuity H8-6
CN101-15 to CN75-4 Continuity H8-6
CN101-5 to CN104-4 No continuity H8-6
CN 101-14 to CN 104-4 No continuity H8-6
CN101-15to CN104-4 No continuity H8-6
CN74-8 to CN74-4 No continuity H8-1,2, 3, 4, 5, 6
CN75-8 to CN75-4 No continuity H8-1.2, 3, 4, 5,6
CN74-4 to P1 No continuity H8-1.2, 3, 4, 5,6
CN74-4 to P4 No continuity H8-1.2, 3, 4, 5,6
CN75-4 to P1 No continuity H8-1.2, 3, 4, 5,6
CN75-4 to P4 No continuity H8-1.2, 3, 4, 5,6

*1: Connect CN74 to the solenoid and measure the resistance between CN101-5 and CN101-14 to see if it falls
between 6 and 12 Q (approx. 7 Q at 20°C).
*2: Connect CN75 to the solenoid and measure the resistance between CN101-5 and CN101-15 to see if it falls
between 6 and 12 Q (approx. 7 Q at 20°C).
 4-171

• Error Code HB-1, -2, -3, (Solenoid power supply circuit over current)

Related portion

CN28-4 (19, F7)

CN102-5(17, SOLCOM) CN223-8 (17, SOLCOM)

CN223-6 (19, VBMBSL)
CN102-6 (17, SOLCOM)

CN102-13 (335, RY1) CN223-4 (335, RY1) CN223-2 (97, FAN+)

CN101-3 (97, FAN+)

CN101-5(9, SLLA2+) CN75-5

Lift PUSH
CN101-16 (11, SLPS-) CN75-1 solenoid

CN101-17 (10, SLPL-) CN74-5

Lift PULL
CN74-1 solenoid

CN101-6 (32, SLTA1+) CN75-6

Tilt PUSH
CN101-13 (34, STPS-) CN75-2 solenoid

CN101-12(33, STPL-) CN74-6

Tilt PULL
Main
CN74-2 solenoid
controller
CN75-7
ATT1 PUSH
CN101-11 (37, SA1PS-) CN75-3 solenoid

CN101-10(36, SA1PL-) CN74-7

ATT1 PULL
CN74-3 solenoid

CN75-8
ATT2 PUSH
CN 101-15 (40, SA2PS-) CN75-4 solenoid

CN101-14 (39, SA2PL-) CN74-8

ATT2 PULL
CN103-5 (N2, N2) CN74-4 solenoid

CN104-4 (N2, N2)

CN 104-5 (N2, N2)

CN104-6 (N2, N2)

777
4-172

Probable cause:
© Connector contact defect © RY1 defect
© Harness defect © Main controller defect

Relay defect (*1)

*1 If the symptom persists after replacement of the relay, there should be any other problems,
so replace the Main controller.

Main controller defect

 4-173

Error code HB-3

1. Disconnect the battery plug, disconnect the CN223 connector, and

HB-3 error does not
visually check inside the connector and the caulked portion of its
occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 'S Connector contact defect
2. Connect the CN223 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.

HB-3 error occurs.

X
Inspection 3: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN102 and CN223 connectors and check the
harnesses for their continuities.

OK
Xf
Inspection: Relay check
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN223, check the relay and measure its NG
Relay defect
resistance on the primary side
(resistance between CN223-4 and CN223-2).
Q.
Standard value: 100 to 320 (aprox. 180 Q at 20°C)

OK
v
Main controller defect

nspection 1: Check each harness for its continuity.

With the battery plug and the CN101, CN102, and CN223 connectors disconnected, visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 102-13 to CN223-4 Continuity HB-1
CN101-3to CN223-2 Continuity HB-1
CN 102-5 to CN223-8 Continuity HB-1
CN 102-6 to CN223-8 Continuity HB-1
CN223-6 to CN28-4 Continuity HB-1
4-174

Inspection 2: Check each harness for its continuity.

With the battery plug and the CN101, CN102, CN103, CN104, CN74 and CN75 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 102-5 to CN 104-4 No continuity HB-2
CN 102-6 to CN 104-4 No continuity HB-2
CN101-5 to CN104-4 No continuity HB-2
CN101-6 to CN104-4 No continuity HB-2
CN 101-16 to CN 104-4 No continuity HB-2
CN101-17 to CN104-4 No continuity HB-2
CN101-13to CN104-4 No continuity HB-2
CN101-12 to CN104-4 No continuity HB-2
CN101-11 to CN 104-4 No continuity HB-2
CN101-10to CN104-4 No continuity HB-2
CN101-15to CN104-4 No continuity HB-2
CN101-14to CN104-4 No continuity HB-2

Inspection 3: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN102 and CN223 connectors, and visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN223-4 to P1 No continuity HB-3
CN223-4 to P4 No continuity HB-3
CN223-4 to CN223-2 No continuity HB-3
 4-175

• Error Code HC-1, -2, -3, -4, (Unload valve solenoid abnormality)

Related portion

CN101-1 (3, SOLLU+) CN51-2

CN 102-17 (5, SLUL-) CN51-1

CN103-5 (N2, N2)

Main Unload valve
controller CN 104-4 (N2, N2) solenoid

CN 104-5 (N2, N2)

CN 104-6 (N2, N2)

73 V

Probable cause:
® Connector contact defect ® Unload valve solenoid defect
@ Unload valve solenoid harness defect @ Main controller defect

f the HC-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code HC-1

Portion where a problem was found during a check of the unload valve solenoid or its harness
Main controller defect
4-176

Track down the cause of the

HC-3 error.

Connector contact defect

Unload valve solenoid defect

Harness defect

Main controller defect

Main controller defect

 4-177

Error code HC-4

1. Disconnect the battery plug, disconnect the CN51 connector, and

HC-4 error does not
visually check inside the connector and the caulked portion of its
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) —------------------- > Connector contact defect
2. Connect the CN51 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

HC-4 error occurs.

Inspection: Check of unload valve solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN51 connector and measure the resistance of the NG
-------------------------------> Unload valve solenoid defect
unload valve solenoid
(Resistance between CN51-1 and CN51-2).
Standard value: 7 to 17 Q (approx. 10 <1 at 20°C )

OK
>f
Inspection 1: Hamess check
1. Turn off the key switch and disconnect the battery plug.
——---------------------- > Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

OK

Main controller defect

nspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN51, CN101, CN102, CN103 and CN104 connectors, and visually
check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 101-1 toCN51-2 Continuity HC-4
CN 102-17 to CN51-1 Continuity HC-4
CN101-1 toCN104-4 No continuity HC-4
CN102-17 to CN104-4 No continuity HC-4
CN51-1 to CN51-2 No continuity HC-1,2, 3,4
CN51-1 to P1 No continuity HC-1,2, 3,4
CN51-1 to P4 No continuity HC-1, 2, 3,4

* Connect the CN51 connector and measure the resistance between CN101-1 and CN102-17 to see if it falls
between 7 and 17 Q (approx. 10 Q at 20°C).
4-178

• Error Code G5-1, -2, -3, -4, -5, -6 (Shock sensor abnormality)

Related portion

Probable cause:
® Connector contact defect ® Shock sensor defect
© Shock sensor harness defect @ Main controller defect

Main controller defect

 4-179

Error code G5-2 or G5-5 (For G-5-5, read the numbers in brackets, which refer to the corresponding error code,
connector number, etc.)

Connector contact defect

Shock sensor 1
[shock sensor 2] defect

Harness defect

Main controller defect

Error code G5-3 or G5-6 (For G-5-6, read the numbers in brackets, which refer to the corresponding error code,
connector number, etc.)

Connector contact defect

Shock sensor 1
[shock sensor 2] defect

Harness defect

Main controller defect

4-180

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect CN30 [CN44], CN101 and CN103 and perform the check without
connecting SST.
Visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard Point

CN 103-8 to CN30-3 Continuity G5-1
CN103-30 to CN30-2 Continuity G5-1
CN 101-32 to CN30-1 Continuity G5-2, -3
CN30-2 to CN30-1 No continuity G5-1
CN30-3 to CN30-1 No continuity G5-1
CN30-3 to CN30-2 No continuity G5-2, -3
CN 103-8 to CN44-3 Continuity G5-4
CN 103-19 to CN44-2 Continuity G5-4
CN 101-32 to CN44-1 Continuity G5-5, -6
CN44-2 to CN44-1 No continuity G5-4
CN44-3 to CN44-1 No continuity G5-4
CN44-3 to CN44-2 No continuity G5-5, -6

*1: Connect CN30-2 and CN30-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN 103-30 and CN103-8.
*2: Connect CN30-1 and CN30-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN 103-32 and CN103-30
*3: Connect CN44-2 and CN44-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-8 and CN103-19.
*4: Connect CN44-2 and CN44-1 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-32 and CN103-19.
WhltN NW tKKUK UUUtZ IO UlOKLAYtZU
Probable causes of problems for which no error code is displayed

Note:
If an error code is displayed or the spanner light is on, be sure to perform checks with priority given to it.
Control How to check
Phenomena that arise on the vehicle Failed portions and failure modes Action and remedies
systems
Emergency switch main body
- • Release the emergency switch.
: Switch is held down.
Check the battery voltage.
Battery
: Battery plug is disconnected. • Charge the Battery
: Low voltage
Check the battery voltage.
Key switch main body
: Open failure
• Check the switch, and replace it if
Emergency switch main body
necessary.
: Open failure
- • Check the harness and repair or
Key switch harness
replace it if necessary.
: Wire breakage, short circuit or
• Replace the F5 fuse.
leakage (harness, connector or F5
fuse)
Although the key switch is turned on,
power is not supplied. Numeric keypad harness (with PIN
Power-supply • Check the harness and repair or
(The multifunction screen does not code entry) -
related control replace it if necessary.
appear, and the vehicle does not : Open failure
move, either.) Check the operation of each switch.
: Check if a response (lighting of LED
or sounding of buzzer) is given only
to a particular switch.
Numeric keypad main body (with PIN If there are two types of switches:
code entry) switch to which a response is given • Replace the numeric keypad.
: Switch failure and switch to which no response is
given in the combination of (1,2 and
3), (4, 5 and 6), (7, 8 and 9) or (OFF,
0 and ON), it is certain that there is a
defective switch.
Multifunction display (with PIN code
Using the Administrator menu, check if • Register PIN using the Administrator
entry)
PIN has been registered. menu.
: PIN not registered
 4-182
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Display power supply and ground
harness (with PIN code entry)
Although the key switch is turned on, : Wire breakage, short circuit,
• Check the harness and repair or
power is not supplied. leakage (harness or connector)
replace it if necessary.
(The multifunction screen does not Multifunction display (with PIN code -
• Replace the display.
appear, and the vehicle does not entry)
• Replace the Main controller.
move, either.) : Internal failure
Main controller
Power-supply : Internal failure (D7V, DGND)
related control
Display power supply or ground
harness
: Wire breakage, short circuit, • Check the harness and repair or
The multifunction screen does not
leakage (harness or connector) replace it if necessary.
appear. -
Multifunction display • Replace the display.
(The vehicle runs normally.)
: Internal failure • Replace the Main controller.
Main controller
: Internal failure
After the key switch was turned on, the
accelerator was not released or the
- Operate them correctly.
direction switch was not returned to
neutral.
Check the direction switch, using
Analyzer.
Direction switch main body
: Accelerator is fully closed. • Check the switch, and replace it if
: Open failure
Operate the direction switch to see if necessary.
Direction switch harness
it turns on and off normally. • Check the harness and repair or
: Wire breakage, short circuit
(The vehicle does not run if the replace it if necessary.
(harness or connector)
forward and reverse switches are
turned on simultaneously.)
The vehicle does not run.
Traveling Direction switch installation portions
(The drive motor does not rotate.)
(D2 pedal and DA pedal)
Check the operation of the direction • Repair or replace the part that does
: One of the installation portions is
switch (microswitch). not operate normally.
broken or damaged or does not
operate normally.
Accelerator sensor main body
: Internal failure Check the accelerator sensor voltage,
Accelerator sensor installation portion using Analyzer. • Check the sensor and replace it if
: The link or the installation portion is : Direction switch is in neutral. necessary.
broken or damaged. Fully open and close the drive to • Check the harness and repair or
Accelerator sensor harness check the change in voltage at that replace it if necessary.
: Wire breakage, short circuit, time.
leakage (harness or connector)
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Accelerator fully closed/fully open
Check the matching value on the
matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Brake sensor main body
Check the brake sensor voltage, using
: Internal failure
Analyzer.
Brake sensor installation portion • Check the sensor and replace it if
: Direction switch in neutral, drive
: The link or the installation portion is necessary.
fully closed
broken or damaged. • Check the harness and repair or
Fully open and close the brake
Brake sensor harness replace it if necessary.
cylinder valve to check the change
: Wire breakage, short circuit,
in voltage.
leakage (harness or connector)
Brake sensor fully closed position and
Check the matching value on the
actuation point matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Check the seat switch, using Analyzer.
Seat switch main body : Direction switch in neutral, drive • Check the seat and replace it if
The vehicle does not run. : Open failure fully closed necessary.
Traveling
(The drive motor does not rotate.) Seat switch harness Check if the switch turns on and off * Check the harness and repair or
: Wire breakage (harness, connecter) normally, sitting in the seat or replace it if necessary.
standing beside it.
Brake Check the brake and the drive motor.
• Check the brake, and repair or
: Dragging (internal failure) : With the battery plug disconnected,
replace it if necessary.
Drive motor the parking brake released and the
• Check the drive motor, and repair or
: Seizure or dragging of drive motor front wheels off the ground, rotate
replace it if necessary.
(internal failure) each tire to see if it rotates smoothly.
Main body of drive motor rotation
sensor Check the voltage of the drive motor
: Internal failure rotation sensor, using Analyzer. • Check the drive motor rotation
Drive motor rotation sensor installation : Seated in seat, direction switch in sensor, and adjust or replace it if
portion forward position, brake released necessary.
: Gap improperly adjusted Operate the accelerator and check • Check the harness and repair or
Drive motor harness the change in the rotation sensor replace it if necessary.
: Wire breakage, short circuit, voltage.
leakage (harness or connector)

4-183
 4-184
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the voltage of the drive motor
Drive motor drive circuit current sensor, using Analyzer.
: Internal failure : Seated in seat, direction switch in • Check the cable, and repair or
Motor cables forward position, brake released replace it if necessary.
The vehicle does not run. : Wire breakage, short circuit or Operate the accelerator and check • Replace the drive motor drive circuit.
(The drive motor does not rotate.) leakage (cable or terminal board) the change in the current sensor
voltage.
Main controller
- • Replace the Main controller.
: Internal failure
• Check the tires and replace them if
Tire main body necessary.
-
:Type, diameter, tire pressure • Check the pressure of each tire and
repair tires if necessary.
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
Traveling
leakage (harness or connector)
Tire angle sensor straight running
Check the matching value on the
angle matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
The vehicle does not run straight. Main body of drive motor rotation
sensor Check the voltage of the drive motor
: Internal failure rotation sensor, using Analyzer. • Check the drive motor rotation
Drive motor rotation sensor installation : Seated in seat, direction switch in sensor, and adjust or replace it if
portion forward position, brake released necessary.
: Gap improperly adjusted Operate the accelerator and check • Check the harness and repair or
Drive motor harness the change in the rotation sensor replace it if necessary.
: Wire breakage, short circuit, voltage.
leakage (harness or connector)
Check the voltage of the drive motor
Drive motor drive circuit current sensor, using Analyzer.
: Internal failure : Seated in seat, direction switch in • Check the cable, and repair or
Motor cables forward position, brake released replace It if necessary.
: Wire breakage, short circuit or Operate the accelerator and check • Replace the drive motor drive circuit.
leakage (cable or terminal board) the change in the current sensor
voltage.
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the brake and the drive motor.
Brake • Check the brake, and repair or
: With the battery plug disconnected,
: Dragging (internal failure) replace it if necessary.
the parking brake released and the
The vehicle does not run straight. Drive motor • Check the drive motor, and repair or
Traveling front wheels off the ground, rotate
: Seizure or dragging of drive motor replace it if necessary.
each tire to see if it rotates smoothly.
Main controller
- • Replace the Main controller.
: Internal failure
Pump motor rotation sensor main body
: Internal failure Check the voltage of the drive motor
• Check the pump motor rotation
Pump motor rotation sensor rotation sensor, using Analyzer.
sensor, and adjust or replace it if
installation portion : Seated in the seat
necessary.
: Gap improperly adjusted Operate the direction switch and
• Check the harness and repair or
Pump motor harness check the change in the rotation
replace it if necessary.
: Wire breakage, short circuit, sensor voltage.
leakage (harness or connector)
Material handling cannot be performed
and the steering is heavy. Measure the voltage of the pump
Pump motor drive circuit
(The pump motor does not work for motor current sensor, using Analyzer. • Check the motor cables, and repair
: Internal failure
material handling operation, steering : Seated in the seat or replace them if necessary.
Motor cables
operation and direction switch Operate the direction switch and • Replace the pump motor drive
: Wire breakage, short circuit or
operation.) check the change in the current circuit.
leakage (cable or terminal board)
sensor voltage.
Material Pump • Check the pump, and repair or
handling and : Seizure replace it if necessary.
-
power steering Pump motor • Check the pump motor, and repair or
: Seizure replace it if necessary.
Main controller
- • Replace the Main controller.
: Internal failure
Main body of material handling lever
potentiometer
: Internal failure Measure the voltage of the material
Only material handling cannot be Installation of material handling lever handling lever potentiometer, using
• Check the sensor and replace it if
performed. potentiometer Analyzer.
necessary.
(The pump motor operates normally : Installation portion is broken or : Seated in the seat
• Check the harness and repair or
during steering operation and direction damaged. Tilt the material handling lever
replace it if necessary.
switch operation.) Material handling lever potentiometer forward and backward to check the
harness change in voltage.
: Wire breakage, short circuit,
leakage (harness or connector)

4-185
 Control

4-186
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the seat switch, using Analyzer.
Seat switch main body • Check the seat and replace it if
: Material handling lever in neutral
: Open failure necessary.
Check if the switch turns on and off
Seat switch harness • Check the harness and repair or
normally, sitting in the seat or
: Wire breakage (harness, connector) replace it if necessary.
standing beside it.
Oil control valve
• Check the oil control valve, and
: Seizure of or leakage from material
repair or replace it if necessary.
handling proportional valve
• Check the material handling
Only material handling cannot be : Seizure of or leakage from unload
proportional valve solenoid, and
performed. valve
- replace it if necessary.
(The pump motor operates normally Harness of material handling
• Check the unload valve solenoid
during steering operation and direction proportional valve solenoid and replace it if necessary.
switch operation.) Hamess of unload valve solenoid
• Check the harness and repair or
: Wire breakage, short circuit,
replace it if necessary.
leakage (harness or connector)
Pump • Check the pump, and repair or
: Leak replace it if necessary.
-
Priority valve • Check the priority valve, and repair
: Leak, seizure or replace it if necessary.
Material
Main controller
handling and • Replace the Main controller.
: Internal failure
power steering
Sit in the seat and check using
Lift electric proportional valve Analyzer that the current increases or
• If a current flows but the fork cannot
Only lowering is impossible. (for lowering) decreases according to the amount of
be lowered by turning on the
(Other material handling operations, : Seizure (internal damage) operation of the lowering lever.
lowering lock solenoid, replace the
including raising, are possible.) Lowering lock valve If a current flows, turn on the lowering
CA/.
: Seizure (internal damage) lock solenoid using Active Test to
lower the fork.
Sit in the seat and check using
Tilt electric proportional valve Analyzer that the current increases or
Only forward tilting is impossible.
(for forward tilting) decreases according to the amount of • If a current flows but the fork cannot
(Other material handling operations,
: Seizure (internal damage) operation of the forward tilt lever. be lowered by turning on the tilt
including backward tilting, are
Tilt control valve If a current flows, turn on the tilt control control solenoid, replace the CA/.
possible.)
: Seizure (internal damage) solenoid using Active Test to lower the
fork.
Check the direction switch, using
Direction switch • Check the switch, and replace it if
The steering is heavy. Analyzer.
: Open failure necessary.
(The pump motor operates normally : Accelerator is fully closed.
Direction switch harness • Check the harness and repair or
during material handling.) Operate the direction switch to see if
: Wire breakage (harness, connecter) replace it if necessary.
it turns on and off normally.
 Control Failed portions and failure modes How to check Action and remedies
Phenomena that arise on the vehicle
systems
Main body of steering angle sensor
: Internal damage
Check the steering angle sensor, using • Check the sensor and replace it if
Installation of steering angle sensor
Analyzer. necessary.
: Cam or steering wheel is defective.
: Turn the steering wheel to check the • Check the harness and repair or
Steering angle sensor harness
input signal. replace it if necessary.
: Wire breakage, short circuit,
leakage (harness or connector)
The steering is heavy.
(The pump motor operates normally Pump • Check the pump, and repair or
Material during material handling.) : Leak replace it if necessary.
handling and Priority valve • Check the priority valve, and repair
-
power steering : Leak, seizure or replace it if necessary.
PS valve • Check the PS valve, and repair or
: Leak, seizure replace it If necessary.
Main controller
- • Replace the Main controller.
: Internal failure
Display setting
Although ATT1 (ATT2) is operated, no : The serial number setting is not in Check the set value on the Option Set • Change the setting (see "MULTI
operation is performed. agreement with that of the vehicle. screen. DISPLAY FUNCTION")
(OCV WAY)
Backup buzzer main body
• Check the backup buzzer and
: Internal breakage
replace it if necessary.
Backup buzzer harness
- • Check the harness and repair or
: Wire breakage, short circuit or
replace it if necessary.
leakage (harness, connector or F5
• Replace the F5 fuse.
fuse)
The backup buzzer (option) does not
Auxiliary equipment relay main body
sound. • Check the auxiliary equipment relay
: Open failure
and replace it if necessary.
Auxiliary Auxiliary equipment relay harness -
• Check the harness and repair or
equipment : Wire breakage, short circuit,
replace it if necessary.
leakage (harness or connector)
Main controller
- • Replace the Main controller.
: Internal failure
Backup buzzer main body
• Check the backup buzzer and
: Internal breakage
The backup buzzer (option) does not replace it if necessary.
Backup buzzer harness -
stop sounding. • Check the harness and repair or
: Short circuit, leakage (harness or
replace it if necessary.
connector)

4-187
 Control

4-188
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Auxiliary equipment relay main body
• Check the auxiliary equipment relay
: Short circuit
and replace it if necessary.
Auxiliary equipment relay harness -
The backup buzzer (option) does not • Check the harness and repair or
: Short circuit, leakage (harness or
stop sounding. replace it if necessary.
connector)
Main controller
- • Replace the Main controller.
: Internal failure
Backup light main body
: Internal breakage, burnout of light • Check the backup light and replace
bulb it if necessary.
-
Backup light harness • Check the harness and repair or
: Wire breakage, short circuit, replace it if necessary.
leakage (harness or connector)
The backup light (option) does not go
Auxiliary equipment relay main body
on. • Check the auxiliary equipment relay
: Open failure
Auxiliary and replace it if necessary.
Auxiliary equipment relay harness --
equipment • Check the harness and repair or
: Wire breakage, short circuit,
replace it if necessary.
leakage (harness or connector)
Main controller
- • Replace the Main controller.
: Internal failure
• Check the backup light and replace
Main controller it if necessary.
-
: Internal failure • Check the harness and repair or
replace it if necessary.
Auxiliary equipment relay main body
The backup light (option) does not go • Check the auxiliary equipment relay
: Short circuit
out. and replace it if necessary.
Auxiliary equipment relay harness -
• Check the harness and repair or
: Short circuit, leakage (harness or
replace it if necessary.
connector)
Main controller
- • Replace the Main controller.
: Internal failure
 control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Stop light main body
: Internal breakage, burnout of light • Check the stop light and replace it if
bulb necessary.
-
Stop light harness • Check the harness and repair or
: Wire breakage, short circuit, replace it if necessary.
leakage (harness or connector)
Auxiliary equipment relay main body
• Check the auxiliary equipment relay
: Open failure
and replace it if necessary.
Auxiliary equipment relay harness -
• Check the harness and repair or
: Wire breakage, short circuit,
replace it if necessary.
The stop light (option) does not go on. leakage (harness or connector)
Brake sensor main body
Check the brake sensor voltage, using
: Internal failure
Analyzer.
Brake sensor installation portion • Check the sensor and replace it if
: Direction switch in neutral, drive
: The link or the installation portion is necessary.
fully closed
broken or damaged. • Check the harness and repair or
Fully open and close the brake
Brake sensor harness replace it if necessary.
cylinder valve to check the change
: Wire breakage, short circuit,
in voltage.
leakage (harness or connector)
Main controller
Auxiliary - • Replace the Main controller.
: Internal failure
equipment
Stop light main body
• Check the stop light and replace it if
: Internal breakage
necessary.
Stop light harness -
• Check the harness and repair or
: Short circuit, leakage (harness or
replace it if necessary.
connector)
Auxiliary equipment relay main body
• Check the auxiliary equipment relay
: Short circuit
and replace it if necessary.
Auxiliary equipment relay harness -
• Check the harness and repair or
: Short circuit, leakage (harness or
replace it if necessary.
connector)
The stop light (option) does not go out.
Brake sensor main body
Check the brake sensor voltage, using
: Internal failure
Analyzer.
Brake sensor installation portion • Check the sensor and replace it if
: Direction switch in neutral, drive
: The link or the installation portion is necessary.
fully closed
broken or damaged. • Check the harness and repair or
Fully open and close the brake
Brake sensor harness replace it if necessary.
cylinder valve to check the change
: Wire breakage, short circuit,
in voltage.
leakage (harness or connector)
Main controller

4-189
- • Replace the Main controller.
: Internal failure
 Control

4-190
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Display setting
: OPS operation notification buzzer Check the set value on the Option Set • Change the setting (see "MULTI
disabled screen. DISPLAY FUNCTION")
OPS operation warning does not (OPS BUZZER, SEAT BUZZER)
sound.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Display setting
: Return-to-neutral warning buzzer Check the set value on the Option Set • Change the setting (see "MULTI
disabled screen. DISPLAY FUNCTION")
The traveling OPS return-to-neutral (OPS BUZZER)
warning does not sound.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Display setting
: Return-to-neutral warning buzzer Check the set value on the Option Set • Change the setting (see "MULTI
Buzzer-related disabled screen. DISPLAY FUNCTION")
control The material handling OPS return-to- (OPS BUZZER)
neutral warning does not sound.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Check the parking brake switch, using
Parking brake switch main body Analyzer.
: Short circuit (The switch can also be checked by • Check the switch, and adjust or
Installation of parking brake switch checking if the parking indicator on the replace it if necessary.
: Switch is held down. display goes on and out.) • Check the harness and repair or
Parking brake switch harness : Direction switch is in neutral. replace it if necessary.
The parking brake release reminder : Short circuit (harness or connector) Operate the parking brake to see if
does not sound. the switch turns on and off normally.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Main controller
- • Replace the Main controller.
: Internal failure
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the parking brake switch, using
Parking brake switch main body Analyzer.
: Open failure (The switch can also be checked by • Check the switch, and adjust or
Installation of parking brake switch checking if the parking indicator on the replace it if necessary.
When the vehicle runs with the parking : Switch is off. display goes on and out.) • Check the harness and repair or
brake released, the parking brake Parking brake switch harness : Direction switch is in neutral. replace it if necessary.
release reminder sounds. : Wire breakage (harness, connecter) Operate the parking brake to see if
the switch turns on and off normally.
Main controller
- • Replace the Main controller.
: Internal failure
Display setting
: Parking brake reminder buzzer Check the set value on the Option Set • Change the setting (see "MULTI
disabled screen. DISPLAY FUNCTION")
(PKB BUZZER)
Buzzer-related Check the parking brake switch, using
control Parking brake switch main body Analyzer.
: Open failure (The switch can also be checked by • Check the switch, and adjust or
Installation of parking brake switch checking if the parking indicator on the replace it if necessary.
: Switch is off. display goes on and out) • Check the harness and repair or
Parking brake switch harness : Direction switch is in neutral. replace it if necessary.
The parking brake reminder does not : Wire breakage (harness, connecter) Operate the parking brake to see if
sound. the switch turns on and off normally.
Seat switch main body Check the seat switch, using Analyzer. • Check the seat and replace it if
: Short circuit : Check if the switch turns on and off necessary.
Seat switch harness normally, sitting in the seat or • Check the harness and repair or
: Short circuit (harness or connector) standing beside it. replace it if necessary.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Main controller
- • Replace the Main controller.
: Internal failure
 4-192
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Parking brake switch main body
Check the parking brake switch, using
: Short circuit • Check the switch, and adjust or
Analyzer.
Installation of parking brake switch replace it if necessary.
: Direction switch is in neutral.
: Switch is held down. • Check the harness and repair or
Operate the parking brake to see if
Parking brake switch harness replace It if necessary.
the switch turns on and off normally.
: Short circuit (harness or connector)
Although the parking brake lever is
Buzzer-related Check the seat switch, using Analyzer.
pulled up, the parking brake reminder
control Seat switch main body : Direction switch in neutral, drive • Check the seat and replace it if
does not stop sounding.
: Open failure fully closed necessary.
Seat switch harness Check if the switch turns on and off • Check the harness and repair or
: Wire breakage (harness, connecter) normally, sitting in the seat or replace it if necessary.
standing beside it.
Main controller
— • Replace the Main controller.
: Internal failure
Display setting
The height selector function setting Check the set value on the Option Set • Change the setting (see "MULTI
: Height selector function disabled
screen does not appear. screen. DISPLAY FUNCTION")
(H-SELECTOR)
Check the lifting height switch, using
Lifting height switch main body Analyzer.
• Check the switch, and replace it if
: Low lifting height is always detected. :ln NL
necessary.
Lifting switch harness Raise and lower the lift to its
Height selector • Check the harness and repair or
The lifting stop position cannot be set. : Wire breakage, short circuit uppermost and lowermost positions
(option) replace it if necessary.
(harness or connector) to see if the switch turns on and off
normally.
Main controller
- • Replace the Main controller.
: Internal failure
Display setting
No limit is placed on the maximum Check the set value on the lifting stop • Change the setting (see "MULTI
: The maximum lifting height is not be
lifting height. position setting screen. DISPLAY FUNCTION")
set.
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Display setting Check the set value on the lifting stop • Change the setting (see "MULTI
: The lifting height limit is not set. position setting screen. DISPLAY FUNCTION")
Check the lifting height limit switch,
Lifting height limit switch main body • Check the switch, and adjust or
Although the lifting height limit switch using Analyzer.
: Open failure replace it if necessary.
is pressed, no limit is placed on the : Vehicle stopped
Lifting height limit switch harness • Check the harness and repair or
lifting height. Operate the lifting height limit switch
: Wire breakage (harness, connecter) replace it if necessary.
to see if it turns on and off normally.
Main controller
- • Replace the Main controller.
: Internal failure
Check the lifting height limit switch,
Lifting height limit switch main body • Check the switch, and adjust or
using Analyzer.
: Short circuit replace it if necessary.
Although the lifting height limit switch : Vehicle stopped
Lifting height limit switch harness • Check the harness and repair or
is not pressed, a limit is placed on the Operate the lifting height limit switch
: Short circuit (harness or connector) replace it if necessary.
lifting height. to see if it turns on and off normally.
Height selector Main controller
(option) - • Replace the Main controller.
: Internal failure
Display setting
Check the set value on the lifting stop • Change the setting (see "MULTI
: The automatic lifting stop position is
position setting screen. DISPLAY FUNCTION")
not set.
Load display switch main body
: Open failure, short circuit
Mechanical detection unit of load Check the load display switch, using
Although the load display switch is • Check the switch, and adjust or
display switch Analyzer.
pressed, the automatic lifting stop replace it if necessary.
: Gap in detection unit is improperly : Vehicle stopped
position cannot be selected. • Check the harness and repair or
adjusted. Operate the load display switch to
replace it if necessary.
Load meter display switch harness see if it turns on and off normally.
: Wire breakage, short circuit
(harness or connector)
Main controller
- • Replace the Main controller.
: Internal failure

4-193
 Control

4-194
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
If the loading conditions, the tilt angle
of the mast, etc at that time are
different from those when the lifting - -
height was set, the fork stop position
may not agree with the set position.
Lifting height sensor main body
: Dragging or improper winding of
Check the lifting sensor voltage, using
wire
Analyzer.
Installation of lifting height sensor • Check the sensor and replace it if
The fork stop position is far away from : In NL
: Breakage of sensor installation necessary.
the lifting height set position (100 mm Raise and lower the lift to its
portion, breakage of wire routing • Check the harness and repair or
or more). uppermost (relief) and lowermost
Height selector portion replace it if necessary.
positions to check the change in the
(option) Lifting height sensor harness
voltage.
: Wire breakage, short circuit,
leakage (harness or connector)
Change over time of lifting sensor
Check the set value on the lifting stop • Change the setting (see "MULTI
detection unit
position setting screen. DISPLAY FUNCTION")
: No agreement with the vehicle state
Main controller
- • Replace the Main controller.
: Internal failure
• Check the positional relationship
The automatic lifting stop position
The automatic lifting stop position among automatic lifting stop
cannot be selected if the maximum
cannot be selected, although it was set - position, maximum lifting height and
lifting height or the lifting height limit is
for sure. lifting height limit, and set them
set below it.
properly.
Shock Display setting
The shock detection function setting Check the set value on the Option Set • Change the setting (see "MULTI
detection : Shock detection function disabled
screen does not appear. screen. DISPLAY FUNCTION")
(option) (SHOCK SENSOR)
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Way in which the vehicle collides
: The degree of shock that the shock
sensor receives vary depending on
the way and direction in which the
- -
vehicle collides and the object with
which it collides. The shock sensor
does not necessarily detect all kinds
of shock.
Display setting
• Change the setting (see "MULTI
: A too large (improper) value is set -
Although shock is applied, the shock DISPLAY FUNCTION")
for shock detection.
detection alarm does not go on.
Shock sensor main body
Check the voltages of shock sensors 1
: Sensitivity reduced
and 2, using Analyzer.
Installation of shock sensor • Check the sensor and replace it if
: Vehicle stopped 2.0 ± 0.21 V
: Improper installation (loosening), necessary.
Apply shock to each sensor to see if
interference • Check the harness and repair or
its voltage changes.
Shock sensor harness replace it if necessary.
(Compare the voltages of sensors 1
: Wire breakage, short circuit,
and 2.)
Shock leakage (harness or connector)
detection Main controller
- • Replace the Main controller.
(option) : Internal failure
• Change the setting.
Display setting
(Set a value that corresponds to
: A too small (improper) value is set -
shock unlikely to be applied during
for shock detection.
normal operation.)
Shock sensor main body
: Internal breakage (excessive
response)
Check the voltages of shock sensors 1
Installation of shock sensor
and 2, using Analyzer.
Although no shock is applied, the : Improper installation (loosening), • Check the sensor and replace it if
: Vehicle stopped 2.0 ± 0.21 V
shock detection alarm sets off. interference necessary.
Apply shock to each sensor to see if
Shock sensor harness • Check the harness and repair or
its voltage changes excessively.
: Wire breakage, short circuit, replace it if necessary.
(Compare the voltages of sensors 1
leakage (harness or connector)
and 2.)
(Especially if there are half-broken
wires in the harness, shock may be
detected frequently.)
Main controller
- • Replace the Main controller.
: Internal failure

4-195
 4-196
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
• Check the tires and replace them if
Tire main body necessary.
-
: Type, diameter, tire pressure • Check the pressure of each tire and
repair tires if necessary.
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
[Wheel indicator]
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
When the vehicle is running straight,
: Installation portion is broken or : Direction switch in neutral, drive necessary.
the wheel indicator does not show that
damaged. fully closed • Check the harness and repair or
it is running straight.
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
leakage (harness or connector)
Tire angle sensor straight running
Check the matching value on the
angle matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Multifunction [Wheel indicator] Display setting
Check the set value on the Option Set • Change the setting (see "MULTI
display Although the vehicle is stopped, the : Wheel indicator display setting
screen. DISPLAY FUNCTION")
wheel indicator is not displayed. (WHEEL IND)
One of the following matching
operations is not performed.
• Tire straight running angle matching * Change the setting.
• Forward tilt limit angle matching
• Tilt horizontal angle matching * If accelerator pedal fully closed and
• Tilt no-load matching fully open matching is finished by
[Spanner light] • Accelerator pedal fully closed simply performing fully closed
Check the matching value on the
Although no error code is displayed, matching matching and fully open matching in
Matching screen.
the Spanner light is left on. • Accelerator pedal fully open this order, the setting will not be
matching saved.
• Brake pedal fully closed matching
• Brake pedal actuation point * The same goes for brake pedal fully
matching closed and fully open matching.
• Mini-lever neutral voltage matching
• Tire diameter data
Load display switch main body
: Open failure
Check the load display switch, using
Mechanical detection unit of load • Check the switch, and adjust or
Multifunction [Load meter] Analyzer.
display switch replace it if necessary.
display Deluxe Although the load display switch is : Vehicle stopped
: Gap in detection unit is improperly • Check the harness and repair or
(option) pressed, the load is not displayed. Operate the load display switch to
adjusted. replace it if necessary.
see if it turns on and off normally.
Load meter display switch harness
: Wire breakage (harness, connecter)
 control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Display setting
On the Analyzer setting screen, check
[Load meter] : Cylinder diameter, mast type, zero­ Make each setting correctly.
if each setting is correct.
Although the load display switch is point adjustment
pressed, the load is not displayed. Main controller
- • Replace the Main controller.
: Internal failure
Load display switch main body
: Short circuit
Check the load display switch, using
Mechanical detection unit of load • Check the switch, and adjust or
Analyzer.
display switch replace it if necessary.
[Load meter] : Vehicle stopped
: Gap in detection unit is improperly • Check the harness and repair or
The load is always displayed during a Operate the load display switch to
adjusted. replace it if necessary.
stop. see if it turns on and off normally.
Load meter display switch harness
: Short circuit (harness or connecter)
Main controller
- • Replace the Main controller.
: Internal failure
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal breakage :ln NL
necessary.
Multifunction Load sensor harness Lower and raise the lift to its
• Check the harness and repair or
display Deluxe : Wire breakage, short circuit, lowermost and uppermost (relief)
replace it if necessary.
(option) leakage (harness or connector) positions to check the change in the
voltage.
Display setting
On the Analyzer setting screen, check • Change the setting (see "MULTI
[Load meter] : Cylinder diameter, mast type, zero­
if each setting is correct. DISPLAY FUNCTION")
The correct load is not displayed. point adjustment, calibration
• To measure the load correctly,
perform a measurement with the
The measurement conditions are not load lifted to a height of approx. 500
-
correct. mm, the mast raised to a vertical
position and both material handling
and traveling operations stopped.
Main controller
- • Replace the Main controller.
: Internal failure
• To measure the load correctly,
perform a measurement with the
[Load meter] The load is measured when it is lifted load lifted to a height of approx. 500
-
The reading blinks. high. mm, the mast raised to a vertical
position and both material handling
and traveling operations stopped.

4-197
 4-198
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the switch, and replace it if
:lnNL
[Load meter] detected. necessary.
Raise and lower the lift to its
The reading blinks. Lifting switch harness • Check the harness and repair or
uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
to see if the switch turns on and off
(harness or connector)
normally.
If the displayed load does not agree
with the carried load, perform the
- -
check described in the "The correct
[Load alarm] load is not displayed" section first.
Although a heavy load is carried, the Check the set value on the Option Set
The load meter is not displayed. Display the load meter.
load alarm does not go on. screen.
Display setting
Check the alarm set value on the • Change the setting (see "MULTI
: The load alarm set value is too
Administrator screen. DISPLAY FUNCTION")
large.
If the displayed load does not agree
with the carried load, perform the
- -
Multifunction check described in the "The correct
display Deluxe load is not displayed" section first.
(option) • The load alarm sets off if a load
heavier than the set load is detected
when the load meter is displayed.
The pressure applied to the lift
The load meter is displayed during cylinder increases during material
-
material handling operation. handling or traveling. Therefore, if
the load is displayed at that time, the
[Load alarm]
load alarm may go on even if the
Although the load is light, the load
actual load is lighter than the set
alarm goes on.
load.
• Change the setting.
* If "LOAD ALM" in Optional Set is set
to B using Analyzer function of the
Display setting
Check the alarm set value on the display, the load alarm will go on
: The load alarm set value is too
Administrator screen. when a load heavier than the set load
small.
Check the set value on the Option Set is detected even if the load meter is
The load alarm is set to Always ON.
screen. not displayed.
(LOAD ALM)
To activate the load alarm only when
the load is displayed, set "LOAD
ALM" to A.
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
[Load alarm]
When a heavy load is carried, the load
Display setting
alarm always sounds. Check the set value on the Option Set
: Load alarm setting • Change the setting.
(It sounds even when a screen other screen.
(LOAD ALM)
than the load display screen is
displayed.)
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is :ln NL replace It if necessary.
broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
[Tilt indicator] : Wire breakage, short circuit, change in voltage.
Multifunction
The correct tilt angle is not displayed. leakage (harness or connector)
display Deluxe
(option) Tilt angle sensor leveling matching
Check the matching value on the
value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
No problem if the tilt angle is 0° under
A load is carried. -
no-load conditions.
When a load is carried, the position
where the fork stops when automatic
[Tilt indicator] fork leveling is finished does not
The tilt angle is not indicated as 0° always agree with the position of the
A load is carried. -
when the automatic fork leveling is fork when its tilt angle is indicated as
finished. 0° on the tilt indicator, so the tilt angle
may not be indicated as 0°, depending
on the load.
• Check the tires and replace them if
Tire main body necessary.
-
: Type, diameter, tire pressure • Check the pressure of each tire and
repair tires if necessary.
The vehicle lacks stability during Lock cylinder main body
traveling. : Leakage, incapable of locking • Check the lock cylinder, and repair
Swing lock Check the lock cylinder, using Active
(The swing mechanism does not lock Installation of lock cylinder or replace it if necessary.
easily or at all during traveling.) Test.
: Installation portion is damaged or • Check the swing solenoid and
: Forcibly turn on (unlocked) and off
broken. replace it if necessary.
(locked) the swing solenoid to check
Swing solenoid harness • Check the harness and repair or
the state of the lock cylinder.
: Short circuit, leakage (harness or replace it if necessary.
connector)

4-199
 Control

4-200
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal breakage : In NL
necessary.
Load sensor harness Raise and lower the lift to its
• Check the harness and repair or
: Wire breakage, short circuit, uppermost (relief) and lowermost
replace it if necessary.
leakage (harness or connector) positions to check the change in the
voltage.
Check the lifting height switch, using
Lifting height switch main body Analyzer.
• Check the switch, and replace it if
: Low lifting height is always detected. :ln NL
necessary.
Lifting switch harness Raise and lower the lift to its
• Check the harness and repair or
: Wire breakage, short circuit uppermost and lowermost positions
replace it if necessary.
(harness or connector) to see if the switch turns on and off
normally.
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
The vehicle lacks stability during Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
traveling. : Installation portion is broken or : Direction switch in neutral, drive necessary.
Swing lock
(The swing mechanism does not lock damaged. fully closed • Check the harness and repair or
easily or at all during traveling.) Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
leakage (harness or connector)
Tire angle sensor straight running
Check the matching value on the
angle matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Main body of drive motor rotation
sensor
• Check the sensor and replace it if
: Internal failure
necessary.
Drive motor rotation sensor harness
- • Check the harness and repair or
: Wire breakage, short circuit,
replace it if necessary.
leakage (harness or connector)
• Replace the drive motor drive circuit.
Drive motor drive circuit
: Internal failure
Main controller
- • Replace the Main controller.
: Internal failure
 uoniroi
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

Lock cylinder main body • Check the lock cylinder, and repair
Check the lock cylinder, using Active
or replace it if necessary.
: Seizure of lock cylinder Test.
• Check the solenoid and replace it if
Swing solenoid harness : Forcibly turn on (unlocked) and off
necessary.
: Wire breakage, short circuit, (locked) the swing solenoid to check
• Check the harness and repair or
leakage (harness or connector) the state of the lock cylinder.
replace it if necessary.
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal breakage :ln NL
necessary.
Load sensor harness Raise and lower the lift to Its
• Check the harness and repair or
: Wire breakage, short circuit, uppermost (relief) and lowermost
replace it if necessary.
leakage (harness or connector) positions to check the change in the
voltage.
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the switch, and replace it if
:ln NL
detected. necessary.
Raise and lower the lift to its
Lifting switch harness • Check the harness and repair or
uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
to see if the switch turns on and off
(harness or connector)
The swing mechanism always locks normally.
Swing lock during traveling or material handling, Tire angle sensor main body
or it locks frequently. : Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
leakage (harness or connector)
Tire angle sensor straight running
Check the matching value on the
angle matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Main body of drive motor rotation
sensor
• Check the sensor and replace it if
: Internal failure
necessary.
Drive motor rotation sensor harness
- • Check the harness and repair or
: Wire breakage, short circuit,
replace it If necessary.
leakage (harness or connector)
Drive motor drive circuit • Replace the drive motor drive circuit.
: Internal failure
Main controller
-

4-201
• Replace the Main controller.
: Internal failure
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is :ln NL replace it if necessary.
broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
: Wire breakage, short circuit, change in voltage.
leakage (harness or connector)
Tilt angle sensor leveling matching
Check the matching value on the
value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
When tilted forward for leveling, the Main body of automatic fork leveling
fork does not stop automatically in a switch
Check the automatic fork leveling
horizontal position. : Open failure
switch, using Analyzer. • Check the switch, and replace it if
(The fork tilts to its forward tilt limit Mechanical detection unit of automatic
: Material handling lever in neutral necessary.
without stopping in a horizontal fork leveling switch
Operate the automatic fork leveling • Check the harness and repair or
position.) : Gap in detection unit is improperly
switch to see if it turns on and off replace it if necessary.
adjusted.
normally.
Automatic fork leveling switch harness
Tilt control : Wire breakage (harness, connecter)
Oil control valve Check the tilt control valve, using • Check the oil control valve, and
: Seizure of or leakage from tilt Active Test. repair or replace it if necessary.
control valve : Tilt solenoid forcibly turned off • Check the solenoid and replace it if
Tilt solenoid harness (forward tilting stopped) necessary.
: Short circuit, leakage (harness or Tilt the fork forward to check the • Check the harness and repair or
connector) operation. replace it if necessary.
Main controller
- • Replace the Main controller.
: Internal failure
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
When the fork tilted forward for : The link or the installation portion is :lnNL replace it if necessary.
leveling, it does not stop automatically broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
in a horizontal position. Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
(The fork does not stop in a horizontal : Wire breakage, short circuit, change in voltage.
position.) leakage (harness or connector)
Tilt angle sensor leveling matching
Check the matching value on the
value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal breakage :ln NL
necessary.
When the fork tilted forward for Load sensor harness Raise and lower the lift to its
• Check the harness and repair or
leveling, it does not stop automatically : Wire breakage, short circuit, uppermost (relief) and lowermost
replace it if necessary.
in a horizontal position. leakage (harness or connector) positions to check the change in the
(The fork does not stop in a horizontal voltage.
position.) Load sensor no-load matching value Check the matching value on the
• Perform matching again.
: No agreement with the vehicle state Matching screen.
Main controller
- • Replace the Main controller.
: Internal failure
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is :lnNL replace it if necessary.
broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
: Wire breakage, short circuit, change in voltage.
leakage (harness or connector)
Tilt angle sensor leveling matching
Tilt control Check the matching value on the
value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
When tilted forward for leveling, the Check the load sensor voltage, using
fork does not stop automatically in a Load sensor main body Analyzer.
• Check the sensor and replace it if
horizontal position. : Internal breakage :ln NL
necessary.
(When tilted forward for leveling, the Load sensor harness Raise and lower the lift to its
• Check the harness and repair or
fork stops where it is when the : Wire breakage, short circuit, uppermost (relief) and lowermost
replace it if necessary.
automatic fork leveling switch is leakage (harness or connector) positions to check the change in the
pressed.) voltage.
Load sensor no-load matching value Check the matching value on the
• Perform matching again.
: No agreement with the vehicle state Matching screen.
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the switch, and replace it if
:ln NL
detected. necessary.
Raise and lower the lift to its
Lifting switch harness • Check the harness and repair or
uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
to see if the switch turns on and off
(harness or connector)
normally.
Main controller
- • Replace the Main controller.

4-203
: Internal failure
 4-204
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is :ln NL replace it if necessary.
broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
: Wire breakage, short circuit, change in voltage.
leakage (harness or connector)
When the fork is tilted backward for Tilt angle sensor leveling matching
Check the matching value on the
leveling, it does not stop automatically value • Perform matching again
Matching screen.
in a horizontal position. : No agreement with the vehicle state
(The fork tilts to its backward tilt limit Main body of automatic fork leveling
without stopping in a horizontal switch
position.) Check the automatic fork leveling
: Open failure
switch, using Analyzer. • Check the switch, and replace it if
Mechanical detection unit of automatic
: Material handling lever in neutral necessary.
fork leveling switch
Operate the automatic fork leveling • Check the harness and repair or
: Gap in detection unit is improperly
switch to see if it turns on and off replace it if necessary.
adjusted.
normally.
Automatic fork leveling switch harness
: Wire breakage (harness, connecter)
Tilt control Main controller
- • Replace the Main controller.
: Internal failure
When the fork is tilted backward for
See "When the fork is tilted forward for
leveling, it does not stop automatically
leveling, it does not stop automatically
in a horizontal position. - -
in a horizontal position (The fork does
(The fork does not stop in a horizontal
not stop in a horizontal position.)"
position.)
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is :ln NL replace it if necessary.
When the fork is tilted backward for broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
leveling, it does not stop automatically Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
in a horizontal position. : Wire breakage, short circuit, change in voltage.
(The fork stops where it is when the leakage (harness or connector)
automatic fork leveling switch is
Tilt angle sensor leveling matching
pressed.) Check the matching value on the
value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Main controller
- • Replace the Main controller.
: Internal failure
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Main body of automatic fork leveling
switch
Check the automatic fork leveling
: Open failure
switch, using Analyzer. • Check the switch, and replace it if
Mechanical detection unit of automatic
: Material handling lever in neutral necessary.
fork leveling switch
Operate the automatic fork leveling • Check the harness and repair or
: Gap in detection unit is improperly
switch to see if it turns on and off replace it if necessary.
adjusted.
normally.
Automatic fork leveling switch harness
: Wire breakage (harness, connecter)
Check the tilt control valve, using • Check the oil control valve, and
Oil control valve
Active Test. repair or replace it if necessary.
: Seizure of tilt control valve
The mast backward tilting speed is not Tilt solenoid harness : Tilt solenoid forcibly turned on • Check the solenoid and replace it if
limited. (backward tilting speed limited) necessary.
: Wire breakage, short circuit,
Tilt the mast backward to check the • Check the harness and repair or
leakage (harness or connector)
operation. replace it if necessary.
Check the lifting height switch, using
Lifting height switch main body Analyzer.
• Check the switch, and replace it if
: Low lifting height is always detected. :lnNL
necessary.
Lifting switch harness Raise and lower the lift to its
• Check the harness and repair or
Tilt control : Wire breakage, short circuit uppermost and lowermost positions
replace it if necessary.
(harness or connector) to see if the switch turns on and off
normally.
Main controller
- • Replace the Main controller.
: Internal failure
Main body of automatic fork leveling
switch
Check the automatic fork leveling
: Short circuit
switch, using Analyzer. • Check the switch, and replace it if
Mechanical detection unit of automatic
: Material handling lever in neutral necessary.
fork leveling switch
Operate the automatic fork leveling • Check the harness and repair or
: Gap in detection unit is improperly
switch to see if it turns on and off replace it if necessary.
adjusted.
The mast backward tilting speed is normally.
Automatic fork leveling switch harness
always slow. : Short circuit (harness or connecter)
Oil control valve Check the tilt control valve, using • Check the oil control valve, and
: Seizure of or leakage from tilt Active Test. repair or replace it if necessary.
control valve : Tilt solenoid forcibly turned off • Check the solenoid and replace it if
Tilt solenoid harness (backward tilting speed not limited) necessary.
: Short circuit, leakage (harness or Tilt the mast backward to check the • Check the harness and repair or
connector) operation. replace it if necessary.
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the switch, and replace it if
:lnNL
detected. necessary.
Raise and lower the lift to its
The mast backward tilting speed is Lifting switch harness • Check the harness and repair or
uppermost and lowermost positions
always slow. : Wire breakage, short circuit replace it if necessary.
to see if the switch turns on and off
(harness or connector)
normally.
Main controller
• Replace the Main controller.
: Internal failure
Display setting
Check the set value on the Option Set • Change the setting
: Forward tilting speed setting
screen. (see "MULTI DISPLAY FUNCTION")
(T F-SPD LIM)
Check the lifting height switch, using
Lifting height switch main body Analyzer.
Although the load is lifted high, the • Check the switch, and replace it if
: Low lifting height is always detected. :ln NL
Tilt control mast forward tilting speed is not necessary.
Lifting switch harness Raise and lower the lift to its
limited. • Check the harness and repair or
: Wire breakage, short circuit uppermost and lowermost positions
replace It if necessary.
(harness or connector) to see if the switch turns on and off
normally.
Main controller
• Replace the Main controller.
: Internal failure
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the switch, and replace it If
:lnNL
detected. necessary.
Raise and lower the lift to its
The mast forward tilting speed is Lifting switch harness • Check the harness and repair or
uppermost and lowermost positions
always slow. : Wire breakage, short circuit replace It if necessary.
to see if the switch turns on and off
(harness or connector)
normally.
Main controller
- • Replace the Main controller.
: Internal failure
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
The knob is displaced from its normal damaged. fully closed • Check the harness and repair or
Knob position
position to a certain position. Tire angle sensor harness Turn the steering wheel and check replace It if necessary.
compensation
(10° or more from the straight running : Wire breakage, short circuit, the change in voltage.
control
position) leakage (harness or connector)
Tire angle sensor straight running
Check the matching value on the
angle matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Main body of steering angle sensor
: Internal damage
Check the steering angle sensor, using • Check the sensor and replace it if
Installation of steering angle sensor
Analyzer. necessary.
: Cam or steering wheel is defective.
: Turn the steering wheel to check the • Check the harness and repair or
Steering angle sensor harness
input signal. replace it if necessary.
: Wire breakage, short circuit,
leakage (harness or connector)
Check the knob position compensation
The knob is displaced from its normal valve, using Active Test.
Knob position compensation valve • Check the knob position
position to a certain position. : Tire end
main body compensation valve, and repair or
(10° or more from the straight running Forcibly turn on (bypass) and off (no
: Leakage, seizure (internal damage) replace it if necessary.
position) bypass) the knob position
Knob position compensation solenoid • Check the solenoid and replace it if
compensation solenoid to check
harness necessary.
how the steering system operates.
: Wire breakage, short circuit, • Check the harness and repair or
Forcibly ON ... Steering idles (light).
leakage (harness or connector) replace it if necessary.
Forcibly OFF ... Steering does not
idles (heavy).
The road surface is inclined. - -
Knob position
Main controller
compensation - • Replace the Main controller.
: Internal failure
control
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
The knob is displaced from its normal leakage (harness or connector)
position. Tire angle sensor straight running
Check the matching value on the
(The knob position is not constant angle matching value • Perform matching again.
Matching screen.
during straight running.) : No agreement with the vehicle state
Main body of steering angle sensor
: Internal damage
Check the steering angle sensor, using • Check the sensor and replace it if
Installation of steering angle sensor
Analyzer. necessary.
: Cam or steering wheel is defective.
: Turn the steering wheel to check the • Check the harness and repair or
Steering angle sensor harness
input signal. replace it if necessary.
: Wire breakage, short circuit,
leakage (harness or connector)
 4-208
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the knob position compensation
valve, using Active Test.
Knob position compensation valve • Check the knob position
: Tire end
main body compensation valve, and repair or
Forcibly turn on (bypass) and off (no
: Leak, seizure replace it if necessary.
bypass) the knob position
Knob position compensation solenoid • Check the solenoid and replace it if
The knob is displaced from its normal compensation solenoid to check
Knob position
harness necessary.
position. how the steering system operates.
compensation : Wire breakage, short circuit, • Check the harness and repair or
(The knob position is not constant Forcibly ON ... Steering idles (light).
control leakage (harness or connector) replace it if necessary.
during straight running.) Forcibly OFF ... Steering does not
idles (heavy).
PS cylinder system link is defective. • Check the cylinder, and repair or
-
: Eccentric pin or kingpin is defective replace it if necessary.
Main controller
- • Replace the Main controller.
: Internal failure
Check the seat switch, using Analyzer.
Seat switch main body : Direction switch in neutral, drive • Check the switch, and replace it if
: Short circuit fully closed necessary.
Neither traveling OPS nor material Seat switch harness Check if the switch turns on and off • Check the harness and repair or
handling OPS operates. : Short circuit (harness or connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Main controller
- • Replace the Main controller.
: Internal failure
Drive motor drive circuit
- • Replace the drive motor drive circuit.
: Internal failure
Only traveling OPS does not operate.
Main controller
- • Replace the Main controller.
OPS : Internal failure
Oil control valve Check the tilt control valve, using • Check the oil control valve, and
: Seizure of or leakage from tilt Active Test. repair or replace it if necessary.
control valve : Tilt solenoid forcibly turned off • Check the solenoid and replace it if
Tilt solenoid harness (forward tilting stopped) necessary.
: Short circuit, leakage (harness or Tilt the fork forward to check the • Check the harness and repair or
Only material handling OPS does not connector) operation. replace it if necessary.
operate. Oil control valve • Check the oil control valve, and
Check the lift lowering lock valve,
: Seizure of or leakage from lift repair or replace it if necessary.
using Active Test.
lowering lock valve • Check the solenoid and replace it if
: Lift lock solenoid forcibly turned off
Lift lock solenoid harness necessary.
(lift lock)
: Short circuit, leakage (harness or • Check the harness and repair or
Lower the lift to check the operation.
connector) replace it if necessary.
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Oil control valve
• Check the oil control valve, and
: Seizure of or leakage from material
repair or replace it if necessary.
handling proportional valve
• Check the material handling
: Seizure of or leakage from unload
proportional valve solenoid, and
valve
- replace it if necessary.
Only material handling OPS does not Hamess of material handling
OPS • Check the unload valve solenoid
operate. proportional valve solenoid
and replace it if necessary.
Hamess of unload valve solenoid
• Check the harness and repair or
: Wire breakage, short circuit,
replace it if necessary.
leakage (harness or connector)
Main controller
- • Replace the Main controller.
: Internal failure
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal breakage :ln NL
necessary.
Load sensor harness Raise and lower the lift to its
• Check the harness and repair or
: Wire breakage, short circuit, uppermost (relief) and lowermost
replace it if necessary.
leakage (harness or connector) positions to check the change in the
voltage.
Display setting
: The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI
agreement with the data on the Matching screen. DISPLAY FUNCTION")
Traveling Although no load is applied, the speed actual vehicle state.
control (option) is limited when the lift is raised high. • In traveling control, the attachment
weight and the mast weight are
treated as part of the load weight,
because they affect the longitudinal
stability of the vehicle. For a very
Heavy attachment, mast with a high
- heavy mast or an FSW or FW mast
lifting height
with a high lifting height, if its inner
middle mast is rather heavy, a limit
may sometimes be placed on the
speed even under no-load
conditions.

4-209
 4-210
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
When the lift is raised to its uppermost
position, the load sensor cannot
distinguish this situation from a
situation in which a heavy load is
carried, because, in that situation, a
relief pressure remains in the lift
- -
Although no load is applied, the speed cylinder pressure that the load sensor
is limited when the lift is raised high. senses.
After a lift relief, however, it becomes
possible to perform operation because
the relief pressure is discharged when
the lift is lowered even a little.
Main controller
- • Replace the Main controller.
: Internal failure
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal breakage :ln NL
necessary.
Load sensor harness Raise and lower the lift to its
• Check the harness and repair or
: Wire breakage, short circuit, uppermost (relief) and lowermost
Traveling replace it if necessary.
leakage (harness or connector) positions to check the change in the
control (option) voltage.
Check the lifting height switch, using
Lifting height switch main body Analyzer.
• Check the switch, and replace it if
: Low lifting height is always detected. :ln NL
necessary.
Lifting switch harness Raise and lower the lift to its
• Check the harness and repair or
: Wire breakage, short circuit uppermost and lowermost positions
Although a load is carried, the speed is replace it if necessary.
(harness or connector) to see if the switch turns on and off
not limited when the lift is raised high. normally.
Display setting
¡Traveling control setting disabled
Check the set value on the Option Set • Change the setting (see "MULTI
Load sensing speed restriction
screen. DISPLAY FUNCTION")
disabled
(ASC W/LOAD, MODE)
Display setting
: The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI
agreement with the data on the Matching screen. DISPLAY FUNCTION")
actual vehicle state.
Main controller
- • Replace the Main controller.
: Internal failure
 Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
: A high lifting height is always ■ Check the switch, and replace it if
:lnNL
detected. necessary.
Although the fork is not raised high, Raise and lower the lift to its
Lifting switch harness • Check the harness and repair or
the speed is limited when a load is uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
carried. to see if the switch turns on and off
(harness or connector)
normally.
Main controller
Traveling - • Replace the Main controller.
: Internal failure
control (option)
Display setting • Change the setting (see "MULTI
Check the set value.
: Maximum speed limit is set very low. DISPLAY FUNCTION")
Display setting
A limit is always placed on the speed
: The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI
regardless of whether a load is carried
agreement with the data on the Matching screen. DISPLAY FUNCTION")
or not.
actual vehicle state.
Main controller
- • Replace the Main controller.
: Internal failure
Display setting
Check the set value on the Option Set • Change the setting (see "MULTI
: Turning control setting
screen. DISPLAY FUNCTION")
(TURN SPEED)
Check the set value of Turning
Display setting • Change the setting (see "MULTI
General No.21 on the Tuning screen of
: Setting of Turning General No.21 DISPLAY FUNCTION")
Analyzer.
Display setting
: The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI
agreement with the data on the Matching screen. DISPLAY FUNCTION")
actual vehicle state.

Turn control Tire angle sensor main body

The speed is not limited during a turn. : Internal failure Check the sensor voltage, using
(For 3W only)
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
leakage (harness or connector)
Tire angle sensor straight running
Check the matching value on the
angle matching value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
Main controller
- • Replace the Main controller.
: Internal failure
 4-212
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Check the set value of Turning
Display setting • Change the setting (see "MULTI
General No.21 on the Tuning screen of
: Setting of Turning General No.21 DISPLAY FUNCTION")
Analyzer.
Turn control The speed is excessively limited Display setting
(For 3W only) during a turn. : The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI
agreement with the data on the Matching screen. DISPLAY FUNCTION")
actual vehicle state.
The steering wheel was turned quickly. - • Avoid quick steering.
 5-1

MOTOR
Page
DRIVE MOTOR........................................................... 5-2
GENERAL..........................................................................5-2
SPECIFICATIONS............................................................. 5-2
COMPONENTS..................................................................5-3
DISASSEMBLYINSPECTIONREASSEMBLY............... 5-5
PUMP MOTOR........................................................... 5-9
GENERAL.......................................................................... 5-9
SPECIFICATIONS............................................................. 5-9
COMPONENTS............................................................... 5-10
REMOVAL-INSTALLATION........................................... 5-11
DISASSEMBLYINSPECTIONREASSEMBLY.............5-15
5-2

DRIVE MOTOR
GENERAL

SPECIFICATIONS
Nominal Body size
Rated Output Weight
Models Voltage Type Diameter x Length IP
(kW) (kg)
(V) (mm)
8FBET15, 16, 18, 20
RH: 65
STD

8FBEKT16, 18 30 6.6 Three phase AC 4>2OO x 241 20

LH: 72
8FBMT15, 16, 18, 20
Fisherman

8FBET15, 16, 18, 20

RH: 66
8FBEKT16, 18 30 4.2 Three phase AC <|>200 x 241 54
LH: 73
8FBMT15, 16, 18, 20
 5-3

COMPONENTS
1401

1401-184
5-4

1401

1401-185A
 5-5

MSASSEMBLY-INSPECTION-REASSEMBLY
T = N m (kgf-cm) [ft-lbf]

42.5 (433.5)[31.3]
5-6

Disassembly Procedure
1. Remove the front axle assy. (See page 6-14)
2. Remove the rpm sensor cover.
3. Remove the rpm sensor and harness.
4. Remove the temperature sensor with clamp.
5. Remove the terminal cover.
6. Remove the spring pin, stator and piston ASSY. (See page 9-6)
7. Remove the motor gear.
8. Remove the front axle bracket w/drive unit ASSY.
9. Remove the rotor ASSY. [Point 1]
10. Remove the bracket and bearing.
11. Remove the oil seal and bearing. [Point 2]
12. Inspect the stator ASSY. [Point 3]

Reassembly Procedure
1. Install the bearing. [Point 4]
2. Install the oil seal.
3. Install the bracket and bearing.
4. Install the rotor ASSY. [Point 5]
5. Install the front axle bracket w/drive unit ASSY.
6. Install the motor gear.
7. Install the spring pin, stator and piston ASSY (See page 9-6)
8. Install the terminal cover.
9. Install the temperature sensor with clamp.
10. Install the rpm sensor and harness.
11. Install the rpm sensor cover.
12. Install the front axle assy. (See page 6-14)
 5-7

Point Operations
[Point 1]
Disassembly:
Use the brass bar to remove the rotor ASSY.

[Point 2]

Disassembly:
1. Use the screw driver to remove the oil seal.

2. Use the SST to remove the bearing.

SST 09950-76018-71 (09950-60010)........ (1)
09950-76020-71 (09950-70010)........ (2)

[Point 3]
Inspection:

1. Measure the insulation resistance of the stator ASSY.

Measurement terminals: between motor cable and body

Standard: 1 MQ or more

2. Check continuity between motor cables.

Measurement terminals: U-V, V-W, W-U
Standard: 0 Q
5-8

3. Measure the resistance of the thermo-sensor.

Measurement terminals:
Both terminals of temperature sensor
connector
Standard: 11 to 15 KQ (at 20 °C)

[Point 4]
Reassembly:
Use the SST to installation the bearing and oil seal.
SST 09950-76019-71 (09950-60020)....... (1)
09950-76020-71 (09950-70010)....... (2)

[Point 5]
Reassembly:
Use the SST to installation the rotor ASSY.
SST 09150-10920-71
 5-9

3UMP MOTOR
3ENERAL

SPECIFICATIONS
Nominal Body size
Rated Output Weight
Models Voltage Type Diameter x Length IP
(kW) (kg)
(V) (mm)
8FBET15, 16, 18, 20
STD

8FBEKT16, 18 29 11.7 Three phase AC <1)176 x 285 33 20

8FBMT15, 16, 18, 20
Fisherman

8FBET15, 16, 18, 20

8FBEKT16, 18 29 7.0 Three phase AC $176x285 33 54
8FBMT15, 16, 18, 20
5-10

COMPONENTS

1402

1402-156

1402

1402-157A
 5-11

REMOVAL-INSTALLATION
T = N m (kgf-cm) [ft-lbf]

Removal Procedure
I. Remove the battery ASSY. (See page 1-5)
Remove the toe board (FR, RR).

3. Remove the front battery panel.

I. Remove the front lower battery panel.

5. Pump the hydraulic oil. [Point 1]

5. Remove the accelerator pedal and brake pedal with the relevant linkages.
r. Disconnect the OCV wiring harness.

3. Remove the fixing brackets of the OCV hoses/pipes.

3. Remove the hoses/pipes from the OCV. [Point 2]

10. Sling the OCV bracket by belts.

II. Unscrew the fixing bolts of the OCV and remove it.
12. Disconnect the piping of the priority valve piping. [Point 3]
13. Disconnect the pump motor wiring and cables.

14. Disconnect the oil pump hoses (suction hose). [Point 4]

 5-12

15. Sling the pump motor by belt.

16. Unscrew the fixing nuts of the pump motor.

17. Remove the priority valve and the inlet pipe from the oil pump ASSY.

18. Lift and remove the pump motor w/oil pump from the chassis.

19. Remove the oil pump.

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

Note:
Apply grease to the spline section of the pump before installation.
 5-13

Point Operations
[Point 1]
Removal:
1. Remove the ring (A) fitted at the base of the gage by inserting
a screwdriver into the opening.
2. Remove the level gage (B).
3. Remove the filter (C).
4. Pump the hydraulic oil.
POINT 2]
istallation:
Tightening torque: A: 32 to 34 Nm (326 to 347 kgf-cm) [23.6 to 25.1 ft-lbf]
B: 59 N-m
5-14

[Point 3]
Inspection:
Tightening torque: A: 34 N-m
B: 59 N-m
C: 34 N-m

[Point 4]
Inspection:
1. Install the suction hose clamp as shown in the illustration.

2. Make sure the marking on the suction hose is pointing.

 5-15

DISASSEMBLY-INSPECTION-REASSEMBLY
T = N-m (kgf-cm) [ft-lbf]

disassembly Procedure
Remove the temperature sensor clamp .
Remove the sensor cover.
I. Remove the rpm sensor.
k Remove the rpm sensor gear.
>. Remove the snap ring.
>. Remove the bolt.
Remove the housing set bolt.
k Remove the end frame. [Point 1]
>. Remove the rotor ASSY.
0. Remove the bearing. [Point 2]
1. Inspect stator ASSY. [Point 3]

Reassembly Procedure
"he reassembly procedure is the reverse of the disassembly procedure.
5-16

Point Operations
[Point 1]
Disassembly:
Use the SST to remove the end frame.
SST 09950-76014-71 (09950-40011)......... (1)
09140-10920-71.................................... (2)

[Point 2]
Disassembly:
Use the SST to remove the bearing.
SST 09950-76014-71(09950-40011) ......... (1)
09950-76018-71 (09950-60010)......... (2)

[Point 3]
Inspection:
1. Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and body
Standard: 1 MQ or more

2. Check continuity between motor cables.

Measurement terminals: U-V, V-W, W-U

Standard: 0 fl

3. Measure the resistance of the thermo-sensor.

Measurement terminals:
Both terminals of temperature sensor
connector

Standard: 11 to 15 kfl (at 20 °C)

 6-1

DRIVE UNIT & FRONT AXLE

Page
GENERAL................................................................. 6-2
SPECIFICATIONS................................................... 6-3
COMPONENTS........................................................6-4
DRIVE UNIT ASSY.................................................. 6-5
REMOVALINSTALLATION............................................. 6-5
DISASSEMBLYINSPECTIONREASSEMBLY ............... 6-7
FRONT AXLE ASSY............................................. 6-14
REMOVAL-INSTALLATION........................................... 6-14
6-2

GENERAL

o
 6-3

SPECIFICATIONS
;W:
"'--^Vehicle models 8FBET15 8FBEKT16
tern STD S/D CABIN S/D+CABIN STD S/D CABIN S/D+CABIN
"rant tire size 18x7-8 4- <- 4- 18x7-8 <- <- 4-

Rim size 4.33R-8 <- 4- 4.33R-8 4- 4- <—

Rim type SIT <— 4- 4
* SIT <- 4- 4-

^\Vehicle models 8FBET16 8FBEKT18

tern STD S/D CABIN S/D+CABIN STD S/D CABIN S/D+CABIN
=ront tire size 18x7-8 4- <— 4- 18x7-8 205/50-10 <- <—
Rim size 4.33R-8 <- 4- 4- 4.33R-8 6.50F-10 4- 4-

Rim type SIT 4- 4- 4- SIT <- 4- 4-

-^^Vehicle models 8FBET18 8FBET20

tern STD S/D CABIN S/D+CABIN STD S/D CABIN S/D+CABIN
-rant tire size 205/50-10 4- 4- 4- 205/50-10 4- 4- 4-
Rim size 6.50F-10 4- 4- 4- 6.50F-10 <- 4- 4-
Rim type SIT 4- 4- 4- SIT <- 4- 4-

W:
"■■\Vehicle models 8FBMT15 8FBMT16
tern STD S/D CABIN S/D+CABIN STD S/D CABIN S/D+CABIN
-rant tire size 18x7-8 <- 4- 4- 18x7-8 4- <- 4-

Rim size 4.33R-8 4- — 4- 4.33R-8 4- 4- <-

Rim type SIT 4- 4- <— SIT 4- 4- 4-

"-^Vehicle models 8FBMT18 8FBMT20

tern STD S/D CABIN S/D+CABIN STD S/D CABIN S/D+CABIN
-rant tire size 205/50-10 <- 4- <— 205/50-10 4- 4- 4-
Rim size 6.50F-10 4— 4- 4- 6.50F-10 4- 4- 4-
Rim type SIT 4- 4- 4- SIT <- 4- 4-
6-4

COMPONENTS
4201

13
I

4201
 6-5

DRIVE UNIT ASSY

REMOVAL INSTALLATION
T=N-m (kgf-cm) [ft-lbf]

(1,200 to 2,000)
[86.8 to 144.7]

Removal Procedure
l. Jack up the vehicle and remove the front wheels. [Point 1]
’. Drain the gear oil. [Point 2]
J. Remove the front axle hub. [Point 3]
k Remove the drive unit ASSY.

retaliation Procedure
rhe installation procedure is the reverse of the removal procedure,
type and quantity of gear oil:
STD
Type TOYOTA genuine oil: ATF type T-4
Cold storage type
Quantity 0.43/(0.11 US gal)

type of grease:
STD
MP grease
Cold storage type
6-6

Point Operations
[Point 1]
Removal:
Always jack up the vehicle at the jack-up point. Jacking up the
vehicle at other location is very dangerous.
Always support the load of jacked-up vehicle with wooden
blocks at specified points.

[Point 2]
Installation:
After installation, fill hypoid gear oil till the specified level.

A=10 mm (0.39 in) or less

[Point 3]
Removal:
SST 09950-76014-71 (09950-40011)

Inspection:
Measure the front axle hub starting force.
Models Standard
27.2 to 62.9 (2.8 to 6.4)
8FBET, 8FBMT
[6.0 to 14.1]

[Point 4]
Installation:
For installation, apply gasket sealant to the mating face with
the drive unit. Be sure to remove the grease on the face.

Selant: 08826-76002-71 (08826-00080)

 6-7

JISASSEMBLYINSPECTIONREASSEMBLY
T=N-m (kgf-cm) [ft-lbf]

disassembly Procedure
. Remove the front axle hub. (See page 6-5)
Remove the mission cover.
k Remove the internal gear. [Point 1]
I. Remove the idle gear bearing. [Point 2]
>. Remove the planetary gear. [Point 3]
k Remove the axle shaft bearing. [Point 4]
Remove the front axle hub bearing. [Point 5]
k Remove the coIler. [Point 6]
k Remove the outer race and inner race. [Point 7]

Reassembly Procedure
I. Install the idle gear bearing. [Point 8]
!. Install the planetary gear.
k Install the axle shaft bearing. [Point 9]
k Install the internal gear.
>. Measure the backlash of planetary gear. [Point 10]
k Install the outer race and inner race. [Point 11]
r. Install the outer seal. [Point 12]
k Install the axle hub. [Point 13]
). Install the axle shaft. [Point 14]
IO. Install the coller. [Point 15]
II. Adjustment preload torque of axle hub. [Point 16]
12. Staking of axle lock nut. [Point 17]
13. Install the axle hub cap. [Point 18]
14. Install the drive unit ASSY. (See page 6-5) [Point 19]
6-8

Point Operations
[Point 1]

Disassembly:
Use the SST to remove the internal gear.
SST 09950-76014-71 (09950-40011)........ (1)
09950-76019-71 (09950-60020)........ (2)

[Point 2]
Disassembly:
1. Use the SST to remove the inner bearing.
SST 09950-76014-71 (09950-40011)........ (1)
09950-76018-71 (09950-60010)........ (2)

2. Use the SST to remove the outer bearing.

SST 09950-76014-71 (09950-40011)........ (1)
09950-76018-71 (09950-60010)........ (2)

[Point 3]

Disassembly:
Use the SST to remove the planetary gear.

SST 09905-76002-71 (09905-00012)

[Point 4]

Disassembly:
Use the SST and hand press to remove the axle shaft bearing.
SST 09420-23002-71
 6-9

[Point 5]
Disassembly:
Use the SST and hand press to remove the axle hub bearing.
SST 09420-23002-71

[Point 6]
Disassembly:
Use the SST to remove the coIler.
SST 09700-30200-71

[Point 7]
Disassembly:

1. Use the SST to remove the outer race.

SST 09700-30200-71

2. Use the SST to remove the inner race.

SST 09700-30200-71
6-10

[Point 8]

Reassembly:
1. Use the SST to install the inner bearing.
SST 09411-41800-71

2. Use the SST to install the outer bearing.

SST 09223-76005-71 (09223-46011)

[Point 9]
Reassembly:
Use the SST to install the axle shaft bearing.
SST 09410-26600-71

[Point 10]
Inspection:
Measure the backlash of the planetary gear, idle gear and ring
gear.

Standard: 0.2mm (0.008 in.) or less

 6-11

[Point 11]
Reassembly:

1. Use the SST to install the inner race.

SST 09331-13240-71..................................... (1)
09950-76020-71 (09950-70010)......... (2)

2. Use the SST to install the outer race.

SST 09331-13240-71..................................... (1)
09950-76020-71 (09950-70010)......... (2)

[Point 12]

Reassembly:
Use the SST to install the oil seal.
SST 09700-30200-71

Note:
Drive in an oil seal up to the position shown in the figure on
the left.

Standard A: 3.5 ± 0.5 mm (0.14 ± 0.02 in.)

6-12

[Point 13]
Reassembly:
Before mounting the axle hub, apply MP grease to the portions
shown in the figure.
SST 09420-13130-71
Note:
Be careful not to allow SST to touch the inner or outer race of
the bearing.

1. Use the SST and hand press to install the axle hub.
SST 09420-13130-71..................................... (1)
09950-76019-71 (09950-60020)......... (2)

[Point 14]
MP gease
Reassembly:
1. Before mounting the axle hub, apply MP grease to the portions
yn shown in the figure.

5
2. Install the washer and hub nut.

JL y □feu
[Point 15]
Reassembly:
1. Use the SST to Install the coIler.
SST 09700-30200-71
Standard A: 0.5 5 mm (0.02 02 in.)
 6-13

[Point 16]
Inspection:
1. Tighten the hub nut to 36.5 Nm (372 kgf cm) [27 ft-lbf].
2. Turn the hub nut 4 or 5 turns to break in the bearing.
3. Tighten the hub nut to 215 N m (2,193 kgf-cm) [159ftbf].
4. Turn the hub nut 4 or 5 turns to break in the bearing.
5. Measure the starting power with a spring scale. Adjust the hub
nut to bring the starting power into the standard range.
Standard: 27.2 to 62.9 N (2.8 to 6.4 kg) [6.17 to 14.1 Ibf]
Note:
• Perform these measurements without mounting either the
internal gear or the retainer.
• If the starting power is outside the standard range, make
an adjustment with a shim.
• When loosing the hub nut, first loose it a little more than
necessary by hammering the hub lightly, and then turn it
in the tightening direction to adjust the tightness.

[Point 17]
Reassembly:
Caulk the hub nut with a pin punch and a chisel.
Limit: A: 1mm (0.04 in.) or less
B: Approx. 5 mm (0.2 in.)
Note;
To avoid cracking, bend the edge carefully around the corner.

[Point 18]
Reassembly:
1. Apply MP grease to the portions shown in the figure.
2. Press-fit the hub cap to the position shown in the figure.
Limit A: 0.5 Tj.s mm (0 02 02 in.)

[Point 19]
Installation:
For installation, apply gasket sealant to the mating face with
the drive unit. Be sure to remove the grease on the face.
Selant: 08826- 76002-71 (08826-00080)
Note:
Be sure to apply grease from the starting point in the direction
shown by the arrow.
6-14

FRONT AXLE ASSY

REMOVAL-INSTALLATION
T=N-m(kgf-cm)[ft-lbf]

Removal Procedure
1. Disconnect the battery plug.

2. Remove the mast ASSY. (See page 12-6)

3. Jack up the vehicle and remove front wheels. [Point 1]

4. Remove the toe board.

5. Remove the accelerator pedal and the brake pedal with the relevant linkages.

6. Disconnect the power cables (RH,LH) from front axle ASSY.

7. Disconnect the parking brake cable.

8. Disconnect the main connector of the speed sensor and temperature sensor of motors wire harness.

9. Remove the drive motor w/drive unit ASSY. [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 6-15

Point Operations
[Point 1]
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 2]
Removal:
1. Put the wood blocks (A) under the drive unit on the RH/LH side
and also put the wood block (B) under the drive unit support (a
part of fixing to the frame).
Note:
Both RH/LH side to keep the drive unit horizontal level and to
avoid turning the drive unit
ABA

2. Use the SST to remove the 3 reamer bolts.

SST 09310-23320-71
6-16

3. Lift up the frame by hoist crane.

Installation:
When installing the front axle assy to the frame, a shim should
be returned to original place.

No. Thickness mm(in.)

1 0.5 (0.0197)
2 1.0 (0.039)
3 1.5 (0.0591)
4 2.0 (0.079)
5 2.5 (0.098)
 7-1

REAR AXLE
Page
8FBET, 8FBEKT (3-WHEEL MODELS)
REAR AXLE ASSY..................................................... 7-2
GENERAL............................................................................. 7-2
SPECIFICATIONS............................................................... 7-3
COMPONENTS.................................................................... 7-3
REMOVAL-INSTALLATION............................................... 7-6
DISASSEMBLYINSPECTIONREASSEMBLY................ 7-9
REAR AXLE HUB..................................................... 7-14
REMOVAL-INSTALLATION............................................. 7-14
REAR AXLE CYLINDER ASSY............................. 7-17
REMOVAL-INSTALLATION............................................. 7-17
DISASSEMBLY-INSPECTION-REASSEMBLY ............. 7-19

8FBMT (4-WHEEL MODELS)

REAR AXLE ASSY................................................... 7-22
GENERAL.......................................................................... 7-22
SPECIFICATIONS............................................................. 7-24
COMPONENTS.................................................................. 7-25
REMOVAL-INSTALLATION.................. 7-28
STEERING KNUCKLE.............................................7-31
REMOVAL-INSTALLATION............................................. 7-31
REAR AXLE CYLINDER......................................... 7-35
REMOVALINSTALLATION............................................. 7-35
DISASSEMBLY-INSPECTION-REASSEMBLY ............. 7-36
7-2

REAR AXLE ASSY

GENERAL

/ V
 7-3

SPECIFICATIONS
8FBET15 8FBEKT16 8FBET16 8FBEKT18 8FBET18 8FBET20
Type Full-F oating
Rear tire size 15-41/2-8/3.00 <- <- 140/55-9/4.00 <-
Rim size 3.00D-8 <- 4.33R-8 <- <-
Rim type SIT <- <— <- <-

COMPONENTS

Rear axle ASSY

4301
7-4
 7-5

4302

01

4302-045
7-6

REMOVAL-INSTALLATION
T=N-m (kgf-cm) [ft-lbfj

Removal Procedure
1. Remove the battery plug.

2. Remove the rear cover.

3. Jack up the vehicle [Point 1]

4. Remove the counterweight.

5. Remove the rear wheels.

6. Remove the battery.
7. Remove the battery rear plate.
8. Remove the main controller.

9. Disconnect the piping of the power steering cylinder.

10. Disconnect the connector from the tire angle sensor and remove the tire angle sensor, sensor cover. [Point 2]
11. Measure the rear axle ASSY starting force. [Point 3]
12. Loosen the rear axle set bolts.
 7-7

3. Hoist the rear axle temporary and remove the set bolts. [Point 4]
4. Remove the rear axle ASSY.

istallation Procedure
he installation procedure is the reverse of the removal procedure.

ote:
Fhen the tire angle sensor is removed and installed or replaced, perform matching. (See page XX-XX)
7-8

Point Operations
[Point 1]
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 2]
Installation:
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.
SST 09580-10920-71

[Point 3]
Inspection:
Measure the rear axle ASSY staring force.
Standards: 112 to 224N (11.4 to 22.9 kgf) [25.2 to 50.5 Ibf]

Installation:
When correct value is obtained, securely caulk the lock nut.

[Point 4]
Removal:
Temporarily hoist the rear axle as shown in the illustration.
 7-9

ISASSEMBLYINSPECTIONREASSEMBLY
T=N-m (kgf-cm) [ft-lbf]

10 to 20
(102 to 203.9)
[7.4 to 14.8]
(Reference value)

isassembly Procedure
Remove the lock nut.
Remove the upper bearing.

Disconnect the rear axle cylinder W/ holder ASSY and rear axle ASSY.

Remove the lower oil seal. [Point 1]

Remove the lower bearing outer race. [Point 2]

Remove the upper bearing outer race. [Point 3]

Remove the lower bearing. [Point 4]

Remove the hub cap, rear axle hub and outer bearing. [Point 5]

Remove the oil seal and inner bearing. [Point 6]

3. Remove the outer bearing outer race. [Point 7]

1. Remove the inner bearing outer race. [Point 8]

7-10

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply grease before installation.

Outer bearing Inner bearing Inside rear axle hub

STD MP grease
Type Cold storage
Esso beacon 325 or Mobil temp SHC100
spec.
11 to 15 14 to 19 22 to 27
Amount g (lb)
(0.02 to 0.03) (0.03 to 0.04) (0.05 to 0.06)

• After tightening the castle nut, fill MP grease (Esso beacon 325) in the hub cap.
 7-11

[Point 3]
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 4]
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 5]
Reassembly:
Use the SST to remove the rear axle hub.
SST 09950-76014-71
(09950-40011)
7-12

Inspection:
Measure the rear axle hub starting force.

Standard: 15 to 39 N (1.5 to 4 kgf) [3.3 to 8.8 Ibf]

Reassembly:
When installing a claw washer, position it with its edge facing
the rear axle.

[Point 6]
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:
Use the SST to install the oil seal.
SST 09700-30200-71
7-13
7-14

REAR AXLE HUB

REMOVALINSTALLATION
T=N m (kgf-cm) [ft-lbf]

Removal Procedure
1 Jack up the vehicle and remove the rear wheels. [Point 1]
2 Remove the hub caps.
3 Remove the rear axle hub. [Point 2]

4 Remove the oil seal and inner bearing. [Point 3]

installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply grease before installation.

Outer bearing Inner bearing Inside rear axle hub

STD MP grease
Type Cold storage
Esso beacon 325 or Mobil temp SHC100
spec.
11 to 15 14 to 19 22 to 27
Amount g (lb)
(0.02 to 0.03) (0.03 to 0.04) (0.05 to 0.06)
After tightening the castle nut, fill MP grease (Esso beacon 325) in the hub cap.
 7-15

Point Operations
[Point 1]
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 2]
Reassembly:
Use the SST to remove the rear axle hub.
SST 09950-76014-71
(09950-40011)

Inspection:
Measure the rear axle hub starting force.
Standard: 15 to 39 N (1.5 to 4 kgf) [3.3 to 8.8 Ibf]

Reassembly:
When installing a claw washer, position it with its edge facing
the rear axle.

[Point 3]
Disassembly:
Use the SST to remove the inner bearing.
SST 09950-76014-71
(09950-40011)
7-16

Reassembly:
Use the SST to install the inner bearing.

SST 09316-76008-71
(09316-60011)

Reassembly:
Use the SST to install the oil seal.

SST 09700-30200-71
 7-17

tEAR AXLE CYLINDER ASSY

lEMOVAL’INSTALLATION
T=N-cm (kgf-cm) [ft-lbf]

Removal Procedure
. Remove the rear axle ASSY. (See page 7-6)

Remove the rear axle cylinder ASSY. [Point 1]

nstallation Procedure
’he installation procedure is the reverse of the removal procedure.
7-18

Point Operations
[Point 1]

Installation:
Adjust the installation of the steering cylinder

(D 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 blue tooth of the rack between the two blue teeth of the pinion. Apply Moly cote grease D-
321RK evenly and thoroughly in the area of more than 180 0 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: 265 to 370 N-m (2700 to 3800 kgf-cm) [195.4 to 272.9 ft-lbf]
 7-19

DISASSEMBLY-INSPECTION-REASSEMBLY

Disassembly Procedure
1. Remove the steering cylinder end.
2. Remove the piston.

3. Remove the bushing.

I. Remove the rack.

5. Remove the steering torque cylinder. [Point 1]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Mote:
• Apply hydraulic oil to each part before installation.
• Replace O-ring, U-packing and dust seal.
7-20

Point Operations
[Point 1]
Inspection:
Measure the steering cylinder bore.

Inside diameter standard: 70.0 mm (2.76 in)

Wear limit: 70.35 mm (2.77 in)
7-22

REAR AXLE ASSY

GENERAL

View A-A
 7-23

tear Axle Cylinder

7-24

SPECIFICATIONS
Rear axle type Elliot type
Rear axle suspension type Center-supported right-left rocking type
Toe-in mm (in) 0(0)
Wheel alignment Camber degree 0°
King pin angle 0°
Maximum turning radius (outermost) degree 95°
Cylinder type Double acting
Piston rod outside
Rear axle cylinder 50
diameter mm (in)
Cylinder bore mm (in) 68
 7-25

COMPONENTS

4301
 o
co
^r

01
7-26
 7-27

4302
01

4302-046A
7-28

REMOVALINSTALLATION
T=N-m (kgf-cm) [ft-lbf]

Removal Procedure
1. Chock the front wheels.
2. Jack up the RR vehicle and remove rear wheels. [Point 1]
3. Remove the swing crank rod pin (lower) of switch lock cylinder. [Point 2]
4. Disconnect the rear axle cylinder hoses.
5. Disconnect the connector from the tire angle sensor.
6. Support the rear axle ASSY with a garage jack.
7. Remove the rear axle ASSY. [Point 3]
8. Remove the center pin bushing. [Point 4]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• When the tire angle sensor is removed and installed or replaced, perform matching. (See page XX-XX)
• After installation, add grease through each grease fitting. Add molybdenum disulfide grease at the rear
axle beam center pins (2 places) and swing lock cylinder crank rod pin. Use MP grease to other grease
fittings.
 7-29

Point Operations
[Point 1]
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 jack-up vehicle with wooden blocks at
specified points.

[Point 2]
The direction of dust seal
Installation:
Install the rod with chamfered side down.

Make sure that the upper and lower sides of the rod pin are
positioned correctly. (The upper and lower grooves and in different
locations.)

[Point 3]

Inspection:
Measure the rear axle front to rear clearance.
(1) Before removing the rear axle ASSY, measure the front to
rear clearance on the rear side.
Standard clearance: 0.3 mm (0.12 in) or less

(2) If the measured value does not satisfy the standard,

remove the rear axle ASSY and make adjustment by
selecting the spacer.
Spacer thickness:
0.3, 0.5,1.2, 2.3, 3.0, 3.5, 4.0, 4.5, 5.0 mm

(0.012, 0.020, 0.047, 0.091, 0.118, 0.138, 0.157, 0.177,

0.197 in)
7-30

Removal:
Draw different match marks on the rear axle bracket caps front
and rear to prevent confusion.
Inspection:
Install after aligning the match mark.

[Point 4]
Inspection:
Inspect the inside diameter of the rear axle center pin bushing.
Limit: 52 mm (2.047 in)
Installation:
Apply molybdenum disulfide grease to the bushing bore
installation.

Installation:
Install the bushing by aligning the grease groove in the
bushing with the grease fitting position.
 7-31

STEERING KNUCKLE
REMOVAL-INSTALLATION

disassembly Procedure
. Jack up the RR vehicle.
!. Remove the rear wheel.
¡. Remove the hub cap. [Point 1]
•. Remove the castle nut and claw washer.
i. Remove the hub w/outer bearing. [Point 2]
i. Remove the hub.
'. Remove the inner bearing and oil seal. [Point 3]
I. Disconnect the tie rod (on the knuckle side).
I. Remove the king pin. [Point 4]
0. Remove the steering knuckle.
1. Remove the king pin oil seal and needle roller bearing. [Point 5]

Reassembly Procedure
"he reassembly procedure is the reverse of the disassembly procedure.

tote:
kfter installation, add MP grease through grease fittings.
7-32

Point Operations
[Point 1]
Installation:
Fill MP grease or autolex in the hub cap, and install by tapping
the flange portion. (Instead of MP grease filling, spraying
grease over the castle nut is also usable.)

[Point 2]
Installation:
SST 09950-76014-71
(09950-40011)

Installation:
Install the outer bearing.

SST 09370-20270-71

[Point 3]

Removal:
SST 09950-76014-71
(09950-40011)

Installation:
Install the oil seal and inner bearing roller.

(1) Use the SST and install the oil seal.

SST: 09370-10140-71
 7-33

(2) Use the SST and install the inner bearing roller.
SST 09370-20270-71

[Point 4]
Inspection:
Measure the king pin outside diameter.
Limit: 27.8 mm (1.094 in)

Installation:
Before installation, check the positional relationships between
the punch mark on top of the king pin and the king pin lock.

Installation:
Adjust the thrust clearance.
(1) Install the thrust bearing with the seal cover side facing
up.
(2) Temporarily install the king pin and king pin lock bolt.
Select the spacer so as to minimize vertical looseness of
the knuckle, and install it on top of the thrust bearing.
Spacer thickness: 3.0, 3.5, 4.0 and 4.5 mm
(0.118, 0.138, 0.157 and 0.177 in)
Standard clearance: 0.5 mm (0.0197 in) or less
7-34

[Point 5]
Removal:
Remove the king pin oil seal and needle roller bearing.
(1) Use a straight-edge screwdriver to remove the dust seal
and oil seal.
(2) Use the SST and remove the needle roller bearing.
SST 09950-76018-71......................... (1)
(09950-60010)
SST 09950-76020-71......................... (2)
(09950-70010)

Installation:
Install the needle roller bearing and king pin oil seal.
(1) Use the SST and install the needle bearing.
Check the needle roller bearing press-fitting surface,
pressing direction and install depth.
SST 09950-76018-71.......................... (1)
(09950-60010)
SST 09950-76020-71.......................... (2)
(09950-70010)
(2) Install the dust seal.
(3) Use the SST and install the oil seal.
SST 09950-76018-71........................ (1)
(09950-60010)
SST 09950-76020-71........................ (2)
(09950-70010)
 7-35

ÎEAR AXLE CYLINDER

REMOVAL-INSTALLATION
T=N-m (kgf-cm) [ft-lbf]

Removal Procedure
. Jack up the vehicle.

. Disconnect the tie rod (on the piston rod side).

. Disconnect the rear axle cylinder hose and remove the fitting. [Point 1]

. Remove the rear axle cylinder.

. Remove the bushing from the piston rod.

installation Procedure
he installation procedure is the reverse of the removal procedure.

Point Operation
[Point 1]

Installation:
Install the fitting in the illustrated direction.
7-36

DISASSEMBLYINSPECTIONREASSEMBLY

Disassembly Procedure
1. Remove the piston rod guide.
2. Remove the piston rod. [Point 1]

3. Inspect the cylinder. [Point 2]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Coat hydraulic oil before reassembly.
 7-37

Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Limit: 49.92 mm (1.965 in)

Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)
Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil or
water before installation. Do not stretch it excessively.
Caution:
Operation carefully to avoid scalding.

[Point 2]
Inspection:
Measure the rear axle cylinder.
Limit: 68.20 mm (2.685 in)
 8-1

STEERING
Page
GENERAL............................................................. 8-2
COMPONENTS.................................................... 8-2
STEERING WHEEL • MAST JACKET............... 8-5
REMOVAL • INSTALLATION........................................8-5
DISASSEMBLY • REASSEMBLY................................ 8-7
HYDROSTATIC STEERING VALVE ASSY........ 8-8
TROUBLESHOOTING...................................................8-8
REMOVAL • INSTALLATION........................................8-9
DISASSEMBLY • INSPECTION • REASSEMBLY .... 8-11
INSPECTION AND ADJUST
RELIEF PRESSURE.................................................... 8-15
PRIORITY VALVE................................................. 8-16 8
COMPONENTS............................................................... 8-16
REMOVAL • INSTALLATION........................................8-18
DISASSEMBLY * INSPECTION * REASSEMBLY .... 8-19
8-2

GENERAL
Specifications
' ------------------------------ - -----------------------------
All Models
Steering wheel diameter mm (in) 300(11.8)
Steering wheel play mm (in) 15 to 45 (0.59 to 1.77)
Power steering type Hydrostatic steering
Discharge: cc (cm3) [ctrin (in3)] 50 (50) [3.05]

Rated flow rate: ¿‘min

Hydrostatic steering 9.3 (2.46)
valve (US gal’min)
Relief set pressure 8FBET: 12.6 to 13.1 (128.5 to 133.7) [1827.7 to 1901.6]
MPa (kgf’cm2) [psi] 8FBMT: 9.1 to 9.6 (92.9 to 98.0) [1321.3 to 1393.9]

COMPONENTS
4501

la ■ ■ a---------------------------------------------------------------------------------------------------------------------------------------------------------a ■ a di

4501-067C
 8-3

4502

4502-274

4503

4503-068
8-4

4503

4503-071
 8-5

STEERING WHEEL • MAST JACKET

REMOVAL • INSTALLATION
T=N-m (kgf-cm) [ft-lbf]

temovai Procedure
Disconnect the battery plug.
! Remove the steering wheel. [Point 1]
I Remove the column cover (front).
Remove the direction cover (front and rear).
» Remove the instrument panel RH.
i Remove the piping cover RH.
’ Remove the instrument panel LH.
I Disconnect the connectors around the direction switch.
I Remove the direction switch.
0 Remove the return spring.
1 Remove the tilt lock mechanism and tilt steering lock release lever.
2 Remove the steering valve set bolts. [Point 2]
3 Remove the mast jacket ASSY from steering valve.
8-6

Installation Procedure
The installation procedure is the reverse of the removal procedure.
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 1]
Removal:
SST: 09609-76002-71
(09609-20011)

Installation:
Steering wheel installation procedure
(1) Before removing 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 2]
Removal • Installation
Pull up the steering valve with a rope or equivalent.
 8-7

MSASSEMBLY • REASSEMBLY

Hsassembly Procedure
Remove the snap ring.
Remove the steering shaft.
Remove the bearing.
Remove the direction switch bracket.

Reassembly Procedure
he reassembly procedure is the reverse of the disassembly procedure.
8-8

HYDROSTATIC STEERING VALVE ASSY

TROUBLESHOOTING

Phenomenon Estimated cause Corrective action

The steering wheel is heavy. • The tire inflating pressure is low Adjust the inflating pressure.
• The oil pressure does not rise. Inspect and adjust the relief
pressure
• The high and low pressure pipes are connected Inspect and correct.
reversely.
The oil pressure does not rise. • The high and low pressure pipes are connected Inspect and correct.
reversely.
• The relief valve is faulty or not closed. Inspect and correct.
• The oil pump function is degraded or the oil volume Inspect and correct.
is insufficient.
• Priority valve spool fuse. Overhaul
• The power steering cylinder piston packing is Replace
damaged.
The steering wheel does not return • The tire inflating pressure is low. Adjust the inflating pressure.
properly. • The steering valve spool does not move smoothly. Correct or replace the steering
valve ASSY.
• The rear axle sliding motion is improper. Add lubricant or correct.
The steering wheel pulls to one • The steering valve spool does not move smoothly. Correct or replace the steering
side when released. valve ASSY.
• The steering drive shaft is damaged. Replace the steering valve ASSY.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
The play is excessive and the • Oil moves in the steering valve. Replace the steering valve ASSY.
vehicle wobbles. • The steering valve spool does not move smoothly. Correct or replace the steering
valve ASSY.
• Air is sucked from the piping. Inspect and correct or replace.
• The steering shaft is defective. Inspect and correct or replace.
The steering wheel shimmies. • The steering valve drive shaft is installed incorrectly. Inspect and correct.
The tires are steered opposite to • The cylinder piping is connected reversely. Inspect and correct.
the steering wheel operation
direction.
Abnormal noise is generated. • The relief valve is defective. Correct, inspect the pressure, and
adjust.
• Air is sucked from the piping. Inspect and correct or replace
• The piping is blocked (crushed or clogged). Inspect and correct or replace
 8-9

REMOVAL • INSTALLATION

temovai Procedure
Disconnect the battery plug.
! Remove the column cover (front).
• Remove the direction cover (front and rear).
Disconnect the connectors around the mast jacket.
i Remove the return spring.
• Remove the tilt lock mechanism and tilt steering lock release lever.
' Remove the steering valve set bolts. [Point 1]
I Remove the mast jacket.
I Remove the front panel.
0 Remove the fittings. [Point 2]
1 Remove the steering valve ASSY W/ knob position correcting valve.

nstallation Procedure
’he installation procedure is the reverse of the removal procedure.
ilote:
Kdd MP grease at the coupling between the steering shaft and steering valve.
Point Operations
[Point 1]
Removal • Installation
Pull up the steering valve with a rope or equivalent.

[Point 2]
Installation:
Install the fitting with the angle shown in the illustration.
T= 32 to 36 N m (326 to 367 kgf cm) [23.6 to 26.6
ft-lbf]

W/ Steel cabin or Front windshield models

Removal • Installation
Using SST, remove the steering valve fittings.
SST 09451-13240-71
 8-11

HSASSEMBLY • INSPECTION • REASSEMBLY

T = N-m (kgf-cm) [ftlbf]

T=40 to 60 (408 to 612)

T=24 to 36 (245 to 367)

[17.7 to 26.6]

iisassembly Procedure
Remove the end cover. [Point 1]

Remove the gear wheel set, cardan shaft (drive shaft) and distributor plate. [Point 2]
Remove the check valve, balls, bush and pin.
Remove the sleeve W/ spool and bearing. [Point 3]
Remove the O-ring, kin-ring and dust seal ring. [Point 4]
Remove the rerief valve. [Point 5]

Reassembly Procedure
he reassembly procedure is the reverse of the disassembly procedure.
lote:
/ash each part with clean hydraulic oil before assembly.
8-12

Point Operations
[Point 1]

Disassembly:
Put a match mark.
Disassembly:
Align the match marks.

Disassembly:
When removing each set bolt, operate carefully so as not to
lose the steel ball.
Reassembly:
Put a steel ball in the illustrated position before installing each
set bolt.
Reassembly:
As one out of seven set bolts is a bolt with pin, install it in the
correct position.

[Point 2]
Reassembly:
Pay attention to the following points at the time of reassembly.
1. Fit the gearwheel (rotor) and cardan shaft so that a tooth base
in the rotor is positioned in relation to the shaft slot as shown.
Turn the gear rim so that the seven through holes match the
holes in the housing.

2. Guide the cardan shaft (drive shaft) down into the bore so that
the slot is parallel with the connection flange.

3. Align the match marks on the distributor plate and gear wheel
made at the time of disassembly.
When these parts are replaced, match the holes in the housing
and plate.
 8-13

[Point 3]
Disassembly:
Extract the spool W/sleeve upward. Otherwise, the spool cross
pin may move during extraction to cause sticking.

Reassembly:
Set and install the neutral position spring correctly.

Reassembly:
Pay attention to the bearing direction for installation. (See the
figure.)

Reassembly:
Place the housing with its flanged side facing down, and insert
the spool W/sleeve into the housing. Set the cross pin of the
spool in horizontal state during insertion.

[Point 4]
Reassembly:
Install the kin-ring and O-ring correctly.
Note:
For SST No. SJ150-9000-11, please inquire at the nearest
Danfoss service shop.
(Refer to Parts & Service News Ref. No. GE-7022 of July 1,
1997 for detail.)
8-14

1. Turn the steering unit until the bore is horizontal. Guide the
outer part of the assembly tool into the bore for the spool/
sleeve.

2. Apply O-ring and kin-ring with hydraulic oil and place them on
the tool.

3. Hold the outer part of the assembly tool in the bottom of the
steering unit housing and guide the inner part of the tool right
to the bottom.

4. Press and turn the O-ring/kin-ring into position in the housing.

5. Draw the inner and outer parts of the assembly tool out of the
steering unit bore, leaving the guide from the inner part in the
bore.

[Point 5]
Disassembly:
Do not remove the relief valve unless it is judged defective.
The valve seat cannot be removed.
Disassembly:
Measure the screwed-in depth of the relief valve adjusting
screw before starting disassembly.

Reassembly:
Reassemble by adjusting to the screwed-in depth of the valve
spring retainer measured before disassembly. After installing
the steering valve ASSY on the vehicle, measure the relief
pressure. If it is not within the standard range, adjust it by
changing the screwed-in depth of the retainer.
 8-15

INSPECTION AND ADJUST

RELIEF PRESSURE
1. Install an oil pressure gauge.

(1) Disconnect the hose from the steering valve P port, and
connect the adapter (SST).
SST 09450-23320-71

(2) Install the pressure gauge.

Plug size: PT1/8

2. Start the engine and turn the steering wheel slowly clockwise
and counterclockwise.

3. Start the engine, rotate the steering wheel and measure the
relief pressure when the relief occurs.
Standard: unit: MPa (kgf/cm2) [psi]
8FBET. 8FBEKT 12.6 to 13.1 (128.5 to 133.7) [1827.7 to 1901.6]
8FBMT 9.1 to 9.6 (92.9 to 98.0) [1321.3 to 1393.9]

4. If the standard is not satisfied, remove the steering valve and

make adjustment by turning the relief valve adjusting screw.
8-16

PRIORITY VALVE
COMPONENTS

8FBET15-20 4507
8FBEKT16,18 -----------

8FBMT15-20 4507
 8-17

4507

77

r ■—------------------------------------ ‘--------------------------------------— - "I

77K=(lNCL. )•

4507-312
8-18

REMOVAL • INSTALLATION

Removal Procedure
1 Remove the battery plug.
2 Remove the battery. (See page 1-5 )
3 Remove the battery front panel.
4 Remove the battery under cover.
5 Disconnect the fitting. [Point 1]
6 Remove the priority valve.

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

Point Operations
[Point 1]
Installation:
Install the fitting with the angle shown in the illustration.
A: T= 56.1 to 61.9 N-m (572 to 631 kgf-cm)
[41.4 to 45.7 ft-lbf]
B: T= 32 to 36 N-m (326 to 367 kgf-cm)
[23.6 to 26.6 ft-lbf]
C: T= 24 to 26 N m (245 to 265 kgf-cm)
[17.7 to 19.2 ft-lbf]
 8-19

DISASSEMBLY • INSPECTION • REASSEMBLY

T=N-m (kgf-cm) [ft-lbf]

30 to 50 (306 to 510) [22.1 to 36.9}

)isassembly Procedure
Remove the plug.
! Remove the plug.
I Remove the spool.

REASSEMBLY Procedure
‘he reassembly procedure is the reverse of the disassembly procedure.
lote:
Vash each part with clean hydraulic oil before assembly.
 9-1

BRAKE
Page
GENERAL..................................................................... 9-2
SPECIFICATIONS....................................................... 9-3
COMPONENTS........................................................... 9-3
PARKING BRAKE................................................................9-3
BRAKE PEDAL.................................................................... 9-4
FOOT BRAKE...................................................................... 9-5
FOOT BRAKE............................................................. 9-6
DISASSEMBLYINSPECTIONREASSEMBLY................ 9-6
BRAKE PEDAL......................................................... 9-11
REMOVALINSTALLATION............................................. 9-11
BRAKE PEDAL ADJUSTMENT...................................... 9-12
BRAKE DISC ADJUSTMENT......................................... 9-13
PARKING BRAKE.................................................... 9-14
REMOVALINSTALLATION............................................. 9-14
PARKING BRAKE ADJUSTMENT.................................. 9-15
9-2

GENERAL
 9-3

SPECIFICATIONS
Vehicle model
All models
tern
zoot brake type Wet disc brake
3arking brake type Wet disc brake
Brake Disc diameter mm $ 140
dumber of Brake Disc 4
Dooling oil TOYOTA genuine oil: ATF type T-4
Xmount of oil £ 0.21 (£)

COMPONENTS
>ARKING BRAKE

4601

4601-216
9-4

BRAKE PEDAL

4701

2611
 9-5

OOT BRAKE

4201
9-6

FOOT BRAKE

DISASSEMBLYINSPECTION-REASSEMBLY
T = N-m (kgf cm) [ft lbfj

25.5 (260.1) [18.8]

 9-7

isassembly Procedure
aution:
• Do not wear cotton working gloves when performing the operation in Step 7 or 10.
• Never wash stator discs.

Remove the front axle ASSY. (See page 6-14)

Remove the brake lever ASSY.

Remove the rpm sensor bracket.

Remove the rpm sensor and harness.

Drain the brake oil.

Remove the housing set bolt.

Remove the return spring pin and stator disc No.1. [Point 1]
Remove the rotor and stator disc No.2. [Point 2]

Remove the piston ASSY.

). Remove the piston pin. [Point 3]

1. Remove the grease nipple.

2. After the nut is loosened, the expanding bolt is removed.
J. Remove the spring.

1. Remove the nut and washer.

5. Remove the brake lever.

5. Remove the brake shaft.

7. Remove the O-ring.

eassembly Procedure
aution:
• Do not wear cotton working gloves when performing the operation in Step 7 or 10.
• Never wash stator discs.
• If brake fluid overflows from the filler port after a fill, leave it as it is for 5 minutes or so without closing
the plug and make sure that the fluid has stopped spilling out before closing the plug.

Install the 0-ring.

Install the brake shaft.

Install the brake lever. [Point 4]

Install the nut and washer.

Install the spring.

Install the adjusting bolt.

Install the piston pin. [Point 5]

Install the piston ASSY. [Point 6]

Install the rotor and stator disc no.2.

). Install the return spring pin and stator disc no.1.

1. Install the housing set bolt. [Point 7]

2. Install the brake lever ASSY. [Point 8]

3. Install the grease nipple. [Point 9]
I. Install the rpm sensor and harness.
9-8

15. Install the rpm sensor bracket.

16. Brake oil is replenished.
17. Install the front axle ASSY. (See page 6-14)

Point Operations
[Point 1]
Inspection:

1. Measure the lengths of the return spring and the stator disc
No.1 with slide calipers.
Return spring: Standard: 22 mm (0.866 in.)
Limit: 20.5 mm (0.807 in.)
Stator disc No.1: Standard: 5.2 mm (0.205 in.)
Limit: 5.0 mm (0.197 in.)

2. Measure the lengths of the spring pin.

Standard: 15 ± 1 mm (0.59 ± 0.04)

[Point 2]
Inspection:
Measure the lengths of the rotor and the stator disc No.2 with
slide calipers.

Rotor: Standard: 17 mm (0.669 in.)

Limit: 16.8 mm (0.661 in.)
Stator disc No.2: Standard: 3.2 mm (0.126 in.)
Limit: 3.0 mm (0.118 in.)

[Point 3]
Removal:
Punch out the needle in the direction shown in the figure and
remove the piston pin.
 9-9

[Point 4]
Reassembly:
Note:
Put the shaft and the lever together while aligning the
matchmarks.

[Point 5]
Installation:
1. Insert the piston and drive in the needle in the direction shown
in the figure.

2. Caulk the needle hole to the specified value.

Standard: Pinched range of cauking (A): 2.8mm (0.11 in.)
Depth of cauking (B): 0.2 to 1.0 mm
(0.008 to 0.04 in.)

[Point 6]
Installation:

<w
Before installing the brake lever assembly, make sure that the
piston pin is in the position shown in the figure.

o x
Installation:
Install the piston ASSY.
Standard: 8.0 N-m (81.6 kgf-cm) [5.9 Ibf]
Note:
Mount the brake assembly and the piston assembly in
combination. Make sure the piston assembly is in place, and
then tighten the set bolt to the specified torque.
9-10

[Point 7]

Reassembly:
Mount the housing with the brake shoe fixed temporarily with a
stay or the like to prevent it from coming off.

A: Approx. 30 mm (1.18 in.)

Caution:
• Never using cotton work grobes.
• Never wash stator dies.

[Point 8]
Installation:

1. After attaching a wrench with a length of about 300 mm

(11.8 in.) as shown in the figure, measure the starting power
with a spring scale.
Standard: 100 ± 5 N (1,020 kg ± 51 kg) [73.8 lb ± 3.7 lb]

2. Adjust the clearance under the conditions in 1.

Standard: 7.0 ± 0.3 mm (0.28 ± 0.01 in.)

3. Tighten the stopper lock nut to the specified torque.

Standard: 30 Nm (306 kgf-cm) [22.1 Ibf]

[Point 9]
Reassembly:
1. Mount the grease nipple in such a way that its angle of
inclination falls within the standard range.
Standard: 90 ± 5° with respect to the reference surface of
the lever.
2. Tighten the brake bracket nuts to the specified torque.
Standard: 185.0 N-m (1,887 kgf-cm) [136.5 Ibf]
Note:
Pump MP grease into the grease nipple until it squeezes out
from under the lever.
 9-11

BRAKE PEDAL

lemoval Procedure
. Remove the toe boards (front and rear).
. Disconnect the brake pedal wiring harness.
Remove the nut. [Point 1]
. Remove the brake pedal fixing bolt.
. Remove the li-pin.
Remove the pin.
Remove the link lod. [Point 2]
. Adjust the brake link and perform matching of the pedal. (See page xx-xxx)

retaliation Procedure
he installation procedure is the reverse of the removal procedure.
lote:
ispect the bushing for wear and damage and replace it if necessary.
9-12

Point Operations
[Point 1]
Installation:
Assembly the ball joint to the brake pedal.

[Point 2]
Inspection:
1. Inspect rod and the brake pedal linkage height from the
wheelbase of the ball joint to wheelbase of the link rod.
Standard; A = 175 ± 1 mm (6.89 ± 0.04 in.)
B = 139mm (5.47 in.)
2. Adjust if the pedal height is outside the specified range with a
stopper bolt.

BRAKE PEDAL ADJUSTMENT

1. Inspect the measure of the bolt that adjust the height of the
brake pedal.
Standard: A = 16 mm (5.47 in.)

2. Inspect the distance from the pedal to the toe board.

Standard: A = 105 +q mm (4.13 + J‘197 in.)
 9-13

BRAKE DISC ADJUSTMENT

Pedal stroke:
1. Checking the brake pedal stroke
(1) Pull the parking brake lever by applying an operating
force of approx. 150 N. (The parking brake lever is held
stationary by a notch.)

55 to 64 mm (2) Measure the operating stroke of the brake pedal by

(2.17 to 2.52 in.) depressing it by hand. (Distance between the position
where the link 1 starts moving and the position where the
_________________ 7
lever 2 starts moving.)
2
Note:
• The play in the brake pedal is not included in the stroke
• Measure the brake pedal stroke when it is within the area
A.
Standard: 55 to 64 mm (2.17 to 2.52 in.)

2. Adjusting the brake pedal stroke

Note:
If the pedal stroke measured in "1. Checking the brake pedal
stroke" above falls outside the standard range, adjust it by
following the procedure below.
(1) Remove the brake pedal assembly.
(2) Pull the parking brake lever by applying an operating
force of approx. 150 N. (The parking brake lever is held
stationary by a notch.)
(3) Loose the nut 3 and adjust the stopper bolt to bring the
value B into the standard range.
Standard:7.4 to 8.0 mm (0.29 to 0.31 in.)
(4) Tighten the nut 3 and mount the brake pedal assembly.
(5) Adjust the brake link and perform matching of the pedal.
(See page 3-62)
9-14

PARKING BRAKE

REMOVAL-INSTALLATION
T = N m (kgf-cm) [ft-lbf]

Removal Procedure
1. Remove the piping cover.

2. Remove the instrument panel LH.

3. Remove the parking brake ASSY.

4. Remove the parking brake wire.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 9-15

’ARKING BRAKE ADJUSTMENT

.djust the parking brake so that the front pole fits at the third or fourth notch of the sector when the parking brake
;ver operating force is at 150 N (15.3 kg) [33.7 lb] (measure at the point in the illustration).
 10-1

BODY
Page
COMPONENTS...................................................... 10-2
BATTERY HOOD ASSY........................................ 10-8
REMOVALINSTALLATION.............................................10-8
COUNTERWEIGHT..............................................10-10
REMOVALINSTALLATION.......................................... 10-10
OPERATOR’S SEAT............................................10-12
REMOVAL-INSTALLATION.......................................... 10-12
FUSES...................................................................10-13
FUSE INSTALLATION LOCATIONS............................ 10-13

10
10-2

COMPONENTS
5101

5101
10-3
10-4
 10-5

5101

5101-641
10-6

5301

5308
 10-7

5401

5401
10-8

BATTERY HOOD ASSY

REMOVAL-INSTALLATION
N-m (kgf-cm) [ft-lbf]

7
T=24 (244.8) [17.7]

Removal Procedure
1. Disconnect the battery plug.

2. Tilt up (or release) the steering column.

3. Open the battery hood.

4. Remove the side hood and pillar cover.

5. Disconnect the mini-lever and seat switch connector.

6. Disconnect the wire harness from the battery.

7. Unscrew the 4 fixing nuts of the seat and remove it. (See page 10-12)
8. Disconnect the battery hood damper (on the frame side).
9. Close the battery hood.
10. Remove the RR cover.
 10-9

. Remove the battery hood hinge set bolt.

. Remove the battery hood ASSY.

stallation Procedure
ie installation procedure is the reverse of the removal procedure.
10-10

COUNTERWEIGHT

REMOVALINSTALLATION
Note:
See page 0-12 to 13 for counterweight and select an appropriate wire rope for the counterweight.
N-m (kgf-cm) [ft-lbf]

Removal Procedure
1 Disconnect the buttery plug.
2 Remove the RR cover.

3 Remove the pillars cover.

4 Remove the draw bar.
5 Fit the wire rope on the counterweight and lift until it is straight.

6 Remove the counterweight set bolts (1 for 8FBMT and 2 for 8FBET, 8FBEKT).
7 Remove the counterweight. [Point 1]

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

Note:
The lifting system used MUST be able to support the counterweight weight.
 10-11

Point Operations
[Point 1]

Installation:
Be sure to keep the balance when installing the counterweight.
10-12

OPERATOR’S SEAT
REMOVALINSTALLATION
N-m (kgf-cm) [ft-lbf]

Removal Procedure
1. Disconnect the battery plug.
2. Tilt up (or release) the steering column.
3. Open the battery hood.
4. Disconnect the mini-lever and seat switch connector.

5. Disconnect the wire harness from the battery hood.

6. Unscrew the 4 fixing nuts of the seat and remove it.
7. Remove the seat w/mini-lever arm ASSY.

8. Remove the mini-lever ASSY from the seat.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 10-13

;USES
USE INSTALLATION LOCATIONS

IAMES (APPLICABLE FUNCITONS) AND CAPACITIES

Fuse Function Capacity
F1 For drive and material handling 500A
F4 For lights 10A
F5 For control circuit 10A
F6 For control circuit 10A
F7 For fan and solenoid 10A

Caution for fuse replacement

efore fuse replacement, be sure to disconnect the battery plug and completely discharge CO (overall condenser)
'ith Approx. 100Q resistor between P4-N1.
 11-1

MATERIAL HANDLING SYSTEM

Page
HYDRAULIC CIRCUIT.............................................. 11-2
COMPONENTS.......................................................... 11-3
RETURN FILTER........................................................ 11-8
REMOVALINSTALLATION.............................................. 11-8
NATURAL DROP TEST............................................ 11-9
NATURAL FORWARD TILT TEST.......................... 11-9
OIL LEAK TEST....................................................... 11-10
LIFT CYLINDER................................................................ 11-10
TILT CYLINDER................................................................ 11-10

11
11-2

HYDRAULIC CIRCUIT

Power Steering
Cylinder
 11-3

COMPONENTS
6801

6801-711

6801 11
11-4

6801

6801

6801-716
 11-5

Mast
6801

6801-709

W Mast
11-6

FSW Mast

6801

$>—DE

6801-718
 11-7

WMast

6802

6802-684

6802

6802-685
11-8

RETURN FILTER
REMOVAL-INSTALLATION

Removal Procedure
1. Disconnect the battery plug.
2. Remove the toe boards (FR, RR) and tilt cylinder cover.
3. Open the tank cup.
4. Remove the return filter. [Point 1]

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

Point Operations
[Point 1]
Removal:
(1) Remove the ring (A) fitted at the base of the gage by
inserting a screwdriver into the opening.

(2) Remove the level gage (B).

(3) Remove the filter (C).
 11-9

Installation:
Install in the reverse order of removal.
When installing the ring (A) fit the projections on the ring into the
grooves between the filter and the tank.

Note:
Holding the filter with the handle pointing up, insert it into the tank.

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

1. Set the mast in the vertical position with the standard load on
the fork, lift the fork by 500 mm (19.7 in), and turn the key
switch to OFF.
11-10

2. Measure the tilt cylinder rod extension after 15 minutes.

Limit: 20 mm (0.79 in) or less

OIL LEAK TEST

LIFT CYLINDER
1. Set the mast in the vertical position with the standard load on
the fork, lift the fork by 1.0 to 1.5 m (39.3 to 59.1 in).
2. Tilt the mast forward slowly. After waiting 5 minutes with the
key switch OFF, disconnect the oil control valve to oil tank
hose. If the oil level is below the maximum level, add oil with
an oil can or other tool until reaches the maximum level. Wait
at least one minute, then measure the amount of oil leakage.

[Measurement method]
If the oil level drops, add oil to the maximum level again. The
amount of oil added indicates the amount of oil leakage.
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
1. Set the mast in the vertical position with the standard load on
the fork, lift the fork by 500 mm (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. If the oil level is below the
maximum level, add oil with an oil can or other tool until
reaches the maximum level. Wait at least one minute, then
measure the amount of oil leakage.

[Measurement method]
If the oil level drops, add oil to the maximum level again. The
amount of oil added indicates the amount of oil leakage.
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.
 12-1

MAST
Page
MAST........................................................... 12-2
GENERAL.................................................................... 12-2
MAST SECTION.......................................................... 12-3
MAST ASSY............................................................ 12-4
COMPONENTS............................................................ 12-4
LIFT BRACKET ASSY AND MAST
REMOVAL.............................................................. 12-6
REMOVAL • INSTALLATION....................................... 12-6
MAST ASSY (W/LIFT BRACKET)........................ 12-9
REMOVAL • INSTALLATION....................................... 12-9
V MAST ASSY....................................................... 12-11
DISASSEMBLY • INSPECTION * REASSEMBLY.... 12-11
FW MAST ASSY................................................... 12-13
DISASSEMBLY * INSPECTION * REASSEMBLY.... 12-13
FSW MAST ASSY................................................ 12-15
DISASSEMBLY • INSPECTION • REASSEMBLY.....12-15
SIDE SHIFT CYLINDER....................................... 12-17 12
DISASSEMBLY * INSPECTION * REASSEMBLY.....12-17
LIFT BRACKET.................................................... 12-18
DISASSEMBLY • INSPECTION • REASSEMBLY.....12-18
LIFT BRACKET GUIDE SHOES
REPLACING........................................................ 12-19
DISASSEMBLY • REASSEMBLY.............................. 12-19
MAST CHAINS...................................................... 12-21
INSPECTION • ADJUSTEMENT................................ 12-21
FORK..................................................................... 12-22
REMOVAL • INSPECTION......................................... 12-22
FW • FSW MAST ASSY....................................... 12-23
COMPONENTS.......................................................... 12-23
12-2

MAST
GENERAL
The profile of the mast with a double strengthening wing features great rigidity to bending and twisting.
It allows wide visibility thanks to the reduced dimensions of the profile itself.
Cylinders are single-acting type.
The sideshift system has been housed inside the profiles.
The mast group is a roller type with a variable center distance (i.e. a fixed roller is fitted on the outer mast and a
mobile one on the inner mast). This solution ensures better grip and stability on operation.

Others: side clearance adjustable from outside. Plastic guide shoes.

Lifting cylinders:
Double mast V. nr. 2 rear cylinders
F.W. nr. 2 rear cylinders
nr. 2 front cylinders
Triple mast F.S.W. nr. 2 rear cylinders
nr. 2 front cylinders
 12-3

/IAST SECTION

A B

MFH mm (in) 1.51 1.6 t 1.8 t 2.0 t

3000 to 4000 (118 to 157) A A B B

V-FW
4200 to 5500 (165 to 217) B B B B

FSW ALL B B B B
12-4

MAST ASSY
COMPONENTS
MAST ASSY (V)

6101
12-5
12-6

LIFT BRACKET ASSY AND MAST REMOVAL

REMOVAL • INSTALLATION
T=N-m (kgf-cm) [ft-lbf]

Removal Procedure
1. Set the mast in the vertical position and fully lower the forks.
2. Disconnect the chain from the mast side. [Point 1]
3. Remove the chain wheel, if needed. [Point 2]
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 harness.
6. Disconnect the overflow hose and high pressure hoses. (Before hose disconnection, fully lower the inner mast.)
7. Slightly hoist the mast ASSY. [Point 3]
8. Remove the tilt cylinder front pin from the mast side. [Point 4]
9. Remove the mast support cap.
10. Remove the mast ASSY.
11. Verify the bushing condition on the mast support. [Point 5]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply molybdenum disulfide grease on 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.
• Adjust the chain tension after installation.
• When the mast is replaced, perform SAS matching after installation. (See section 16.)
 12-7

Point Operations
[Point 1]
Removal:
After the hoses should be removed.
Chain adjusting nut tightening torque:
66.5 to 73.5 N m (678 to 749 kgf-cm) [49.0 to 54.2 ft-lbf]
Remove the 2 nuts (A) from the chain tie rod.

Inspection:
Remove the fork, completely lower the fork carriage and
measure the height X:
Standard measure X = 52 mm (2.05 in).
If the height have a different measure, set the
adjustment nuts of the chains.

Inspection:
Check the clearence between the inner mast and the
pad of lift bracket:
Standard clearence: 0.2-0.4 mm (0.0079-0.0157 in)

[Point 2]
Removal:
If the fitting is stiff, use the SST for removal.
SST 09950-76014-71
(09950-40011)

[Point 3]
Removal:
To remove the mast, use the eyebolt at the top of fix
mast.
12-8

[Point 4]
Removal:
If the fitting is stiff, use the SST for removal.
SST1 09810-20172-71
SST2 09820-31040-71

[Point 5]
Inspection:
Measure the mast support bushing thickness.
Standard measure: 5 mm (0.0195 in)
Limit: 4 mm (0.16 in)
After install the mast, apply Shell Mobil Grease Special
or equivalent to grease nipple.
 12-9

/IAST ASSY (W/LIFT BRACKET)

IEMOVAL • INSTALLATION

Set the mast in the vertical position.

Remove the forks.
Disconnect the lifting height switch harness.
Disconnect the overflow hose and high pressure hoses. (Before hose disconnection, fully lower the inner mast.)
Tie the lift bracket and outer mast with a wire rope.
Slightly hoist the mast assy. [Point 1]
Remove the tilt cylinder front pin. [Point 2]
Remove the mast support cap.
Remove the mast ASSY W/lift bracket.

istallation Procedure
he installation procedure is the reverse of the removal procedure.

ote:
• 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.
• Adjust the chain tension after installation.
• When the mast is replaced, perform SAS matching after installation. (See section 16.)
• For the tightening torque see page 12-6.
12-10
 12-11

! MAST ASSY
DISASSEMBLY • INSPECTION • REASSEMBLY

OUTER MAST

disassembly Procedure
Remove the lifting height switch.
Remove the overflow hose and high pressure hoses.
Disconnect the chain.
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.)
Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]
Remove each cylinder support.
Remove each cylinder bottom set bolt, and remove each lift cylinder.
Remove the outer mast.

Reassembly Procedure
he reassembly procedure is the reverse of the disassembly procedure.
12-12

Point Operations
[Point 1]
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.
Max clearence: 4 mm (0.16 in)
Spacer thickness: 0.4-1 mm (0.016-0.039 in)

Reassembly:
Tighten the ring nut and leave a clearance as shown in a
picture.
 12-13

:W MAST ASSY
MSASSEMBLY • INSPECTION • REASSEMBLY

OUTER MAST INNER MAST

lisassembly Procedure
. Remove the lifting height switch.
. Remove the overflow hose and high pressure hoses.
. Disconnect the chain.
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.)
. Remove the pulley support. (Chain and hydraulic pipes.)
. Remove the front lifting cylinder support and the bottom set bolts.
. Remove the front lifting cylinder.
. Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]
. Remove each cylinder support.
0. Remove each cylinder bottom set bolt, and remove each rear lift cylinder.
1. Remove the outer mast in rollers and inner mast rollers.

Reassembly Procedure
he reassembly procedure is the reverse of the disassembly procedure.
12-14

Point Operations
[Point 1]
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.
Max clearence: 4 mm (0.16 in)
 12-15

:SW MAST ASSY

DISASSEMBLY • INSPECTION • REASSEMBLY

OUTER MAST MIDDLE MAST INNER MAST

15 7

isassembly Procedure
Remove the lifting height switch.
Remove the overflow hose and high pressure hoses.
Disconnect the chain.
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.)
Remove the pulley support.
Remove each front lift cylinder rod end set bolts and take each rod end off.
Remove the front lift cylinder support and the bottom set bolts.
Remove the front lift cylinder.
Remove the chains of middle mast.
). Remove each rear lift cylinder rod end set bolts and take each rod end off. [Point 1]
1. Remove the rear lift cylinder support and the bottom set bolts.
2. Remove the rear lift cylinder support.
3. Slide the inner mast downward and remove the lift rollers and pads.
4. Remove the inner mast.
5. Slide the middle mast downward and remove the lift rollers and pads.
5. Remove the central mast.

eassembly Procedure
ie reassembly procedure is the reverse of the disassembly procedure.
12-16

Point Operations
[Point 1]
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.
Max clearance: 4 mm (0.16 in)

Reassembly:
Tighten the ring nut and leave a clearance as shown in a
picture.
 12-17

>IDE SHIFT CYLINDER

DISASSEMBLY • INSPECTION • REASSEMBLY

Remove one of the two side panels from the side shift.
Remove the fork carriage.
Remove the head of cylinder.
Remove the piston rod guide.
Remove the piston rod.
Inspection of the rod. [Point 1]

eassembly Procedure
ie reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Limit: 29.92 mm (1.178 in)
Inspection:
Measure the bend of the piston rod.
Limit: 0.1 mm (0.0039 in)
12-18

LIFT BRACKET
DISASSEMBLY • INSPECTION • REASSEMBLY

Disassembly Procedure
1. Remove the guide shoes.
2. Loosen the adjuster screw.
3. Remove the snap ring.
4. Remove the roller. [Point 1]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71
(09950-40011)
 12-19

JFT BRACKET GUIDE SHOES REPLACING

)ISASSEMBLY • REASSEMBLY

Park the truck on a flat surface and apply the parking brake.
Switch off the truck.
Disconnect the battery plug.
Remove the 2 forks from the lift bracket.
Remove one of the two side panels from the lift bracket.
Remove the fork plate sliding it to RH or LH side.
. Replace the upper and lower guide shoes.
Set the correct shim for the bottom shoes. [Point 1]

'eassembly Procedure
he reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Installation:
Shim thickness: 0.5-0.8 mm (0.020-0.032 in)
Max clearence: 3 mm (0.12 in)
Shim wear limit: 2 mm (0.079 in)
12-20

Mast and Lift Bracket pads adjustment

MAST LIFT BRACKET

Standard clearance 0.2-0.4 mm (0.0079-0.0157 in) (1) Unscrew the adjustment screw.
p- (2) Set the frames (mast or lift bracket) as shown in above
figure.
(3) Put the frames (mast or lift bracket) in one side.
(4) Measure the clearance between the frame and the pads.
(5) Adjust RH pads (upper and lower) for half of clearance
(considering that for each turn the screw move 1.25mm
(0.0492 in): 1/4=0.3mm (0.0118 in)).
(6) Put shim (0.3mm (0.0118 in)) on the LH side and tight the
adjustment screw until the shim don’t move.
(7) Remove the shim.
0.2-0.5 mm (0.0079-0.0200 mm)
 12-21

l/IAST CHAINS
NSPECTION • ADJUSTEMENT
Inspection:
1. To check if the chain links are worn out, use the appropriate
rule:
SST 09631-22000-71

2. The chains must be replaced when, in a portion corresponding

to 34 pitches, only 33 pitches are found.

Note:
Perform measurement without removing the chain from the
vehicle.
Inspect elongation over the entire chain length as it may be
localized.

Adjustment:
(1) Park the vehicle on a flat surface and set the mast in
vertical position.
(2) Remove the forks.

(3) Check if the measure X respect the standard:

Standard measure X = 52 mm (2.05 in).
(4) Adjust to eliminate any chain sag by turning the adjusting
nylon nut.
(5) Check to see if the chain tension is equal on left and right
sides.
(6) Check that the chain is not twisted.
(7) Check that the lifting higher meets the standard.
(8) In the upper position, check that the end stroke plate is
not in contact with the fork carriage.
12-22

FORK

Removal:
1. Lift the fork to approx. 20 cm (7.87 in) from the ground
2. Place a wood block under the notched section of the fork rail
3. Unlock the fork by lifting the fork stopper pin and shift one fork
per time to the fork carriage bottom notch
4. Slowly lower the fork for removal.

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

Inspection:
Fork arm inspection must be carried out carefully by
trained personnel to detect any damage, failure,
deformation, etc., which may impair safe use.
(1) Surface cracks:
The fork arm must be thoroughly examined visually for
cracks giving special attention to the heel (D) and top (E)
and bottom (F) hooks. If necessary, the forks may be
subjected to a non-destructive crack detection process.
(2) Difference in height of fork tips:
Check the difference in height between the blade tips on
each pair of forks, this must not be more than 3% of blade
length with the forks fitted on the fork plate.
(3) Positioning lock:
Check that the fork positioning lock (G) is in good working
order.
(4) Legibility of marking:
If the fork arm marking is not clearly readable, it must be
renewed by the original fork supplier.
(5) Fork wear control:
The fork arm blade and shank must be thoroughly
checked for wear, paying special attention to the area
around the heel (D). The forks must be replaced when the
wear has reduced their thickness of the 10% of the
original one.
(6) Fork mounting wear control:
The horizontal supporting surface of the top hook (E) and
the contact surfaces of both hooks (E) and (F) must be
checked for wear and any damage.
(7) Withdrawal of the forks from service:
Any fork with defects revealed during the above controls
must be withdrawn from service.
Note:
Any component or system tampering can endanger the
vehicle safety.
Any repair and replacement operation should be
performed by personnel adequately trained and
authorised.
 12-23

:W • FSW MAST ASSY

COMPONENTS
1AST ASSY(FW)

6101

BG
12-24

MAST ASSY (FSW)

6ÏÖÏ

42

FORK

6301
02
 12-25

6301
12-26

CHAIN & CHAIN WHEEL (FW)

CHAIN & CHAIN WHEEL (FSW)

6302
 13-1

CYLINDER
Page
LIFT CYLINDER....................................................... 13-2
GENERAL..........................................................................13-2
SPECIFICATIONS............................................................ 13-5
PARACHUTE VALVE (SAFETY DOWN VALVE).......... 13-6
FRONT DISPLACEMENT CYLINDER WITH
BRAKING EFFECT ON LIFTING........................ 13-7
REAR TELESCOPIC CYLINDER WITH BRAKING
EFFECT ON LOWERING..................................... 13-8
FRONT DISPLACEMENT CYLINDER WITH
BRAKING EFFECT ON LIFTING AND
LOWERING......................................................... 13-9
REAR TELESCOPIC CYLINDER WITHOUT
BRAKING EFFECT............................................ 13-10
REAR DISPLACEMENT CYLINDER WITH
BRAKING EFFECT ON LOWERING................ 13-11
REAR OIL FULL CYLINDER WITH BRAKING
EFFECT ON LOWERING.................................... 13-12
DISASSEMBLY « INSPECTION • REASSEMBLY...... 13-13
TILTING CYLINDER.............................................. 13-15
GENERAL....................................................................... 13-15
REMOVAL • INSTALLATION........................................ 13-16
DISASSEMBLY • INSPECTION • REASSEMBLY...... 13-18
13-2

LIFT CYLINDER
GENERAL

FRONT CYLINDER
1.5 to 1.81 2.01

2 displacement cylinder with brake effect on the lifting 2 displacement cylinder with brake effect on the lifting
(standard) (standard)

FW/
2 displacement cylinder with brake effect on the lifting 2 displacement cylinder with brake effect on the lifting FSW
and lowering (optional) and lowering (optional)
 13-3

REAR CYLINDER
1.5 to 1.81 2.01
: telescopic cylinder without braking effect (standard) 2 telescopic cylinder without braking effect (standard)

telescopic cylinder with brake effect on the lowering 2 telescopic cylinder with brake effect on the lowering
optional) (optional)

displacement cylinder with brake effect on the lowering 2 displacement cylinder with brake effect on the lowering
oil full, optional) (oil full, optional)

displacement cylinder with brake effect on the lowering 2 displacement cylinder with brake effect on the lowering
standard) (standard)

FW

telescopic cylinder with brake effect on the lowering 2 telescopic cylinder with brake effect on the lowering
standard) (standard)

displacement cylinder with brake effect on the lowering 2 displacement cylinder with brake effect on the lowering FSW 13
oil full, optional) (oil full, optional)
13-4

MODEL HEIGHT ALL MODELS

MAST OR OPT
mm (in) FORWARD (°) BACKWARD (°) MARK
3000 (118) 5 7 A
3300 (130) 5 7 A
3500 (138) 5 7 A
3700 (146) 5 7 A
V 4000 (157) 5 7 A
4200 (165) 5 7 A
4500 (177) 5 7 A
4700 (185) 5 7 A
5000 (197) 5 7 A
3000 (118) 5 7 A
3300 (130) 5 7 A
FW
3500 (138) 5 7 A
3700 (146) 5 7 A
4300 (169) 5 7 A
4500 (177) 5 7 A
4700 (185) 5 7 A
5000 (197) 5 7 A
FSW 5500 (217) 5 7 A
6000 (236) 5 5 B
6500 (256) 5 5 B
7000 (276) 5 5 B
7500 (295) 5 5 B
CABIN & AFS ALL 5 5 B
 13-5

SPECIFICATIONS

REAR LIFTING CYLINDER V MAST (2M T.V.)

1.5 to 1.81 2.01

Load capacity t 1.8 2.0

Cylinder type Single effect

Cylinder inside diameter mm (in) 45 (1.77) 48 (1.89)

Diston rod outside diameter mm (in) 38(1.50) 40(1.57)

Parachute valve R (See page 13-6) mm (in) 1.2 (0.047) 1.8 (0.071)

:RONT LIFTING CYLINDER FW-FSW MAST (2M F.F.L. - 3M F.F.L.)

1.5 to 1.81 2.01

_oad capacity t 1.8 2.0

Cylinder type Single effect

Cylinder inside diameter mm (in) 48(1.89) 52 (2.05)

3iston rod outside diameter mm (in) 40(1.57) 42 (1.65)

3arachute valve R (See page 13-6) mm (in) 1.2 (0.047) 1.8 (0.071)

REAR LIFTING CYLINDER FW MAST (2M F.F.L.)

1.5 to 1.81 2.0 t

_oad capacity t 1.8 2.0

Cylinder type Single effect

Cylinder inside diameter mm (in) 40(1.57) 45(1.77)

3iston rod outside diameter mm (in) 32(1.26) 35(1.38)

’arachute valve R (See page 13-6) mm (in) 1.2 (0.047) 1.8 (0.071)

REAR LIFTING CYLINDER FSW MAST (3M F.F.L.)

1.5 to 1.81 2.01

.oad capacity t 1.8 2.0

Cylinder type Single effect

Cylinder inside diameter mm (in) 45(1.77) 48(1.89)

3iston rod outside diameter mm (in) 38(1.50) 40(1.57)

Parachute valve R (See page 13-6) mm (in) 1.2 (0.047) 1.8 (0.071)
13-6

PARACHUTE VALVE (SAFETY DOWN VALVE)

The parachute valve enables the locking of the load in the position
where the actuator is in the moment of failure (as it might happen in
case of hose failure, the flow is blocked).

Note: We recommend to verify the integrity of the valve and

eventually to replace it in event that the pressure spike
generated by hose failure was such to damage permanently
some valve components.
Standard: 1.5 to 1.81 1.2 mm (0.047 in)
2.0 t 1.8 mm (0.071 in)
 13-7

RONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

IFTING
Lifting phase:
When acting on the control valve, the oil flows into the cylinder via
the “oil inlet”. Through channels 1, 2 and 3 the oil fills the chamber
A until the internal pressure of the oil exerts an upward thrust
against the surface X. The rod coming out will close the above
mentioned channels.
Near the limit of the stem, the channels 1 and 2 are plugged by the
head, so the oil flowing between the two chambers passes only
through channel 3 (calibrated hole), obtaining a lower flow of oil.

Lowering phase:
if Opening the supply circuit (oil inlet) allows the stem to come down
so that the oil can return to the tank via the control valve. At the
start of this phase, chamber A contains no oil. Better constant filling
is enabled by the channel 3 that by opening avoid jerking.
After passing the cylinder head, the oil flow between the two
chambers passes through channels 1 and 2 which are now open.

Channel 1/2

Chamber A

Channel 3

Surface X
Parachute
valve

T.Torque=3Nm
Chamber B
13-8

REAR TELESCOPIC CYLINDER WITH BRAKING EFFECT ON

LOWERING
Lifting phase:
By operating on the control valve with the lifting lever, the oil flows
to the cylinder through the oil inlet.
It reaches channels 1 and 2 until the hydraulic pressure formed in
chamber A produces a thrust upwards on the surface X thereby
stem extraction.

Lowering phase:
Lowering is permitted by operating on the hydraulic control valve,
opening the oil return circuit to the tank through the control valve.
At the start of this phase, all the oil in chamber A flows out through
the channel 1. Only afterwards, when the bush comes into contact
with the top of the brake body, does the braking action begin,
directing the oil through surface Y, which being very small in
proportion causes the oil coming out to slow down (braking effect).
 13-9

:RONT DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

.IFTING AND LOWERING
Lifting phase:
When acting on the control valve, the oil flows into the cylinder via
the “oil inlet”. Through channels 1, 2 and 3 the oil fills the chamber
A until the internal pressure of the oil exerts an upward thrust
against the surface X. The rod coming out will close the above
mentioned channels.
Near the limit of the stem, the channels 1 and 2 are plugged by the
head, so the oil flowing between the two chambers passes only
through channel 3 (calibrated hole), obtaining a lower flow of oil.

Lowering phase:
Lowering is permitted by operating on the hydraulic control valve,
opening the oil return circuit to the tank through the control valve.
At the start of this phase, all the oil in chamber A flows out through
the channel 3. Only afterwards, when the bush comes into contact
with the top of the brake body, does the braking action begin,
directing the oil through surface Y, which being very small in
proportion causes the oil coming out to slow down (braking effect).

Channel 1/2

Channel 3

Surface Y

Bush

Chamber A

Surface X

©yChamber B
Parachute
valve
T.Torque=3Nm
13-10

REAR TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT

In these cylinders a seal has been fitted on the piston that works on
the inner surface of the cylinder liner.
The rod guide is made by the top cap and by the piston through
anti-friction rings.
The dust control ring prevents any dirty and water from penetrating
control the cylinder.

Lifting phase:
ti-friction By operating on the control valve with the lifting lever, the oil flows
to the cylinder through the oil inlet.
3
Through this channels the oil fills the chamber A until the internal
Cap pressure of the oil exerts an upward thrust against the surface X
thereby stem extraction.

Lowering phase:
Opening the supply circuit (oil inlet) allows the stem to come down
so that the oil can return to the tank via the control valve.
 13-11

<EAR DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON

-OWERING
Lifting phase:
When the control valve is operated, the oil flows into the cylinder
from the “oil inlet”.
Flowing through channel A and chamber B it fills first primary
cylinder (front). The oil exerts an upward force against the surface
X, which set off the outward sliding of the road.

Lowering phase:
Lowering is permitted by operating on the hydraulic control valve,
opening the oil return circuit to the tank through the control valve.
At the start of this phase, all the oil in chamber A flows out through
the channel 1. Only afterwards, when the bush comes into contact
with the top of the brake body, does the braking action begin,
directing the oil through surface Y, which being very small in
proportion causes the oil coming out to slow down (braking effect).
13-12

REAR OIL FULL CYLINDER WITH BRAKING EFFECT ON

LOWERING
Lifting phase:
When acting on the control valve, the oil flows into the cylinder via
the "oil inlet”.
The rod coming out when the internal pressure of the oil exerts an
upward thrust against the surface X.
During the lifting phase, the oil on the chamber A goes to the oil
tank via channel B (siphon effect- the pipe between channel B and
the oil tank will be always full of oil).

Lowering phase:
During this phase, the oil flows out through the channel A.
When the stem beginning the lowering, the oil fills again the
chamber A via channel B (siphon effect).
Only afterwards, when the bush comes in contact with the top of
the brake body, the braking action begins, directing the oil through
surface Y, which being very small in proportion causes the oil
coming out to slow down (braking effect).
 13-13

DISASSEMBLY • INSPECTION • REASSEMBLY

T=N-m (kgf-cm) [ft-lbf]

isassembly Procedure
Remove the cylinder cup (upper side).
Remove the cylinder rod guide.
Remove the piston rod. [Point 1]
Remove the seals on the piston rod.
Remove the cylinder cup (botton side).
Remove the brake system (bushing brake body).
Remove the parachute valve (safety down valve). [Point 2]
Remove the cylinder. [Point 3]

eassembly Procedure
ie installation procedure is the reverse of the removal procedure.

ote:
■ Apply hydraulic oil to packings, O-rings and dust seal lips.
• Apply sealant (Loctite 222) to the threaded portion of the cylinder cup (upper-botton side).
• Add 50±20 ml of hydraulic oil to the cylinder from its top, before installing the cylinder cup.
13-14

Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
(see page 13-5)

Inspection:
Measure the bend of the piston rod.
Limit: 2.0 mm (0.079 in)

[Point 2]
Removal:
SST09610-T1000-71

T= 3 N-m (30.6 kgf-cm) [2.2 ft-lbf]

[Point 3]
Inspection:
Measure the lift cylinder bore, (see page 13-5)

Reassembly:
Only for the oil full cylinder version, after the adjustment
of the draining pipe position (see the picture) tighten the
botton gear with a torque of A: 295 to 305 N m (3009 to
3111 kgf-cm) [217.6 to 225.0 ft-lbf]
 13-15

riLTING CYLINDER

Cylinder specification
Piston rod outside
Cylinder inside diameter Stroke
Tilting degree diameter
mm (in) mm (in)
mm (in)
5° front - 5° back 30 (1.18) 70 (2.76) 60 (2.36)
5° front - 7° back 30 (1.18) 70 (2.76) 72 (2.83)
13-16

REMOVAL • INSTALLATION
T=N-m (kgf cm) [ft-lbf]

Removal Procedure
1. Remove the footboard.
2. Remove the tilt cover.
3. Set the mast in vertical position and disconnect the hose.
4. Remove the tilting cylinder front pin.
5. Remove the tilting cylinder rear pin.
6. Remove the tilting cylinder.

Note:
If both tilting cylinder are removed, fix the mast with a chain in
order to avoid the mast overturning.

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

Note:
• Apply grease to the insertion portions of the tilting cylinder front and rear pins before installation (Shell
Mobil Grease special or equivalent).
• Don’t tilt the mast backward maximum before adjust the mast tilt angle.
• Check the hydraulic oil level and add if insufficient.
• After the installation, slowly tilt the mast forward and backward a few times without change to bleed the
air in the hydraulic circuit and to check the normal functioning.
• After the installation, perform SAS matching if the tilt angle sensor is removed.
 13-17

adjustment

y adjusting the internal-lock lenght of the screw between the rod and the joint, it is possible to adjust the mast tilting
ngle by turning the rod (1).

he tolerance range of the mast tilting angle:

3 wheel models 4 wheel models

Forward 0° to -0.4° 0° to 0.4°
Backward 0.2° to 0.4° 0.6° to 0°

he difference of the stroke between both tilt cylinder shall be within 1 mm.

ote:
• Adjust the mast forward and backward tilting angle (to prevent uneven tilting) when the tilting cylinder
and the mast are replaced or disassembled.
• After adjustment perform SAS matching.
• When adjusting the rod joint by loosening it, make sure that the remaining thread length is 25 mm (0.98
in) or less.
13-18

DISASSEMBLY • INSPECTION • REASSEMBLY

T=N-m (kgf-cm) [ft-lbf]

Disassembly Procedure
1. Remove the rod connection.
2. Loosen the rod guide. [Point 1]
3. Extract the piston rod W/piston.
4. Loosen the piston nuts.
5. Inspect the cylinder. [Point 2]
6. Inspect the piston rod. [Point 3]

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

Note:
• Apply hydraulic oil to packings, O-rings and dust seal lips.
• Apply antioxidant on rod eye threads.
• Replace the piston nut after every removal procedure.
13-19
 14-1

OIL PUMP
Page
GENERAL..................................................... 14-2
COMPONENTS......................................................... 14-3
DISASSEMBLY • INSPECTION •
REASSEMBLY......................................................... 14-4
TEST METHOD......................................................... 14-6

14
14-2

GENERAL

Vehicle model 8FBET (8FBMT) 15 to 20

Oil pump name Single gear pump
Oil pump type TMG1A21A9H5-L (Shimadzu)
Drive system Direct motor drive
Delivery (pump at 1500rpm) l(US gal)/min 30.8 (8.14)
Theoretical discharge cm3(in3)/rev 21.9(1.336)
 14-3

6701
 14-4

DISASSEMBLY • INSPECTION • REASSEMBLY

T=Nm (kgf-cm) [ft-lbf]

Disassembly Procedure
1. Remove the oil pump assy. (See page 5-11)
2. Make match marks between the front cover and body and between the rear cover and body. [Point 1]
3. Place the front cover face downward, and remove the bolts. (4 pcs.)
4. Remove the rear cover ASSY (rear cover, bushing, gasket and figure 3 gasket). [Point 2]
5. Remove the drive gear, driven gear and side plate. [Point 3]
6. Remove the driver gear, driven gear and side plate. [Point 4]
7. Remove the oil seal. [Point 5]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Wash each parts, blow compressed air and apply hydraulic oil before installation.
• Always use new seals for reassembly.

Point Operation
[Point 1]

Disassembly:
Make match marks between the front cover and body and between
the rear cover and body.

Reassembly:
Align match marks when reassembling.
 14-5

[Point 2]
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.

[Point 3]
Wear limit: 0.15 mm Inspection:
(0.0059 in) or less The side plate surface (LBC surface) in contact with gears should
LBC surface not be worn beyond the limit shown at left.
(yellow)
Discharge Suction port
port

Erosion by cavitation Strong contact

Wipe depth Inspection:

Inspect the body inner surface for the wipe mark.
Normal wipe depth: 0.01 to 0.06 mm (0.0004 to 0.0024 in.)

[Point 4]
Inspection:
Make match marks on the tooth flanks of the drive and driven 14
gears.
Reassembly:
Align match marks when reassembling.

[Point 5]
Inspection:
1. 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 seal are not swollen.
14-6

TEST METHOD
A bench 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.
• Measure the time of full stroke of the lift cylinder with the hydraulic oil temperature at 50 to 55 °C (122 to 131 °F)
and calculate the lifting speed. However, due to soft start by material handling chopper circuit, lifting speed is 10
to 20 mm/sec (2.0 to 3.9 fpm) lower than the value obtained from the table. The lifting speed can be calculated
more accurately by may 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 on a certain condition.

Lifting speed reference value

mm/s

8FBET15 8FBET16 8FBET18 8FBET20

8FBEKT16 8FBEKT18
Vehicle model
8FBMT15 8FBMT16 8FBMT18 8FBMT20
No load Load No load Load No load Load No load Load
H 610 440 610 430 610 420 540 380
Lifting P 550 350 550 340 540 310 480 280
V
S 480 260 480 250 480 240 420 200
Lowering ALL 550 530 550 530 550 530 500 520
H 570 390 570 390 570 380 500 340
Lifting P 500 320 500 310 500 280 440 260
FSW
S 440 240 440 230 440 200 380 180
Lowering ALL 450 510 450 510 450 510 390 490
H 570 400 570 400 570 390 490 340
Lifting P 510 330 510 310 510 290 430 260
FW
S 440 250 440 230 450 210 380 190
Lowering ALL 420 500 420 500 420 500 340 470

Note:
The lowering speed might change within the range of ± 15% by the specification of the hydraulic system.
 15-1

OIL CONTROL VALVE

Page
OIL CONTROL VALVE ASSY................................. 15-2
GENERAL.......................................................................... 15-2
SPECIFICATIONS............................................................. 15-7
COMPONENTS.................................................................. 15-8
TROUBLESHOOTING................................................... 15-14
REMOVALINSTALLATION...........................................15-31
DISASSEMBLYINSPECTIONREASSEMBLY .......... 15-33
RELIEF PRESSURE ADJUSTMENT.................. 15-38
MANUAL DOWN VALVE....................................... 15-40

15
15-2

OIL CONTROL VALVE ASSY

GENERAL

X1
15-3
15-4

X3-X3

X4-X4
 15-5

5-X5

olenoid Connector Diagram

rroponionai soienoia (d; connector

15-6

Hydraulic Circuit Diagram

 15-7

SPECIFICATIONS
8FBET15 8FBEKT16 8FBET16 8FBEKT18 8FBET18 8FBET20
type Add-on type
18.3(187)
Lift <- <- <- <- <-
belief set pressure [2660]
MPa (kgf/cm2) [psi] 18.3(187)
Tilt <- <- <- <- <-
[2660]
:low regulator flow rate
50 (13.2) <- <- <- <- 55 (14.5)
//min (US gal/min)
No-load 520 (102) <- <- <- <- 500 (98)
V
Loaded 520(102) <— <- <- 510(100)
.owering speed No-load 400 (79) <— <- <— <- 370 (73)
ipecification FSW
mm/sec (fpm) Loaded 500 (98) <- <- <- <- 480 (94)
No-load 360(71) <- <- <- <- 320 (63)
FW
Loaded 490 (96) — <- <- <- 450 (89)

8FBMT15 8FBMT16 8FBMT18 8FBMT20

ype Add-on type
18.3(187)
Lift <- <- <-
belief set pressure [2660]
MPa (kgf/cm2) [psi] 18.3(187)
Tilt <—
[2660]
:low regulator flow rate
50 (13.2) <— <- 55 (14.5)
//min (US gal/min)
No-load 550(108) <- <— 500 (98)
V
Loaded 530(104) <- <- 520 (102)
.owering speed No-load 450 (88) <- <- 390 (77)
ipecification FSW
mm/sec (fpm) Loaded 510(100) <— <— 490 (97)
No-load 420 (83) <- <- 340 (67)
FW
Loaded 500 (98) <- <- 470 (92)
15-8

COMPONENTS

6705

6705-C89
 15-9

6705

L . . .--------------------------------------------------- ... J
[INLET]

6705-C94
15-10

6705
01

74ÍLIFT1

6705-C95A
 15-11

6705
01
r'" ■1
01K=(INCL. )•
74[LIFT]
[INLET]

10[ATT]

[OUTLET]

■
75[TILT] i
■
L. J

75[TILT]
15-12

6705

75[TILT]
L . . .-------------------------------------------------------- . . . J

10[ATT, 3-WAY]

6705-C97
 15-13

6705
01

75[TILT]

[OUTLET] [CLAMP]

6705-C98
TROUBLESHOOTING

15-14
Note:
For the portions of (1) ~ (12) in the table, refer to page 15-27 to 30.
Operation Phenomenon Probable cause Inspection item
During lift operation Cannot lift Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Manual down valve is loose • Whether the manual down valve is tightened
Load pressure detection circuit check valve (2) stuck closed • Not possible to inspect
Lift by-pass check valve (1) stuck closed and the lift lock • Whether the lift by-pass check valve and lift lock plunger can
plunger stuck closed be removed
• Whether there are any scratches on the lift by-pass check
valve and lift lock plunger
• Whether foreign matter is stuck in the lift by-pass check
valve or lift lock plunger
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Decompression valve piston stuck closed • Whether the decompression valve piston can be removed
• Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston stuck closed • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
 ** r

During lift operation Cannot lift Main spool stuck closed • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Lift speed is low Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL seat defect • Not possible to inspect
Manual down valve is loose • Whether the manual down valve is tightened
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve (2) malfunction • Not possible to inspect
Lift by-pass check valve (1) malfunction • Whether there are any scratches on the lift by-pass check
valve
• Whether foreign matter is stuck in the lift by-pass check
valve
Lift lock plunger malfunction • Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Lift spool malfunction • Whether the lift spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)

15-15
 15-16
Operation Phenomenon Probable cause Inspection item
During lift operation Lift speed is low Decompression valve piston malfunction • Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston malfunction • Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Cannot lower Lift lock SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Lift lock plunger stuck closed • Whether the lift lock plunger can be removed
• Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice (5) • Whether foreign matter is stuck in the lift lock plunger orifice
Lift spool stuck closed • Whether the lift spool can be operated
Foreign matter is stuck in the lift lock valve pilot circuit (4) • Whether foreign matter is stuck in the lift lock valve pilot
circuit
Lowering speed is slow Lift lock SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Lift lock plunger malfunction • Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
 ( > iwi ivi ( ivi ivi i 1 1 VMMMIVI WUMW II 1 ILGIII

During lift operation Lowering speed is slow Foreign matter is stuck in the lift lock plunger orifice (5) • Whether foreign matter is stuck in the lift lock plunger orifice
Foreign matter is stuck in the lift lock valve pilot circuit (4) • Not possible to inspect
Flow regulator valve piston malfunction • Whether there are any scratches on the flow regulator valve
piston
• Whether foreign matter is stuck in the flow regulator valve
piston
Insufficient spring force of the flow regulator valve piston • Whether the return spring is broken
spring • Whether the return spring base surface (6) is worn
Decompression valve piston malfunction • Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston malfunction • Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck In the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Cannot tilt forward Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Tilt control valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Tilt control valve plunger stuck closed • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger

15-17
 Operation Phenomenon Probable cause Inspection item

15-18
During lift operation Cannot tilt forward Foreign matter is stuck in the tilt control valve plunger orifice • Whether foreign matter is stuck in the tilt control valve
(7) plunger orifice
Tilt spool stuck closed • Whether the tilt spool can be operated
Foreign matter is stuck in the tilt control valve pilot circuit (8) • Whether foreign matter is stuck in the tilt control valve pilot
circuit
Tilt lock plunger stuck closed • Whether the tilt lock plunger can be removed
• Whether there are any scratches on the tilt lock plunger
• Whether foreign matter is stuck in the tilt lock plunger
Load pressure detection circuit check valve (9) stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Foreign matter is stuck in the tilt lock plunger pilot orifice (three • Whether foreign matter is stuck in the tilt lock plunger pilot
places) orifice
Decompression valve piston stuck closed • Whether the decompression valve piston can be removed
• Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston stuck closed • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Forward tilt speed is Unload SOL operated • Whether you can hear the operating sound of the solenoid
slow when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Tilt control valve SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
During lift operation Forward tilt speed is Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
slow plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL seat defect • Not possible to inspect
Tilt control valve malfunction • Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Foreign matter is stuck in the tilt control valve plunger orifice • Whether foreign matter is stuck in the tilt control valve
(7) plunger orifice
Foreign matter is stuck in the tilt control valve pilot circuit (8) • Whether foreign matter is stuck in the tilt control valve pilot
circuit
Tilt lock plunger malfunction • Whether there are any scratches on the tilt lock plunger
• Whether foreign matter is stuck in the tilt lock plunger
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve (9) malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Decompression valve piston malfunction • Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston malfunction • Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool

15-19
 Operation Phenomenon Probable cause Inspection item
During lift operation Cannot tilt backward Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Tilt spool stuck closed • Whether the tilt spool can be operated
Load pressure detection circuit check valve stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Decompression valve piston stuck closed • Whether the decompression valve piston can be removed
• Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston stuck closed • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Backward tilt speed is Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
slow when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
 VrpCI CIIIUI1 r 1101 ivi i lei ivi i i luuauiu uauou il IQpUVUUl 1 tltzlll

During lift operation Backward tilt speed is Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
slow plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL seat defect • Not possible to inspect
Tilt spool malfunction • Whether the tilt spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Decompression valve piston malfunction • Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston malfunction • Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck In the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Key switch OFF Natural drop is big Lift lock SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Lift lock plunger seat malfunction • Whether there are any scratches on the seat surface
• Whether foreign matter is stuck on the seat surface
Lift lock plunger stuck open • Whether the lift lock main plunger can be removed
• Whether there are any scratches on the lift lock main
plunger
• Whether foreign matter is stuck in the lift lock main plunger
 Operation Phenomenon Probable cause Inspection item
Key switch OFF Natural drop is big Insufficient spring force of the lift lock plunger return spring • Whether the return spring is broken
• Whether the return spring base surface is worn
Lift by-pass check valve seat defect • Whether there are any scratches on the seat surface
• Whether foreign matter is stuck on the seat surface
Lift by-pass check valve plunger stuck open • Whether the lift by-pass check valve plunger can be
removed
• Whether there are any scratches on the lift by-pass check
valve plunger
• Whether foreign matter is stuck in the lift by-pass check
valve plunger
Insufficient spring force of the lift by-pass check valve return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Manual down valve is loose • Whether the manual down valve is tightened
Lift lock SOL seat defect • Not possible to inspect
Wear or damage of the flow regulator valve sleeve (10 or
• Whether the sleeve or O-ring is worn or damaged
O-ring No.2 (12)
Natural forward tilt is Tilt control valve SOL stuck open • Whether you can hear the operating sound of the solenoid
big when operating the lever with the key switch ON
Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
• Whether foreign matter is present on the seat surface
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball • Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect • Not possible to inspect
Forward tilt automatic Does not stop Tilt control valve SOL stuck open • Whether you can hear the operating sound of the solenoid
leveling stop automatically when operating the lever with the key switch ON
Proportional solenoid malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Forward tilt automatic Does not stop Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
leveling stop automatically • Whether foreign matter is present on the seat surface
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball • Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect • Not possible to inspect
Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Tilt spool stuck open • Whether the tilt spool can be removed
• Whether there are any scratches on the tilt spool
• Whether foreign matter is stuck in the tilt spool
Backward tilting speed Speed is fast Tilt control valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
regulation when operating the lever with the key switch ON
Tilt control valve malfunction • Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Foreign matter is stuck in the tilt control valve pilot circuit • Whether foreign matter is stuck in the tilt control valve pilot
circuit
During ATT operation ATT does not move Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON

15-23
 15-24
Operation Phenomenon Probable cause Inspection item
During ATT operation ATT does not move Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
ATT spool stuck closed • Whether ATT spool can be operated
Load pressure detection circuit check valve stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Decompression valve piston stuck closed • Whether the decompression valve piston can be removed
• Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston stuck closed • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
ATT movement is slow Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
 UIIV1 1 1 1 IXzl IV/t 1 IVI IWI 1 1 IWMUUIU UUUUV II lOpOL/LIUI 1 ILC7I 1 1

During ATT operation ATT movement is slow Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL seat defect • Not possible to inspect
ATT spool malfunction • Whether ATT spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Decompression valve piston malfunction • Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston malfunction • Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
During OPS operation Forks do not stop when Unload SOL stuck closed • Whether you can hear the operating sound of the solenoid
moving upward when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger stuck closed • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger

15-25
 Phenomenon Probable cause Inspection item

15-26
Operation
During OPS operation Forks do not stop when Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
moving upward removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Main spool stuck open • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Forks do not stop when Lift lock SOL stuck open • Whether you can hear the operating sound of the solenoid
moving downward when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Lift lock plunger stuck open • Whether the lift lock plunger can be removed
• Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice • Whether foreign matter is stuck in the lift lock plunger orifice
Foreign matter is stuck in the lift lock valve pilot circuit • Whether foreign matter is stuck In the lift lock valve pilot
circuit
Wear or damage of the flow regulator valve sleeve (10) or
• Whether the sleeve or 0-ring is worn or damaged
O-ring No.2 (12)
Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Main spool stuck open • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Forks do not stop when Tilt control valve SOL stuck open • Whether you can hear the operating sound of the solenoid
tilting forward when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
• Whether foreign matter is present on the seat surface
During OPS operation Forks do not stop when Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
tilting forward • Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball • Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect • Not possible to inspect
Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Main spool stuck open • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Forks do not stop when Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
tilting backward removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Main spool stuck open • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
ATT does not stop Unload SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Proportional SOL malfunction • Remove the proportional SOL (while harness is connected),
and check whether the pin at the tip is operating when the
lever is operated.
Relief valve main plunger stuck closed • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
• plunger
• Whether foreign matter is stuck in the relief valve main

15-27
plunger
 15-28
Operation Phenomenon Probable cause Inspection item
During OPS operation ATT does not stop2 Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional valve
piston
Main spool stuck open • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
15-29
15-30

/ h A

(4)
 15-31

EMOVALINSTALLATION
ote:
perate the control lever to bring the mast and fork to the vertical and lowermost positions, respectively, to
lease the residual pressure in the material handling system before starting removal.
T = N-m (kgfcm) [ft-lbf]

emoval Procedure
Remove the battery ASSY. (See page 1-5).

Remove the toe board (FR, RR).

Remove the front battery panel.
Remove the accelerator pedal and brake pedal with the relevant linkages.

Disconnect the oil control valve wiring harness.

Remove the fixing brackets of the oil control valve hoses/pipes.

Remove the hoses/pipes from the oil control valve. [Point 1]

Sling the oil control valve bracket by belts.
Remove the bracket from the oil control valve.

istallation Procedure
ie installation procedure is the reverse of the removal procedure.

ote:
neck the hydraulic oil level, and add if insufficient.
15-32

Point Operations
[POINT 1]

Inspection:
Tightening torque:
A: 32 to 34 N m (326 to 347 kgf-cm) [23.6 to 25.1 ft-lbf]
B: 59 N m (601.8 kgf-cm) [43.5 ft-lbf]
 15-33

HSASSEMBLYINSPECTIONREASSEMBLY
ote:
• Work in a clean location.
• Since individual parts are finished with high precision, carefully operate so as not to damage them.
T = N-m (kgf-cm) [ft-lbf]

isassembly Procedure
Remove the lift lock SOL and flow regulator valve. [Point 1]
Remove the tilt control SOL. [Point 2]

Remove the proportional SOL (a). [Point 3]

Remove the proportional SOL (b). [Point 4]

Remove the tilt spool, tilt spool and attachment spool.
Remove the unload SOL. [Point 5]

Remove the relief valve. [Point 6]

Remove the rod bolt, and then remove the housing.

15-34

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.

Point Operations
[Point 1]
Disassembly:
Put match marks to prevent solenoid installation in an incorrect
position.
Reassembly:
Align match marks for reassembly.

Inspection:
Check the lift lock solenoid resistance.
Standard: 7 to 17 Q

Inspection:
Check and clean any clogged filter.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool, etc.

[Point 2]
Inspection:
Check the tilt solenoid resistance.
Standard: 7 to 17 Q
 15-35

Inspection:
Check and clean any clogged filter.

Inspection:
Check and clean any clogged orifice.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.

[Point 3]
Inspection:
Check the proportional solenoid (a) continuity.
Measurement terminal 1 <=> 5: Continuity exists.
Measurement terminal 2 <=> 6: Continuity exists.
Measurement terminal 3 <=> 7: Continuity exists.
Measurement terminal 4 <=> 8: Continuity exists. (4-way valve)
Check the proportional solenoid (a) resistance.
Standard: 5 to 12 &

Disassembly:
Before disassembly, measure the installation position
(dimension A) of the material handling start timing adjusting
screw.
Reassembly:
Reassemble according to the dimension A measured before
disassembly.
Adjustment:
After installing the control valve to the vehicle, check whether
there are any abnormalities in material handling start timing by
slowly operating the lever. If you feel any abnormalities,
perform tuning with the display. (See section 3)
15-36

[Point 4]

Inspection:
Check the proportional solenoid (b) for continuity.
Measurement terminal 1 <=> 5: Continuity exists.

Measurement terminal 2 <=> 6: Continuity exists.

Measurement terminal 3 <=> 7: Continuity exists.
Measurement terminal 4 <-> 8: Continuity exists. (4-way valve)

Check the proportional solenoid (b) resistance.

Standard: 5 to 12 Q

Disassembly:
Before disassembly, measure the installation position
(dimension A) for the material handling start timing adjusting
screw.

Reassembly:
Reassemble according to the dimension A measured before
disassembly.
Adjustment:
After installing the control valve to the vehicle, check whether
there are any abnormalities in material handling start timing by
slowly operating the lever. If you feel any abnormalities,
perform tuning with the display. (See section 3)

[Point 5]
Inspection:
Check the unload solenoid resistance.
Standard: 7 to 17 Q

Inspection:
Check and clean any clogged filter.
 15-37

Installation:
Before installing the unload solenoid, turn the solenoid
clokwise at 6 times.

Installation:
Install the wire harness in the area shown in the figure.

[Point 6]
Inspection:
Check and clean any clogged filter.

Reassembly:
When the relief valve is disassembled, temporarily install it

Q
■< ’r* ï
after fitting the nuts as illustrated.

a = 27.0 mm (1.06 in)

r—s
.1J J
(
<- -
c—>

L L 2
15-38

RELIEF PRESSURE ADJUSTMENT

Note:
• Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause high
pressure generation that may result in damage to the oil pump and other hydraulic devices.
• Before starting adjustment, check if the no-load maximum rpm is as specified.

1. Open the battery hood.

2. Remove the lower panel and toe board.
3. Install an oil pressure gauge.
Remove the oil-pressure detecting plug installed on the left
side of the oil control valve, and install the oil pressure gauge
there.
Fitting: 90407-13469-71

4. Set the adjusting screw A and adjusting sleeve B of the relief

valve as described below.
(1) Loosen lock nut 1. After fully tightening adjusting screw A
once, loosen it by 1 to 2 turns.
(2) Loosen lock nut 2, and position adjusting sleeve B to the
following dimension.
a = 27.0 mm (1.06 in)

5. Operate the lift lever, and check for oil leaks and abnormal
noise.
6. Install the toe board.
7. Close the battery hood.
8. Adjust the lift side relief pressure.
(1) Set the seat switch to ON. (Operate by two workers with
one sitting on the seat.)
(2) Operate the lift lever to lift the fork fully.
(3) Operate the lift lever to the lifting side. Gradually tighten
adjusting sleeve B to make the oil pressure in the relief
state satisfy the standard in the table on the next page,
and fix the sleeve position by tightening lock nut 2.
 15-39

9. Adjust the tilt side relief pressure.

(1) Set the seat switch to ON. (Operate by two workers with
one sitting on the seat.)

(2) Operate the tilt lever to tilt the mast fully backward.

(3) Operate the tilt lever to the backward side. Gradually

tighten adjusting screw A to make the oil pressure in the
relief state satisfy the standard in the table below, and fix
the sleeve position by tightening lock nut 1.

10. Turn the key switch OFF.

11. Remove the oil pressure gauge, and install and tighten the
removed plug.
*o
Standard: 18.3 5 MPa (187
*5 kfg/cm2) [2260
*J 2,5 psi]
15-40

MANUAL DOWN VALVE

T = N m (kgf-cm) [ft-lbf]

If the forks do not descend due to a malfunction or other cause, loosen the manual down valve to lower the forks in
emergencies.
When loosening the manual down valve, do not rotate it more than one full turn.
After making repairs, tighten it securely.
 16-1

SAS FUNCTIONS
Page
GENERAL.................................................................. 16-2
COMPONENTS........................................................ 16-4
FOR REPAIR WORK..................................................... 16-10
KNOB POSITION CORRECTING VALVE........... 16-11
REMOVAL-INSTALLATION.......................................... 16-11
TIRE ANGLE SENSOR (3 WHEEL MODELS) ..16-13
REMOVAL-INSTALLATION.......................................... 16-13
TIRE ANGLE SENSOR (4 WHEEL MODELS) ..16-15
REMOVAL-INSTALLATION .......................................... 16-15
TILT ANGLE SENSOR.......................................... 16-17
REMOVAL-INSTALLATION.......................................... 16-17
LOAD SENSOR...................................................... 16-18
REMOVAL-INSTALLATION.......................................... 16-18
SWING LOCK CYLINDER....................................16-19
REMOVAL-INSTALLATION.......................................... 16-19
HEIGHT SWITCH................................................... 16-21
REMOVAL-INSTALLATION.......................................... 16-21
MATCHING.............................................................. 16-22
GENERAL....................................................................... 16-22
16
VEHICLE STANDARD STATE.......................................16-24
CAUTIONS ON MODIFYING VEHICLES............ 16-25
16-2

GENERAL
SAS (System of Active Stability) System
Sensors and switches installed at each portion of the vehicle detect the vehicle movement and output signals to the
controllers. These signals are processed in the controllers to drive each actuator for active mast function control (T)
and active steering synchronizer with FHPS (K) and active control rear stabilizer (S)
*1 .

S: Active Control Rear Stabilizer

T: Active Mast Function Control
K: Active Steering Synchronizer with FHPS

Input Output

—Control
Sensor / Switch

1
""

Height switch
S

Oo
T K

» s

O
T K
Control

10 Swing lock cylinders

Actuator

2 Tilt angle sensor o o 11 Tilt control valve

o
-►
L-
3 Tilt lever angle sensor
Ö
O
L.
o 12
Tilt electric proportional
valve
-w
4 Lift lever angle sensor o o
c
o -► o 13 Lift lock valve
c
5 Load sensor o o ‘co
-► 0 14
Knob position correcting
valve

6
Automatic fork leveling
control switch o
7 Steering wheel angle sensor o
8 Tire angle sensor o
9 Vehicle speed sensor *2 o o
*1: Only for 4 wheel models
*2: The vehicle speed is detected by the motor speed sensors via the drive motor drivers.
 16-3

No. Name No. Name

1 Height switch 9 Vehicle speed sensor

2 Tilt angle sensor 10 Swing lock cylinder

3 Tilt lever angle sensor 11 Tilt control valve

4 Lift lever angle sensor 12 Tilt electric proportional valve

5 Load sensor 13 Lift lock valve

6 Automatic fork leveling control switch 14 Knob position correcting valve

7 Steering wheel angle sensor 15 Main controller

8 Tire angle sensor

16
16-4

COMPONENTS
Main controller (8FBET, 8FBEKT)

2401

2401-373

Main controller (8FBMT)

2401
 16-5

ire angle sensor (8FBET, 8FBEKT)

4301

ire angle sensor (8FBMT)

4301
16-6

Swing lock cylinder (8FBMT only)

4301

Knob position correcting valve

4507
 16-7

leight switch (V mast)

5803

5803-514

leight switch (FW, FSW mast)

5803

5803-515
16-8

Tilt angle sensor

5803

5803-510A

Load sensor

5803

5803-512
 16-9

ehicle speed sensor

1402

1402-157A
16-10

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 waterjet 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) and SST 09580-10920-71.

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) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(3) 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.
(4) Tighten the set bolts of respective functional parts to the specified torque.
(5) No adjustment is necessary for each sensor at the time of installation, but be sure to perform matching after
the installation.
(6) When disconnecting a connector, don’t pull it at the harness.
(7) When inspecting the harness, be sure to avoid taken not to damaging the connector terminals.
(8) Swing look cylinder cannot be disassembled. If disassembled, the air will enter, and it will become non-
reusable.
(9) Don't turn the key switch to ON with one side (either right - or left-hand side) of the vehicle jacked up.
Turning the key switch to ON unlocks the lock cylinder and causes the vehicle to be tilted suddenly, leading
to great danger.
(10) Never use an impact wrench for removing or installing the controller. Full care should be taken not to drop
controller by mistake avoid impact from dropping that may damage parts inside.
(11) The meanings of high and low fork heights in the troubleshooting section are as follows:
- Low fork height: From the lowermost position to immediately before actuation of the fork height switch
- High fork height: Height above the position where the fork height switch is actuated

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 manual down valve
and operate the lift lever to the down position.

Note:
After repair, do not forget to retighten the manual down valve
bolt. If the manual down valve is loosened, the lifting speed is
remarkably decreased.
 16-11

[NOB POSITION CORRECTING VALVE

IEMOVAL-I INSTALLATION
T = N-m (kgfcm) [ft-lbf]

emoval Procedure
Disconnect the battery plug.
Remove the column cover (FR).
Remove the direction cover (FR, RR).
Disconnect the connectors around the mast jacket.
Remove the return spring.
Remove the tilt lock mechanism and tilt steering lock release lever.
Remove the steering valve set bolts. [Point 1]
Remove the mast jacket.
Remove the front panel.
). Remove the fittings. [Point 2]
i. Remove the steering valve ASSY W/ knob position correcting valve.
>. Remove the knob position correcting valve from the steering valve.
16-12

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Add MP grease at the coupling between the steering shaft and steering valve.

Point Operations
[Point 1]

RemovaHnstallation:
Pull up the steering valve with a rope or equivalent.

[Point 2]

Inspection:
Install the fitting with the angle shown in the illustration.
T= 32 to 36 N-m (326 to 367 kgf-cm) [23.6 to 26.6 ft-lbf]

W/ Steel cabin or Front windshield models

RemovaHnstallation:
Using SST, remove the steering valve fittings.
SST 09451-13240-71
 16-13

IRE ANGLE SENSOR (3 WHEEL MODELS)

tEMOVAL-l INSTALLATION
T = N-m (kgf-cm) [ft-lbq

emoval Procedure
Disconnect the battery plug.

Remove the counterweight. (See page 10-10)

Disconnect the connector from the tire angle sensor.
Remove the tire angle sensor and joint.
Remove the tire angle sensor plate.

Remove the bracket.

Remove the joint cover.

istallation Procedure
Install the joint cover.
Temporarily install the bracket and sensor plate.

Using SST, to adjust the concentricity of the rear axle and sensor plate hole. [Point 1]

Tighten the bracket set bolt.

Install the tire angle sensor. [Point 2]

Connect the connector to the tire angle sensor.

Install the counterweight and connect the battery plug.

lution:
ign the tapping screw axis and the sensor plate hole straight for installation. If screwed out of position,
place the sensor plate with a new one.
hen the tapping screw is removed, the sensor plate should be replaced with a new one.

>te:
* 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.
16-14

Point Operations
[Point 1]
Inspection:
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.
SST 09580-10920-71

[Point 2]
Inspection:
Insert the tire angle sensor in the position as the upper figure
and align the holes with turning clockwise about 110°.

Note:
Attention in use of the tapping screw (how to cope on the manufacture line):
1. Thrust the tapping screw straight so that the hole axis may align with the screw axis.
2. Exchange the tire angle sensor plate for new one when you thrust a screw obliquely. Then, scrap that.
3. Exchange the tire angle sensor plate for new one when you remove a screw once even if you thrust a
screw normally. Then, scrap that.
 16-15

IRE ANGLE SENSOR (4 WHEEL MODELS)

REMOVAL-INSTALLATION
T = N-m (kgf-cm) [ft-lbf]

Removal Procedure
Disconnect the battery plug.
Disconnect the connector from the tire angle sensor.
Remove the tire angle sensor. [Point 1]
Remove the tire angle sensor and joint. [Point 2]

Remove the tire angle sensor plate.

retaliation Procedure
he installation procedure is the reverse of the removal procedure.
aution:
lign the tapping screw axis and the sensor plate hole straight for installation. If screwed out of position,
»place the sensor plate with a new one.
fhen the tapping screw is removed, the sensor plate should be replaced with a new one.
ote:
• 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.
16-16

Point Operations
[Point 1]
Inspection:
Insert the tire angle sensor in the position as the upper figure
and align the holes with turning clockwise about 110°.

[Point 2]
Removal:
Remove the O-Ring on the tire angle sensor and the bracket.

Inspection:
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.
SST 09580-10920-71
 16-17

ILT ANGLE SENSOR

tEMOVALINSTALLATION
T = N-m (kgf-cm) [ft-lbf]

T=10 to 16 (100 to 160) [7.4 to 11.8]

emoval Procedure
Disconnect the battery plug.
Remove the toe boards (FR, RR).
Remove the right instrument panel.
Remove the tilt cylinder cover.
Disconnect the tilt angle sensor linkage. [Point 1]
Disconnect the wiring connector.
Remove the tilt angle sensor.

istallation Procedure
ie installation procedure is the reverse of the removal procedure.
ate:
• Perform matching if the tilt angle sensor is removed or replaced.
• For installation, apply MP grease on sliding section of the end.

Point Operations
[Point 1]
Removal:
(1) Apply the adhesive 08833-76002-71 (08833-00080) or
equivalent on screw part of rod.
(2) Before tighten the nut of the rod hold on to prevent
rotation.
16-18

LOAD SENSOR
REMOVALINSTALLATION

Removal Procedure
1. Lower the forks to the ground, tilt the mast all forward and switch off.
2. Disconnect the battery plug.
3. Remove the toe-board (FR, RR).
4. Disconnect the load sensor wiring connector.
5. Unscrew the load sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Perform matching when the load sensor is removed, installed or replaced.
 16-19

¡WING LOCK CYLINDER

EMOVAL'INSTALLATION

emoval Procedure
Remove the counterweight ASSY. (See page 10-10)
Jack up the vehicle until the rear wheels leave the ground.
Disconnect the swing lock solenoid connector. [Point 1]

Remove the swing lock cylinder crank pin. [Point 2]

Remove the swing lock cylinder pin.

Remove the swing lock cylinder ASSY W/crank. [Point 3]

Remove the swing crank from the swing lock cylinder.

stallation Procedure
ie installation procedure is the reverse of the removal procedure.
)te:
• Apply molybdenum disulfide grease on the spherical portion of the cylinder pin before installation.
* Apply thread tightener 08833-76001-71 (08833-00070) to the threaded portions of the cylinder pin and
crank pin set bolts before tightening them.
Add molybdenum disulfide grease through the grease fitting after installation.
16-20

Point Operations
[Point 1]
Inspection:
Before install the pins, check the shape.

[Point 2]
Removal:
Make match marks on the swing crank and crankpin.

Inspection:
Install by aligning the match marks.

[Point 3]
Inspection:
Accumulator inspection
(1) Remove the plug from the tip end of the accumulator.

(2) Check the accumulator depth by gauge.

(3) Measure accumulator depth L.

Standard : L = 46 mm (1.81 in) (20°C (68°F))

Limit: L = 52 mm (2.05 in) (20°C (68°F))

If the limit value is exceeded, replace the swing lock

cylinder ASSY.
(4) After inspection, tighten the plug to be flush with the end
face of the accumulator (do not tighten it excessively).
 16-21

IEIGHT SWITCH

'EMOVAL-INSTALLATION
T = N-m (kgf-cm) [ft-lbf]

emoval Procedure
Remove the cover. (FW, FSW mast)

Disconnect the wiring connector.

Remove the height switch.

istallation Procedure
ie installation procedure is the reverse of the removal procedure.
16-22

MATCHING
GENERAL
Each function is controlled by using the sensors and each the signal voltage at standard vehicle condition stored in
the controller at the time of shipment
Therefore, a matching (updating of the signal voltage of a sensor at standard vehicle condition) is required when
performing maintenance on a section or replacing parts related to the sensors.

Matching Items and Prerequisite for Implementation

1. DRIVE
See Control System on page 3-62.

2. SAS

Prerequisite for
No. Indication Description
implementation
1 TILT LEVEL Tilt angle sensor output value with fork in the horizontal position. *1, *4, *5, *8, *9, *10
Tilt angle sensor output value at the forward tilt limit position and the *1,
*4, *5, *6, *8, *9,
2 TILT FWD LIMIT
load sensor output value with without load. *10
3 TIRE POSITION Tire angle sensor output value while the vehicle is traveling straight. *1, *7

3. MINI LEVER (or joystick)

Prerequisite for
No. Indication Description
implementation
1 LEVER 1 Lift lever angle sensor output value at the lift lever neutral position. *11
*1,
2 LEVER 2 Tilt lever angle sensor output value at the tilt lever neutral position. *12
*1,
Attachment (1 ) lever angle sensor output value at the attachment (1 )
3 LEVER 3 *13
*1,
lever neutral position.
Attachment (2) lever angle sensor output value at the attachment (2)
4 LEVER 4 *14
*1,
lever neutral position.

4. LOAD METER (Vehicle with multi-function display deluxe model only)

Prerequisite for
No. Indication Description
implementation
The mast type.
1 MAST TYPE *9, *15
[V—»FSW—>FW-»FSV—>FV—>[-]—>(N/A)]
CYL. SIZE Diameter of the lift cylinder. (V mast only) *9, *15
2 CYL. SIZE 1 Diameter of the lift cylinder. (Except V mast) *9, *15
CYL. SIZE 2 Diameter of the lift cylinder. (Except V mast) *9, *15
ZERO SET Zero point of the load meter. (V mast only) *6, *8, *9, *15
3 ZERO SET 1 Zero point of the load meter. (Except V mast) *6, *8, *9, *15
ZERO SET 2 Zero point of the load meter. (Except V mast) *6, *8, *9, *15
As requested by
4 COMPENSATION The value of load meter compensation datad. customer to adjust
the accuracy

5. TIRE DATA
Prerequisite for
No. Indication Description
implementation
1 TIRE DATA The tire data according to the tire size. *1, *16
 16-23

rerequisite content for implementation

: When replacing main controller
!: When removing/installing or replacing accelerator sensor
I: When removing/installing or replacing break sensor
I: When removing/installing or replacement tilt angle sensor
>: When replacement of tilt angle sensor rod
>: When removing/installing or replacing load sensor
When removing/installing or replacing tire angle sensor or sensor cover
I: When installing or changing attachment or fork
l: When removing/installing or replacing mast
0: When removing/installing or replacing tilt cylinder
1: When replacing lift lever angle sensor
2: When replacing tilt lever angle sensor
3: When replacing attachment (1) lever angle sensor
4: When replacing attachment (2) lever angle sensor
5: When replacing multifunction display
6: When the tire size or type is changed

efore Starting Matching

afore performing matching, you must set the vehicle to "standard condition". For "standard vehicle condition", refer
16-24.
16-24

VEHICLE STANDARD STATE

Set the vehicle to "Standard vehicle condition" before starting matching. "Standard vehicle condition" means that the
vehicle satisfies the conditions described below.

Standard Vehicle Condition

Note:
• Items 1 ~ 4 below show the standard vehicle condition for SAS matching.
• Before carrying out matching, move the armrest to the driving position and check the neutral state of the
levers.
• In case of a detachable attachment, keep the attachment installed on the vehicle.

1. Tire pressure check

Adjust the tire pressure to the specified level. Matching will be
inaccurate if the pressure is low, or if there are air pressure
fluctuations between front and rear as well as left and right.
2. Surface levelness check
If matching is conducted on an inclined or rough floor surface,
errors in standard vehicle condition will occur, so perform
matching on a flat, level surface (inclination: within 0.5°).
3. No-load vertical condition check
Store the output voltage of the load sensor in no-load state in
the controller. At this time, the following conditions must be
satisfied:
(1) For the V mast, set the lifting height to about 500 mm
(19.7 in) and use a goniometer to check that the mast is
vertical.
(2) For the FW/FSW mast, set the rear cylinder rod projection
to about 100 mm (3.93 in) and use a goniometer to check
that the mast is vertical.
(3) In case that the heavy attachment is installed, if the
additional weight (due to attachment) value exceeds the
values shown in the following table, it is impossible to use
the automatic fork leveling control at high lift height on
such a truck model. And tilt forward angle is always
restricted up to 1 degree at high lift height stage.
(4) Set the mast in the vertical position from the backward
tilted position by operating the tilt lever in the forward
tilting direction.
 16-25

dditional Weight Table kg (lbs)

¡ft height 8FBEKT16 8FBEKT18
8FBET15 8FBET20 8FBMT15 8FBMT16 8FBMT18 8FBMT20
mm (in) 8FBET16 8FBET18
700 700 700 800 700 700 700 800
3000 (118)
(1544) (1544) (1544) (1764) (1544) (1544) (1544) (1764)
3300 to 4000 550 550 550 700 550 550 550 700
(130 to 157.5) (1213) (1213) (1213) (1544) (1213) (1213) (1213) (1544)
4200 to 5000 500 500 500 600 500 500 500 600
(165 to 197) (1103) (1103) (1103) (1323) (1103) (1103) (1103) (1323)
5500 to 6000 400 400 450 500 400 400 450 500
(216.5to236) (882) (882) (992) (1103) (882) (882) (992) (1103)
6500 to 7000 250 250 300 350 250 250 300 350
(256 to 275.5) (551) (551) (661) (772) (551) (551) (661) (772)
200 200 230 250 200 200 230 250
7500 (295)
(441) (441) (507) (551) (441) (441) (507) (551)

4. Tire straight traveling position check

Store the tire angle sensor output voltage in the controller in
the condition of the vehicle traveling straight ahead.
Condition of the vehicle traveling straight ahead means that
the deviance to left or right is within 50 mm (2.0 in) when the
vehicle travels for 5 meters (16 ft) with the steering being fixed.
5. Loadmeter 0 set (0 set of the load gauge) check
For all the V/FW/FSW mast, the mast is to be vertical and the
fork height is to be 500 mm (19.7 in).

¡autions on modifying vehicles

hen 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 (height switch, load sensor, mast
harness, and other SAS-related parts) and place an order accordingly.
• Be sure to perform matching after replacement.
ther functional parts
• See Section 2 for the accelerator potentiometer and brake potentiometer.
• See Section 5 for the sensor.
» See Section 8 for the steering wheel angle sensor.
• See Section 15 for the oil control valve solenoid.
• For the inspection of functional parts, see Section 4 TROUBLESHOOTING
 17-1

MAIN OPTIONS
Page
HEIGHT SELECTOR................................................ 17-2
GENERAL.......................................................................... 17-2
COMPONENTS.................................................................. 17-4
REMOVAL • INSTALLATION........................................... 17-5
SHOCK SENSOR..................................................... 17-9
GENERAL.......................................................................... 17-9
COMPONENTS................................................................ 17-11
REMOVAL • INSTALLATION........................................ 17-12
PIN CODE ENTRY SYSTEM................................. 17-13
GENERAL........................................................................ 17-13
COMPONENTS............................................................... 17-15
REMOVAL • INSTALLATION........................................ 17-16

17
17-2

HEIGHT SELECTOR
GENERAL
This option consists of three functions that automatically stop the forks at the appropriate height as follows.
1 Maximum height limiter
It gets impossible for forks to be lifted from the memorized position by this function.
This function is effective and useful in such a case that an administrator limits the height to operators unfamiliar
to the operation in the high position for safety.
The height position can be set by only administrators or technicians, so the operator cannot cancel this function.
2 Height limiter
Operators can set the height position and switch its activation easily by the height limiter switch.
It is useful at worksites where different maximum heights are regulated indoors and outdoors.
3 Automatic height control
Improvement of the working property will be expected by this function because even beginner operators can
easily stop forks at the selected memorized height with the easy operation.
The operator can set up to three height positions.

Note:
• The fork height positions can be memorized only at the higher area more than 200mm from the height
where the inner mast begins to rise in all three functions. Of course, it cannot be memorized at the free
area.
• Even if the Height Selector has stopped same height position, the actual fork height is varied by the
weight of loads or by the mast angle.

For details, refer to “New Model Feature”.

Input Output

Sensor / Switch Actuator

1 Height switch 6 Lift electric proportional valve

2 Height reel sensor Multi-function display

■ Height limit indicator
3 Lift lever angle sensor *-
7
■ Assist screen on LCD
4 Load display switch ■ On-board buzzer
5 Height limiter switch
 17-3

ach Component

No. Name No. Name

(D Height switch (5) Height limiter switch
(2) Height reel sensor (6) Lift electric proportional valve
(3) Lift lever angle sensor (7) Multi-function display
(4) Load display switch (8) Main controller

sature of Each Component

No. Name Feature

The limit switch installed on the outer mast detects the height of the
(1) Height switch inner mast. Then it is determined whether the lift is on the lower stage
or upper stage with respect to the specified height.
The height reel sensor is installed on the right outer mast rail detects
(2) Height reel sensor
the stretched length of the inner mast as the height.
The lift lever angle sensor Installed in the mini-lever or joystick-lever
(3) Lift lever angle sensor
detects the lift operation.
The switch installed on the lift lever is usually used as the load display
switch on the models with the multi-function display deluxe (OPT). On
(4) Load display switch
the models with Height Selector, this switch is also used to select the
height memory.
This switch on the mini-lever armrest switches the activation of the
(5) Height limiter switch
Height Limiter function.
Two electric proportional solenoids (downward / upward) on this
(6) Lift electric proportional valve valve control the lift speed and the direction by controlling the current
from the controller.
The multi-function display installed on the dash board informs of
(7) Multi-function display various activations of this function by the height limiter indicator,
buzzer sounds, and the LCD screen.
17-4

COMPONENTS

5803

5803-517
 17-5

REMOVAL • INSTALLATION

eight Reel Sensor

N-m (kgf-cm) [ft-lbf]

emoval Procedure
Disconnect the battery plug.
Disconnect the connector.
Remove the sensor wire.
Remove the height reel sensor. [Point 1]

istallation Procedure
ie installation procedure is the reverse of the removal procedure.
ote: 17
the higher reel sensor is removed and reinstalled, the lifting height stored in memory may change, so make
ire that it has not changed and set it again if necessary.
17-6

Point Operations
[Point 1]
Inspection:
1. Check that the resistance between terminals.
Standard:
Terminal 1-2 2000±10Q
When pull the sensor wire, resistance
Terminal 1-3
changes from 0 to 2000 Q

RemovaHnstallation:
Note:
When removing the height reel sensor, lower the lift to its
lowermost position, remove and reattach the stopper about
300 mm (11.8 in) back from the height reel sensor main body,
and then remove the height reel sensor.
When install the height reel sensor, install the height reel
sensor securely then reattach the stopper to the position
shown in the figure.
 17-7

eight switch

emoval Procedure
Disconnect the battery plug.
Disconnect the connector.
Remove the height switch. [Point 1]

stallation Procedure
ie installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1]

Inspection:
Check the continuity between terminals.

Standard:

Not operated:

Terminal 1 - 2 No continuity
Terminal 1-3 Continuity

Operated:

Terminal 1-2 Continuity

Terminal 1-3 No continuity
17-8

Lift Lever Angle Sensor, Height Limiter Switch

For removal and installation procedure, refer to 2-44 page.

A .I B Point Operations
\ I /
\ I Lift lever angle sensor

Inspection:
Check that the resistance between terminals.
Standard:

Terminal 1 - 3 2500 ± 500 Q

Terminal 2-3 The resistance decreases when the lever
is tilted to the Lower side, while it
increases when the lever is tilted to the
Raise side.
Terminal 3-4 The resistance increases if the lever is
tilted to the Lower side, while it
tn pH ni decreases when the lever is tilted to the
Raise side.

Height limiter switch

Inspection:
Check that there is continuity between terminal 1 and 2

Standard:
Neutral position: No continuity

When Switch is pushed: Continuity

 17-9

►HOCK SENSOR

¡ENERAL
'hen this feature detects the intense shock on the vehicle, it warns the operator with the buzzer sound, and it
cords its date and time into the memories in the multi-function display.
scause only the administrator can cancel the buzzer sounds, the operator necessarily must report it to the
iministrator. This is effective to suppress the rough operation.
are, this feature can record the PIN into the memories in addition to the date and time when the option "PIN Entry”
taken simultaneously. It becomes easier to identify the operator who has made the intense shock.
)r details, refer to “New Model Feature”.
ote:
• The strength of the shock generated on the vehicle depends on the objects where the vehicle collided.
Thus all of the collisions cannot be necessarily detected.
• The shock generated in the usual operation depends on the road conditions, the treated loads, and the
material handling operations. The administrator has to set the detection level not to detect erroneously
in the usual operation.
» All the detected records may not be necessarily based on a actual collision. Please investigate the
records in consideration of the possibility of erroneous detections in the usual operation in addition to
actual collisions.

Input Output

Sensor / Switch Actuator

0)
zj'
1 Shock sensor 1 (Front-back) ---------------------------

o Multi-function display
kJ
Z5
r—f- 4 ■ LCD screen
2 Shock sensor 2 (Lateral) “1
o ■ On-board buzzer
o
3 *1
Vehicle speed sensor

*1: The vehicle speed is detected by the motor speed sensors via the drive motor drivers.
17-10

No. Name
(D Shock sensor 1 (Front-back)
(2) Shock sensor 2 (Lateral)
(3) Vehicle speed sensor
(4) Multi-function display
(5) Main controller

Each Component
No. Name Feature
The shock sensor installed near the left tilt cylinder detects the shock
(1) Shock Sensor 1 (Front-back)
generated in the front-back direction.
The shock sensor installed near the left tilt cylinder detects the shock
(2) Shock Sensor 2 (Lateral)
generated in the lateral direction.
The vehicle speed is detected by the motor speed sensors via the
(3) Vehicle speed sensor drive motor drivers. The motor speed sensors are installed on each
the left and right drive motors.
The multi-function display installed on the dash board indicates the
detection of a shock on its screen and by the buzzer sounds.
(4) Multi-function Display Administrator can monitor the generated shock, adjust the detection
level, and check the records of detections by using this multi-function
display.
 17-11

COMPONENTS

5803

CW

5803-516
17-12

REMOVAL • INSTALLATION

Shock Sensor
Note:
• Extremely be careful not to apply mechanical shock in order to protect the shock sensor. Do not use an
impact wrench.
• Do not use the shock sensor which you accidentally dropped.
N-m (kgf-cm) [ft-lbf]

Removal Procedure
1. Disconnect the battery plug.

2. Remove the toe board.

3. Disconnect the connectors from shock sensors.

4. Remove the shock sensors W/ bracket.

5. Remove the shock sensor from the bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 17-13

*IN CODE ENTRY SYSTEM

¡ENERAL
nly operators who have registered PINs (Personal Identification Number) can activate the vehicle with this feature,
his can contribute to avoidance of irregular uses by uncertified persons.
his system also can register ten different vehicle settings called “PROFILE”, and each PIN can be assigned one
siting out of the ten settings.
dministrators can use this feature to limit various vehicle performances for safety management, or to fit the vehicle
sitings to each operator’s favorites.
or details, refer to “New Model Feature”.

Certification of PIN
Assignment of profile number
PIN entry

Multi-function
Ten-key
display

CAN-BUS

Main controller

Key-on management
Vehicle setting corresponding to profile No.
17-14

No. Name Feature

This ten-key installed on the instrumental panel is used for entry of the PIN,
1 Ten-key
login and logoff.
Multi-function display judges if the entered PIN is certificated by searching the
registered PINs on its memory.
When the entered PIN has been registered, the display sends the assigned
2 Multi-function Display
profile number of the PIN to the Main Controller by using this display,
administrators can register the PINs, delete them, assign the profile number to
each PIN, or set the vehicle settings of each profile.
Main Controller manages “KEY-ON” of the vehicle corresponding to “LOGIN /
3 Main controller LOGOFF” judgment by the display. The controller loads the vehicle setting
data of the instructed profile number, and changes the behavior of the vehicle.
 17-15

COMPONENTS

5301
17-16

REMOVAL • INSTALLATION

Ten-Key

Removal Procedure
1. Disconnect the battery plug.

2. Remove the column cover (front).

3. Remove the wire harness from the instrument panel RH.

4. Remove the instrument panel RH.

5. Remove the ten-key from the instrument panel RH. [Point 1]

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 17-17

oint Operations
»OINT 1]
spection :
Check that the resistance between terminals.

Terminal CN33-3 CN33-2 CN33-1 CN33-6

OFF button 7 button 4 button 4 button
N33-8 Push: Continuity Push: Continuity Push: Continuity Push: Continuity
Release: No continuity Release: No continuity Release: No continuity Release: No continuity
0 button 8 button 5 button 2 button
N33-4 Push: Continuity Push: Continuity Push: Continuity Push: Continuity
Release: No continuity Release: No continuity Release: No continuity Release: No continuity
ON button 9 button 6 button 3 button
N33-9 Push: Continuity Push: Continuity Push: Continuity Push: Continuity
Release: No continuity Release: No continuity Release: No continuity Release: No continuity
 18-1

APPENDIX
Page
SST LIST....................................................................18-2
SERVICE STANDARDS.......................................... 18-6
CONNECTOR DRAWING...................................... 18-12
CONNECTING DIAGRAM..................................... 18-28
ELECTRIC WIRING DIAGRAM (STD)................ 18-30
ELECTRIC WIRING DIAGRAM
(FOR CABIN MODEL)......................................... 18-32

18
18-2

SST LIST
Section
must Part number Part name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Clamp-on
09140-13130-71 AC/DC high O
tester

09150-10920-71 Spacer o

09223-76005-71 Crankshaft
front oil seal O
(09223-46011) replacer

MCB check
09230-13240-71 O O
sub-harness

AC controller
09230-13130-71 diagnosis kit O

(09232-13130-71) Sub-harness o

(09238-13130-71) Sub-harness o

09230-13700-71 IC check pin o

AC driver

*< 09240-13240-71 check

sub-harness
o
 18-3

Section
must Part number Part name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

( > 09310-23320-71
Reamer bolt
remover O

4»
**

Transmission
09316-76008-71 & Transfer
(09316-60011)
bearing o
replacer

Front axle
hub inner
09320-10410-71 bearing o
replacer

©
( 09331-13240-71 Replacer
O

Front axle
bearing
09370-10140-71
replacer o

Drive pinion
bearing
09370-20270-71
replacer
o

P 09410-26600-71
Drive pinion
bearing
replacer
o

» 09411-41800-71
Second drive
shaft dust
seal replacer
o 18

Bearing o
09420-23002-71
remover
18-4

Section
must Part number Part name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Union nut
09451-13240-71 wrench O O

Tire angle
09580-10920-71 sensor set o
tool

tip 09609-76002-71
(09609-20011)
Steering
wheel puller O o

Inner mast
09610-22000-71 stopper O

Parachut
valve
09610-T1000-71 (safety down O
valve)
replacer

Tilt cylinder o
09620-T1000-71
cap replacer

Wear acale
09631-22000-71 chain O

X 09700-30200-71
Spring pin
tool remover O O

Joint pin O
09810-20172-71 remover
 18-5

Section
must Part number Part name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

09820-31040-71 Joint bolt O

09905-76002-71 Snap ring

No.1 o
(09905-00012) expander

09950-76014-71
Puller B set
O o o O
(09950-40011)

09950-76018-71
Replacer set O o o
(09950-60010)

Z^-TjOOOO 09950-76019-71 Replacer set

/ 6 jyQQOQ
—=y/OGiQQ.i
(09609-60020)
No.2 o o o

09950-76020-71
Handle set o o o
(09950-70010)

1'
25009-13201-71 Battery o

A hanger

18
18-6

SERVICE STANDARDS
BATTERY
Item All models

Specific gravity upon perfect charging 1.280 [20 °C (68 °F)]

Specific gravity upon end of discharge 1.150 [20 °C (68 °F)]
Voltage upon end of discharge 40.8 V
Insulation resistance 1 MQ or more

CONTROLLER
Item All models
F1 (for drive and pump circuit) 500 A
F4 (for lights) 10A
F5 (for control circuit) 10A
F6 (for control circuit) 10 A
F7 (for fan and solenoid) 10 A
OCL standard value 250 to 335 A
Control panel insulation 3 MQ or more
Tightening torque: N-m (kgf-cm) [ft-lbf]
Contactor panel See page 2-27
Pump and drive motor driver set bolt 13 to 17 (133 to 173) [9.6 to 12.5]
Contactor panel set bolt 13 to 17 (133 to 173) [9.6 to 12.5]
Pump and drive motor driver terminal 11 to 15 (112 to 153) [8.1 to 11.0]

ACCELERATOR POTENTIOMETER
Item All models
Accelerator potentiometer resistance See page 2-32

BRAKE POTENTIOMETER
Item All models
Brake potentiometer resistance See page 2-34

DRIVE MOTOR
Item All models
Stator ASSY insulation resistance mq 1 or more
Motor cable resistance Q 0
Temperature sensor resistance kn 11 to 15 (at 20 °C)
Tightening torque: N-m (kgf-cm) [ft-lbf]
Motor gear set bolt Standard: 122.5(1249.5) [90.4]
Stator ASSY set bolt Standard: 115(1173) [84.8]
Front axle bracket set bolt Standard: 42.5 (433.5) [31.3]
Bearing cover set bolt Standard: 23.7 (241.7) [17.5]
 18-7

UMP MOTOR
Item All models
Stator ASSY insulation resistance MQ 1 or more
/lotor cable resistance Q 0
emperature sensor resistance kQ 11 to 15 (at 20 °C)
‘ightening torque: N-m (kgf-cm) [ft-lbf]
accelerator pedal set bolt Standard: 18.5(189) [13.7]
irake pedal set bolt Standard: 18.5(189) [13.7]
)il control valve set bolt Standard: 16.2 to 37.8 (165 to 386) [11.9 to 27.9]
)il pump set bolt Standard: 28 (285.6) [20.7]
rant battery panel set bolt Standard: 17.5(179) [12.9]
ront lower battery panel set bolt Standard: 38 (387.6) [28.0]
’riority valve set bolt Standard: 8.8 to 12.8 (90 to 130) [6.5 to 9.4]
1otor housing set bolt Standard: 20 (204) [14.8]
tpm sensor gear set bolt Standard: 13 (132.6) [9.6]

'RIVE UNIT & FRONT AXLE

Item All models
'lanetary gear backlash mm (in) 0.2 (0.008)
lub starting torque N (kgf) [Ibf] 27.2 to 62.9 (2.8 to 6.4) [6.2 to 14.1]
'ightening torque: N-m (kgf-cm) [ft-lbf]
)rive unit ASSY set bolt Standard: 30 to 45 (306 to 459) [21.3 to 33.2]
Sear case set bolt Standard: 25 (255) [18.4]
lub nut Standard: 117.6 to 196.0 (1200 to 2000 ) [86.8 to 144.6]
accelerator pedal set bolt Standard: 18.5(189) [13.7]
ront axle ASSY mounting bolt Standard: 220 to 279 (2244 to 2846) [162.3 to 205.9]

EAR AXLE (3 WHEEL MODELS)

Item All models
tear axle ASSY
tear axle ASSY starting force N (kgf) [Ibf] Standard: 112 to 224 (11.4 to 22.9 ) [25.2 to 50.5]
tear axle hub
tear axle hub starting force N (kgf) [Ibf] Standard: 15 to 39 (1.5 to 4.0 ) [3.3 to 8.8]
tear axle cylinder
Standard: 70.0 (2.76)
tear axle cylinder inside diameter mm (in)
Limit: 70.35 (2.77)
ightening torque: N-m (kgf-cm) [ft-lbf]
tear axle ASSY lock nut Reference: 10 to 20 (102 to 203.9 ) [7.4 to 14.8]
tear axle cylinder set bolt Standard: 265 to 370 (2700 to 3800 ) [195.4 to 272.9]
ire angle sensor cover set bolt Standard: 10 to 16 (100 to 160 ) [7.4 to 11.8]
lain controller set bolt Standard: 5.5 (56) [4.1]
lub nut Standard: 117.6 to 196.0 (1200 to 2000 ) [86.8 to 144.6]
tear axle hub nut Reference: 12 to 32 (122.4 to 326.0 ) [8.9 to 23.6]
18-8

REAR AXLE (4 WHEEL MODELS)

Item All models
Rear axle ASSY
Rear axle front to rear clearance mm (in) Standard: 0.3 (0.12)
Rear axle center pin bushing mm (in) Limit: 52 (2.047)
Steering knuckle
King pin outside diameter mm (in) Limit 27.8 (1.094)
Thrust bearing clearance mm (in) Standard: 0.5 (0.0197) or less
Rear axle cylinder
Piston rod outside diameter mm (in) Limit: 49.92 (1.965)
Piston rod bend mm (in) Limit: 0.5 (0.020)
Rear axle cylinder inside diameter mm (in) Limit: 68.20 (2.685)
Tightening torque: N-m (kgf-cm) [ft-lbf]
Hub nut Standard: 117.6 to 196.0 (1200 to 2000 ) [86.8 to 144.6]
Rear axle cylinder set bolt Standard: 108 to 132 (1100 to 1350 ) [79.6 to 97.6]
Rear axle cylinder hose Standard: 34 (346.8) [25.1]
Axle bracket cap set bolt Standard: 128 to 175 (1305 to 1785 ) [94.4 to 129.1]

STEERING
Item All models
Hydrostatic steering valve ASSY
8FBET
Relief pressure Standard: 12.6 to 13.1 (128.5 to 133.7) [1827.7 to 1901.6]
8FBEKT
MPa (kgf/cm2) [psi]
8FBMT Standard: 9.1 to 9.6 (92.9 to 98.0) [1321.3 to 1393.9]
Tightening torque: N-m (kgf-cm) [ft-lbf]
Steering wheel set nut Standard: 25 to 45 (254.9 to 458.9) [18.4 to 33.2]
Steering valve set bolt Standard: 31 to 38 (316.2 to 387.6) [22.9 to 28.0]
Mast jacket set nut Standard: 35 to 52 (357.0 to 530.4) [25.8 to 38.4]
Tilt steering lock release lever set bolt Standard: 9 to 13 (91.8 to 132.6) [6.6 to 9.6]
Piping cover set bolt Standard: 9 to 21 (91.8 to 214.2) [6.6 to 15.5]
Relief valve Standard: 40 to 60 (408 to 612) [29.5 to 44.3]
Steering valve end cover set bolt Standard: 24 to 36 (245 to 367) [17.7 to 26.6]

BRAKE
Item All models
Foot brake
Standard: 22 (0.866)
Wet disc brake return spring fully length mm (in)
Limit: 20.5 (0.807)
Standard: 5.2 (0.205)
Wet disc brake stator disc No.1 thickness mm (in)
Limit: 5.0 (0.197)
Standard: 17.0 (0.669)
Wet disc brake rotor thickness mm (in)
Limit: 16.8 (0.661)
Standard: 3.2 (0.126)
Wet disc brake stator disc No.1 thickness mm (in)
Limit: 3.0(0.118)
Brake pedal
Brake lever clearance mm (in) Standard: 6.7 to 7.3 (0.263 to 0.287)
Pedal stroke mm (in) Standard: 55 to 64 (2.17 to 2.52)
 18-9

ODY & FRAME

Item AU models
"ightening torque: N-m (kgf-cm) [ft-lbf]
tperatoris seat set nut Standard: 24(244.8) [17.7]
lattery hood damper Standard: 21 (214.2) [15.5]
mattery hood hinge set bolt Standard: 56 (571.2) [41.3]
tounterweight set bolt Standard: 360 (3672) [265.6]

IATERIAL HANDLING SYSTEM

Item All models
latural drop test
latural drop mm (in) Limit: 45 (1.77)
latural forward tilt test
latural forward tilt mm (in) Limit: 20 (0.79)
)il leak test
¡ft cylinder oil leak amount cm3 (in3) Standard: 8 (0.49) or less
ilt cylinder oil leak amount
Standard: 16 (0.98) or less
otal for lift and tilt) cm3 (in3)

IAST
Item All models
last ASSY
¡ft bracket clearance mm (in) Standard: 0.2 to 0.5 (0.008 to 0.020)
' mast
ylinder rod end clearance mm (in) Maximum: 4(0.16)
W mast
ylinder rod end clearance mm (in) Maximum: 4(0.16)
SW mast
ylinder rod end clearance mm (in) Maximum: 4(0.16)
¡ide shift cylinder
iston rod outside diameter Limit: 29.92 (1.178)
iston rod bend Limit: 0.1 (0.0039)
ift bracket guide shoes
him thickness Standard: 0.5 to 0.8 (0.020 to 0.032)
laximum clearance Standard: 3 (0.12)
him wear limit Limit: 2 (0.079)
ightening torque: N-m (kgf-cm) [ft-lbf]
last support cap set bolt Standard: 110(1122) [81.2]
ilt cylinder front pin set bolt Standard: 27 (275) [19.9]
18-10

CYLINDER
Item All models
Lifting cylinder (V mast)
1.5 to 1.81 45(1.77)
Cylinder inside diameter mm (in)
2.0 t 48(1.89)
1.5 to 1.81 38 (1.50)
Piston outside diameter mm (in)
2.01 40 (1.57)
1.5 to 1.8 t 1.2 (0.047)
Parachute valve mm (in)
2.01 1.8(0.071)
Piston rod bend Limit: 2 (0.079)
Lifting cylinder (FW, FSW mast: Front)
1.5 to 1.81 48 (1.89)
Cylinder inside diameter mm (in)
2.01 52 (2.05)
1.5 to 1.81 40(1.57)
Piston outside diameter mm (in)
2.0 t 42(1.65)
1.5 to 1.8 t 1.2 (0.047)
Parachute valve mm (in)
2.01 1.8 (0.071)
Piston rod bend Limit: 2 (0.079)
Lifting cylinder (FW mast: Rear)
1.5 to 1.81 40(1.57)
Cylinder inside diameter mm (in)
2.01 45(1.77)
1.5 to 1.81 32 (1.26)
Piston outside diameter mm (in)
2.01 35(1.38)
1.5 to 1.81 1.2(0.047)
Parachute valve mm (in)
2.01 1.8(0.071)
Lifting cylinder (FSW mast: Rear)
1.5 to 1.81 45(1.77)
Cylinder inside diameter mm (in)
2.0 t 48(1.89)
1.5 to 1.81 38 (1.50)
Piston outside diameter mm (in)
2.0 t 40(1.57)
1.5 to 1.81 1.2 (0.047)
Parachute valve mm (in)
2.01 1.8 (0.071)
Tilting cylinder
Standard: 30(1.18)
Piston rod outside diameter mm (in)
Limit: 29.92 (1.178)
Standard: 70 (2.76)
Cylinder inside diameter mm (in)
Limit: 70.35 (2.770)
5° front - 5° back 60 (2.36)
Stroke mm (in)
5° front - 7° back 72 (2.83)
Piston rod bend Limit: 0.2 (0.0079)
Tightening torque: N-m (kgf-cm) [ft lbf]
Lifting cylinder cap (upper) Standard: 445 to 455 (4539 to 4641) [328.3 to 335.7]
Lifting cylinder cap (button) Standard: 445 to 455 (4539 to 4641) [328.3 to 335.7]
Tilting cylinder front pin set bolt Standard: 27 (275) [19.9]
Tilting cylinder set bolt Standard: 110(1122) [81.2]
Tilt cylinder joint set nut Standard: 110 (1122) [81.2]
Tilting cylinder rod guide Standard: 860 to 880 (8772 to 8976) [634.5 to 649.2]
Tilting cylinder piston nut Standard: 285 to 315 (2907 to 3213) [210.3 to 232.4]
 18-11

IL PUMP
Item All models
'¡I pump body inner surface wipe depth mm (in) Standard: 0.01 to 0.06 (0.0004 to 0.0024)
rive gear shaft diameter mm (in) Limit: 21.997 (0.86602)
rive gear tooth width mm (in) Limit: 25.5(1.004)
ightening torque: N-m (kgf-cm) [ft-lbf]
ront cover Standard: 88 to 98 (897 to 999) [64.9 to 72.3]

IL CONTROL VALVE
Item All models
Hi control valve
Lift 18.3(187) [2660]
elief pressure MPa (kgf/cm2) [psi]
Tilt 18.3 (187) [2660]

AS FUNCTION
Item All models
ightening torque: N-m (kgf-cm) [ft-lbf]
re angle sensor set screw Standard: 1.6 to 2.0 (16 to 20) [1.16 to 1.45]
re angle sensor plate set bolt Standard: 10 to 16 (100 to 160) [7.2 to 11.6]
It angle sensor set bolt Standard: 10 to 16 (100 to 160) [7.2 to 11.6]
Dad sensor Standard: 22 to 26 (224 to 265) [16.2 to 19.2]
Standard: 16.2 to 37.8 (165.2 to 385.6) [11.9 to 27.9]
eight switch set bolt (FW, FSW mast)
Standard: 7.8 to 18.2 (79.6 to 185.6) [5.8 to 13.4]
18-12

CONNECTOR DRAWING
CN3 CN8
HORN SW TURN SW
n i— —1 n
1 1

2 2
V---- J
TAB REC
NO P C J NO P C J TAB REC
1 41 - HO+ 1 41 L-R J4 NO P C J NO P C J
2 48 - HO- 2 48 L-0 J5 1 - 1 - -
2 - 2 - -
3 - 3 - -
4 - 4 - -
CN4
5 - 5 - -
KEY SW
6 - 6 - -
7 116 BT 7 116 B-L CN46-3
|2 1 2 8 115 BH 8 115 B-0 CN45-3
4 3 3 4 9 N2 T 9 N2 W-B J3
10 - - 10 - - -
TAB REC 11 N2 EL 11 N2 W-B J3
NO P C J NO P C J 12 109 TL 12 109 L-0 J11
1 41 - AM 1 41 L-R J4 13 110 TB 13 110 G-B CN12-2
2 - - - 2 - - - 14 108 TR 14 108 L-R J10
3 - - - 3 - - -
4 43 - IG 4 43 W-L CN42-3

CN6
BRAKE SSR

TAB REC
NO P C J NO P C J
1 74 VRB2+ 1 74 BR-R CN101-33
2 51 POT- 2 51 C J1
3 73 VRB2 3 73 Y-R CN 102-25
4 71 VRB1 4 71 Y-B CN 102-33
5 72 VRB1+ 5 72 L-0 CN101-34
6 50 VRA- 6 50 B-0 J8

CN7
LOAD SW

TAB REC
NO P C J NO P C J
1 60 - IG 1 60 P-L J17
2 51 - E 2 51 BR J9
3 68 - P1 3 68 B-R CN42-8
 18-13

CN9 CN13
DIRECTION SW (LH DIR) FR STAY RH

n
1 2 3 4
n5 6 7 8
n
9
2 1
_____
1
Q2
1ÏÏ 11 12 13 14 15 16 17 18 6 5 4 3 3 4 5 6
X z X z
JL
rAB FIEC TAB REC
IO P C j NO P C J NO P C J NO P C J
1 - - 1 - - - 1 - - - 1 - - -
2 - - 2 - - - 2 - - - 2 - - -
3 - - 3 - - - 3 - - - 3 - - -
4 46 DSR 4 46 B-O CN240-18 4 N2 W-B J12, CN20-2 4 N2 W-B J3
5 45 DSF 5 45 GR-R CN240-22 5 108 L-R CN14-4 5 108 L-R J10
6 51 LS- 6 51 BR CN240-13 6 102 L CN14-3, CN20-1 6 102 L CN45-4
7 7
8 8
9 9
CN14
0
FR COMBI RH
10
H 11
2 12 3 2 1 1 2 3
I3 13 6 5 4 4 5 6
4 14 X /
5 15
TAB REC
6 16
7 17
NO P C J NO P c J
1 N2 LC-R 1 N2 W-B J12
8 18
2 - - 2 - - -
DIRECTION SW 3 102 LF-R 3 102 L CN13-6
NO P C J 4 108 LF-R 4 108 L-R CN13-5
1 - - - 5 N2 LC-R 5 N2 W-B J12
2 - - - 6 - - 6 - - -
3 - - -
4 46 B-0 CN42-12
5 45 GR-R CN42-11 CN15
6 51 BR J9 PKBSW
7
8
9
10 TAB REC
11 NO P C J NO P C J
12 1 66 - SPB 1 66 G-W CN 104-20
13 2 - - - 2 - - -
14 3 51 - SPB 3 51 B CN240-1
15
16
17 CN16
18 HEAD LAMP LH

CN12
FLASHER RELAY
TAB REC
NO P C J NO P C J
|2 T| 1 102 - LH-L 1 102 L CN17-6
4 3 2 N2 - LH-L 2 N2 W-B CN17-4

TAB
IO P c J NO P c J
1 N2 - FRY- 1 N2 W-B J3
2 110 - FRY 2 110 G-B CN8-13
3 - - - 3 - - -
4 101 - FRY+ 4 101 B-R J2
18-14

CN17 CN23
FR STAY LH BACK BUZZER

2
□
1 1 i r1 2

-
6 5 4 3 3 4 5 6
/
TAB REC
TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 198 BZ+ 1 198 W-R J14
1 - - - 1 - - -
2 N2 BZ- 2 N2 W-B J3
2 - - - 2 - - -
3 - - - 3 - - -
4 N2 W-B CN16-2, J13 4 N2 W-B J13 CN26
5 109 L-0 CN18-4 5 109 L-O J11 ACCEL SSR
6 102 L CN16-1, CN18-3 6 102 L CN45-4

CN18
FR COMBI LH
TAB REC
3 2 1 1 2 3 NO P C J NO P C J
t---- 1 55 VRA2+ 1 55 GR-R CN101-26
6 5 4 4 5 6
X / 2 51 POT- 2 51 G J1
3 54 VRA2 3 54 BR-Y CN102-32
TAB REC 4 52 VRA1 4 52 BR-R CN102-30
NO P C J NO P C J 5 53 VRA1 + 5 53 BR-W CN101-27
1 N2 LC-L 1 N2 W-B J13 6 50 VRA- 6 50 B-O J8
2 - - 2 - - -
3 102 LF-L 3 102 L CN17-6
4 109 LF-L 4 109 L-0 CN17-5
CN27
LC-L 5 N2 W-B J13
F4 & F5 FUSE
5 N2
6 - - 6 - - -

¡2 lì 1 2
CN19 4 3 4
STEERING SSR
TAB REC
__ □ NO P C J NO P C J
2 1 P3 - F4 1 P3 Y-R CN136-6
2 101 - F4 2 101 B-R J2
6 5 4 3
x— 3 P2 - F5 3 P2 L-0 CN 136-3
Z
4 41 - F5 4 41 L-R J4
TAB REC
NO P C J NO P C J
1 311 SSTR+ 1 311 P-L CN 103-13 CN28
2 51 LS- 2 51 B CN239-2
F6 & F7 FUSE
3 312 SSTR1 3 312 B-Y CN 104-30
4 313 SSTR2 4 313 L-W CN104-31
5 314
-
SSTRC
-
5 314 G-Y
6 - -
CN 104-24
-
I24 31 I 1
3
2
4
6

TAB REC
CN20 NO P C J NO P C J
HEAD LAMP RH 1 P3 - F6 1 P3 R-L CN 136-5
2 44 - F6 2 44 R-B CN 104-2
3 P3 - F7 3 P3 R-L CN 136-5
4 19 - F7 4 19 P-G CN239-6

TAB REC
NO P C J NO P C J
1 102 - LH-R 1 102 L CN13-6
2 N2 - LH-R 2 N2 W-B CN13-4
 18-15

CN30 CN34
IMPACT SSR1 RR COMBI RH

-A......... n
f—'—
3 2 1 1 2 3

--
6 5 4 4 5 6
TAB REC TAB REC
□ p C J NO P C J
NO P C J NO P C J
51 POT- 1 51 G J1
1 104 TL 1 104 G-R CN31-1
> 301 IPL1 2 301 W-L CN103-30 2 - - 2 - - -
i 300 IPL+ 3 300 L-B J8 3 111 STL+ 3 111 R-L CN31-3
4 103 DSBU 4 103 W-R CN31-4
5 108 TRN 5 108 L-R CN38-5
CN31
6 N2 E 6 N2 W-B CN31-6
RR COMB LH

□ HL
—1—.
l3 2 1 I 1 2 3
CN38
6 5 4 4 5 6 RRUPRSUB

TAB REC nr 2 1 1 2
1—1
3
NO P C J 8 7 6 5 4 4 5 6 7 8
1 104 G-R CN34-1, 38-2 —
2 - - - TAB REC
3 111 R-L CN34-3, 38-7
NO P C J NO P C J
4 198 W-R CN34-4, 38-8
1 N2 W-B J3 1 N2 W-B CN31-6
5 109 L-O CN38-6
2 104 G-R CN46-4 2 104 G-R CN31-1
6 N2 W-B CN34-6, 38-1
3 - - - 3 - - -
4 - - - 4 - - -
CN32 5 108 L-R J10 5 108 L-R CN34-5
TIRE ANGLE SSR 6 109 L-O J11 6 109 L-O CN31-5
7 111 R-L CN49-4 7 111 R-L CN31-3
8 198 W-R J14 8 198 W-R CN31-4

--
TT

TAB CN41
D P C J NO P
HOOD1
C J
51 POT- 1 51 GR CN240-11
317 VRTRA 2 317 L-R CN 102-31
316 VRTRA+ 3 316 L-W CN101-23

CN33
TEN KEY
TAB REC
NO P C J NO P C J
1 29 R-Y CN101-28 1 29 R-Y CN78-4
2 22 R-W CN 102-23 2 22 R-W CN78-3
3 51 GR CN239-10 3 51 GR J15
4 23 R-L CN 102-22 4 23 R-L CN78-2
TAB 5 24 R-B CN 102-21 5 24 R-B CN79-3
0 P C J NO P C J 6 25 P-L CN 102-20 6 25 P-L CN79-2
160 ITKY1 1 160 B-Y CN70-8 7 26 P-B CN 102-29 7 26 P-B CN80-3
161 ITKY2 2 161 R-B CN70-20 8 31 P-G CN101-30 8 31 P-G CN80-4
162 ITKY3 3 162 G CN70-6 9 27 L-Y CN 102-28 9 27 L-Y CN80-2
165 OTKY2 4 165 R-Y CN70-10 10 30 R-G CN101-29 10 30 R-G CN79-4
167 LEDTKY1 5 167 G-Y CN70-12
163 IPSTKY1 6 163 W-L CN70-21
169 TGND 7 169 GR-R CN70-3
164 OTKY2 8 164 L-O CN70-11
166 OTKY3 9 166 GR-L CN70-9
i 168 LEDTKY2 10 168 L-B CN70-19
18-16

CN42 CN46
H00D2 TAIL LP RELAY

AYsY^ 7 isYjYffy X1Y2Y3) frlsXgX |2 1 | 1 2

(6 5XUJ13X12711X10X9X8X7)) (7A8X9X10X31X12I1W)
4 3 3 4

TAB REC TAB REC

NO P C J NO P C J
NO P C J NO P C J
1 41 L-R J4 1 41 L-R CN54-1
1 101 - COIL+ 1 101 B-R J2
2 118 B-Y CN238-1 2 118 B-Y CN54-2
- 2 101
2 101 SW+ B-R J2
3 43 W-L CN4-4 3 43 W-L CN93-2
3 116 - COIL- 3 116 B-L CN8-7
4 21 V-G CN103-18 4 21 V-G CN77-2
4 104 - SW- 4 104 G-R CN38-2
5 20 V-R CN 103-26 5 20 V-R CN77-3
6 28 V-W CN101-25 6 28 V-W CN77-4
7 60 P-L CN 104-15 7 60 P-L J17 CN47
8 68 B-R CN 104-28 8 68 B-R CN7-3 DIAGNOSIS
9 67 L-0 CN104-18 9 67 L-0 CN43-2
10 221 R-B CN 103-25 10 221 R-B CN67-2
11 45 GR-R CN239-21 11 45 GR-R CN9-5
12 46 B-O CN239-17 12 46 B-0 CN9-4
13 51 BR CN239-12 13 .51 BR J9
14 47 G-0 CN101-19 14 47 G-0 CN93-1
CN103-32 15 70 B-L J16
TAB REC
15 70 B-L
NO P C J NO P C J
CN43 1 - - 1 - -
SEAT SW 2 - - 2 - -
3 N2 GND 3 N2 W-B J3
4 101 FLP 4 101 L-R J2
5 - - 5 - -
6 - - 6 - -
7 - - 7 - -
TAB REC 8 145 CAN1H 8 145 R-L CN231-11
NO P C J NO P C J 9 146 CAN1L 9 146 L-Y CN231-8
1 51 - SDM- 1 51 BR J9 10 - - 10 - -
2 67 - SDM+ 2 67 L-O CN42-9 11 - - 11 - -
12 334 PASCC+ 12 334 L-O CN231-1
13 147 CAN2H 13 147 R-L CN231-3
CN44 CAN2L 14 148 L-Y CN231-5
14 148
IMPACT SSR2
15 - - 15 - -
16 - - 16 - -
17 - - 17 - -

TAB REC
J
CN49
NO P C J NO P C
REVERSE/STOP RELAY
1 51 - POT- 1 51 G J1
2 302 - IPL2 2 302 V-Y CN 103-19
3 300 - IPL+ 3 300 L-B J18

CN45
HEAD LP RELAY
TAB REC
| 2 1 I 1 2 NO P C J NO P C J
4 3 3 4 1 334 - PSACC+ 1 334 P-L CN234-1
2 331 - OACC1 2 331 W-G CN 102-11
TAB REC 3 332 - OACC2 3 332 GR-L CN 102-9
NO P C J NO P C J 4 111 - STL+ 4 111 R-L CN38-7
1101 - COIL+ 1 101 B-R J2 5 198 - LBU+ 5 198 W-R J14
- 2 101 B-R J2 6 41 - B48V 6 41 L-R J4
2 101 SW+
3 115 - COIL- 3 115 B-G CN8-8
4 102 - SW- 4 102 L CN13-6, CN17-6
 18-17

CN51 CN56
UNLOAD SOL PM SPD SSR

TAB REC TAB REC

□ p C J NO P C J NO P C J NO P C J
5 B-W CN102-17 1 85 - SLUL- 1 82 - SSP1 1 82 R-B CN111-10
1
3 V J19 2 84 - SOLLU+ 2 81 - SSP+ 2 81 GR-G CN111-3

CN52 CN58
DM TEMP RH DM TEMP LH

TAB REC TAB REC

3 p C J NO P C J NO P C J NO P C J
85 - STDMR 1 85 R-W CN110-6 1 87 - STDML 1 87 R-W CN 109-6
; 84 - STDMR+ 2 84 GR-R CN110-5 2 86 - STDML+ 2 86 GR-R CN 109-5

CN59
CN53 SSDR1
DM SPD SSR

TAB REC
NO P C J NO P C J
1 76 - SSDR1 1 76 O CN53-1
TAB REC 2 75 - SSDR+ 2 75 LG CN53-2
3 P C J NO P C J
76 0 CN59-1 1 76 B-O CN110-10
CN59-2 2
CN60
: 75 LG 75 B-W J20
SSDR2
■ 80 GR CN62-1 3 80 LG-R CN 109-4
78 BR CN62-2 4 78 LG J21
I 77 P CN60-1 5 77 B-R CN110-4
; 75 SB CN60-2 6 75 B-W J20
79 G CN61-1 7 79 LG-B CN109-10 TAB REC
78 Y CN61-2 8 78 LG J21
NO P C J NO P C J
1 77 - SSDR2 1 77 P CN53-5
CN54 2 75 - SSDR+ 2 75 SB CN53-6
HORN SW
CN61
SSDL1

TAB REC
3 P C J NO P C J TAB REC
41 L-R CN41-1 1 41 - SHR+
118 R-Y CN41-2 2 118 - SUR- NO P C J NO P C J
1 79 - SSDL1 1 79 G CN53-7
2 78 - SSDL+ 2 78 Y CN53-8
CN55
PM TEMP SSR
CN62
SSDL1

TAB REC
D P C J NO P C J
TAB REC
89 - STPM 1 89 R-W CN111-6 NO P C J NO P C J
88 - STPM+ 2 88 GR-R CN111-5 1 80 - SSDL2 1 80 GR CN53-3
2 78 - SSDL+ 2 78 BR CN53-4
18-18

CN67 CN74
HS SW C/V PULL SOL

TAB REC
I 1
NO P C J NO P C J
1 51 - SHL- 1 51 BR J9
TAB REC
2 221 - SHL+ 2 221 R-B CN42-10 NO P C J NO P C J
1 10 B-Y CN101-17 1 10 SLPL-
2 33 W-G CN101-12 2 33 STPL-
CN70 3 36 W-R CN101-10 3 36 SA1PL-
DISPLAY 4 39 Y-B CN101-14 4 39 SA2PL-
REC 5 9 G-W J6 5 9 SLLA2+
SLTA1+
n_n n__j~~v~u__n , j~lt
I 1 I 2 I 3 I 4 I 5 |6 I 7 I 8 I 9 1101111121131141151161171181
6
7
32
32
L
L
J7
J7
6 32
7 32 SLTA1+
8 9 G-W J6 8 9 SLLA2+
|19|2O|21|22|23|24|25|26|27|28|29|3Q|31|32|33|34|35|36|

TAB
CN75
n_n_ J"L _r~v~~u_n
118|17|16|15|14|13112|11 |1O| 9|8|7|6|5|4|3|2|l|
.ult C/V PUSH SOL

|36|35|34|33|32|31|30|29|28|27|26|25|24|23|22|21|20|19|

TAB REC
NO P C J NO P C J
1 - - 1 - - -
- - 2 - - -
TAB REC
2
3 169 TGND 3 169 GR-R CN33-7 NO P C J NO P C J
4 14 DGND 4 14 W-G CN 103-3 1 11 B-W CN101-16 1 11 SLPS-
5 16 D7V 5 16 Y-B CN 103-14 2 34 W-L CN101-13 2 34 STPS-
6 162 ITKY3 6 162 G CN33-3 3 37 G-B CN101-11 3 37 SA1PS-
7 - - 7 - - - 4 40 B-R CN101-15 4 40 SA2PS-
8 160 ITKY1 8 160 B-Y CN33-1 5 9 G-W J6 5 9 SLLA2+
OTKY3 9 166 GR-L CN33-9 6 32 L J7 6 32 SLTA1 +
9 166
10 165 OTKY2 10 165 R-Y CN33-4 7 32 L J7 7 32 SLTA1+
11 164 L-0 CN33-8 8 9 G-W J6 8 9 SLLA2+
11 164 OTKY1
12 167 LEDTKY1 12 167 G-Y CN33-5
13 - - 13 - - -
-
CN76
14 - - 14 - -
PRESS SSR
15 146 CAN1L 15 146 L CN231-7
16
17
18 -
145
-
CAN1H
-
-
16 145
17 -
18 -
B-W
-
-
CN231-10
-
- r s
X
7
19 168 LEDTKY2 19 168 - CN33-10
20 161 ITKY2 20 161 - CN33-2
21 163 IPSTKY1 21 163 - CN33-6
22 - 22 - -
23 - 23 - - TAB
24 - 24 - -
NO P C J NO P C J
25 - 25 - -
SPLF+ 1 58 Y-R CN 104-12
1 58 -
26 - 26 - -
SPLF 2 59 Y-G CN 103-29
2 59 -
27 - 27 - -
51 POT- 51 G J1
3 - 3
28 - 28 - -
29 - 29 - -
30 - 30 - -
31 - 31 - -
32 - 32 - -
33 - 33 - -
34 - 34 - -
35 - 35 - -
36 - 36 - -
 18-19

CN77 CN85
LIFT LEVER NTRL TILT SW

TAB REC
D P C J NO P C J TAB REC
51 - POT- 1 51 GR J15 NO P C J NO P C J
21 - VRL2 2 21 V-G CN42-4 1 60 - PSSW+ 1 60 P-L J17
20 - VRL1 3 20 V-R CN42-5 2 51 - LS- 2 51 BR J9
28 - VRL+ 4 28 V-W CN42-6 3 70 - STK 3 70 B-L J16

CN78 CN86
TILT LEVER TILT ANGLE SSR

TAB REC TAB REC

P C J NO P C J
NO P C J NO P C J
51 - POT- 1 51 GR J15 -
1 57 VRTA+ 1 57 L-Y CN101-20
23 - VRT2 2 23 R-L CN41-4 2 56 - VRTA 2 56 Y-R CN103-17
22 - VRT1 3 22 R-W CN41-2 -
3 51 POT- 3 51 G J1
29 - VRT+ 4 29 R-Y CN41-1

CN88
CN79 LIFT SOL
ATT1 LEVER

REC TAB REC

TAB
3 P C J NO P C J NO P C J NO P C J
51 - POT- 1 51 GR J15 1 4 B-Y CN102-16 1 4 - SLLL-
25 - VRA12 2 25 P-L CN41-6 2 3 V J19 2 3 - SOLLU+
24 - VRA11 3 24 R-B CN41-5
30 - VRAT1 + 4 30 R-G CN41-10
CN89
TILT SOL
CN80
ATT2 LEVER

TAB REC
NO P C J NO P C J
TAB REC
1 7 W CN102-19 1 3 - SLTFL-
) P C J NO P C J CN 101-2 -
2 6 Y-R 2 4 SLTFB+
51 - POT- 1 51 GR J15
27 - VRA22 2 27 L-Y CN41-9
26 - VRA21 3 26 P-B CN41-7
31 - VRAT2+ 4 31 P-G CN41-8
18-20

CN90 CN98
MAST STEERING SOL

V 2
5

TAB
5

REC
SJ NO P
1 329
C
-
TAB
J
SLS+
NO P
1 329 R
C
REC
J
CN 102-7
P C J 2 330 - SLS- 2 330 W-L CN102-14
NO NO P C J
1 90 R CN92-2 1 90 R CN104-22
2 91 W CN92-3 2 91 W CN 103-24 CN99
3 51 B CN92-1 3 51 B CN240-2 HS SSR
4 219 BR-Y CN99-2 4 219 BR-Y CN101-24
5 220 R-W CN99-3 5 220 R-W CN103-28
6 51 G CN99-1 6 51 G J1

CN92

TAB
HEIGHT SW

REC
NO P
1 51
2 219
3 220
--
C J
POT-
VRH+
VRH
NO P
1 51
C
O
2 219 BR-Y
3 220 R-W
J
CN90-6
CN90-4
CN90-5
4 - - 4 - - -
NO P C J NO P C J
1 51 B CN90-3 1 51 - LS-
2 90 R CN90-1 2 90 - SH1
3 91 W CN90-2 3 91 - SH2-1

CN93
EMERGENCY SW

TAB REC
NO P C J NO P C J
1 106 G-0 CN42-14 1 104 - -
2 47 W-L CN42-3 2 47 - +

CN95
SWING SOL

NO P

2
1 327
328
-
C
TAB
J
SLSW+
SLSW-
NO P
1 327 Y
C

2 328 P-G
REC
J
CN103-1
CN103-2
 18-21

CN101 CN102
CPU1 CPU2

n
6 5 4 3 s ƒ 1

19 18 17 16 1 5 14 13 12 11 10 9 8
27 26 = 25 24 23 22 21 20
35 34 3 3 32 31 30 29 28
X C
i

□____
1
./ ..
2
./
3 4 5 6 7 1^

8
2 3 4z 5

9 10 11 12 13 14 15 16 17 18 19
/
6^
3
20 21 22 23 24 25 26 27
28 29 30 31 32 32 34 35

TAB REC
TAB FIEC
0 P C J NO P C J
NO P C J NO P C J
3 SOLLU+ 1 3 V J19
» 1 98 FNDC1 1 98 V-Y CN113-2
6 SLTFB+ 2 6 Y-R CN89-2
2 99 FNDC2 2 99 B-L CN114-2
» 97 FAN+ 3 97 R-W CN239-9
3 19 VBMBSL 3 19 P-G CN240-6
41 VBBT 4 41 L-R J4
4 19 VBMBSL 4 19 P-G CN239-7
» 9 SLLA2+ 5 9 G-W J6
5 17 SOLCOM 5 17 G-W J22
i 32 SLLA1+ 6 32 L J7
6 17 SOLCOM 6 17 G-W J22
•
- - 7 - - -
7 329 SLS+ 7 329 R CN98-1
I - - 8 - - -
8 - - 8 - - -
I - - 9 - - -
9 332 OACC2 9 332 GR-L CN49-3
) 36 SA1PL- 10 36 W-R CN74-3
10 51 LS- 10 51 B CN239-1
1 37 SA1PS- 11 G-B 37 CN75-3
11 331 OACC1 11 331 W-G CN49-2
2 33 STPL- 12 33 W-G CN74-2
12 - - 12 - - -
3 34 STPS- 13 34 W-L CN75-2
13 335 RY1 13 335 LG CN223-4
39 SA2PL- 14 39 Y-B CN74-4
14 330 SLS- 14 330 W-L CN98-2
5 40 SA2PS- 15 40 B-R CN75-4
15 - - 15 - - -
5 11 SLPS- 16 11 B-W CN75-1
16 4 SLLL- 16 4 B-Y CN88-2
r 10 SLPL- 17 10 B-Y CN74-1
17 5 SLUL- 17 5 B-W CN51-1
3 - - 18 - - -
18 - - 18 - - -
3 47 VBKY 19 47 G-O CN42-14
19 7 SLTFL- 19 7 W CN89-1
) 57 VRTA+ 20 57 L-Y CN86-1
20 25 VRA12 20 25
P-L CN41-6
1 - - 21 - - -
21 24 VRA11 21 24
R-B CN41-5
> 50 VRA- 22 50 B-0 J8
22 23 VRT2 22 23 R-L CN41-4
3 316 VRTRA+ 23 316 L-W CN32-3
23 22 VRT1 23 22 R-W CN41-2
1 219 VRH+ 24 219 BR-Y CN90-4
24 304 CSBAT 24 304 L-O CN 137-3
5 28 VRL+ 25 28 V-W CN42-6
25 73 VRB2 25 73 Y-R CN6-3
5 55 VRA2+ 26 55 GR-R CN26-1
26 51 POT- 26 51 GR CN239-11
r 53 VRA1 + 27 53 BR-W CN26-5
27 - - 27 - - -
3 29 VRT+ 28 29 R-Y CN41-1
28 27 VRA22 28 27 L-Y CN41-9
3 30 VRAT1+ 29 30 R-G CN41-10
29 26 VRA21 29 26 P-B CN41-7
) 31 VRAT2+ 30 31 P-G CN41-8
30 52 VRA1 30 52 BR-R CN26-4
1 - - 31 - - -
31 317 VRTRA 31 317 L-R CN32-2
? 51 POT- 32 51 G J1
32 54 VRA2 32 54 BR-Y CN26-3
3 74 VRB2+ 33 74 BR-R CN6-1
33 71 VRB1 33 71 Y-B CN6-4
1 72 VRB1 + 34 72 L-O CN6-5
34 - - 34 - - -
35 305 CSBAT- 35 305 B-0 CN 137-2
18-22

CN103 CN104
CPU3 CPU4

4 \/ □__ ___ J___ ___ __ L___ Q

1 2 3 5 6
/ / //\ / 1 2 3 4 5 6 7
___ z ____ y '___ /. / —/
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 26 2/ 28 29 30 31

TAB REC TAB REC

NO P C J NO P C J
NO P C J NO P C J
1 327 SLSW+ 1 327 Y CN95-1
1 41 B48V 1 41 L-R J4
2 328 SLSW- 2 328 P-G CN95-2
2 44 VBMB 2 44 R-B CN28-2
3 14 DGND 3 14 W-G CN70-4
3 1 CBAT+ 3 1 LG-B CN 136-2
4 42 KYSAT 4 42 R-Y CN239-4 J24
4 N2 N2 4 N2 W-B
5 N2 N2 5 N2 W-B J23
N2 J24
5 N2 5 N2 W-B
6 51 LS- 6 51 BR CN239-15 N2 W-B J23
6 N2 N2 6
7 - - 7 - - - -
7 - - 7 - -
8 300 IPL+ 8 300 L-B CN231-3 - - - -
8 - 8
9 147 CAN2H 9 147 G-R CN234-3 2 B-W
9 2 CBAT- 9 CN 136-1
10 148 CAN2L 10 148 LG-B CN234-5
10 303 CSBAT- 10 303 GR-L CN 137-1
11 145 CAN1H 11 145 GR-R CN231-12
11 - - 11 - - -
12 146 CAN1L 12 146 P-B CN231-9 12 58 SPLF+ 12 58 Y-R CN76-1
13 311 SSTR+ 13 311 P-L CN19-1
13 - - 13 - - -
14 16 D7V 14 16 Y-B CN70-5
14 334 PASCC+ 14 334 R-W CN231-2
15 - - 15 - - -
15 60 PSSW+ 15 60 P-L CN42-7
16 - - 16 - - - -
16 - - 16 - -
17 56 VRTA 17 56 Y-R CN86-2 - -
17 - - 17 -
18 21 VRL2 18 21 V-G CN42-4
18 67 SDM 18 67 L-0 CN42-9
19 302 IPL2 19 302 V-Y CN44-2
B-O CN239-18
19 46 DSR 19 46
20 - - 20 - - -
20 66 SPB 20 66 G-W CN15-1
21 - - 21 - - - -
21 - - 21 - -
22 - - 22 - - -
22 90 SH1 22 90 R CN90-1
23 - - 23 - - - -
23 - - 23 - -
24 91 SH2-1 24 91 W CN90-2 CN19-5
24 314 SSTRC 24 314 G-Y
25 221 SHL 25 221 R-B CN42-10 -
25 - - 25 - -
26 20 VRL1 26 20 V-R CN42-5 DSF CN240-22
26 45 26 45 GR-R
27 - - 27 - - - - 27 - - -
27 -
28 220 VRH 28 220 R-W CN90-5 CN42-8
28 68 SLM 28 68 B-R
29 59 SPLF 29 59 Y-G CN76-2 -
29 - - 29 - -
30 301 IPL1 30 301 W-L CN30-2
30 312 SSTR1 30 312 B-Y CN19-3
31 - - 31 - - -
31 313 SSTR2 31 313 L-W CN19-4
32 70 STK 32 70 B-L CN42-15
33 - - 33 - - -
34 - - 34 - - -
35 - - 35 - - -
 18-23

CN109 CN111
DRIVE INV LH PUMP INV

1 1
3 2 1 1 2 3 4 5 6 1 2 3 4 5 6
9 8 7 7 8 9 lok 11 12 13 14 7 8 9 10m 11 12 13 14

TAB REC TAB REC

0 P C J NO P C J NO P C J NO P C J
- - 1 - - - 1 - - - 1 - - -
42 KYSAT 2 42 R-Y CN240-3 2 42 - KYSAT 2 42 R-Y CN240-4
78 SSDL+ 3 78 LG J21 3 81 SSP+ 3 81 GR-G CN56-2
80 SSDL2 4 80 LG-R CN53-3 4 - - 4 - - -
86 STDML+ 5 86 GR-R CN58-2 5 88 STPM+ 5 88 GR-R CN55-2
87 STDML 6 87 R-W CN58-1 6 89 STPM 6 89 R-W CN55-1
151 SETDL2 7 151 BR-W CN 109-9 7 - - 7 - - -
- - 8 - - - 8 152 SETP 8 152 BR-R CN111-9
151 OSETLD 9 151 BR-W CN 109-7 9 152 OSETP 9 152 BR-R CN111-8
79 SSDL1 10 79 LG-B CN53-7 10 82 SSP1 10 82 R-B CN56-1
- - 11 - - - 11 - - 11 - - -
145 CAN1H 12 145 GR-G CN234-11 12 145 CAN1H 12 145 P CN234-12
146 CAN1L 13 146 P-G CN234-8 13 146 CAN1L 13 146 V CN234-9
- - 14 - - - 14 - - 14 - - -

CN110 CN112
DRIVE INV RH RESISTOR

1 1
1 2 3 4 5 6
7 8 9 ioh 11 12 13 14

TAB REC TAB REC

NO P C J NO P C J
D P C J NO P C J
1 145 R-Y CN234-4 1 145 GR-L CAN1H
- - 1 - - -
2 146 L-W CN234-6 2 146 B-0 CAN1L
42 KYSAT 2 42 R-Y CN239-3
3 - - - 3 - - -
75 SSDR+ 3 78 B-W J20
77 SSDR2 4 77 B-R CN53-5
84 STDMR+ 5 84 GR-R CN52-2 CN113
85 STDMR 6 85 R-W CN52-1 FAN (LH)
- - 7 - - -
- - 8 - - -
- - 9 - - -
76 SSDR1 10 79 B-0 CN53-1
- - 11 - - - TAB REC
145 CAN1H 12 145 W CN234-10 NO P C J NO P C J
146 CAN1L 13 146 R CN234-7 1 97 - FAN+ 1 97 R-W CN240-9
- - 14 - - - 2 98 - FNDC1 2 98 V-Y CN102-1

CN114
FAN (RH)

TAB REC
NO P C J NO P C J
1 97 - FAN+ 1 97 R-W CN240-8
2 99 - FNDC2 2 99 B-L CN 102-2
18-24

CN136 JOINT

3
6
(—1

2
5

TAB
1
4
CONTACTOR

f—1—
1 2
4 5

REC
3* ”
6
CN231
J/C1-1
□
•- -• •- -•
TAB
lr=n
-9

9“
9-
n
CN234
J/C1-2

NO P C J NO P C J REC
1 2 G-W CN104-9 1 2 CBAT- zl,_ fi=n__ n n ir=ii r
2 1 LG-B CN104-3 2 1 CBAT+ 6 5 4 3 2 1 1 2 3 4 5 6
3 P2 L-0 CN27-3 3 P2 P2 12 11 10 9 8 7 7 8 9 10 11 12
4 - - - 4 - - K
5 P3 R-L CN28-1.3 5 P3 P3 NO P C J NO P C J
6 P3 Y-R CN27-1 6 P3 P3 1 334 L-0 CN47-12 1 334 P-L CN49-1
2 334 R-W CN104-14 2 - - -
3 147 R-L CN47-13 3 147 G-R CN103-9
CN137
4 - - - 4 145 R-Y CN112-1
CONTACTOR
(CURRENT) 5 148 L-Y CN47-14 5 148 LG-B CN103-10
6 - - - 6 146 L-W CN112-2
7 146 L CN70-15 7 146 R CN110-13
8 146 W-L CN47-9 8 146 P-G CN 109-13
9 146 P-B CN 103-12 9 146 V CN111-13
10 145 B-W CN70-16 10 145 W CN110-12
TAB REC 11 145 Y-L CN47-8 11 145 GR-G CN 109-12
NO P C J NO P C J 12 145 GR-R CN103-11 12 145 P CN111-12
1 303 - CSBAT+ 1 303 GR-L CN104-10
2 305 - CSBAT- 2 305 B-O CN102-35
3 304 - CSBAT 3 304 L-0 CN 102-24
CN235
JOYSTICK
SHORT CONNECTOR
CN223
RY1

IT rsi 2 1 1 2 rsi 3
8 7|6 5 4 4 5 6I 7 8
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 - - - 1 - - -
1 - - 1 - - - 2 - - - 2 - - -
2 97 FAN+ 2 97 R-W CN239-8 3 70 B-L J16 3 70 - +
3 - - 3 - - -
4 335 RY1 4 335 LG CN 102-13
CN236
5 - - 5 - - -
GRIP HORN
6 19 VBMBSL 6 19 P-G CN239-5
7 - - 7 - - -
8 17 SOLCOM 8 17 G-W J22

CN230
D2, DA PEDAL
DIRECTION
NO P C
1 41 L-R
2 118 B-Y
TAB
J
CN237-1
CN237-2
NO P
1 41
2 118
-
C
REC
J
SHA+
SHA-

CN237
RR HORN

REC
NO P C J NO P C J
1 51 LS- 1 51 BR CN239-13 TAB REC
2 - - 2 - - -
NO P C J NO P C J
3 45 DSF 3 45 GR-R CN240-21
1 41 L-R J4 1 41 L-R CN236-1
4 51 LS- 4 51 BR CN240-12
2 118 B-Y CN238-1 2 118 B-Y CN236-2
5 - - 5 - - -
6 46 DSR 6 46 B-O CN240-17
 18-25

CN238 CN6-2
HORN RELAY

2 1 1 2
4 3 3 4
CN76-3
TAB REC
JO P C J NO P C J 51, G 9, G-W
1 118 - COIL+ 1 118 B-Y CN42-2, 237-2
2 41 - SW+ 2 41 L-R J4
3 N2 - COIL- 3 N2 W-B J3
4 48 - SW- 4 48 L-O J5

JOINT
TAB

J CZ3
E
•- -• •- -• •- -9 •- -• •- -«
/ y y J i y
N239 •- -• 9— -9- -9 •-
/ 4

-9- -• 32, L
J/C2-1 / —> -------- 4 —/ 4 -------- 4 4 4 ---- /

REC
I (ZZ3 □ CN240
11 JO s8 J >6 >5 X <3 >2 J
J/Lr/'-Z
22 ,21 20 J9 (18 ,17 J6 J5 s14 J3 J2 CN8-9 CN6-6
N2 I CN8-11
n CZJ n TERMINAL^yX/z.CN12-1 A

j X .3 -4 >5 >7 >8 >9 JO ji ( J3 V— CN13-4

21— 22
J2 J3 J4 J6 J6 J7 J8 J9 20 <-
CN228-----
CN238-3'X CN17-4
CN101-22
Jal
ACAA
CN26-6
JO P C J P C CN47-3 CN38-1CN23-2
NO J
1 51 B CN102-10 1 51 B CN15-3
2 51 B CN19-2 2 51 B CN90-3 N2, W-B 50, B-O
3 42 R-Y CN110-2 3 42 R-Y CN109-2
4 42 R-Y CN 103-4 4 42 R-Y CN111-2
5 19 P-G CN223-6 5 - - -
6 19 P-G CN28-4 6 19 P-G CN 102-3
7 19 P-G CN 102-4 7 - - -
8 97 R-W CN223-2 8 97 R-W CN114-1
CN9-6
9 97 R-W CN101-3 9 97 R-W CN113-1
IO 51 GR CN41-3 10 - - -
11 51 GR CN102-26 11 51 GR CN32-1 CN42-13
I2 51 BR CN42-13 12 51 BR CN230-4
I3 51 BR CN230-1 13 51 BR CN9-6
I4 - - - 14 - - - 51, BR
I5 51 BR CN103-6 15 - - -
I6 - - - 16 - - -
I7 46 B-O CN42-12 17 46 B-O CN230-6
I8 46 B-O CN104-19 18 46 B-O CN9-4
I9 - - - 19 - - - CN3-2
>0 - - - 20 - - -
>1 45 GR-R CN42-11 21 45 GR-R CN230-3
12 45 GR-R CN104-26 22 45 GR-R CN9-5
CN227 CN238-4

48, L-O 108, L-R

18-26

CN17-5 CN85-3

109, L-0 70, B-L 78, LG

FR STAY HOOD

N2, W-B 60, P-L 17, G-W

FR STAY CN17-4 CN30-3 CN103-5

(LH) A I

CN18-5X CN18-1 CN 103-8 CN44-3

N2
TERMINAL
Ak CN104-6

N2, W-B 300, L-B N2, W-B

CN51-2

CN101-1 CN88-1 CN104-5

198, W-R 3, V N2, W-B

51, GR 75, B-W

18-28

CONNECTING DIAGRAM

<OPT> <OPT> <OPT>

CN52
CL

a: P
§ u
TAB
REC
TAB
REC
TAB
REC CN59IÖ
t—
<□>
Q
CN45 CN46 CN238 CL DRIVE MOTOR©-
CN15 cn
RH
CN
CN60 O CD
Q
Q.
cn

CONTROL VALVE
LIFT
SOL

UNLOAD
SOL

C/V PUSH
REC REC
SOL
TAB REC TAB TAB
REC TAB CN44 CN30
CN92
C/V PULL
I Pa: SOL
I
MAST WIRE ¡ CN76 IH? PRESS
LU
tr F SSR
I

CN90
PEDAL UNIT
<OPT>
CN26! |a|g] ACCEL
I |g g] SSR

BRAKE
CN58 a:
RR COMBI

RR COMBI

I SSR
RH
LH

TEMP Q co D2.DA
CN61 PEDAL <OPT>
TAB tr £
ISPD2I ISPD11

TAB co DIRECTION
¡S
DRIVE MOTOR
LH
CN56
<$) © $ o
a:
CN55 PUMP MOTOR©
Üm
ar i
CN113
CN38

£
TAB cn49 TAB
CN95
CN234 CN231
<OPT> REC REC
TAB TAB
J/C1-2 J/C1-1

CN111
CN109
REC
TAB TAB
PUP INV

á- 5
DRIVE INV LH
 73
RESISTOR m
O œ o
RR HORN WIRE~1 Ô ¡FLASHER 73
m
£ DIRECTION
SW(LH DIR)
<OPT> I-
J ------ lol RELAY o 00
TIRE GRIP I!
¡2
ANGLE m HORN £
HORN SW
m
o 73
SSR
o
O
ÿ STEERING 3
CD SSR c
F6&F7 z
FUSE -1

¡REC
£
<£ TURN SW
F4&F5
g <OPT>
BATTERY

FUSE
73
RY1
g REEC REC
00 O
TZ TAB
CONTACTOR 73
> m
J (CURRENT) CD o o
SEAT SW
CONTACTOR

2 2
O -»
o EMERGENCY
3V SW
73
¡5 mo Oz
73
m
O g o
HS SW
co o>
A A
o 73 73 JOYSTICK o
HORN SW m m SHORT
3 GO O O
z
00 o o CONNECTOR
z
3
O O
z
—
N24

8
o co
REC REC
TAB TAB
h REClg
d REEC
NJ NJ O o TAB « TZ<B
nj Z z
g —J
CD

TAB TAB TAB TAB TAB O TAB

NTRL TILT

Z
■n
A

SISONOVl
<OPT>

<OPT>

73

ANGLE
<OPT>
LOAD
o
ATT2

ATT1

TILT

SSR
LVR

LVR

TILT
l.VR

SW

SW

s| 73 £ 73 O

LIFT
TO
LVR zo —< ZO
2
5
i 2

co
rb
co
18-30

ELECTRIC WIRING DIAGRAM (STD)

18-31
13-32

ELECTRIC WIRING DIAGRAM (FOR CABIN MODEL)

F5 FUSE DESIGNATION

F5= 4 A > SUPPLY DC/DC FOR PC

F5= 4 A > SUPPLY DC/DC FOR CAR RADIO
F5= 6.3 A > SUPPLY DC/DC FOR PC + CAR RADIO
48V BATTERY

KEY ON

J 34/1

CABIN
DC-DCCONVERTER

F8-10A

RIGHT

WORKING
LIGHTS

ROTARY/FLASH

S3 53
M1
31b
FRONT WIPER
31
MOTOR
53a

FRONT WINDSCREEN
WASHER MOTCR

M3
REAR WIPER
MOTOR
0
REAR WINDSCREEN
WASHER MOTCR

REAR WINDOW
HEATER

AERIAL

CAR RAD O
RIGHT REAR
LOUDSPEAKER

LEFT REAR
LOUDSPEAKER
 18-33

J6
1 T
SW4
£J *
<
■ 2
—-\_N STROBE
LIGHT
SWITCH

♦24V PC SUPPLY |
WITH STANDARD
CABIN

I
I
I
I
I
L

J49
+12V PC SUPPLY
WITH CONFORT CABIN
 Published by

TOYOTA Material Handling Company

A Division of TOYOTA INDUSTRIES CORPORATION

1st Printing: Dec. 2008

Pub. No. CE345

Printed in Japan