8FBCU 20, 25, 28, 30, 32

8FBCHU 25

VOL. 1

Pub. No. CU346

PRINTED IN USA Pub. No. CU346
FORWORD.fm 1 ページ ２０１０年４月１４日 水曜日 午後１時２分

FOREWORD
This Manual (Volume 2) contains diagnosis, service procedures of electrical
controller and multi-function display of the TOYOTA ELECTRIC POWERED
FORKLIFT 8FBCU, 8FBCHU series.

For maintenance, specifications and repair procedures for the chassis, body
and load handling system, refer to Volume 1 (Pub. No. CU346)

Please use these manuals for providing quick, correct servicing of the corre-
sponding forklift models.

This manual deals with the above models as of May, 2010. 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.
FORWORD.fm 2 ページ ２０１０年４月１４日 水曜日 午後１時２分
Sec Index.fm 1 ページ ２０１０年３月３１日 水曜日 午後４時２１分

SECTION INDEX
NAME SECTION

GENERAL 0
BATTERY 1
CONTROL SYSTEM 2
MULTI-FUNCTION DISPLAY 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
SAS FUNCTIONS 17
APPENDIX 18
Sections indicated by solid characters are included in this manual.
Sections indicated by half-tone characters: See vol. 2.
Sec Index.fm 2 ページ ２０１０年３月３１日 水曜日 午後４時２１分
Sec Index.fm 1 ページ ２０１０年４月１２日 月曜日 午後５時４２分

SECTION INDEX
NAME SECTION

GENERAL 0
BATTERY 1
CONTROL SYSTEM 2
MULTI-FUNCTION DISPLAY 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
SAS FUNCTIONS 17
APPENDIX 18
Sections indicated by solid characters are included in this manual.
Sections indicated by half-tone characters: See vol. 1.
Sec Index.fm 2 ページ ２０１０年４月１２日 月曜日 午後５時４２分
sec00.book 1 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-1

GENERAL
Page
EXTERIOR VIEWS .................................................0-2
VEHICLE MODEL...................................................0-3
FRAME NUMBER...................................................0-3 0
OPERATIONAL TIPS .............................................0-4
ATTENTIVE POINTS ON SAS ...............................0-5
CIRCUIT TESTER ..................................................0-6

Note:
See Vol. 1 (Pub. No. CU346) for the GENERAL items not included in this manual
sec00.book 2 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-2

EXTERIOR VIEWS
0
sec00.book 3 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-3

VEHICLE MODEL
Model
Load Capacity Vehicle Model Voltage Remarks
Code
20 4000 lbs 8FBCU20 36V/48V
8FBCU25 ¦
25 5000 lbs
8FBCHU25 ¦
28 5500lbs 8FBCU28 ¦ 0
30 6000 lbs 8FBCU30 ¦
32 6500 lbs 8FBCU32 ¦ USA·CANADA·MEXICO only

FRAME NUMBER
Frame No. Punching Position

Punching position

Vehicle Model Punching format

8FBCU20 8FBCU25-60011
8FBCU25 * 8FBCU25 60011
8FBCHU25 8FBCHU25-60011
8FBCU28-60011
8FBCU28
* 8FBCU28 60011
8FBCU30 8FBCU32-60011
8FBCU32 * 8FBCU32 60011

*: EEC spec.
sec00.book 4 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-4

OPERATIONAL 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 plug 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, packing 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.
(9) (Tighten to the center of the specified tightening torque range.)
(10) If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.
3 Protection of functional parts
(1) Thoroughly check each connector for any failure in or imperfect connection before reconnecting the battery
plug after the end of vehicle inspection or maintenance.
Failure in or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
4 Confirming defect status
Do not start immediate disassembly or replacement, but first confirm if such disassembly or replacement is
actually needed.
5 Handling of waste fluid, etc.
When draining waste fluid from the vehicle, always receive it with an appropriate container.
Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other harmful
substance may cause adverse affect to people or environmental destruction, sort each waste and always ask an
authorized contractor for appropriate disposal.
6 Handling of electronic parts

(1) Never apply impacts to electronic parts such as a

microcomputer or relay.
(2) Never let electronic parts be exposed to a high
temperature or humidity.
(3) Do not touch connector pins since they may be deformed
or be damaged due to static electricity.
sec00.book 5 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-5

ATTENTIVE POINTS ON SAS

1 Reference should be made to seperate manual “New Model Feature 8FBCU20 to 32 Pub. No.PU319” for the
explanations of SAS functions and operations.
2 Read Section 17 “SAS Precautions for Repair” on Page 17-9 in this repair manual in advance.
3 Whenever the repair or replacement is performed to the place where relative to SAS function, maching
procedure by which the SAS regain proper function must be performed. (See 17-18)
4 The warning on the SAS caution label must be confirmed when the modification or change is such as to change 0
the original specification.
If improper, change the label. (See Page 17-22)
5 Care should always be exercised for safety operation whenever you operate the truck.
Make distinction between the SAS featured trucks and those of none, because the control features are different.
6 The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oil will
adversely affect the functions of these valves, always wash the parts clean at the time of installation after
disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replacement of the hydraulic oil
is very important.
7 Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults.
Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts,
etc.)
sec00.book 6 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-6

CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according to the
purpose of measurement.

Analog type: This type is convenient for observing movement during operation, but the measured value should only
be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.

1 Difference in measurement results with the digital type and analog type
* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual.
Cautions when the polarities are different between the analog type and digital type are described below.
(1) Analog circuit tester
Forward direction Reverse direction Measurement result example
Tester range: kΩ range
Analog type
Continuity exists
Forward
11 kΩ
No continuity
Reverse
•

(2) Digital circuit tester

Forward direction Reverse direction

Measurement result example
Tester range: MΩ range
Digital type
No continuity
Forward
1
Continuity exists
Reverse
2 MΩ
sec00.book 7 ページ ２０１０年４月２２日 木曜日 午後１時６分

0-7

2 Difference in result of measurement with circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.
The diode characteristics are shown in the figure below.
(mA) The resistance values of the same semiconductor measured
6
with two types of circuit testers having different power supply
5 voltages are different.
Forward current

4 Germanium This manual describes the results of measurement with a

3 diode circuit tester whose power supply voltage is 3.0 V.
2 Silicon
diode
1
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)

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

In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the
circuit resistance. Even when the same diode is measured, the measurement result varies with the
measurement range.
Always use the range described in the repair manual for
measurement.
Resistor Meter

0Ω
Variable resistor
Current flow

Resistor

Range:×10 (SW1)

Resistor

Range:×1

Power source: 1.5V

Red Black
sec00.book 8 ページ ２０１０年４月２２日 木曜日 午後１時６分
sec01.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-1

BATTERY
1

Page
BATTERY COMPARTMENT AND
REQUIRED WEIGHT ..................................................... 1-2
SERVICE STANDARD .................................................... 1-3 1
DISPLAY ............................................................................. 1-3
TROUBLESHOOTING .................................................... 1-4
BATTERY ASSY ............................................................... 1-5
REMOVAL·INSTALLATION ............................................... 1-5
INSPECTION ..................................................................... 1-6
BATTERY STOPPER......................................................... 1-8
sec01.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-2

BATTERY COMPARTMENT AND REQUIRED WEIGHT

1

When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
See New Model Features (Pub. No. PU319) for the battery recommendation.

Compartment dimensions mm (in.) mm (in.) Battery weight kg (lb)

Height
Height from
Z ground
Models Mast Forward- Necessary Referenced
Width V
Rear minimum maximum
X Y Battery Battery with case with case
STD ROLL-OUT ROLL-OUT
SLIDE-OUT SLIDE-OUT

Except 775 992 605 585 470 1090 1430

8FBCU20 QFV (30.5) (39.1) (23.8) (23.0) (18.5) (2400) (3154)
8FBCU25 1200
QFV ↑ ↑ ↑ ↑ ↑ ↑
(2650)
1090
8FBCU28 ALL ↑ ↑ ↑ ↑ ↑ ↑
(2400)
8FBCHU25
870 1360 1613
8FBCU30 ALL ↑ ↑ ↑ ↑
(34.3) (3000) (3555)
8FBCU32

Forward-rear
Forward-Rear
X
in.)
90 mm 5 mm

Hole for cables

(3.5 in.) (0.2

Hole for cables

Z

Height
Height 50 mm
(2 in.)
130 mm
(5.1 in.)
V

Height from ground

Height from ground
Y
Width
Width
sec01.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-3

SERVICE STANDARD
Specific gravity upon full charge 1.280 [20°C (68°F)]
Specific gravity upon end of discharge 1.150 [20°C (68°F)]
36 V 32.0 V
Discharge end voltage
48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled (deionized) water
Insulation resistance 1MΩ or more
1
DISPLAY
Battery Charge Indicator

The battery charge indicator indicates 10 levels of battery

charge on the LCD.

Battery Overdischarge Warning Function

When the battery becomes over discharged below the preset

level in active “low battery level warning”, all segments in the
battery level indicator blink and a buzzer sounds to warn the
operator.

Low Remaining Battery Charge Warning

When the battery becomes below the preset level, the

battery level indicator blinks. When the operator turns the key
switch from OFF to ON with this condition, a buzzer will
sound for five seconds to warn the operator.
sec01.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-4

TROUBLESHOOTING

Plate corrosion Sulfation Plate wargage and active substance freeing

Improper charging
Long storage Repeated overdischarge/
without operation overcharge
End of life Short circuit
between cells
Charging current
Defect of electrolyte excessive
Electrolyte
Defective insufficient
electrolyte
Temperature
capacity

Battery defect
Overdischarge
excessive

Crack or
chipping of cell
Separator Improper
defective water Imperfect
supply connection
Overcharge
of the terminal

Deposition of free Fouled terminal or

active substance connecting plug
at bottom of cell

Short circuit Electrolyte leakage end reduction Loosened or corroded connection

sec01.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-5

BATTERY ASSY
REMOVAL·INSTALLATION
Always remove or install the battery in no-load state (without any load on the fork).

3
1

Removal Procedure
1 Disconnect the battery plug.
2 Slide the operator’s seat to the front most position, and lift up the armrest. (Mini lever/Joystick lever)
3 Open the battery hood.
4 Remove the rear toe board.
5 Loosen battery stoppers (RH and LH) and the fixing bolts.
6 Remove the battery ASSY. [Point 1]

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

Point Operation
[Point 1]
SST
Removal Installation:
SST 25009-13201-71
sec01.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-6

INSPECTION
1. Electrolyte inspection
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.

2. Specific gravity inspection

Use a hydrometer and measure the specific gravity of
the electrolyte.
Specific gravity upon full charge:
........................................ 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 as the standard.

Equation for conversion

S20 = St+0.0007 (t-20)
S20 = Specific gravity at 20°C
St:Specific gravity measured at t°C
t:Electrolyte temperature upon measurement (°C)

* How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the
Hydrometer
electrolyte port and allow the electrolyte to be
sucked into its outer tube.
Rubber (2) Let the hydrometer float correctly without
bulb contact with the outer tube, top or bottom, and
Outer tube read the scale at the highest point of the
electrolyte surface as illustrated at left when
the bubbles in the electrolyte disappear.
Nozzle
(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.
sec01.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-7

3. Insulation resistance inspection

Use an insulation resistance meter (megohmmeter) and
measure the resistance between the battery and battery
case.
Insulation resistance:1 MΩ or more

Note:
• When the insulation resistance is less than 1 MΩ,
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 MΩ or more.

* Battery control table

Prepare a control table for each battery to record and maintain the inspection results.
sec01.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時５３分

1-8

BATTERY STOPPER
The battery stopper adjusts the gap between the battery and battery compartment.
Adjust A and B so that total gap between the battery and battery compartment is under 12.7 mm (1/2 in).
This is the UL Standards requirement.
Install spacer plate if B is larger than 12.7 mm (1/2 in).
Spacer plate has two sets of installation holes.
Change the installion hole and bolt depend on wether B is larger than 30 mm (1.2 in).
Battery stopper 1

Tapped hole M12 × 1.25

A
Battery stopper 1 in detail

B 0 ～ 0.5° 0.5°～ 1° 1°～ 1.5° 1.5°～ 3.2° 3.2°～ 3.8° 3.8°～ 4.3° 4.3°～ 5.5° 5.5°～ 5.55°

CTR Cross
Plate
sec02.book 1 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-1

CONTROL SYSTEM
Page
GENERAL...............................................................2-2
SPECIFICATIONS ..................................................2-3
COMPONENTS ......................................................2-4
BEFORE REPAIR ...................................................2-7
INSPECTION ...........................................................2-7
CONNECTOR INSPECTION ..................................2-8 2
TO USE SST............................................................2-8
INSPECTION ...........................................................2-8
CONTROLLER .....................................................2-28
REMOVAL·INSTALLATION .....................................2-28
CONTACTOR PANEL ASSY................................2-30
REMOVAL·INSTALLATION .....................................2-30
INSPECTION .........................................................2-31
OCL MEASUREMENT ............................................2-32
REASSEMBLY .......................................................2-35
DISPLAY ...............................................................2-36
LAMP SWITCH.....................................................2-37
REMOVAL·INSTALLATION .....................................2-37
DISASSEMBLY·INSPECTION·REASSEMBLY ...........2-39
ACCELERATOR SENSOR
(POTENTIOMETER) ...........................................2-40
MINI LEVER..........................................................2-42
JOYSTICK.............................................................2-44
COMPONENTS ....................................................2-46
REMOVAL·INSTALLATION .....................................2-48
DISASSEMBLY·INSPECTION·REASSEMBLY ...........2-49
DISASSEMBLY·INSPECTION·REASSEMBLY ...........2-51
sec02.book 2 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-2

GENERAL
8FBC series models are equipped with traveling/load handling controllers that control traveling and load handling
system. They are multi-functional controllers equipped with micro computers.
The traveling/load 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, 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 load 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.

Contactor panel
Load handling AC driver

Traveling AC driver

Main controller
sec02.book 3 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-3

SPECIFICATIONS
All models
F1 (for drive and pump circuit) 600A
F4 (for lights) 10A
Fuses F5 (for control circuit) 10A
F6 (for controller) 10A
F7 (for controller) 10A
Contactor MB (for power supply) CP304T-A32

2
sec02.book 4 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-4

COMPONENTS
2401

05

AR

AR
AR

AR

2400-234
sec02.book 5 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-5

2401

GK MO
ML AI
BL RJ
XH AI
LZ
BL PL AI
LU LZ

LZ RJ
LZ LZ BL
BL
HW
BL LZ
LZ BL
LU
LZ RJ AA
LZ
XF LZ 20
LZ
LZ AA
AA
AA AA HI
TI HI

HI
BV
KP
HI
HI
AA 20 HI
HI
HI
2401-379
 sec02.book

2-6
6 ページ

01
２０１０年４月１６日

EC
CJ
金曜日

CJ
午前９時５２分

CO BP

AZ
BW GR
BP
AZ
AK AZ
CZ
BP
CZ 22
FK
BP
61
GJ
FK CS CT
62 EN
CZ
AJ CZ

FK 44
44
AC 44
44

GJ

BX

2402-119
2402
sec02.book 7 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-7

BEFORE REPAIR
INSPECTION

1. Insulation resistance measurement

Note:
Always measure before inspecting the traveling/load 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. 1MΩ 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/load 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.
sec02.book 8 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-8

CONNECTOR INSPECTION
TO USE SST
Use SSTs for quick and accurate measure on the 8FBCU20~32, 8FBCHU25. 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 to CN104
main controller.

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. ļ Connector No. Conditions Standard Remarks

CN101-1 CN101-26
Key switch OFF, DSF ON. Approx. 0V
(45, DSF) (51, LS-)

Terminal name Conditions for measurement

Electric Level No.

Connector pin No.

sec02.book 9 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-9

MAIN CONTROLLER
CPU board

CN101 CN102 CN103 CN104

7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1

17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 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 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18

34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26

Conventional Lever
CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN101-1 CN102-16 Lift lock solenoid ON Approx. 11V
(3, SOLLU+) (4, SLLL-) Lift lock solenoid OFF Approx. 0V
CN101-2 CN102-19 Tilt forward solenoid ON Approx. 11V
(6, SLTFB+) (7, SLTFL-) Tilt forward solenoid OFF Approx. 0V
CN101-3 CN102-1 Fan stop Approx. 1V
(97, FAN+) (98, FNDC1) Fan rotate Battery voltage
CN101-4 CN104-4
- Battery voltage
(41, VBBT) (N2, N2)
CN101-5 - Unused -
CN101-6 - Unused -
CN101-7 - Unused -
CN101-8 - Unused -
CN101-9 - Unused -
CN101-10 - Unused -
CN101-11 - Unused −
CN101-12 - Unused −
CN101-13 - Unused −
CN101-14 - Unused −
CN101-15 - Unused −
CN101-16 - Unused −
CN101-17 - Unused −
sec02.book 10 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-10

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN101-18 CN101-32
- Approx. 1V to 4V
(308, STCB) (51, POT-)
CN101-19 CN104-4 Key switch OFF Approx. 0V
(47, VBKY) (N2, N2) Key switch ON Battery voltage
CN101-20 CN101-32
- Approx. 5V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN101-32
- Approx. 5V
(316, VRTRA+) (51, POT-)
CN101-24 - Unused -
CN101-25 CN101-32
- Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN101-32
- Approx. 4.8V
(55, VRA2+) (51, POT-)
CN101-27 CN101-32
- Approx. 4.8V
(53, VRA1+) (51, POT-)
CN101-28 - Unused -
CN101-29 CN101-32
- Approx. 4.6V *1
(30, VRAT1+) (51, POT-)
CN101-30 CN101-32
- Approx. 4.6V *2
(31, VRAT2+) (51, POT-)
CN101-31 - Unused -
CN101-32
- - -
(51, POT-)
CN101-33 - Unused -
CN101-34 - Unused -

*1: W/ ATT1
*2: W/ ATT2

CN102 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN102-1 CN104-4 Fan stop Battery voltage
(98, FNDC1) (N2, N2) Fan rotate Approx. 0V
CN102-2 CN104-4 Fan stop Battery voltage
(99, FNDC2) (N2, N2) Fan rotate Approx. 0V
CN102-3 CN104-4 Key switch OFF Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-4 CN104-4 Key switch OFF Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-5 - Unused -
CN102-6 - Unused -
Knob position correcting solenoid ON Approx. 11V
CN102-7 CN102-14
Knob position correcting solenoid Approx. 0V
(329, SLS+) (330, SLS-)
OFF
CN102-8 - Unused -
CN102-9 CN104-4 EZ pedal neutral position Approx. 14V
*1
(332, OACC2) (N2, N2) EZ pedal backward position Approx. 0V
sec02.book 11 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-11

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN102-10
- - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
CN102-13 - Unused -
CN102-14 CN102-7 Resistance measurement with battery
Approx. 10Ω
(330, SLS-) (329, SLS+) plug disconnected
CN102-15 - Unused -
CN102-16 CN101-1 Resistance measurement with battery
Approx. 10Ω
(4, SLLL-) (3, SOLLU+) plug disconnected
CN102-17 CN101-1 Resistance measurement with battery
Approx. 10Ω
(5, SLUL-) (3, SOLLU+) plug disconnected
CN102-18 - Unused -
CN102-19 CN101-2 Resistance measurement with battery
Approx. 10Ω
(7, SLTFL-) (6, SLTFB+) plug disconnected
Attachment 1 lever in the neutral Approx. 2.3V
CN102-20 CN102-26 position
*2
(25, VRA12) (51, POT-) Attachment 1 lever in the forward or Approx. 0.5V to 4V
backward position
Attachment 1 lever in the neutral Approx. 2.3V
CN102-21 CN102-26 position
*2
(24, VRA11) (51, POT-) Attachment 1 lever in the forward or Approx. 0.5V to 4V
backward position
Key switch OFF, tilt lever in the Approx. 0V
CN102-22 CN102-10 backward position
(62, SWTR) (51, LS-) Key switch OFF, tilt lever in the Approx. 5V
neutral position
Key switch OFF, tilt lever in the Approx. 0V
CN102-23 CN102-10 forward position
(61, SWTF) (51, LS-) Key switch OFF, tilt lever in the Approx. 5V
neutral position
CN102-24 - Unused -
CN102-25 - Unused -
CN102-26
- - -
(51, POT-)
CN102-27 - Unused -
Attachment 2 lever in the neutral Approx. 2.3V
CN102-28 CN102-26 position
*3
(27, VRA22) (51, POT-) Attachment 2 lever in the forward or Approx. 0.5V to 4V
backward position
Attachment 2 lever in the neutral Approx. 2.3V
CN102-29 CN102-26 position
*3
(26, VRA21) (51, POT-) Attachment 2 lever in the forward or Approx. 0.5V to 4V
backward position
CN102-30 CN102-26 Key switch OFF, accelerator pedal
Approx. 0.5V to 3.8V
(52, VRA1) (51, POT-) fully depressed
CN102-31 CN102-26
Tire position is neutral Approx. 2V
(317, VRTRA) (51, POT-)
CN102-32 CN102-26 Key switch OFF, accelerator pedal
Approx. 09V to 4.1V
(54, VRA2) (51, POT-) fully depressed
sec02.book 12 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-12

Connector No. ⇔ Connector No. Conditions Standard Remarks

Key switch OFF, brake pedal is free Approx. 0V
CN102-33 CN102-10
Key switch OFF, brake pedal is Approx. 5V
(65, SWBK) (51, LS-)
depressed
CN102-34 - Unused -
CN102-35 - Unused -

*1: W/ EZ pedal
*2: W/ ATT1
*3: W/ ATT2

CN103 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN103-1 CN103-2 Swing lock solenoid ON Approx. 9V
(327, SLSW+) (328, SLSW-) Switcn lock solenoid OFF Approx. 0V
CN103-2 CN103-1 Resistance measurement with battery
Approx. 6Ω
(328, SLSW-) (327, SLSW+) plug disconnected
CN103-3
- - -
(14, DGND)
CN103-4 CN104-4 Key switch OFF Approx. 0V
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 CN102-26
- Approx. 5V
(307, STCB+) (51, POT-)
CN103-8 CN102-26
- Approx. 5V
(300, IPL+) (51, POT-)
CN103-9
- Immeasureble -
(147, CAN2H)
CN103-10
- Immeasureble -
(148, CAN2L)
CN103-11
- Immeasureble -
(145, CAN1H)
CN103-12
- Immeasureble -
(146, CAN1L)
CN103-13 CN103-6
- Approx. 14V
(311, SSTR+) (51, LS-)
CN103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - Unused -
CN103-16 - Unused -
CN103-17 CN102-26 Variation upon changeover from
Approx. 1V to 4V
(56, VRTA) (51, POT-) forward to backward tilting
Lift lever in the neutral position Approx. 2.3V
CN103-18 CN102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(21, VRL2) (51, POT-)
position
CN103-19 CN102-26
- Approx. 2V
(302, IPL2) (51, POT-)
CN103-20 - Unused -
CN103-21 - Unused -
CN103-22 - Unused -
sec02.book 13 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-13

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN103-23 - Unused -
Key switch OFF, mast height switch Approx. 0V
CN103-24 CN103-6 ON
(91, SH2-1) (51, LS-) Key switch OFF, mast haight switch Approx. 5V
OFF
CN103-25 - Unused -
Lift lever in the neutral position Approx. 2.3V
CN103-26 CN102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(20, VRA1) (51, POT-)
position
CN103-27 CN104-11
- Approx. 2.5V
(322, SYR) (323, SYR-)
CN103-28 - Unused -
Forks on the ground Approx. 1V or less
CN103-29 CN102-26
Amount of change between raising Approx. 0.5V to 4.5V
(59, SPLF) (51, POT-)
and lowering on the lift with a load
CN103-30 CN102-26
- Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - Unused -
Key switch OFF, automatic fork Approx. 0V
CN103-32 CN103-6 leveling switch ON
(70, STK) (51, LS-) Key switch OFF, automatic fork Approx. 5V
leveling switch OFF
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -

CN104 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN104-1 CN104-4
- Battery voltage
(41, B48V) (N2, N2)
CN104-2 CN104-4 Key switch OFF Approx. 0V
(44, VBMB) (N2, N2) Key switch ON Battery voltage
CN104-3 CN104-9 Key switch ON Approx. 11V
(1, CBAT+) (2, CBAT-) Key switch OFF Approx. 0V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
CN104-6
- - -
(N2, N2)

CN104-7 - Unused -

CN104-8 - Unused -

CN104-9 CN104-3 Resistance measurement with battery

Approx. 20Ω
(2, CBAT-) (1, CBAT+) plug disconnected

CN104-10 - Unused -

CN104-11
- - -
(323, SYR-)
sec02.book 14 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-14

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN104-12 CN102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 CN104-11
- Approx. 5V
(321, SYR+) (323, SYR-)
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)

CN104-15 - Unused -

CN104-16 - Unused -

CN104-17 - Unused -

CN104-18 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

CN104-19 CN103-6 forward
(46, DSR) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral

Key switch OFF, parking brake switch Approx. 0V

CN104-20 CN103-6 release
(66, SPB) (51, LS-) Key switch OFF, parking brake switch Approx. 5V
lock

CN104-21 - Unused -

Key switch OFF, mast height switch Approx. 0V

CN104-22 CN103-6 ON
(90, SH1) (51, LS-) Key switch OFF, mast haight switch Approx. 5V
OFF

CN104-23 - Unused -

CN104-24 CN103-6
Steering operation Approx. 0V to 5V
(314, SSTRC) (51, LS-)

CN104-25 - Unused -

Key switch OFF, direction switch Approx. 0V

CN104-26 CN103-6 forward
(45, DSF) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral

CN104-27 - Unused -

CN104-28 - Unused -

CN104-29 - Unused -

CN104-30 CN103-6
Steering operation Approx. 0V to 5V
(312, SSTR1) (51, LS-)
CN104-31 CN103-6
Steering operation Approx. 0V to 5V
(313, SSTR2) (51, LS-)
sec02.book 15 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-15

Mini lever/Joystick lever

CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN101-1 CN102-16 Lift lock solenoid ON Approx. 11V
(3, SOLLU+) (4, SLLL-) Lift lock solenoid OFF Approx. 0V
CN101-2 CN102-19 Tilt forward solenoid ON Approx. 11V
(6, SLTFB+) (7, SLTFL-) Tilt forward solenoid OFF Approx. 0V
CN101-3 CN102-1 Fan stop Approx. 1V
(97, FAN+) (98, FNDC1) Fan rotate Battery voltage
CN101-4 CN104-4
- Battery voltage
(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. 7Ω *1
(36, SA1PL-) (32, SLTA1+) plug disconnected
CN101-11 CN101-6 Resistance measurement with battery
Approx. 7Ω *1
(37, SA1PS-) (32, SLTA1+) plug disconnected
CN101-12 CN101-6 Resistance measurement with battery
Approx. 7Ω
(33, STPL-) (32, SLTA1+) plug disconnected
CN101-13 CN101-6 Resistance measurement with battery
Approx. 7Ω
(34, STPS-) (32, SLTA1+) plug disconnected
CN101-14 CN101-5 Resistance measurement with battery
Approx. 7Ω *2
(39, SA2PL-) (9, SLLA2+) plug disconnected
CN101-15 CN101-5 Resistance measurement with battery
Approx. 7Ω *2
(40, SA2PS-) (9, SLLA2+) plug disconnected
CN101-16 CN101-5 Resistance measurement with battery
Approx. 7Ω
(11, SLPS-) (9, SLLA2+) plug disconnected
CN101-17 CN101-5 Resistance measurement with battery
Approx. 7Ω
(10, SLPL-) (9, SLLA2+) plug disconnected
CN101-18 CN101-32
- Approx. 1V to 4V
(308, STCB) (51, POT-)
CN101-19 CN104-4 Key switch OFF Approx. 0V
(43, VBKY) (N2, N2) Key switch ON Battery voltage
CN101-20 CN102-32
- Approx. 5V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN102-32
- Approx. 5V
(316, VRTRA+) (51, POT-)
CN101-24 CN102-32
- Approx. 5V
(219, VRH+) (51, POT-)
CN101-25 CN102-32
- Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN102-32
- Approx. 4.8V
(55, VRA2+) (51, POT-)
sec02.book 16 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-16

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN101-27 CN102-32
- Approx. 4.8V
(53, VRA1+) (51, POT-)
CN101-28 CN102-32
- Approx. 4.6V
(29, VRT+) (51, POT-)
CN101-29 CN102-32
- Approx. 4.6V *1
(30, VRAT1+) (51, POT-)
CN101-30 CN102-32
- Approx. 4.6V *2
(31, VRAT2+) (51, POT-)
CN101-31 - Unused -
CN101-32
- - -
(51, POT-)
CN101-33 - - -
CN101-34 - - -

*1: W/ ATT1
*2: W/ ATT2
sec02.book 17 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-17

CN102 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN102-1 CN104-4 Fan stop Battery voltage
(98, FNDC1) (N2, N2) Fan rotate Approx. 0V
CN102-2 CN104-4 Fan stop Battery voltage
(99, FNDC2) (N2, N2) Fan rotate Approx. 0V
CN102-3 CN104-4 Key switch OFF Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-4 CN104-4 Key switch OFF Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-5 CN104-4 Key switch OFF Approx. 0V
(17, SOLCOM) (N2, N2) Key switch ON Battery voltage
CN102-6 CN104-4 Key switch OFF Approx. 0V
(17, SOLCOM) (N2, N2) Key switch ON Battery voltage
Knob position correcting solenoid ON Approx. 11V
CN102-7 CN102-14
Knob position correcting solenoid Approx. 0V
(329, SLS+) (330, SLS-)
OFF
CN102-8 - Unused -
CN102-9 CN104-4 EZ pedal in the neutral position Approx. 14V
*1
(332, OACC2) (N2, N2) EZ pedal in the backward position Approx. 0V
CN102-10
- - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
Key switch OFF Battery voltage
CN102-13 CN104-4
Key switch ON (Battery voltage -
(335, RY1-) (N2, N2)
Approx. 12V)
CN102-14 CN102-7 Resistance measurement with battery
Approx. 10Ω
(330, SLS-) (329, SLS+) plug disconnected
CN102-15 - Unused -
CN102-16 CN101-1 Resistance measurement with battery
Approx. 10Ω
(4, SLLL-) (3, SOLLU+) plug disconnected
CN102-17 - Unused -
CN102-18 - Unused -
CN102-19 CN101-2 Resistance measurement with battery
Approx. 10Ω
(7, SLTFL-) (6, SLTFB+) plug disconnected
ATT1 lever in the neutral position Approx. 2.3V
CN102-20 CN102-26
ATT1 lever in the forward or Approx. 0.5 to 4V *2
(25, VRA12) (51, POT-)
backward position
ATT1 lever in the neutral position Approx. 2.3V
CN102-21 CN102-26
ATT1 lever in the forward or Approx. 0.5 to 4V *2
(24, VRA11) (51, POT-)
backward position
Tilt lever in the neutral position Approx. 2.3V
CN102-22 CN102-26
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: W/ EZ pedal
*2: W/ ATT1
sec02.book 18 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-18

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN102-24 - Unused -
CN102-25 - Unused -
CN102-26
- - -
(51, POT-)
CN102-27 - Unused -
ATT2 lever in the neutral position Approx. 2.3V
CN102-28 CN102-26
ATT2 lever in the forward or Approx. 0.5 to 4V *3
(27, VRA22) (51, POT-)
backward position
ATT2 lever in the neutral position Approx. 2.3V
CN102-29 CN102-26
ATT2 lever in the forward or Approx. 0.5 to 4V *3
(26, VRA21) (51, POT-)
backward position
CN102-30 CN102-26 Key switch OFF, accelerator pedal
Approx. 0.5 to 3.8V
(52, VRA1) (51, POT-) fully depressed
CN102-31 CN102-26
Tire position is neutral Approx. 2V
(317, VRTRA) (51, POT-)
CN102-32 CN102-26 Key switch OFF, accelerator pedal
Approx. 0.9 to 4.1V
(54, VRA2) (51, POT-) fully depressed
Key switch OFF, brake pedal is free Approx. 0V
CN102-33 CN102-10
Key switch OFF, brake pedal is Approx. 5V
(65, SWBK) (51, LS-)
depressed
CN102-34 - Unused -
CN102-35 - Unused -

*3: W/ ATT2

CN103 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN103-1 CN103-2 Swing SOL ON Approx. 9V
(327, SLSW+) (328, SLSW-) Swing SOL OFF Approx. 0V
CN103-2 CN103-1 Resistance measurement with battery
Approx. 6Ω
(328, SLSW-) (327, SLSW+) plug disconnected
CN103-3
- - -
(14, DGND)
CN103-4 CN104-4 Key switch OFF Approx. 0V
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 CN102-26
- Approx. 5V
(307, STCBT) (51, POT-)
CN103-8 CN102-26
- Approx. 5V
(300, IPL+) (51, POT-)
CN103-9
- Immeasurable -
(147, CAN2H)
CN103-10
- Immeasurable -
(148, CAN2L)
sec02.book 19 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-19

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN103-11
- Immeasurable -
(145, CAN1H)
CN103-12
- Immeasurable -
(146, CAN1L)
CN103-13 CN103-6
- Approx. 14V
(311, SSTR+) (51, LS-)
CN103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - Unused -
CN103-16 - Unused -
CN103-17 CN102-26 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
CN103-18 CN102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(21, VRL2) (51, POT-)
position
CN103-19 CN102-26
- Approx. 2V
(302, IPL2) (51, POT-)
CN103-20 - Unused -
CN103-21 - Unused -
CN103-22 - Unused -
CN103-23 - Unused -
Key switch OFF, mast height switch Approx. 0V
CN103-24 CN103-6 ON
(91, SH2-1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN103-25 - Unused -
Lift lever in the neutral position Approx. 2.3V
CN103-26 CN102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(20, VRL1) (51, POT-)
position
CN103-27 CN104-11
- Approx. 2.5V
(322, SYR) (323, SYR-)
CN103-28 CN102-26 Variation upon changeover from
Approx. 0.5V to 4.3V
(220, VRH) (51, POT-) upward to downward lifting
Forks on the ground Approx. 1V or less
CN103-29 CN102-26
Amount of change between raising Approx. 0.5V to 4.5V
(59, SPLF) (51, POT-)
and lowering of the lift with a load
CN103-30 CN102-26
- Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - Unused -
Key switch OFF, automatic lift leveling Approx. 0V
CN103-32 CN103-6 switch ON
(70, STK) (51, LS-) Key switch OFF, automatic lift leveling Approx. 5V
switch OFF
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -
sec02.book 20 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-20

CN104 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN104-1 CN104-4
- Battery voltage
(41, B48V) (N2, N2)
CN104-2 CN104-4 Key switch OFF Approx. 0V
(44, VBMB) (N2, N2) Key switch ON Battery voltage
CN104-3 CN104-9 Key switch OFF Approx. 0V
(1, CBAT+) (2, CBAT-) Key switch ON Approx. 11V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
CN104-6
- - -
(N2, N2)
CN104-7 - Unused -
CN104-8 - Unused -
CN104-9 CN104-3 Resistance measurement with battery
Approx. 20Ω
(2, CBAT-) (1, CBAT+) plug disconnected
CN104-10 - Unused -
CN104-11
- - -
(323, SYR-)
CN104-12 CN102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 CN104-11
- Approx. 5V
(321, SYR+) (323, SYR-)
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)
CN104-15 CN104-4
- Approx. 14V
(60, PSSW+) (N2, N2)
CN104-16 - Unused -
CN104-17 - Unused -
CN104-18 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
CN104-19 CN103-6 backward
(46, DSR) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
Key switch OFF, parking brake switch Approx. 0V
CN104-20 CN103-6 release
(66, SPB) (51, LS-) Key switch OFF, parking brake switch Approx. 5V
lock
CN104-21 - Unused -
Key switch OFF, mast height switch Approx. 0V
CN104-22 CN103-6 ON
(90, SH1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN104-23 - Unused -
CN104-24 CN103-6
Steering operation Approx. 0V to 5V
(314, SSTRC) (51, LS-)
CN104-25 - Unused -
sec02.book 21 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-21

Connector No. ⇔ Connector No. Conditions Standard Remarks

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

TRAVELING AC DRIVER

CN110 and CN111

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

CN110 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN110-1 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN110-2 N1
- Approx. 15V
(78, SSD+) (N1, N1)
CN110-3 - Unused -
CN110-4 N1
- Approx. 5V
(88, STDM+) (N1, N1)
CN110-5 N1
- Approx. 1V to 4V
(87, STDM) (N1, N1)
CN110-6 N1 L: Approx. 0.5V or
-
(79, SSD1) (N1, N1) H: Approx. 1.5V
sec02.book 22 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-22

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN110-7 N1 L: Approx. 0.5V or
-
(80, SSD2) (N1, N1) H: Approx. 1.5V
CN110-8 N1
- Approx. 5V
(151, OSETD) (N1, N1)
CN110-9 - Unused -
CN110-10 N1
- Approx. 5V
(151, SETD2) (N1, N1)
CN110-11
- Immeasurable -
(145, CAN1H)
CN110-12
- Immeasurable -
(146, CAN1L)

LOAD HANDLING AC DRIVER

CN111 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN111-1 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN111-2 N1
- Approx. 15V
(81, SSP+) (N1, N1)
CN111-3 - Unused -
CN111-4 N1
- Approx. 5V
(88, STPM+) (N1, N1)
CN111-5 N1
- Approx. 1V to 4V
(89, STPM) (N1, N1)
CN111-6 N1 L: Approx. 0.5V or
-
(82, SSP1) (N1, N1) H: Approx. 1.5V
CN111-7 - Unused -
CN111-8 N1
- Approx. 5V
(152, OSETP) (N1, N1)
CN111-9 N1
- Approx. 5V
(152, SETP) (N1, N1)
CN111-10
- Unused -
(151, SETD2)
CN111-11
- Immeasurable -
(145, CAN1H)
CN111-12
- Immeasurable -
(146, CAN1L)
sec02.book 23 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-23

CONTACTOR PANEL ASSY

CN134
2 1

CN131
2 1

CN130
1 2 3
4 5 6

CN130 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN130-1 CN130-2 Battery plug disconnected, and
Approx. 28Ω
(2, CBAT-) (1, CBAT+) CN130 disconnection
Apply the negative probe to the
CN130-2 CN130-1
CN130-1 terminal to measure Approx. 12V
(1, CBAT+) (2, CBAT-)
voltage.
CN130-3 P1 Battery plug disconnected, and
Approx. 0Ω
(101, FLP) (P1, P1) CN130 disconnection
CN130-4 P1 Battery plug disconnected, and
Approx. 0Ω
(41, VBMB) (P1, P1) CN130 disconnection
CN130-5 P4 Battery plug disconnected, and
Approx. 0Ω
(44, VBMB) (P4, P4) CN130 disconnection
CN130-6 P4 Battery plug disconnected, and
Approx. 0Ω
(19, VBMBSL) (P4, P4) CN130 disconnection

CN131 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN131-1 N1 Apply the negative probe to the N1
Approx. 5V
(307, STCB+) (N1, N1) terminal to measure voltage.
CN131-2 N1 Apply the negative probe to the N1
0.5 V to 4.5V
(308, STCB) (N1, N1) terminal to measure voltage.

CN134 connector basic conditions (battery plug connected, key switch OFF)
Connector No. ⇔ Connector No. Conditions Standard Remarks
Battery plug disconnected, and
CN134-1 CN134-2 Approx. 28Ω
CN134 disconnection
sec02.book 24 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-24

BACK RELAY (W/ EZ pedal)

CN28

3 2 1

6 5 4

CN28 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN28-1 CN28-3 EZ pedal in the neutral Approx. 0V
(334, PSACC+) (332, OACC2) EZ pedal in the backward Approx. 14V

CN28-2 - Unused -

CN28-3
- - -
(332, OACC2)

CN28-4 - Unused -

CN28-5
- - -
(103, LBU+)
CN28-6 CN28-5 EZ pedal in the neutral Battery voltage
(105, B48V) (103, LBU+) EZ pedal in the backward Approx. 0V

MULTI-FUNCITON DISPLAY

CN27

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19

CN27 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN27-1 - Unused -
CN27-2 - Unused -
CN27-3
- - -
(169, TGND)
CN27-4
- - -
(14, DGND)
CN27-5 CN27-4
- Approx. 6.3V
(16, D7V) (14, DGND)
sec02.book 25 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-25

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN27-6 CN27-3
- Approx. 5V *1
(162, ITKY3) (169, TGND)
CN27-7 - Unused -
CN27-8 CN27-3
- Approx. 5V *1
(160, ITKY1) (169, TGND)
CN27-9
- Immeasurable -
(166, OTKY3)
CN27-10
- Immeasurable -
(165, OTKY2)
CN27-11
- Immeasurable -
(164, OTKY1)
CN27-12 CN27-3
- Approx. 0V *1
(167, LEDTKY1) (169, TGND)
CN27-13 - Unused -
CN27-14 - Unused -
CN27-15
- Immeasurable -
(146, CAN1L)
CN27-16
- Immeasurable -
(145, CAN1H)
CN27-17 - Unused -
CN27-18 - Unused -
CN27-19 CN27-3
- Approx. 3V *1
(168, LEDTKY2) (169, TGND)
CN27-20 CN27-3
- Approx. 5V *1
(161, ITKY2) (169, TGND)
CN27-21 CN27-3
- Approx. 5V *1
(163, IPSTKY1) (169, TGND)
CN27-22 - Unused -
CN27-23 - Unused -
CN27-24 - Unused -
CN27-25 - Unused -
CN27-26 - Unused -
CN27-27 - Unused -
CN27-28 - Unused -
CN27-29 - Unused -
CN27-30 - Unused -

*1: W/ PIN code entry system

sec02.book 26 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-26

TEN-KEY (W/ PIN code entry system)

CN18

5 4 3 2 1

10 9 8 7 6

CN18 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN18-1 CN18-7
- Approx. 5V
(160, ITKY1) (169, TGND)
CN18-2 CN18-7
- Approx. 5V
(161, ITKY2) (169, TGND)
CN18-3 CN18-7
- Approx. 5V
(162, ITKY3) (169, TGND)
CN18-4
- Immeasurable -
(165, OTKY2)
CN18-5 CN18-7
- Approx. 0V
(167, LEDTKY1) (169, TGND)
CN18-6 CN18-7
- Approx. 5V
(163, IPSTKY1) (169, TGND)
CN18-7
- - -
(169, TGND)
CN18-8
- Immeasurable -
(164, OTKY1)
CN18-9
- Immeasurable -
(166, OTKY3)
CN18-10 CN18-7
- Approx. 3V
(168, LEDTKY2) (169, TGND)
sec02.book 27 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-27

SOLENOID RELAY (Mini lever/Joystick lever)

CN132

3 2 1
8 7 6 5 4

CN132 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN132-1 - Unused -
CN132-2 CN132-4
- Approx. 12V
(97, FAN+) (335, RY1-)
CN132-3 - Unused -
CN132-4 Battery plug disconnected and
Approx. 180Ω
(335, RY1-) CN132 disconnection
CN132-5 - Unused -
CN132-6 N1
- Battery voltage
(19, VBMBSL) (N1, N1)
CN132-7 - Unused -
CN132-8 N1
- Battery voltage
(17, SOLCOM) (N1, N1)
sec02.book 28 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-28

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. 100Ω between P4 and GND to discharge the capacitor.
N·m (kgf·cm) [ft·lbf]

T=10~15 (102~153) [7.38~11.07]

Removal Procedure
1. Disconnect the battery plug.
2. Remove the step RH.
3. Disconnect the wiring of the main controller.
4. Remove the main controller ASSY.

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
sec02.book 29 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-29

Traveling, Load 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. 100Ω between P4 and GND to discharge the capacitor.
N·m (kgf·cm) [ft·lbf]

6 T=9.2~13.8 (94~141)
5 [6.79~10.18]

T=11.2~16.8 (114~171)
[8.26~12.39]

Removal Procedure
1. Disconnect the battery plug.
2. Remove the cover LH.
3. Disconnect the power cables.
4. Remove the copper bar.
5. Remove the traveling AC driver.
6. Remove the load handling 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.
sec02.book 30 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-30

CONTACTOR PANEL ASSY

REMOVAL·INSTALLATION
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. 100Ω between P4 and GND to discharge the capacitor.
N·m (kgf·cm) [ft·lbf]

Removal Procedure
1. Disconnect the battery plug.
2. Remove the cover LH.
3. Remove the contactor cover.
4. Disconnect the power cable.
5. Disconnect the connector.
6. Remove the contactor.
sec02.book 31 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-31

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
CN134 Disconnect CN134 connector, and measure the resistance of
the MB coil.
Portion to be Measurement Tester
Standard
inspected terminals range
2 1 Both terminals
of Approx. 28Ω
MB coil Ωx1
CN134-1 (at 20°C)
CN134-2

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 0Ω Ωx1
fuse
sec02.book 32 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-32

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.
sec02.book 33 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-33

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

(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.
sec02.book 34 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-34

(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
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:

[8FBCU20, 25, 8FBCHU25]
48 V: 450 ~ 575 A
36 V: 445 ~ 570 A
[8FBCU28, 30 32]
48 V: 460 ~ 590 A
36 V: 445 ~ 580 A

[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.
sec02.book 35 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-35

REASSEMBLY
Contactor Panel ASSY Reassembly Drawing
T=N·m (kgf·cm) [ft·lbf]

T=11.2~16.8 (114.2~171.3)
[8.26~12.39]
T=2.0~3.0 (20~30)
[1.48~2.17]

T=11~15 (112.2~153.0)
[8.1~11.1]

T=1.3~1.7 (13.3~17.3)
[0.96~1.25]

T=11~15 (112.2~153.0)
[8.1~11.1]

T=2.9~3.9 (29.6~39.8)
[2.14~2.88] T=11~15 (112.2~153.0)
[8.1~11.1]

Assembly Procedure
1. Install the top cover so that the 㧗 sticker is on the harness
side.
Note:
㧗 A magnet is attached to the back of the top cover, allowing
arcs from the contacts to escape to the outside. If the top
cover is installed the wrong way round, the arcs will scatter on
Harness T=1.3~1.7 the inside, causing a faulty connection.
(13.26~17.34)
[0.96~1.25]

Copper bar 2. Install the copper bars so that the +0

ψ marks are on the inside.
+0
Note:
If the copper bars are installed the wrong way round, the
+0
+0
contacts on the movable side and the contacts on the fixed
ψ
ψ
+0 +0

side will be misaligned, resulting in overheating or adhesion.

Caution:
Contact wear tolerance
Movable side: 1 mm (0.039 in)
Fixed side: 1 mm (0.039 in)
sec02.book 36 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-36

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

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19

CN27 connector basic condition (Battery plug connected)

Connector No. ⇔ Connector No. Conditions Standard: Remarks
CN27-5 CN27-4
- Approx. 6.3V
(16, D7V) (14, DGND)
sec02.book 37 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-37

LAMP SWITCH
REMOVAL·INSTALLATION
T=N·m (kgf·cm) [ft·lbf]

T=24.5~45.5
(250~464) 4
[18.1~33.6]

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.
sec02.book 38 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-38

Point Operations
SST
[Point 1]
Disassembly:
Use the SST to remove the steering wheel.
SST 09950-76003-71
(09950-50012)
sec02.book 39 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-39

DISASSEMBLY·INSPECTION·REASSEMBLY

2
3

Disassembly Procedure
1. Remove the cam.
2. Remove the horn 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.
sec02.book 40 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-40

ACCELERATOR SENSOR
(POTENTIOMETER)
6 5 4 3 2 1
1. Remove the accelerator potentiometer.
2. Check that the resistance between terminals.
Terminal 5 - 6 1.8 to 3.4 kΩ
When the potentiometer is
rotated, the resistance must
Terminal 4 - 6
increase in proportion to its
number of rotations.
Terminal 1 - 2 1.8 to 3.4 kΩ
When the potentiometer is
rotated, the resistance must
Terminal 2 - 3
increase in proportion to its
number of rotations.

3. Temporarily install the accelerator potentiometer.

Note:
10 degrees 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.
VRA1 Currently stored value
Standard: VRA1 0.75 ± 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.
sec02.book 41 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-41

Note:
For EZ 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.
sec02.book 42 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-42

MINI LEVER

Armrest

Lift lever

Tilt lever

Direction switch

Lever for fixing rotation

of lever box
Automatic fork leveling switch

Lift Lever-Attachment Lever

22.5 to 26° 22.5 to 26°

5 V (1)

PS1 (2)

GND (3)

PS2 (4)
sec02.book 43 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-43

Tilt Lever

22.5 to 26° 22.5 to 26°

5V
(1)

PS1
(2)

GND
(3)

PS2
(4)

Connector pin arrangement

(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green

Direction Switch

P T VBKY DSF DSR DSFo DSBu LS-

9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10

MARK TERMINAL
1 -
2 DSBu
3 DSFo
4 DSR
5 DSF
6 LS-
7 VBKY
8 VBKY
sec02.book 44 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-44

JOYSTICK

Armrest
Automatic fork
leveling switch

Direction switch

Lever for fixing rotation

of lever box
Joystick for lift and tilt
operation

Joystick for Lift and Tilt Operation

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

5V
(1)

PS1
(2)

GND
(3)

PS2
(4)

1 2 4 3
3 4 2 1

Connector pin arrangement

(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green
sec02.book 45 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-45

Joystick for Attachment Operation

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

5 V (1)

PS1 (2)

GND (3)

PS2 (4)
1 2 4 3
3 4 2 1

Direction Switch

P T VBKY DSF DSR DSFo DSBu LS-

9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10

MARK TERMINAL
1 -
2 DSBu
3 DSFo
4 DSR
5 DSF
6 LS-
7 VBKY
8 VBKY
sec02.book 46 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-46

COMPONENTS
6712

DA DK
BK BC
DK
DE
DF CS CU

BJ

CT
CP CL AT
CR
BM CN
CB CO CV
DD
BL
23 DJ
CX BB

BR DL DL
CW
DC
CQ DH
BA
AE
AE
AU
DK
BX

6712-052
sec02.book 47 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-47

Mini Lever

6712

(LH LEVER) 20

CH

(HEIGHT SELECTOR) AL

CJ 21 BI
22 BP
22 CJ
21
22 21
21
22

45 CK 10
CG

AM

AQ
AP

6712-055

Joystick

6712

20

(LH LEVER)
CH

AL

24
25
BI
BP 24
25

45
CK
CG

10

AM

AP AQ

6712-056
sec02.book 48 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-48

REMOVAL·INSTALLATION
T=N·m (kgf·cm) [ft·lbf]

4
5

Removal Procedure
1. Disconnect the battery plug.
2. Remove the counterweight.
3. Disconnect the connectors.
4. Remove the cover.
5. Remove the mini lever ASSY from the operator’s seat.

Removal Procedure
The installation procedure is the reverse of the removal procedure.
sec02.book 49 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-49

DISASSEMBLY·INSPECTION·REASSEMBLY
T=N·m (kgf·cm) [ft·lbf]

4
T= 14 (143) [10.3]

1 T= 35~40
(357~408) 3
[26~30]
5

T= 2.0~4.0
(20.4~40.8)
2 3 [1.5~3.0]
3
T= 2.0~4.0
(20.4~40.8)
[1.5~3.0]

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.
sec02.book 50 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-50

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).
B 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 lbf].

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

Nut A
sec02.book 51 ページ ２０１０年４月１６日 金曜日 午前９時５２分

2-51

DISASSEMBLY·INSPECTION·REASSEMBLY

Mini lever Joystick

1
1

3
3

4
4

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.
sec02.book 52 ページ ２０１０年４月１６日 金曜日 午前９時５２分
sec03.book 1 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-1

MULTI-FUNCTION DISPLAY
3

Page
GENERAL...............................................................3-2
GENERAL FUNCTIONS.........................................3-3
GENERAL ...............................................................3-3
ADMINISTRATOR FUNCTIONS .................................3-6
MASK FUNCTIONS..............................................3-20
GENERAL .............................................................3-20
PASSWORD ..........................................................3-21
3
ANALYZER ...........................................................3-23
TUNING ................................................................3-48
OPTION SET .........................................................3-58
MATCHING............................................................3-62
OTHERS MENU .....................................................3-71
MULTI-FUNCTION DISPLAY ASSY.....................3-83
COMPONENTS ......................................................3-83
REMOVAL·INSTALLATION .....................................3-84
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-85
sec03.book 2 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-2

GENERAL
The multi-function display has various functions that indicate/notify the vehicle’s information such as vehicle speed,
the battery discharge level and so on. And the operator or administrator can set the vehicle performance with this
display. Furthermore, it has functions to perform maintenance, feeling adjustments and specification setting as a
service function.
On this model, a graphic LCD (Liquid Crystal Display) has been adopted and this provides various information to be
easy-to-understand with expressive capability.

(6) (9)
(7) (10)

(8)

(5)

(1) (2) (3) (4)

No. Description
(1) Switch (1): Low speed setting switch / Down switch
(2) Switch (2): Power select switch / Left switch
(3) Switch (3): Time or date select switch / Right switch
(4) Switch (4): Meter mode select switch / Enter switch
(5) Multiple screen display area
(6) OPSS indicator
(7) Parking brake indicator
(8) Low speed setting indicator
(9) Diagnostic mode indicator
(10) Overheat warning indicator
sec03.book 3 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-3

GENERAL FUNCTIONS
GENERAL
General Function List
{: Provided OPT: Option
Remarks
Calendar watch {
Indication that maximum speed limiter is in active setting. {
Indication that overspeed alarm is in active setting. {
Initial display after Indication that auto speed control is in active setting. OPT With Auto Speed Control
key-ON Indication that maximum lift-height limiter is in active setting. OPT With Height Selector
Indication that shock sensor is built in. OPT With Shock Sensor 3
Indication that active mast front tilt control is in inactive
{
setting.
OPSS indicator {
Parking brake indicator {
Low speed setting (turtle) indicator {
Diagnostic mode indicator {
Overheat warning indicator {
Battery capacity indicator {
Digital speedometer {
Status display
Power select (SPH) indicator {
Direction indicator {
Mast tilt indicator {
Maintenance indicator {
Auto speed control indicator OPT With Auto Speed Control
Menu lock indicator {
Date/Time {
Key switch on hour meter {
Lap time meter {
Traveling hour meter {
Load handling hour meter {
Integrating meter Traveling/Load handling hour meter {
Seat on hour meter {
Odometer {
Trip meter {
Planed maintenance hour meter {
sec03.book 4 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-4

Remarks
Battery over-discharge warning { {
Low battery level warning { {
Overheat warning { {
Parking brake ON warning { {
Parking brake OFF warning { {
Warning Return to neutral warning for travel OPS { {
Return to neutral warning for load handling OPS {* {
Return to neutral warning at starting { {
Diagnostic code display { {
Overspeed alarm { {
Shock detection alarm OPT With Shock Sensor
Clock set {
Power select (SPH) function {
Travel power control setting {
Load handling power setting {
Low speed setting {
Setting function Maximum speed limitation setting {
Overspeed alarm setting {
Planned maintenance hour setting {
Auto power off time setting {
Second password registration for administrator {
Menu lock setting {
Indication of target height memory OPT
Support function for
Automatic height control setting OPT With Height Selector
Height Selector
Maximum height limitation OPT
Indication of shock detection histories OPT
Support function for Cancellation of shock detection warning OPT
With Shock Sensor
Shock Sensor Shock detection level setting OPT
Measurement of shock OPT
Support function for PIN code entry and setting OPT
With PIN Code Entry
PIN code entry Profile setting OPT

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

sec03.book 5 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-5

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
screen.

Display Description

JAN/ 1/2010 (FRI) Calendar watch is displayed.

3

Indicate if the maximum speed limitation in active setting.

Indicate if the overspeed alarm is in active setting.

Indicate if the auto speed control is in active setting.

Indicate if the maximum height limitation is in active setting.

Indicate if the shock sensor is in operation.

Indicate if the active mast front tilt control is in inactive setting.

sec03.book 6 ページ ２０１０年４月２１日 水曜日 午後１時２７分

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 these settings.

W/O PIN code entry system

Setting menu Setting Screen
Power Mode Select*
Power Control Functions Setting of Travel Power Control Level*
Setting of Load Handling Power Control Level*
Speed Setting of Low Speed*
Travel Functions Speed Setting of Speed Limiter
Speed Setting of Overspeed Alarm*
Height Position Setting of Height Selector
Load Handling Functions
Height Position Clearing of Height Selector
(Height Selector)
Height Position Setting of Maximum Height Limiter
Setting of Maintenance Hour Meter
Setting of Auto Power Off
Vehicle Management Functions
Setting of Administrator’s Second Password
Switching of Menu-Lock
Checking Shock Memories
Shock Sensor Functions Reset of Shock Alarm
(Shock Sensor) Measurement and Setting of Shock
Clearing Shock Memories

*: When menu lock setting is released, the operator can set it.

W/ PIN code entry system

Setting menu Setting Screen
Registry of PINs
PIN Code Entry Functions Change of Profile assignment
PIN Code Entry Profile Data Setting
Change of Initial PIN
Height Position Setting of Height Selector*
Load Handling Functions
Height Position Clearing of Height Selector*
(Height Selector)
Height Position Setting of Maximum Height Limiter
Setting of Maintenance Hour Meter
Setting of Auto Power Off
Vehicle Management Functions Setting of Auto Log Off
Setting of Administrator’s Second Password
Switching of Menu-Lock
Checking Shock Memories
Shock Sensor Functions Reset of Shock Alarm
(Shock Sensor) Measurement and Setting of Shock
Clearing Shock Memories

*: When menu lock setting is released, the operator can set it.
sec03.book 7 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-7

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

When pressing the switches, a

Press switch (2) and switch (4) at
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.

Switch (3)

Press switch (3) within 10

3 A short beep sounds.
seconds.

Switch (3)

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.

6 Administrator menu screen is displayed automatically.

sec03.book 8 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-8

Administrator MENU screen

W/O PIN code entry W/ PIN code entry

Icons
Icon Description Icon Description

This icon can set the shock sensor

This icon can set the drive and lift
function. (Models with shock sensor
power control function.
only)

This icon can set the PIN code entry

This icon can set the travel control
system function. (Models with PIN code
function.
entry system only)

This icon can set the load handling

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

This icon can set the vehicle

management function.
sec03.book 9 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-9

Administrator Menu Screen (W/O PIN code entry)

Status screen

Operating Procedure
1. Input the password on the status screen to display the
Administrator Menu screen.

Switch (1) Switch (2) Switch (3) Switch (4)

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.

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

Note:
Select the return tab on the Administrator Menu screen, and
press switch (4) (enter) to display the status screen.
sec03.book 10 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-10

Power control setting screen

• Power Mode Select
• Setting of Travel Power Control Level
• Setting of Load Handling Power Control Level

Setting screen for travel function

• Speed Setting of Low Speed
• Speed Setting of Speed Limiter
• Speed Setting of Overspeed Alarm

Setting screen for load handling functions (Height Selector)

• Height Position Setting of Height Selector
• Height Position Clearing of Height Selector
• Height Position Setting of Maximum Height Limiter

Vehicle management setting screen

• Setting of Planned Maintenance Hour Meter
• Setting of Auto Power Off
• Setting of Administrator’s Second Password
• Switching of Menu-Lock
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3-11

Support screen for shock sensor

• Checking Shock Memories
• Reset of Shock Alarm
• Monitor and Setting of Shock Detection Level
• Clearing Shock Memories

Return to status screen

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3-12

1. Power Control Setting Menu Screen

This menu screen can set the travel and load handling power
control function.
Note:
When the H mode lock setting is “YES”, H mode cannot be
selected. Please refer to a service function about the way to
release the H mode lock.

(1) Power select screen

The power select mode (S, P, H or Original) can be selected by
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.
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) Travel power control level setting

The travel power of the original mode can be set in five steps.
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) Load handling power control level setting

The load handling power of the original mode can be set in five
steps.
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.
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3-13

2. Travel Setting Menu Screen

This menu screen can set the travel control function.

(1) Low speed setting screen

The speed limit of the Low speed setting function can be
changed.
Switch (2): Setting speed limit down.
Switch (3): Setting speed limit up.
Switch (4): Returning to setting menu screen.
It is adjustable from 2 to 30 mph by 1 mph. When MPH setting
is “NO” in optionset, it is adjustable from 2 to 50 km/h by
1 km/h.
If the operator set the speed to more than 30mph (50km/h), the
low speed function is disabled. In that case “OFF” is displayed.

(2) Maximum speed limiter setting screen

The speed limit of the Maximum speed limiter can be changed.
Switch (2): Setting traveling speed down.
Switch (3): Setting traveling speed up.
Switch (4): Returning to setting menu screen
It is adjustable from 2 to 30 mph by 1 mph. When MPH setting
is “NO” in optionset, it is adjustable from 2 to 50 km/h by
1 km/h.
If the operator set the speed to more than 30mph (50km/h), the
low speed function is disabled. In that case “OFF” is displayed.

(3) Overspeed alarm setting screen

The speed to activate the overspeed alarm function can be
changed.
Switch (2): Setting traveling speed down.
Switch (3): Setting traveling speed up.
Switch (4): Returning to setting menu screen
It is adjustable from 2 to 30 mph by 1 mph. When MPH setting
is “NO” in optionset, it is adjustable from 2 to 50 km/h by
1 km/h.
If the operator set the speed to more than 30mph (50km/h), the
low speed function is disabled. In that case “OFF” is displayed.
sec03.book 14 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-14

3. Load Handling Setting Menu Screen

This menu screen can set the load handling control function.

Automatic height control setting screen (W/ Height Selector)

Clear all memories screen (W/ Height Selector)

Maximum height limiter setting screen (W/ Height Selector)

sec03.book 15 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-15

4. Vehicle Management Setting Menu Screen

This menu screen can set the vehicle management function.

(1) Planned maintenance hour meter setting screen

Time for planned maintenance hour meter can be set from 10
up to 2000 hours by 10 hour for 10 to 200 hours, and 50 hour
for 200 to 2000 hours.
Switch (2): Decreasing setting time
Switch (3): Increasing setting time
Switch (4): Returning to menu screen
Pressing switch (1) for more than 2 seconds will reset the
current hour meter value to 0.
Note:
This reset operation doesn’t reset the setting value and keeps
it with the same value.
Pressing the switch (2) to decrease the set time, next to 10h is
“OFF” setting of the maintenance hour meter function.
The current value is kept but the maintenance indicator and the
buzzer are deactivated with this “OFF” setting.

(2) Auto power off time setting

The time to activate the auto power off function can be
changed.
Switch (2): Decreasing set time
Switch (3): Increasing set time
Switch (4): Returning to menu screen
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”.
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3-16

(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 the
password by using switch (1) to (4). If press the switch (4) for 2 seconds or more, the screen returns to the menu
screen.
Administrator should manage the second password so that it doesn’t get unknown.
Even if it has got unknown, the service technician can clear it on the masked menu.

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.

Switch (1) Switch (2) Switch (3) Switch (4)

sec03.book 17 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-17

(5) Menu lock screen

This function can limit the change of the vehicle setting by the
operator.
When menu lock setting is “YES”, the following items are
limited.
• Operator setting menu is NOT displayed.
• Power control setting menu is NOT displayed.
• Operator cannot change the power select mode.
Switch (2): Selecting “Yes”
Switch (3): Selecting “No”
Switch (4): Returning to menu screen
Note:
• The lock release setting (“NO”) is effective till key-OFF. (It
means set “YES” automatically when the key is turned
off.)
• This is not available (NOT Locked) before “hour meter
start”.

5. Shock Sensor Setting Menu Screen (OPT)

This menu screen can set the Shock Sensor function.

6. End Menu Screen

Switch (4): Returning to status screen
sec03.book 18 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-18

Administrator Menu Screen (W/ PIN code entry)

Status 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
• Change of Profile Assignment
• Delete of PINs for operators
• Profile Data Setting
• Change of Initial PIN

2. Load Handling Setting Menu Screen (W/ Height

Selector)
This menu screen can set the Load Handling control function.
For details, refer to “Load Handling Setting Menu Screen” (W/O
PIN code entry).
• Height Position Setting of Height Selector
• Height Position Clearing of Height Selector
• Height Position Setting of Maximum Height Limiter
sec03.book 19 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-19

3. Vehicle Management Setting Menu Screen

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

4. Shock Sensor Setting Menu Screen (W/ Shock

Sensor)
This menu screen can set the Shock Sensor function.
• Checking Shock Memories
• Reset of Shock Alarm
• Monitor and Setting of Shock Detection Level
• Clearing Shock Memories

5. End Menu Screen

Switch (4): Returning to status screen
sec03.book 20 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-20

MASK FUNCTIONS
GENERAL
In the multifunction display, aside from the general functions that an operator or an administrator normally use, the
following mask functions for use by the service staff for vehicle maintenance and specification setting are also
provided. The service functions are protected by the password so that the important internal data will not be
damaged 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
{ As requested
Tuning traveling and load handling -
*2 by customer
functions.
Specification Sets each vehicle option and {
- -
setting other specifications. *1 *2,*3
Option setting Each control
Enables or disables each control {
function enable/ - -
function. *2,*3
disable
Drive Updates voltage values of
{
SAS sensor signals under the - -
*2,*3
Matching Mini lever standard vehicle condition.
Makes the speedometer reading { {
Tire data
appropriate. *2 *4
Starts counting the hour meter,
{
Meter start odometer, trip meter and { -
*3
maintenance hour meter.
Enables simultaneous operation
Before starting
Demo mode of traveling and load handling - -
the hour meter
before starting the hour meter.
Initialize a set value with the { When it is
To default set -
Others menu default value. *2,*3 necessary
Mask second { When it is
Sets the mask second password. -
password setting *3 necessary
Administrator’s
Delete the administrator’s { As requested
second password -
second password. *3 by customer
clear
Adjusts the contrast of the { 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
*4: When tire size is changed or tire is replaced
sec03.book 21 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-21

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

When pressing the switches, a

Press switch (2), switch (3) and
short beep sounds, and after 2
1 switch (4) at the same time for
seconds another short beep
more than 2 seconds.
sounds.
Switch (2) Switch (4)
Switch (3)

Press switch (4) within 10

2 A short beep sounds.
seconds.
Switch (4)

Press switch (1) within 10

3 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.
Switch (2)
Switch (3)

When the mask second password has been set:

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

6 Mask function initial screen is displayed for 5 seconds.

7 ANALYZER MENU screen is automatically displayed.

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3-22

MASK MENU Screen

Operating Procedure
1. Enter the password on the general screen (See page 3-21) to
display the MASK MENU screen.

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.

Switch (2) Switch (4)

Switch (3)

Reads out information about the error detected by a controller

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

Fine adjusts the settings for traveling control, material handling

TUNING MENU screen
control, etc.

Adjusts the display and the controllers according to the

OPTION SET MENU screen
specifications of each vehicle or the control conditions set for it.

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

This allows you to:

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

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

*: After completing the hour meter start setting, “METER START” and “DEMO MODE” will not displayed on the
OTHERS MENU screen.
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3-23

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 multi-function display.
By switching the multi-function display to analyzer mode, operative conditions of the sensors and actuators which are
used for traveling, load 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. Diagnostic memory function (DIAG MEMORY)
The controller stores up to 10 diagnostic codes (diagnostic codes) detected in the electrical system in the past.
The diagnostic function reads these diagnostic codes and indicates them on the display.
Each diagnostic codes 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, load 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 M. HANDLING
Displays the load handling and mast control switch ON/OFF states and analog input voltages from load
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, and the ON/OFF state of
display’s optional switch.
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 diagnostic code indication:
One diagnostic code is displayed in the upper right-hand portion on the I/O MONITOR or
ACTIVE TEST screen, when an error is detected.
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3-24

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 motor temperature: °C
TDMDH Drive motor driver heat sink temperature: °C
1/4
TDMDB Drive motor driver board temperature: °C
TCMB MB contactor 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
VDMD Drive motor driver main circuit voltage: V
4/4
VPMD Pump motor driver main circuit voltage: V
3. I/O TRAVELING SPEED Traveling speed: km/h or mph
Accelerator sensor1 voltage: V
1/5 VRA
Accelerator sensor2 voltage: V
SWBK Brake switch
SDM Seat switch
DSF Forward switch
2/5
DSR Reverse switch
SPB Parking brake switch
SYR Yaw rate sensor voltage: V
SLSW Swing lock solenoid
3/5 SH Lifting height switch
SPLF Load sensor voltage: V (MPa display)
SPEED Traveling speed: km/h or mph
Drive motor rpm: rpm
4/5 SPDDM
[Target rpm]: rpm
Drive motor rotation sensor 1 voltage: V
SSD
Drive motor rotation sensor 2 voltage: V
5/5
Drive motor current sensor 1 voltage: V
CSDM
Drive motor current sensor 2 voltage: V
4. I/O M.HANDLING SLUL Unload solenoid
SLLL Lift lowering lock solenoid
SLTFL Tilt lock solenoid
SLTBL (Not used)
1/8
SHS Height selector switch
STK Tilt knob switch
SDM Seat switch
SHL (Not used)
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3-25

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 display)
2/8
SH Lifting height switch
VRH Height reel sensor voltage: V
Pump motor rpm: rpm
3/8 SPDPM
[Target rpm]: rpm
SSP Pump motor driver rotation sensor voltage: V
4/8 Pump motor driver current sensor 1 voltage: V
CSPM
Pump motor driver current sensor 2 voltage: V
Conventional Lever models SLUL Unload solenoid
SLLL Lift lowering lock solenoid
5/8
Lift lever angle sensor 1 voltage: V
VRL
Lift lever angle sensor 2 voltage: V
SLUL Unload solenoid
SLTFL Tilt lock solenoid
6/8 SLTBL (Not used)
SWTF Forward tilt switch
SWTR Backward tilt switch
SLUL Unload solenoid
7/8 Attachment (1) lever angle sensor 1 voltage: V
VRA1
Attachment (1) lever angle sensor 2 voltage: V
SLUL Unload solenoid
8/8 Attachment (2) lever angle sensor 1 voltage: V
VRA2
Attachment (2) lever angle sensor 2 voltage: V
Mini Lever/Joystick Lever SLUL Unload solenoid
models SLLL Lift lowering lock solenoid
5/8 CSL Lift proportional valve solenoid current: A
Lift lever angle sensor 1 voltage: V
VRL
Lift lever angle sensor 2 voltage: V
SLUL Unload solenoid
SLTFL Tilt lock solenoid
6/8 CST Tilt proportional valve solenoid current: A
Tilt lever angle sensor 1 voltage: V
VRT
Tilt lever angle sensor 2 voltage: V
SLUL Unload solenoid
CSA1 Attachment (1) proportional valve solenoid current: A
7/8
Attachment (1) lever angle sensor 1 voltage: V
VRA1
Attachment (1) lever angle sensor 2 voltage: V
SLUL Unload solenoid
CSA2 Attachment (2) proportional valve solenoid current: A
8/8
Attachment (2) lever angle sensor 1 voltage: V
VRA2
Attachment (2) lever angle sensor 2 voltage: V
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3-26

Analyzer menu screen Screen No. Display item Description

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
SSTR Steering angle sensor signal
6. I/O OTHERS Shock sensor 1 voltage: V
IPL
1/1 Shock sensor 2 voltage: V
DOPT (Not used)
7. ACTIVE TEST SWING SOL 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 output1 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 Drive motor driver program version
2/2
PM DRIVER Pump motor driver program version
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3-27

ANALYZER MENU screen

Operating Procedure
Enter the password on the status screen (See page 3-21) to display
the mask function initial screen. After 5 seconds, the ANALYZER
MENU screen is automatically displayed.

“1. DIAG MEMORY”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “DIAG MEMORY” screen
“2. I/O TEMP/VOLT”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
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. I/O STEERING”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
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
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3-28

“7. ACTIVE TEST”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “ACTIVE TEST” screen
“8. VERSION”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “VERSION” screen

Diagnostic Memory Function (DIAG MEMORY)

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

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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

press switch (4) to display “DIAG MEMORY 1/2” screen.
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3-29

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

the ANALYZER MENU screen.
Note:
• When no diagnostic code is displayed on the screen and
the hour meter time is 0.0h, it indicates that no errors
occurred in the past after that row.
Switch (4)
• It is impossible to directly jump from the DIAG MEMORY
screen to other function screen. Return to the ANALYZER
MENU screen.
• For details of diagnostic code, refer to section 4,
Diagnostic Code List.

“DIAG MEMORY 1/2”

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

“DIAG MEMORY 1/2”

Displays diagnostic codes 6 to 10.
Switch (4) : Returning to the ANALYZER MENU screen.
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3-30

In/Out Monitor Function (I/O MONITOR)

This function displays the analog input voltage from each of traveling, load 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)

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.
3. After it, “I/O TEMP/VOLT 2/4” to “I/O TEMP/VOLT 4/4” is
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.
Note:
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
Temperature of the drive motor is displayed.
TDMDH: Drive motor driver heat sink temperature: °C
Temperature of the drive motor driver heat sink is displayed.
TDMDB: Drive motor driver board temperature: °C
Temperature of the drive motor driver board is displayed.
TCMB: MB contactor temperature: °C
Temperature of the MB contactor is displayed.
Switch (4): To “I/O TEMP/VOLT 2/4” screen
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3-31

“I/O TEMP/VOLT 2/4”

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

“I/O TEMP/VOLT 3/4”

B48V: Battery voltage: V
Battery voltage is displayed.
VBKY: Voltage after key switch: V
Voltage after key switch is displayed.
VBMBSL: Solenoid power source voltage: V
Voltage of solenoid power source is displayed.
VBMB: Voltage after MB contactor: V
Voltage of after MB contactor is displayed.
Switch (4): To “I/O TEMP/VOLT 4/4” screen

“I/O TEMP/VOLT 4/4”

VDMD: Drive motor driver main circuit voltage: V
Voltage of drive motor driver main circuit is displayed.
VPMD: Pump motor driver main circuit voltage: V
Voltage of pump motor driver main circuit is displayed.
Switch (4): Returning to the ANALYZER MENU screen
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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. Press the switch (1) to select the “3. I/O TRAVELING” and
press the switch (4) to display the “I/O TRAVELING 1/5”
screen.
Note:
You cannot move directly from I/O TRAVELING screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each time.

“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: 2.00 to 4.80 V
Accelerator sensor 2
When accelerator is not operated: 0.65 to 2.32 V
When accelerator pedal is fully depressed: 2.42 to 4.80 V
SWBK: Brake switch
Switch ON/OFF quality judgment by operating the brake
switch.
SWBK: 0 = OFF (in a state of brake being operated)
SWBK: 1 = ON (in a state of brake being released)
Switch (4): To “I/O TRAVELING 2/5” screen
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3-33

“I/O TRAVELING 2/5”

SDM: Seat switch
Switch ON/OFF quality judgment by sitting on and leaving the
operator’s seat
SDM: 1 = ON when sitting on the seat
SDM: 0 = OFF when leaving the seat
DSF: Forward switch
DSR: Reverse switch
Switch ON/OFF quality judgment by operating the direction
lever
Display
Direction lever
DSF: DSR:
Forward 1 (= ON) 0 (= OFF)
Neutral 0 (= OFF) 0 (= OFF)
Reverse 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)
Switch (4): To “I/O TRAVELING 3/5” screen

“I/O TRAVELING 3/5”

SYR:Yaw rate sensor voltage: V
Displays input voltage from the yaw rate sensor to the
controller.
Standard value when vehicle is stopped: 2.20 ~ 2.80 V
SLSW: Swing lock solenoid
Judges the quality of the switch ON/OFF by operating the
swing lock solenoid
SLSW: 1 = ON Energized (swing lock released) state
SLSW: 0 = OFF Non-energized (swing lock) state
SH: Lifting height switch
Judges the quality of the switch ON/OFF by raising and
lowering the fork.

SH2-2
SH1
SH2-1

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
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3-34

“I/O TRAVELING 4/5”

SPDDM: Drive motor revolution [target]: rpm
This screen indicates the measured and target numbers of
revolutions of the drive motor.
The rotation sensor is checked by actually running the vehicle.
The number of revolutions of the drive motor increases with an
increase in the traveling speed.
Switch (4): To “I/O TRAVELING 5/5” screen

“I/O TRAVELING 5/5”

SSD: Drive motor rotation sensor 1 / 2 voltage: V
This screen indicates the voltages of the drive motor rotation
sensors.
Standard:
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
CSDM: Drive motor 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 traveling: 0.50 to 4.50 V
Switch (4): Returning to the ANALYZER MENU screen

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

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

Operating Procedure
1. Display the ANALYZER MENU screen. (See page 3-27)
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3-35

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.

“I/O M.HANDLING 1/8”

SLUL: Unload solenoid
Displays output signal to the unload solenoid.
SLLL: Lift lock solenoid
Displays output signal to the lift lock solenoid.
SLTFL: Tilt control solenoid
Displays output signal to the tilt control solenoid.
SLTBL: Not used

Seat condition Sitting on seat

Not Lift lever Tilt lever Leaving seat
Lever condition
operated Raising Lowering Forward tilt Backward tilt
SLUL 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON)
SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
Conventional
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
Lever
SLTBL - - - - - -
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
SLUL - - - - - -
SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
Mini Lever/
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
Joystick Lever
SLTBL - - - - - -
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)

SHS: Height selector switch

Switch ON/OFF quality judgment by operating the height
selector switch.
SHS: 0 = OFF
SHS: 1 = ON
STK: Automatic fork leveling control switch
Switch ON/OFF quality judgment by operating the tilt knob
switch.
STK: 0 = OFF
STK: 1 = ON
SDM: Seat switch
See “I/O TRAVELING 2/5”
SHL: Not used
Switch (4): To “I/O M.HANDLING 2/8” screen
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3-36

“I/O M.HANDLING 2/8”

VRTA: Tilt angle sensor voltage: V
Displays input voltage from the tilt angle sensor to the
controller.
Standard with mast in the vertical position: 1.20 to 3.95 V
Mast vertical → forward tilt: Input voltage decreases
Mast vertical → backward tilt: Input voltage increases
SPLF: Load sensor voltage: V (MPa)
See “I/O TRAVELING 3/5”
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 [target]: rpm
This screen indicates the measured and target numbers of
revolutions of the pump motor.
The number of revolutions of the pump motor increases with
an increase in the material handling speed.
Switch (4): To “I/O M.HANDLING 4/8” screen

“I/O M.HANDLING 4/8”

SSP: Pump motor driver rotation sensor voltage: V
Displays the voltage from the pump motor driver rotation
sensor.
Standard:
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
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. 2.50 V
Standard value when vehicle is traveling: 0.50 to 4.50 V
Switch (4): To “I/O M.HANDLING 5/8” screen
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3-37

Conventional Lever “I/O M.HANDLING 5/8”

SLUL: Unload solenoid
See “I/O M.HANDLING 1/8”
SLLL: Lift lock solenoid
See “I/O M.HANDLING 1/8”
CSL: Lift proportional solenoid current: A
(Mini Lever/Joystick Lever)
Displays the current from the lift proportional solenoid.
Standard:
Lever pull position: 0.35 to 0.85 A
Lever push position: 0.35 to 0.85 A
Lever neutral position: 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
Mini Lever/Joystick Lever Displays input voltage from lift lever angle sensor 1 / 2 to the
controller.
Standard:
(Conventional Lever)
Lift lever angle sensor 1
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.50 to 3.00 V
(Mini Lever/Joystick Lever)
Lever pull position: neutral voltage to 4.50 V
Lever push position: 0.30 to neutral voltage
Lever neutral position: 1.78 to 2.76 V
The voltage increases during lever backward operation, while
it decreases during lever forward operation.
Standard:
(Conventional Lever)
Lift lever angle sensor 2
Lever pull position: neutral voltage to 4.50 V
Lever push position: 0.30 to neutral voltage
Lever neutral position: 1.40 to 3.15 V
(Mini Lever/Joystick Lever)
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.78 to 2.76 V
The voltage decreases during lever backward operation, while
it increases during lever forward operation.
Switch (4): To “I/O M.HANDLING 6/8” screen
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Conventional Lever “I/O M.HANDLING 6/8”

SLUL: Unload solenoid
See “I/O M.HANDLING 1/8”
SLTFL: Tilt control solenoid
See “I/O M.HANDLING 1/8”
SLTBL: Not used
SWTF: Forward tilt switch
Switch ON/OFF quality judgment by operating the forward tilt
switch.
SWTR: Backward tilt switch
Switch ON/OFF quality judgment by operating the backward
tilt switch.

Mini Lever/Joystick Lever Display

Tilt lever
SWTF: SWTR:
Forward 1 ( = ON) 0 ( = OFF)
Neutral 0 ( = OFF) 0 ( = OFF)
Backward 0 ( = OFF) 1 ( = ON)

CST: Tilt proportional valve solenoid current: A

(Mini Lever/Joystick Lever)
Displays the current from the tilt proportional solenoid.
Standard:
Lever pull position: 0.35 to 0.85 A
Lever push position: 0.35 to 0.85 A
Lever neutral position: 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 (Mini Lever/Joystick Lever)
Lever pull position: neutral voltage to 4.50 V
Lever push position: 0.30 to neutral voltage
Lever neutral position: 1.78 to 2.76 V
The voltage increases during lever backward operation, while
it decreases during lever forward operation.
Standard:
Tilt lever angle sensor 2 (Mini Lever/Joystick Lever)
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.78 to 2.76 V
The input voltage decreases during lever backward operation,
while it increases during lever forward operation.
Switch (4): To “I/O M.HANDLING 7/8” screen
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3-39

Conventional Lever “I/O M.HANDLING 7/8”

SLUL: Unload solenoid
See “I/O M.HANDLING 1/8”
CSA1: Attachment (1) proportional valve solenoid current: A
(Mini Lever/Joystick Lever)
Displays the current from the attachment (1) proportional
solenoid.
Standard:
Lever pull position: 0.35 to 0.85 A
Lever push position: 0.35 to 0.85 A
Lever neutral position: 0.00 A
The current increases according to the amount of operation of
the attachment (1) lever.
VRA1: Attachment (1) lever angle sensor 1 / 2 voltage: V
Displays input voltage from the attachment 1 lever angle
Mini Lever/Joystick Lever sensor 1 / 2 to the controller.
Standard:
(Conventional Lever)
Attachment 1 lever angle sensor 1
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.50 to 3.00 V
(Mini Lever/Joystick Lever)
Lever pull position: neutral voltage to 4.50 V
Lever push position: 0.30 to neutral voltage
Lever neutral position: 1.78 to 2.76 V
The voltage increases during lever backward operation, while
it decreases during lever forward operation.
Standard:
(Conventional Lever)
Attachment 1 lever angle sensor 2
Lever pull position: neutral voltage to 4.50 V
Lever push position: 0.30 to neutral voltage
Lever neutral position: 1.40 to 3.15 V
(Mini Lever/Joystick Lever)
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.78 to 2.76 V
The input voltage decreases during lever backward operation,
while it increases during lever forward operation.
Switch (4): To “I/O M.HANDLING 8/8” screen
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3-40

Conventional Lever “I/O M.HANDLING 8/8”

SLUL: Unload solenoid
See “I/O M.HANDLING 1/8”
CSA2: Attachment (2) proportional valve solenoid current: A
(Mini Lever/Joystick Lever)
Displays the current from the attachment (2) proportional
solenoid.
Standard:
Lever pull position: 0.35 to 0.85 A
Lever push position: 0.35 to 0.85 A
Lever neutral position: 0.00 A
The current increases according to the amount of operation of
the attachment (2) lever.
VRA2: Attachment (2) lever angle sensor 1 / 2 voltage: V
Displays input voltage from the attachment (2) lever angle
Mini Lever/Joystick Lever sensor 1 / 2 to the controller.
Standard:
(Conventional Lever)
Attachment 2 lever angle sensor 1
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.50 to 3.00 V
(Mini Lever/Joystick Lever)
Lever pull position: neutral voltage to 3.00 V
Lever push position: 1.50 to neutral voltage
Lever neutral position: 1.50 to 3.00 V
The voltage increases during lever backward operation, while
it decreases during lever forward operation.
Standard:
(Conventional Lever)
Attachment 2 lever angle sensor 2
Lever pull position: neutral voltage to 2.76 V
Lever push position: 1.78 to neutral voltage
Lever neutral position: 1.78 to 2.76 V
(Mini Lever/Joystick Lever)
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.78 to 2.76 V
The input voltage decreases during lever backward operation,
while it increases during lever forward operation.
Switch (4): Returning to the ANALYZER MENU screen
sec03.book 41 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-41

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:
1.80 to 2.50 V
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)
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3-42

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.
159 Clockwise turn of the steering wheel: Increase in value
0 Counterclockwise turn of the steering wheel: Decrease in value
1
SSTR: Steering angle sensor signal
80

Standard position
SS1 SSC
SS2

1 = ON
0 = OFF
When the steering wheel is rotated once, SS1 and SS2 repeat ON
and OFF. SSC only turns on when the knob is in the standard
position.

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

Displays the analog input voltages from battery current sensor and shock sensor.

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

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.
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3-43

“I/O OTHERS 1/1”

IPL: Shock sensor voltage: V
Displays input voltage from the shock sensor to the controller.
Standard value when vehicle is stopped: Approx. 2.0 V
DOPT: Not used
Switch (4): Returning to the ANALYZER MENU screen
sec03.book 44 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-44

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.
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 (Conventional lever) (Conventional lever)
OFF Material handling ON Material handling not
possible possible*1
FAN Cooling fan for controller forced Fan stops Fan rotates
OFF ON
operation
ACC OUT1*2 Accessory output 1 (brake auxiliary Stop lamp does not Stop lamp operates
OFF ON
equipment output) forced operation operate
ACC OUT2*3 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

*1: 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.
*2: Shipped from the factory; OFF
*3: With EZ pedal only
(Refer to below)
Operation guidance Condition

Selected item not forcibly operated

Selected item forcibly turned ON

Selected items forcibly turned OFF

Applicable function not provided or its state signal not received

sec03.book 45 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-45

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

2. Press the switch (1) to select the “7. ACTIVE TEST” and press
the switch (4) to display the “ACTIVE TEST” 1/3 screen.

“ACTIVE TEST 1/3”

SWING SOL: Swing lock solenoid
Jack up the rear axle, and check that the rear axle swings.
ON (Solenoid ON): Unlock
OFF (Solenoid OFF): Lock
STEERING SOL: Knob position correcting solenoid (OPT)
Slowly turn the steering wheel, and check the difference of the
rear tire movement.
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
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3-46

“ACTIVE TEST 2/3”

UNLOAD SOL: Unload valve solenoid (Conventional lever)
Check the quality by material handling operation.
ON (Solenoid ON):
Material handling operation not possible (Except lowering)
OFF (Solenoid OFF):
Material handling operation possible (It may slowly lower
according to load condition, but this is not a fault).
FAN: Cooling fan for controller
Forcibly output the ON/OFF signal to check the fan operation
ON: Fan rotates
OFF: Fan stops
*1 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
*2 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
*1: Shipped from the factory; OFF
*2: With EZ pedal only

“ACTIVE TEST 3/3”

SWG TEST LMP:
Check the swing lock operation states by OPSS indicator.
ON (Indicated):
Operation situation is indicated with OPSS indicator
OPSS indicator ON: Swing lock operated
OPSS indicator OFF: Swing lock released
OFF (not indicated):
OPSS indicator operates as OPSS indicator (normal operation)
Switch (1): Not used
Switch (2): Check mode; OFF
Switch (3): Check mode; ON
Switch (4): Returning to the ANALYZER MENU screen
sec03.book 47 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-47

VERSION (Program Version)

Displays program version of each controller.

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

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
press switch (4) again to return from the VERSION 2/2 screen
to the ANALYZER MENU screen.
Note:
You cannot move directly from a VERSION screen to another
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
MAIN C/R: Program version of the main controller
Switch (4): To “VERSION 2/2” screen

“VERSION 2/2”
DM DRIVER: Program version of the drive motor driver
PM DRIVER: Program version of the pump motor driver
Switch (4): Returning to the ANALYZER MENU screen
sec03.book 48 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-48

TUNING
GENERAL
This feature performs fine adjustment of traveling and load handling controls. When receiving requests from users,
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 75 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
Fast
1 warning and battery over-discharge Slow Disabled
●
warning
Slow Fast
2 Battery charge indicator calibration No.1 ●
decrease decrease
3 Not used — ● —
Motor torque when the battery discharge Power Power
4 ●
has proceeded. Down Keep
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.
The time of simultaneously operable
20 Short ● Long
accelerator and brake (OPT)
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3-49

Level (●: Initial setting value)

Menu No. Item
1 2 3 4 5 6 7 8
21 Not used — ● —
Maximum speed limitation during Fast
22 Slow
backward traveling ●
Low speed setting during backward Fast
23 Slow
traveling ●
Deceleration during accelertaor-off Weak
24 Strong
when going up on a slope ●
Strong
25 Regenerative braking torque at brake on Weak
●
Pump motor output during lift up Fast
26 Slow
operation ●
Pump motor output during tilt forward
27 Slow ● Fast
TUNE and backward operation
GEN Pump motor output during the
28 attachment (1) lever push and pull Slow ● Fast
operation
Pump motor output during the
29 attachment (1) lever push and pull Slow ● Fast
operation
30 Not used — ● —
Inching speed during Height Selector
31 Slow ● Fast
operation
32 Not used — ● —
33 Not used — ● —
34 Not used — ● —
35 Not used — ● —

O: Avaliable
—: NOT available

Lever Level (●: Initial setting value)

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
Start at the beginning of lift
START
lever down operation
— O Small ● Wide

Inching speed during lift

INCH
lever down operation
— O Slow ● Fast

LIFT Maximum speed during lift

DOWN
MAX
lever down operation
— O Slow ● Fast

Acceleration speed during

ACC
lift lever down operation
— O Weak ● Strong

Deceleration speed during

DEC
lift lever down operation
— O Weak ● Strong
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3-50

Lever Level (●: Initial setting value)

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
Start at the beginning of lift
START
lever up operation
— O Small ● Wide

Inching speed during lift

INCH
lever up operation
O O Slow ● Fast

LIFT Maximum speed during lift

UP
MAX
lever up operation
— O Slow ● Fast

Acceleration speed during

ACC
lift lever up operation
O O Weak ● Strong

Deceleration speed during

DEC
lift lever up operation
O O Weak ● Strong

Start at the beginning of tilt

START
lever forward operation
— O Small ● Wide

Inching speed during tilt

INCH
lever forward operation
— O Slow ● Fast

TILT Maximum speed during tilt

FWD
MAX
lever forward operation
— O Slow ● Fast

Acceleration speed during

ACC
tilt lever forward operation
O O Weak ● Strong

Deceleration speed during

DEC
tilt lever forward operation
O O Weak ● Strong

Start at the beginning of tilt

START
lever backward operation
— O Small ● Wide

Inching speed during tilt

INCH
lever backward operation
— O Slow ● Fast

Maximum speed during tilt

TILT
MAX
lever backward operation
— O Slow ● Fast
BWD Acceleration speed during
ACC tilt lever backward O O Weak ● Strong
operation
Deceleration speed during
DEC tilt lever backward O O Weak ● Strong
operation
Start at the beginning of the
START attachment (1) lever push — O Small ● Wide
operation
Inching speed during the
INCH attachment (1) lever push O O Slow ● Fast
operation
Maximum speed during the
ATT1
PUSH
MAX attachment (1) lever push — O Slow ● Fast
operation
Acceleration speed during
ACC the attachment (1) lever O O Weak ● Strong
push operation
Deceleration speed during
DEC the attachment (1) lever O O Weak ● Strong
push operation
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3-51

Lever Level (●: Initial setting value)

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
Start at the beginning of the
START attachment (1) lever pull — O Small ● Wide
operation
Inching speed during the
INCH attachment (1) lever pull O O Slow ● Fast
operation
Maximum speed during the
ATT1
PULL
MAX attachment (1) lever pull — O Slow ● Fast
operation
Acceleration speed during
ACC the attachment (1) lever O O Weak ● Strong
pull operation
Deceleration speed during
DEC the attachment (1) lever O O Weak ● Strong
pull operation
Start at the beginning of the
START attachment (2) lever push — O Small ● Wide
operation
Inching speed during the
INCH attachment (2) lever push O O Slow ● Fast
operation
Maximum speed during the
ATT2
PUSH
MAX attachment (2) lever push — O Slow ● Fast
operation
Acceleration speed during
ACC the attachment (2) lever O O Weak ● Strong
push operation
Deceleration speed during
DEC the attachment (2) lever O O Weak ● Strong
push operation
Start at the beginning of the
START attachment (2) lever pull — O Small ● Wide
operation
Inching speed during the
INCH attachment (2) lever pull O O Slow ● Fast
operation
Maximum speed during the
ATT2
PULL
MAX attachment (2) lever pull — O Slow ● Fast
operation
Acceleration speed during
ACC the attachment (2) lever O O Weak ● Strong
pull operation
Deceleration speed during
DEC the attachment (2) lever O O Weak ● Strong
pull operation

*1: Mini Lever/Joystick Lever models

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3-52

TUNING MENU Screen

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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.
Switch (2) Switch (3)

“1. GENERAL”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To TUNING LEVEL setting screen
“2. LIFT LEVER”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To TUNING LEVEL setting screen

“3. TILT LEVER”

Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To TUNING LEVEL setting screen
“4. ATT1 LEVER”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To TUNING LEVEL setting screen
“5. ATT2 LEVER”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To TUNING LEVEL setting screen
sec03.book 53 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-53

GENERAL
Sets tuning levels for standard functions.

Operating Procedure
1. Display the TUNING MENU screen.

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

Switch (4)

“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
sec03.book 54 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-54

LIFT LEVER (TUNING LIFT LEVER)

Sets tuning levels for the lift lever.

Operating Procedure
1. Display the TUNING MENU screen and press the switch (1),
select the “2. LIFT LEVER”.

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

Switch (4)

“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
sec03.book 55 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-55

TILT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever.

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

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

Switch (4)

“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
sec03.book 56 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-56

ATT1 LEVER (TUNING ATT1 LEVER)

Sets tuning levels for the ATT1 lever.

Operating Procedure
1. Display the TUNING MENU screen and press the switch (1),
select the “4. ATT1 LEVER”.

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

Switch (4)

“ATT1 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
sec03.book 57 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-57

ATT2 LEVER (TUNING ATT2 LEVER)

Sets tuning levels for the ATT2 lever.

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

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

Switch (4)

“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
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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* Setting the traveling speed display unit YES mph NO km/h
DATE TYPE* Setting the calendar format D/M/Y(E) / Y/M/D(J) / M/D/Y(U)
Setting the battery voltage between 36V
36V* YES 36V NO 48V
and 48V
B-TYPE* Adjust the charge indicator calculation A1 / A2 / B1 / B2
CLOSED Setting to enable/disable closed type
YES Enabled NO Disabled
MOTOR* (EE Type:) motor
H MODE LOCK Setting to enable/disable H mode lock YES Enabled NO Disabled
Unlock (“NO”) Unlock (“NO”)
MENULOCK
Setting the mode of menu lock release A effective till B effective till set
SPEC*
key-OFF “YES”
Setting the traction limitation mode when
accelerator
operating the accelerator and the brake A B brake priority
priority
simultaneously
The motor
[YFS specification (E34A)only]
output
ACCEL & BRK* Both A/B are given priority to an The output of
gradually stops
accelerator the drive motor
by the anti-roll
Drive motor output setting after the A stops just after B
back control
accelerator and brakes simultaneous the restriction
after the
operation time progress set by tuning activates.
restriction
No. 20.
activates.
Setting the number of ways for oil control 2 / 3 / 4 / 5
OCV WAY*
valve ∗“5” is no used this model.
Setting the mode of buzzer sound when
BUZZER SPEC* A / B / C
OPS and Return-to-neutral operate
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
Setting to enable/disable overspeed
SPD ALM2 YES Enabled NO Disabled
alarm 2
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

Traction
Traction
Setting the traction limitation mode at
restrictions restrictions
D-LIM MODE A regardless of B
over-discharge warning according to
discharge discharge level
level
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3-59

Switching settings
Indication Description Setting Setting
Indication Indication
content content
Setting the load handling limitation mode Lift interrupt
P-LIM MODE A Lift interrupt B
at over-discharge warning while travelling
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 to enable/disable the steering
KNOB CONT* YES Enabled NO Disabled
knob synchronizer
SHOCK
Setting to enable/disable shock-sensor YES Enabled NO Disabled
SENSOR*
H-SELECTOR* Setting to enable/disable height selector YES Enabled NO Disabled
Operate while
the vehicle
Operate while
moves to
Setting the mode of back up buzzer and operating the
BACK BUZZER A backward or B
back-up lamp operation direction lever
operating the
to backward
direction lever
to backward
Turn on while
regenerative Turn on while
STOP LAMP Setting the mode of stop lamp operation A braking or B brake pedal is
brake pedal is operated
operated

*: These are set according to the vehicle specification at the time of shipment.

OPTIONSET Screen
Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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)

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3-60

3. Check that “1. OPTION SET” is selected, and press switch (4)
to display OPTION SET screen.
Note:
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
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
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Switching to next screen

“OPTION SET” Screen 2

Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Switching to next screen

“OPTION SET” Screen 3

Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Switching to next screen
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“OPTION SET” Screen 4

Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Switching to next screen

“OPTION SET” Screen 5

Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Returning to OPTION SET MENU screen
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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 used for drive functions, the signal voltage values at accelerator fully released,
accelerator fully closed 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 load-handling lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment. When servicing these sensors or replacing
related parts, MATCHING (updating the sensor signal voltage value 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 *1, *2
to the controller.
Accelerator sensor output value with fully stepped accelerator position to
2 ACCEL ON *1, *2
the controller.

2. SAS
Prerequisite for
No. Indication Description
implementation
Tilt angle sensor output value with fork in the horizontal position to the *1, *3, *4, *5, *7, *8,
1 TILT LEVEL
controller. *9
Tilt angle sensor output value at the forward tilt limit position and the load *1, *3, *4, *5, *7, *8,
2 TILT FWD LIMIT
sensor output value without load to the controller. *9
Tire angle sensor output value while the vehicle is traveling straight to
3 TIRE POSITION *1, *6
the controller.
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3. LEVER
Prerequisite for
No. Indication Description
implementation
Lift lever angle sensor output value in the lift lever neutral position is
1 LEVER 1 *1, *10
stored in the controller.
Tilt lever angle sensor output value in the tilt lever neutral position is
2 LEVER 2 *1, *11
stored in the controller.
Attachment (1) lever angle sensor output value in the attachment (1)
3 LEVER 3 *1, *12
lever neutral position is stored in the controller.
Attachment (2) lever angle sensor output value in the attachment (2)
4 LEVER 4 *1, *13
lever neutral position is stored in the controller.

4. TIRE DATA
Prerequisite for
No. Indication Description
implementation
1 TIRE DATA The tire data according to the tire size is stored. *1, *15

Prerequisite content for implementation

*1: When replacing main controller
*2: When removing/installing or replacing accelerator sensor
*3: When removing/installing or replacement tilt angle sensor
*4: When length change or replacement of tilt angle sensor rod
*5: When removing/installing or replacing load sensor
*6: When removing/installing or replacing tire angle sensor or sensor cover
*7: When installing or changing attachment or fork
*8: When removing/installing or replacing mast
*9: When removing/installing or replacing tilt cylinder
*10: When replacing lift lever angle sensor
*11: When replacing tilt lever angle sensor
*12: When replacing attachment (1) lever angle sensor
*13: When replacing attachment (2) lever angle sensor
*14: When replacing multi-function display
*15: 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 17, “SAS/OPS”.
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MATCHING MENU Screen

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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.

Switch (2) Switch (3)

“1. DRIVE”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To MATCHING DRIVE screen
“2. SAS”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To MATCHING SAS screen

“3. LEVER”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To MATCHING MINI LEVER screen
“4. TIRE DATA”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (3): Selecting MASK MENU. (See page 3-22)
Switch (4): To TIRE DATA screen
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DRIVE (MATCHING DRIVE)

Matching is performed for drive function.
Note:
After performing the ACCEL OFF matching, be sure to perform ACCEL ON matching.
Operating Procedure
1. Display the MATCHING MENU screen and press the switch
(1), select the “1. DRIVE”.

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
Switch (4) required.

3. Make sure that the Diagnostic indicator on the display is

blinking.
Caution:
During drive matching, the Diagnostic indicator blinks, inform-
ing 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
display.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): To “ACCEL ON” screen
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“ACCEL ON” Screen

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

SAS (MATCHING SAS)

Matching is performed for SAS function.
Operating Procedure
1. Display the MATCHING MENU screen and press the switch
(1), select the “2. SAS”.

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
Switch (4) required.

“TILT LEVEL” Screen

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

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

“TIRE POSITION” Screen

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

LEVER (MATCHING LEVER)

Matching is performed for mini lever or joystick functions.

Operating Procedure
1. Display the MATCHING MENU screen and press the switch
(1), select the “3. LEVER” menu.

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

Conventional Lever “LEVER2” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
display.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): To “LEVER3” screen

Mini Lever/Joystick Lever

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

“LEVER4” Screen
If matching is performed (press switch (1)), “OK” is indicated on the
display
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): Returning to MATCHING MENU screen.
Note:
“Lever4” screen will be displayed according to the number of
ways being set.
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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 “4. TIRE
DATA”.

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

Switch (4)

“TIRE DATA” Screen

Switch (2): Setting tire data smaller
Switch (3): Setting tire data larger
Switch (4): Returning to MASK MENU screen.
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Tire Data List

2 ton models
Vehicle model Tire size Tire type Tire constant
Smooth tire
Non-marking tire
8FBCU20 21 X 7 X 15 283
Smooth non-marking tire
Lug tire
Smooth tire
Non-marking tire
8FBCU25 21 X 7 X 15 283
Smooth non-marking tire
Lug tire
Smooth tire
Non-marking tire
8FBCHU25 21 X 7 X 15 283
Smooth non-marking tire
Lug tire

3 ton models
Vehicle model Tire size Tire type Tire constant
Smooth tire
Non-marking tire
8FBCU28 21 X 8 X 15 284
Smooth non-marking tire
Lug tire
Smooth tire
Non-marking tire
8FBCU30 21 X 8 X 15 284
Smooth non-marking tire
Lug tire
Smooth tire
Non-marking tire
8FBCU32 21 X 8 X 15 284
Smooth non-marking tire
Lug tire
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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

Operating Procedure
Enter the password on the status screen (See page 3-21) to display
the mask function initial screen. After 5 seconds, the ANALYZER
MENU screen is automatically displayed.

“1. METER START”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “METER START” screen
“2. DEMO MODE”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
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
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“4. MASK PASSWORD”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (3): Selecting MASK MENU
Switch (4): To “MASK PASSWORD” screen
“5. MANAGER PASS CLR”
Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
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

METER START (HOUR METER START)

This menu item is used to make the following meters start counting: hour meters, odometer, trip meter and
maintenance hour meter.
With this menu option, you can also enable the following functions or operations regardless of whether the demo
mode is enabled or disabled.
• Enables the load handling operation during traveling.
• Enables the parking brake reminder function.
• Enables the detection, warning and recording function, while clearing the data on shock detected by the
simplified shock sensor (option).
• Enables all functions of the PIN code entry system (option).
Note:
• This option does not the clear the PIN code authentication data or the simplified shock 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
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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

selected.

Switch (2) Switch (3)

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

“METER START” Screen

Hour meter start procedure
1. Press the switch (2) for more than 2 seconds to display the
right arrow (guidance) on the screen.

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

3. Press the switch (4) to return to MASK MENU screen.

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DEMO MODE
This menu item is used to enable or disable the demo mode.
Before 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

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

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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

selected.

Switch (2) Switch (3)

3. Display the OTHERS MENU screen and press the switch (1),
select the “2. DEMO MODE”.
4. Press the switch (4) to display DEMO MODE screen.

Note:
• After the hour meter start operation completes, “METER
START” and “DEMO MODE” items of other mask function
menus will not be displayed.
• When “YES” is selected, H mode lock becomes NO
automatically. The demo mode screen always displays H
mode lock condition.
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“DEMO MODE” screen

Switch (2): Setting from YES
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.
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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 status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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
selected.
4. Press the switch (4) to display TO DEFAULT SET screen.
After hour meter start
3. Display the OTHERS MENU screen and press the switch (1),
select the “1. TO DEFAULT SET” .
4. Press the switch (4) to display TO DEFAULT SET screen.

After hour meter start

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“TO DEFAULT SET” Screen

1. Press the switch (2) and select the “YES”.

2. To initialize the settings, press and hold down the switch (1) for
more than 2 seconds.
Note:
• When the Default Set operation is in progress, do not turn
off the ignition key switch or disconnect the battery plug.
• You can return to another mask function menu by
pressing the switch (4), except when the Default Set
operation is in progress.
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MASK SECOND PASSWORD SETTING (MASK PASSWORD)

This menu item is used to set or clear a mask second password.
You can enter any four-digit number as a mask second password, using the 4 switches on the multifunction display.
If you set a mask second password, you will be prompted to enter the second password after you enter the ordinary
password necessary to display the MASK FUNCTION screen, and you can move to the MASK FUNCTION screen
only when the passwords you entered coincide with the registered ones.
No mask second password has been set by default.
Note:
Do not forget the password you set. In the event you forget it, consult your dealer.

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function. After 5 seconds, the ANALYZER
MENU screen is automatically displayed.

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
selected.
4. Press the switch (4) to display MASK SECOND PASSWORD
screen.
After hour meter start
3. Display the OTHERS MENU screen and press the switch (1),
select the “2. MASK PASSWORD” menu.
4. Press the switch (4) to display MASK SECOND PASSWORD
After hour meter start setting screen.
Note:
Once the meter starts, it cannot return to the condition of
shipment.
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Mask second password set

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

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 [ „ ]).
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ADMINISTRATOR SECOND PASSWORD CLEAR (MANAGER PASS CLR)

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

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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 “5. MASK PASSWORD” is
selected.
4. Press the switch (4) to display MANAGER PASS CLR screen.
After hour meter start
3. Display the OTHERS MENU screen and press the switch (1),
select the “3. MANAGER PASS CLR”.
4. Press the switch (4) to display MANAGER PASS CLR screen.

After hour meter start

sec03.book 81 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-81

“ADMINISTRATOR SECOND PASSWORD CLEAR”

(MANAGER PASS CLR) Screen
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.
Switch (1) : Clears the password if pressed and held
down for more than 2 seconds.
Switch (4) : Returning to OTHERS MENU screen

LCD CONTRAST ADJUSTMENT

This menu item is used to adjust the contrast of the multifunction LCD display.

Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.

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

selected.

Switch (2) Switch (3)

sec03.book 82 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-82

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.
After hour meter start
3. Display the OTHERS MENU screen and press the switch (1),
select the “4. CONTRAST”.
4. Press the switch (4) to display contrast setting screen.

After hour meter start

“CONTRAST” Screen
Switch (2): Contrast level down
Switch (3): Contrast level up
Switch (4): Returning to OTHERS MENU screen
sec03.book 83 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-83

MULTI-FUNCTION DISPLAY ASSY

COMPONENTS
5702
sec03.book 84 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-84

REMOVAL·INSTALLATION

Removal Procedure
1. Remove the battery plug.
2. Remove the instrument panel RH.
3. Remove the multi-function display from the instrument panel RH.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
sec03.book 85 ページ ２０１０年４月２１日 水曜日 午後１時２７分

3-85

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.
sec03.book 86 ページ ２０１０年４月２１日 水曜日 午後１時２７分
sec04.book 1 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-1

TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING............................4-2
CONNECTOR HANDLING.........................................4-2
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE ........................................................4-2
TROUBLESHOOTING METHOD ...........................4-4
TO USE SST...........................................................4-5
DIAGNOSIS CODE LIST........................................4-6
WHEN ERROR CODE IS DISPLAYED ................4-23 4
WHEN NO ERROR CODE IS DISPLAYED........4-179
sec04.book 2 ページ ２０１０年４月２３日 金曜日 午後２時４３分

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.
sec04.book 3 ページ ２０１０年４月２３日 金曜日 午後２時４３分

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 MΩ or above
ǡ

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 MΩ or above

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

defective clamping.
4
ǡ ǡ

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.
sec04.book 4 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-4

TROUBLESHOOTING METHOD
Inspection: Check of seat switch condition Defective portion
1. Turn off the key switch and disconnect the battery Repair or replacement
SDM: 0
plug.
2. Disconnect the CN43 connector, connect the battery Seat switch defect
plug, and turn on the key switch.
3. Check the value of SDM, using the Analyzer menu.
[ANL] I/O TRAVELING 2/5

SDM: 1 To the next step depending on the result.

Inspection 1:
1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN103, CN0104 and CN43
connectors and check the harnesses for their
continuities.

OK

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.
[ANL] I/O TRAVELING 2/5

Test item.
sec04.book 5 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-5

TO USE SST
Use SSTs for quick, accurate electrical troubleshooting on the 8FBCU 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)
09230-13700-71 CN76 short harness 61-1, 2
C2-2
C4-1 to 6
C5-1 to 6
C8-1, 2

CN7 IC check pin E2-2

09232-13130-71 Check harness E8-1, 2
Each short harness FB-1, 2
4
62-1, 2
71-1 to 3
72-1 to 4
G5-1 to 6
CN97 harness
09238-13130-71 68-1 to 3
CN99 check harness

Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
connected, various boards may be damaged.
 sec04.book
DIAGNOSIS CODE LIST
4-6
Indication : Information can be checked on the display when vehicle trouble occurs.
6 ページ

Memory : Use indication information that can be checked when the mask function DIAG MEMORY is used.
Indicator : Diagnostic mode
O/H

Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

O/H
DCR A0-1 Drive motor drive power circuit overheating abnormality Traveling stop.
lighting
２０１０年４月２３日

O/H Load handling stop.

PCR A0-2 Pump motor drive power circuit overheating abnormality
lighting Steering become stiff.
金曜日

Diagnostic
Unable to traveling and load handling
A1-1 A1-1 mode Main controller high voltage
Steering become stiff.
blinking
Diagnostic
午後２時４３分

A1-2 A1-2 mode Drive motor drive circuit high voltage Traveling stop.
blinking
Diagnostic
Load handling stop.
A1-4 A1-4 mode Pump motor drive circuit high voltage
Steering become stiff
blinking
O/H Drive motor output restricted.
C/R A2-1 Main controller circuit board overheating abnormality
lighting Unable to load handling
O/H
DCR A2-2 Drive motor drive circuit board overheating abnormality Traveling stop.
lighting
O/H Load handling stop.
PCR A2-3 Pump motor drive circuit board overheating abnormality
lighting Steering become stiff.
Diagnostic
Traveling and load handling stop.
A3-1 A3-1 mode Battery connection incorrect
Steering become stiff.
blinking
Diagnostic
OPSS function invalidity
A5-1 A5-1 mode Seat switch GND short abnormality
Parking brake reminder alarm partially disable.
blinking
Diagnostic
A6-3 A6-1 mode Tilt switch GND short abnormality Tilt stop.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic Traveling stop.
A8-1 A8-1 mode F1 fuse abnormality (Open) Load handling stop.
7 ページ

blinking Steering become stiff.

Diagnostic
Traveling stop.
A8-2 A8-2 mode F6 fuse abnormality (Open)
Load handling stop.
blinking
Diagnostic
A9-2 A9-2 mode F7 fuse abnormality (Open) Load handling stop.
２０１０年４月２３日

blinking
Diagnostic
Drive motor output restricted.
AA-1 AA-1 mode Main controller temperature sensor abnormality
金曜日

Load handling stop.

blinking
Diagnostic
AA-2 AA-2 mode Drive motor drive board temperature sensor abnormality Drive motor output restricted.
blinking
午後２時４３分

Diagnostic
AA-4 AA-4 mode Pump motor drive board temperature sensor abnormality Pump motor output restricted.
blinking
Diagnostic
Cooling fan stop.
AB-1 AB-1 mode Cooling fan drive circuit abnormality
Drive motor output restricted.
blinking
Diagnostic Traveling stop.
AC-1 AC-1 mode Semiconductor switch abnormality Load handling stop.
blinking Steering become stiff.
Diagnostic
AD-1 AD-1 mode Drive motor driver → Main controller communication abnormality
blinking Traveling stop.
Diagnostic Knob position correcting stop.
Drive motor driver → Main controller communication abnormality (on
AD-2 AD-2 mode
start up)
blinking
Diagnostic
AD-5 AD-5 mode Pump motor driver → Main controller communication abnormality
blinking Load handling stop.
Diagnostic Steering become stiff.
Pump motor driver → Main controller communication abnormality (on
AD-6 AD-6 mode
start up)
blinking
4-7
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-8
Diagnostic
AF-1 AF-1 mode Main controller CPU error
8 ページ

blinking
Diagnostic
AF-2 AF-2 mode Main controller CPU error
blinking Unable to traveling and load handling
Diagnostic Steering become stiff.
AF-3 AF-3 mode Main controller CPU error
２０１０年４月２３日

blinking
Diagnostic
AF-4 AF-4 mode Main controller CPU error
金曜日

blinking
Diagnostic
AF-5 AF-5 mode Main controller CPU error
blinking
午後２時４３分

Diagnostic
AF-6 AF-6 mode Main controller CPU error
blinking
Some control operations not stable.
Diagnostic
AF-7 AF-7 mode Main controller CPU error
blinking
Diagnostic
AF-8 AF-8 mode Main controller CPU error
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
C0-2 C0-2 mode Drive motor power-circuit short
9 ページ

blinking
Diagnostic
C1-1 C1-1 mode Drive motor current sensor neutral voltage error. Traveling stop.
blinking
Diagnostic
C1-2 C1-2 mode Drive motor current sensor over current.
２０１０年４月２３日

blinking
O/H
DM C2-1 Drive motor overheating abnormality.
lighting
金曜日

Diagnostic
C2-2 C2-2 mode Drive motor temperature sensor abnormality.
blinking Drive motor output restricted.

Diagnostic
午後２時４３分

C3-1 C3-1 mode Drive motor power circuit temperature sensor abnormality.
blinking
Diagnostic
C4-1 C4-1 mode Accelerator sensor POT1 open.
blinking
Diagnostic
C4-2 C4-2 mode Accelerator sensor POT2 open.
blinking
Display only
Diagnostic
C4-3 C4-3 mode Accelerator sensor POT1 VCC short.
blinking
Diagnostic
C4-4 C4-4 mode Accelerator sensor POT2 VCC short.
blinking
Diagnostic
C4-5 C4-5 mode Accelerator sensor offset abnormality. Traveling stop.
blinking
4-9
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-10
Diagnostic
C4-6 C4-6 mode Accelerator sensor matching value error. Drive motor output restricted.
10 ページ

blinking
Diagnostic
C8-1 C8-1 mode Drive motor speed sensor open.
blinking
Traveling stop.
Diagnostic
C8-2 C8-2 mode Drive motor speed sensor short.
blinking
２０１０年４月２３日

Diagnostic Traveling stop.

CB-1 CB-1 mode MB contactor open. Load handling stop.
金曜日

blinking Steering become stiff.

Diagnostic
CB-2 CB-2 mode MB contactor short. Display only
blinking
午後２時４３分

Diagnostic
CB-3 CB-3 mode MB contactor drive circuit open.
blinking
Diagnostic Traveling stop.
CB-4 CB-4 mode MB contactor drive circuit short. Load handling stop.
blinking Steering become stiff.
Diagnostic
CB-5 CB-5 mode MB contactor drive circuit short.
blinking
O/H
C/P CB-6 MB contactor panel overheating abnormality.
lighting
Drive motor output restricted.
Diagnostic Pump motor output restricted.
CB-7 CB-7 mode MB contactor panel temperature sensor abnormality.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
CC-1 CC-1 mode Drive motor drive CPU error.
11 ページ

blinking
Diagnostic
CC-2 CC-2 mode Drive motor drive CPU error.
blinking
Traveling stop.
Diagnostic
CC-3 CC-3 mode Drive motor drive CPU error.
blinking
２０１０年４月２３日

Diagnostic
CC-4 CC-4 mode Drive motor drive CPU error.
金曜日

blinking
Diagnostic
CC-5 CC-5 mode Drive motor drive CPU error.
blinking
午後２時４３分

Diagnostic
CC-6 CC-6 mode Drive motor drive CPU error.
blinking
Display only
Diagnostic
CC-7 CC-7 mode Drive motor drive CPU error.
blinking
Diagnostic
CC-8 CC-8 mode Drive motor drive CPU error.
blinking
Diagnostic
E0-2 E0-2 mode Pump motor drive power circuit abnormality.
blinking
Diagnostic
Unable to load handlling.
E1-1 E1-1 mode Pump motor current sensor neutral voltage error.
Steering become stiff.
blinking
Diagnostic
E1-2 E1-2 mode Pump motor current sensor over current.
blinking
4-11
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-12
O/H
PM E2-1 Pump motor overheating abnormality.
lighting
12 ページ

Diagnostic
E2-2 E2-2 mode Pump motor temperature sensor abnormality.
Pummp motor output restricted.
blinking
Diagnostic
E3-1 E3-1 mode Pump motor drive power circuit temperature sensor abnormality.
blinking
２０１０年４月２３日

Diagnostic
E8-1 E8-1 mode Pump motor speed sensor open.
blinking
金曜日

Diagnostic
E8-2 E8-2 mode Pump motor speed sensor short.
blinking
Diagnostic
午後２時４３分

EC-1 EC-1 mode Pump motor drive CPU error.

blinking Unable to load handlling.
Diagnostic Steering become stiff.
EC-2 EC-2 mode Pump motor drive CPU error.
blinking
Diagnostic
EC-3 EC-3 mode Pump motor drive CPU error.
blinking
Diagnostic
EC-4 EC-4 mode Pump motor drive CPU error.
blinking
Diagnostic
EC-5 EC-5 mode Pump motor drive CPU error.
blinking
Diagnostic
EC-6 EC-6 mode Pump motor drive CPU error.
blinking
Display only
Diagnostic
EC-7 EC-7 mode Pump motor drive CPU error.
blinking
Diagnostic
EC-8 EC-8 mode Pump motor drive CPU error.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
EE-1 EE-1 mode Display → Main controller communication error. Settings cannot be changed by display operation.
13 ページ

blinking
Diagnostic
EE-2 EE-2 mode Display → Main controller communication error. Unable to display operation
blinking
Diagnostic
F1-1 F1-1 mode Main controller → Display communicaiton error.
blinking Vehicle settings cannot be changed by display
２０１０年４月２３日

Diagnostic operation.
F1-2 F1-2 mode Main controller → Display communicaiton error.
金曜日

blinking
Diagnostic
F4-1 F4-1 mode Display CPU error.
blinking Traveling and load handling cannot be performed
午後２時４３分

Diagnostic simultaneously.
F4-2 F4-2 mode Display CPU error. Disable the traveling control function.
blinking W/ PIN Code Entry System:
Diagnostic PIN code entry system disable.
F4-3 F4-3 mode Display CPU error.
blinking
Diagnostic
F4-4 F4-4 mode Display CPU error. Display only
blinking
Diagnostic
F4-5 F4-5 mode Display CPU error. Display function not stable.
blinking
Diagnostic
F4-6 F4-6 mode Display CPU error.
blinking
Diagnostic
F4-7 F4-7 mode Display CPU error. Some control operations not stable.
blinking
Diagnostic
F4-8 F4-8 mode Display CPU error.
blinking
Diagnostic
FF-1 FF-1 mode D7V power supply circuit over current. Display turns OFF.
blinking
4-13
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-14
Diagnostic
Knob position correcting stop.
FF-2 FF-2 mode SSTR+ power supply circuit over current.
Steering become stiff.
14 ページ

blinking
Diagnostic
32-1 32-1 mode Drive motor driver ID abnormality.
blinking
Display only
Diagnostic
32-3 32-3 mode Pump motor driver ID abnormality.
blinking
２０１０年４月２３日

Diagnostic
52-1 52-1 mode Yaw late sensor open.
金曜日

blinking
Diagnostic
52-2 52-2 mode Yaw late sensor short. Swing lock disable.
blinking
午後２時４３分

Diagnostic
52-3 52-3 mode Yaw late sensor neutral voltage error.
blinking
Diagnostic
54-1 54-1 mode Swing lock solenoid open.
blinking
Diagnostic
54-2 54-2 mode Swing lock solenoid short. Swing lock failed.
blinking
Diagnostic
54-3 54-3 mode Swing lock solenoid drive circuit abnormality.
blinking
Diagnostic
54-4 54-4 mode Swing lock solenoid abnormality. Partial limitation of rear wheel swing control function.
blinking
Diagnostic
61-1 61-1 mode Load sensor open.
blinking Partial limitation of mast control function.
Partial limitation of traveling control function.
Diagnostic Partial limitation of OPSS function.
61-2 61-2 mode Load sensor short.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
62-1 62-1 mode Tilt angle sensor open.
15 ページ

blinking
Diagnostic
62-2 62-2 mode Tilt angle sensor short.
blinking
Diagnostic
63-1 63-1 mode Tilt switch forward/backward simultaneous operation short. Partial limitation of mast control function.
blinking
２０１０年４月２３日

Diagnostic
63-2 63-2 mode Tilt switch forward position short.
金曜日

blinking
Diagnostic
63-3 63-3 mode Tilt switch backward position short.
blinking
午後２時４３分

Diagnostic
64-1 64-1 mode Lift lock solenoid open. Lift lower may stop.
blinking
Diagnostic
64-2 64-2 mode Lift lock solenoid short. Lift lower may stop.
blinking
(Conventional lever)
Diagnostic
Lower may operate while OPS is operating.
64-3 64-3 mode Lift lock solenoid drive circuit abnormaliry.
(Mini lever/Joystick lever)
blinking
Lower may not operate.
(Conventional lever)
Diagnostic
Lower may operate while OPS is operating.
64-4 64-4 mode Lift lock solenoid its continuity.
(Mini lever/Joystick lever)
blinking
Lower may not operate.
Diagnostic
65-1 65-1 mode Tilt control solenoid open. Tilt forward may stop.
blinking
Diagnostic
65-2 65-2 mode Tilt control solenoid short. Tilt forward may stop.
blinking
(Conventional lever)
Diagnostic
Tilt forward may operate while OPS is operating.
65-3 65-3 mode Tilt control solenoid drive circuit abnormaliry.
(Mini lever/Joystick lever)
blinking
Tilt forward may not operate.
4-15
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-16
(Conventional lever)
Diagnostic
Tilt forward may operate while OPS is operating.
65-4 65-4 mode Tilt control solenoid its continuity.
16 ページ

(Mini lever/Joystick lever)

blinking
Tilt forward may not operate.
Diagnostic
66-1 66-1 mode Outside matching value range for tilt angle sensor. Partial limitation of mast control function.
blinking
Partial limitation of mast control function.
Diagnostic
Partial limitation of traveling control function.
２０１０年４月２３日

67-1 67-1 mode Lifting height switch abnormality.

Height selector disable.
blinking
Partial limitation of OPSS function.
金曜日

Diagnostic
68-1 68-1 mode Lifting height sensor open.
blinking
Diagnostic
Height selector disable.
68-2 68-2 mode Lifting height sensor short.
午後２時４３分

Lift speed limited.

blinking
Diagnostic
68-3 68-3 mode Lifting height sensor abnormality.
blinking
Diagnostic
71-1 71-1 mode Tire angle sensor oepn.
blinking
Knob position correcting stop.
Diagnostic
71-2 71-2 mode Tire angle sensor short.
blinking
Diagnostic
72-1 72-1 mode Steering angle sensor SS1 open.
blinking Knob position correcting stop.
Diagnostic Steering become stiff.
72-2 72-2 mode Steering angle sensor SS2 open.
blinking
Diagnostic
72-3 72-3 mode Steering angle sensor SSC open. Knob position correcting stop.
blinking
Diagnostic
Knob position correcting stop.
72-4 72-4 mode Steering angle sensor power circuit open.
Steering become stiff.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
73-1 73-1 mode Knob position synchronizer solenoid open.
17 ページ

blinking
Diagnostic
73-2 73-2 mode Knob position synchronizer solenoid short.
blinking
Diagnostic
73-3 73-3 mode Knob position synchronizer solenoid power circuit abnormality. Knob position correcting stop.
blinking
２０１０年４月２３日

Diagnostic
73-4 73-4 mode Knob position synchronizer solenoid abnormality.
金曜日

blinking
Diagnostic
74-1 74-1 mode Outside matching value range for tire angle error.
blinking
午後２時４３分

Diagnostic
H1-1 H1-1 mode Lift lever potentiometer open.
blinking
Diagnostic
H1-2 H1-2 mode Lift lever potentiometer short. Lift stop.
blinking
Diagnostic
H1-3 H1-3 mode Lift lever poetentiometer output abnnormality.
blinking
Diagnostic
Lift stop. (Conventional lever)
H1-4 H1-4 mode Lift lever potentiometer neutral error.
Load handling stop. (Mini lever/Joystick lever)
blinking
Diagnostic
H1-5 H1-5 mode Lift lever potentiometer matching value error. Lift stop.
blinking
Diagnostic
H2-1 H2-1 mode Tilt lever potentiometer open.
blinking
Diagnostic
H2-2 H2-2 mode Tilt lever potentiometer short. Tilt stop.
blinking
Diagnostic
H2-3 H2-3 mode Tilt lever poetentiometer output abnnormality.
blinking
4-17
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-18
Diagnostic
H2-4 H2-4 mode Tilt lever potentiometer neutral error. Load handling stop.
18 ページ

blinking
Diagnostic
H2-5 H2-5 mode Tilt lever potentiometer matching value error. Tilt stop.
blinking
Diagnostic
H3-1 H3-1 mode Attachment 1 lever potentiometer open.
blinking
２０１０年４月２３日

Diagnostic
H3-2 H3-2 mode Attachment 1 lever potentiometer short. Attachment 1 stop.
金曜日

blinking
Diagnostic
H3-3 H3-3 mode Attachment 1 lever poetentiometer output abnnormality.
blinking
午後２時４３分

Diagnostic
Attachment 1 stop. (Conventional lever)
H3-4 H3-4 mode Attachment 1 lever potentiometer neutral error.
Load handling stop. (Mini lever/Joystick lever)
blinking
Diagnostic
H3-5 H3-5 mode Attachment 1 lever potentiometer matching value error. Attachment 1 stop.
blinking
Diagnostic
H4-1 H4-1 mode Attachment 2 lever potentiometer open.
blinking
Diagnostic
H4-2 H4-2 mode Attachment 2 lever potentiometer short. Attachment 2 stop.
blinking
Diagnostic
H4-3 H4-3 mode Attachment 2 lever poetentiometer output abnnormality.
blinking
Diagnostic
Attachment 2 stop. (Conventional lever)
H4-4 H4-4 mode Attachment 2 lever potentiometer neutral error.
Load handling stop. (Mini lever/Joystick lever)
blinking
Diagnostic
H4-5 H4-5 mode Attachment 2 lever potentiometer matching value error. Attachment 2 stop.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
H5-1 H5-1 mode Lift proportional solenoid open. (PULL)
19 ページ

blinking
Upward lift stop.
Diagnostic
H5-2 H5-2 mode Lift proportional solenoid short. (PULL)
blinking
Diagnostic
H5-3 H5-3 mode Lift proportional solenoid open. (PUSH)
blinking
２０１０年４月２３日

Downward lift stop.

Diagnostic
H5-4 H5-4 mode Lift proportional solenoid short. (PUSH)
金曜日

blinking
Diagnostic
H5-5 H5-5 mode Lift proportional solenoid power circuit abnormality.
blinking
Load handling stop.
午後２時４３分

Diagnostic
H5-6 H5-6 mode Lift proportional solenoid (PULL/PUSH) abnormality.
blinking
Diagnostic
H6-1 H6-1 mode Tilt backward solenoid open.
blinking
Backward tilt stop.
Diagnostic
H6-2 H6-2 mode Tilt backward solenoid short.
blinking
Diagnostic
H6-3 H6-3 mode Tilt forward solenoid open.
blinking
Forward tilt stop.
Diagnostic
H6-4 H6-4 mode Tilt forward solenoid short.
blinking
Diagnostic
H6-5 H6-5 mode Tilt solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H6-6 H6-6 mode Tilt forward/backward solenoid abnormality.
blinking
4-19
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-20
Diagnostic
H7-1 H7-1 mode Attachment 1 PULL solenoid open.
20 ページ

blinking
Diagnostic
H7-2 H7-2 mode Attachment 1 PULL solenoid short.
blinking
Attachment 1 stop.
Diagnostic
H7-3 H7-3 mode Attachment 1 PUSH solenoid open.
blinking
２０１０年４月２３日

Diagnostic
H7-4 H7-4 mode Attachment 1 PUSH solenoid short.
金曜日

blinking
Diagnostic
H7-5 H7-5 mode Attachment 1 (PULL/PUSH) solenoid power circuit abnormality.
blinking
Load handling stop.
午後２時４３分

Diagnostic
H7-6 H7-6 mode Attachment 1 PULL/PUSH solenoid abnormality.
blinking
Diagnostic
H8-1 H8-1 mode Attachment 2 PULL solenoid open.
blinking
Diagnostic
H8-2 H8-2 mode Attachment 2 PULL solenoid short.
blinking
Attachment 2 stop.
Diagnostic
H8-3 H8-3 mode Attachment 2 PUSH solenoid open.
blinking
Diagnostic
H8-4 H8-4 mode Attachment 2 PUSH solenoid short.
blinking
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks
Diagnostic
H8-5 H8-5 mode Attachment 2 (PULL/PUSH) solenoid power circuit abnormality.
21 ページ

blinking
Diagnostic
H8-6 H8-6 mode Attachment 2 PULL/PUSH solenoid abnormality.
blinking
Diagnostic
HB-1 HB-1 mode Proportional solenoid power supply circuit (RY1) open. Load handling stop.
blinking
２０１０年４月２３日

Diagnostic
HB-2 HB-2 mode Proportional solenoid power supply circuit short.
金曜日

blinking
Diagnostic
HB-3 HB-3 mode Proportional solenoid power supply circuit over current.
blinking
午後２時４３分

Diagnostic
Upper or backward may operate while OPS is
HC-1 HC-1 mode Unload solenoid open.
operating.
blinking
Diagnostic
Upper or backward may operate while OPS is
HC-2 HC-2 mode Unload solenoid short.
operating.
blinking
Diagnostic
HC-3 HC-3 mode Unload solenoid drive circuit abnormality. Loading operations other than lower may not operate.
blinking
Diagnostic
Upper or backward may operate while OPS is
HC-4 HC-4 mode Unload solenoid abnormality.
operating.
blinking
4-21
 sec04.book
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

4-22
Diagnostic
G5-1 G5-1 mode Shock sensor 1 open.
22 ページ

blinking
Diagnostic
G5-2 G5-2 mode Shock sensor 1 short.
blinking
Diagnostic
G5-3 G5-3 mode Shock sensor 1 neutral voltage error.
blinking
２０１０年４月２３日

Shock sensor disabled.

Diagnostic
G5-4 G5-4 mode Shock sensor 2 open.
金曜日

blinking
Diagnostic
G5-5 G5-5 mode Shock sensor 2 short.
blinking
午後２時４３分

Diagnostic
G5-6 G5-6 mode Shock sensor 2 neutral voltage error.
blinking
sec04.book 23 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-23

WHEN ERROR CODE IS DISPLAYED

z Error Code A0-1 (Drive motor power-circuit overheating abnormality)
Related portion

CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

Drive motor drive circuit

N1
Temperature-sensor

Probable cause:
(1) The power cable and motor cable tightening is defective. (5) Cooling fan defect
(2) Connector contact defect (6) Overheating (continuous overload operation)
(3) Harness defect (7) Drive motor drive circuit defect
(4) Cooling fan clogging (8) Main controller defect

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

Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor cable
loosen.
Do not leave the vehicle standing in a hot place.
Error code A0-1

Operate check of three cooling fans , Please apply the

cooling fan compulsorily by using Active Test. The fans
do not rotate.
[ANL]ACTIVE TEST 2/3 FAN 1
FAN OFF → ON

The fans rotate.

Inspection: Temperature check

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

[ANL] I/O TEMP/VOLT 2/4

Record the value of

TDMDH.
2
sec04.book 24 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-24

Turn off the key switch and leave the vehicle standing
for a while (about 15 minutes).
The TDMDH temperature is 78°C or more for both
cooling fans 1 and 2 and it has lowered by 5°C or more
compared to the TDMDH temperature previously
checked.
Inspection: Temperature check
Turn on the key switch and check the value of TDMDH
using the Analyzer menu.

[ANL] I/O TEMP/VOLT 2/4

The TDMDH temperature is
TDMDH: 78°C or more and it has not
Less than lowered by 5°C or more compared
78°C to the TDMDH temperature
previously checked.

Drive motor drive circuit defect

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
Jp

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN112, CN113 and CN114
connectors and check the harnesses for their continuities.
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN112, CN113 and CN114 connectors. Either
3. Connect the battery plug and turn on the key switch. 48V type: Excluding approx. 48V
4. Forcibly turn on the cooling fans, using Active Test. 36V type: Excluding approx. 36V
[ANL]ACTIVE TEST 2/3 Main controller defect
FAN OFF → ON
5. Check each connector for its voltage at the Fan ON.
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
48V type: Approx. 48V
36V type: Approx. 36V
Inspection:
1. Turn off the key switch and disconnect the battery plug.
2. Connect the CN112 and disconnect the CN113 and CN114. The fans do
3. Turn on the key switch and connect the battery plug. not rotate.
Cooling fan 1 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 1.
The fans rotate.
3
sec04.book 25 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-25

Jp

Inspection:
1. Turn off the key switch and disconnect the battery plug.
The fans do
2. Connect the CN113 and disconnect the CN112 and CN114.
not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 2 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 2.

The fans rotate.

Inspection:
1. Turn off the key switch and disconnect the battery plug.
2. Connect the CN114 and disconnect the CN112 and CN113. The fans do
3. Turn on the key switch and connect the battery plug. not rotate.
Cooling fan 3 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 3.

The fans rotate.

Connector contact defect

Inspection 1: Harness check

Check each harness for its continuity.
Perform this check with the battery plug and the CN101, CN102, CN112, 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 CN112-1 Continuity
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN102-1 to CN112-2 Continuity
CN102-2 to CN113-2 Continuity
CN102-1 to CN114-2 Continuity
CN101-4 to P1 Continuity
CN101-3 to CN102-1 No ontinuity
CN101-3 to CN102-2 No ontinuity
CN102-1 to CN102-2 No ontinuity
sec04.book 26 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-26

z Error Code A0-2 (Pump motor power-circuit overheating abnormality)

Related portion

CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

Drive motor drive circuit

N1
Temperature-sensor

Probable cause:
(1) The power cable and motor cable tightening is defective. (5) Cooling fan defect
(2) Connector contact defect (6) Overheating (continuous overload operation)
(3) Harness defect (7) Drive motor drive circuit defect
(4) Cooling fan clogging (8) Main controller defect

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

Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor cable
loosen.
Do not leave the vehicle standing in a hot place.
Error code A0-2

Operate check of three cooling fans , Please apply the

cooling fan compulsorily by using Active Test. The fans
do not rotate.
[ANL]ACTIVE TEST 2/3 1
FAN OFF → ON

The fans rotate.

Inspection: Temperature check

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

[ANL] I/O TEMP/VOLT 2/4

Record the value of

TPMDH.

2
sec04.book 27 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-27

Turn off the key switch and leave the vehicle standing
for a while (about 15 minutes).
The TPMDH temperature is 78°C or more for both
cooling fans 1 and 2 and it has lowered by 5°C or more
compared to the TPMDH temperature previously
checked.
Inspection: Temperature check
Turn on the key switch and check the value of TPMDH
using the Analyzer menu.

[ANL] I/O TEMP/VOLT 1/4

The TPMDH temperature is
TPMDH:
78°C or more and it has not
Less than
lowered by 5°C or more compared
78°C
to the TPMDH temperature
previously checked.

Pump motor drive circuit defect

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
Jp

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN112, CN113 and CN114
connectors and check the harnesses for their continuities.
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug. Either
2. Disconnect the CN112, CN113 and CN114 connectors. 48V type: Excluding approx. 48V
3. Connect the battery plug and turn on the key switch. 36V type: Excluding approx. 36V
4. Forcibly turn on the cooling fans, using Active Test.
[ANL]ACTIVE TEST 2/3 Main controller defect
FAN OFF → ON
5. Check each connector for its voltage at the Fan ON.
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
48V type: Approx. 48V
36V type: Approx. 36V
Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN112 and disconnect the CN113 and CN114. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 1 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 1.
The fans rotate.

3
sec04.book 28 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-28

Jp

Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN113 and disconnect the CN112 and CN114. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 2 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 2.

The fans rotate.

Inspection:
1. Turn off the key switch and disconnect the battery plug.
The fans do
2. Connect the CN114 and disconnect the CN112 and CN113.
not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 3 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 3.

The fans rotate.

Connector contact defect

Inspection 1: Harness check

Check each harness for its continuity.
Perform this check with the battery plug and the CN101, CN102, CN112, 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 CN112-1 Continuity
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN102-1 to CN112-2 Continuity
CN102-2 to CN113-2 Continuity
CN102-1 to CN114-2 Continuity
CN101-4 to P1 Continuity
CN101-3 to CN102-1 No ontinuity
CN101-3 to CN102-2 No ontinuity
CN102-1 to CN102-2 No ontinuity
sec04.book 29 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-29

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

Related portion

F7 P3
CN102-3 (19, VBMBSL) CN130-6 (19, VBMBSL)

Main
controller
CN102-4 (19, VBMBSL)

Probable cause:
(1) Battery defect (4) Battery plug defect
(2) MB contactor defect (5) Battery overvoltage
(3) F7 fuse open (6) 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.
A1-1
An error
occurs.
Turn off and back on the key switch. Inspection: Check of VBMBSL voltage
Check the VBMBSL voltage, using the Analyzer menu.
A1-1 No error occurs [ANL] I/O TEMP/VOLT 3/4

VBMBSL: Less than 65 V VBMBSL: More than 65 V

Inspection: Check of battery voltage

1. Turn off the key switch and disconnect the
battery plug.
2. Measure the voltage between both ends of the
battery plug with a circuit tester.
Inspection: Check of F7 fuse Approx. 48 V 65 V or more
1. Turn off the key switch and disconnect the
battery plug. Main controller defect Replace the battery.
2. Remove the F7 fuse and measure the
resistance between its both ends with a circuit NG (∞ Ω)
F7 fuse open
tester.

OK (0 Ω)

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

NO

Check the battery plug.

Check the battery electrolyte.
sec04.book 30 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-30

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

Related portion

MB
P1 F1 P4

Drive motor
drive circuit

Probable cause:
(1) Battery defect (4) Battery plug defect
(2) MB contactor defect (5) Drive motor drive circuit defect
(3) F1 fuse open (6) 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.

Error code A1-2

A1-2
error
Turn the key switch from OFF to ON to check for occurs.
Inspection:
errors. (Check of voltage of drive motor drive circuit)
A1-2 error does not Check the value of VDMD, using the Analyzer menu.
occur [ANL] I/O TEMP/VOLT 4/4

VDMD: Less than 55 V VDMD: 55 V or more

Inspection 1: (Check the battery voltage.)

1. Turn off the key switch and disconnect the
battery plug.
2. Measure the voltage between both ends of the
battery plug with a circuit tester.
Inspection 2: (Check of F1 fuse) Less than 55 V 55 V or more
1. Turn off the key switch and disconnect the
battery plug. Drive motor drive circuit defect Battery defect
2. Remove the F1 fuse and measure the
resistance between its both ends with a circuit NG (∞ Ω)
F1 fuse open
tester.

OK (0 Ω)

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

NO

* Check the battery plug.

* Check the battery electrolyte.
sec04.book 31 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-31

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

Related portion

Main controller

Temperature sensor

TH101

Probable cause:
(1) The ambient temperature around the Main controller is high. (3) Temperature sensor defect (Main controller defect)
(2) Overheating (continuous overload operation)

Do not leave the vehicle standing in a hot place.

Error code A2-1

Inspection: Temperature check

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

[ANL] I/O TEMP/VOLT 2/4

Record the value of
TMCB.
Turn off the key switch and leave the vehicle standing
for a while (about 30 minutes).
The TMCB temperature is 79°C or more and it has
lowered by 5°C or more compared to the TMCB
temperature previously checked.
Inspection: Temperature check
Turn on the key switch and check the value of TMCB
using the Analyzer menu.

[ANL] I/O TEMP/VOLT 2/4

The TMCB temperature is 79°C or more and it has not lowered by 5°C
TMCB: Less than 79°C
or more compared to the TMCB temperature previously checked.

Main controller defect

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.)
sec04.book 32 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-32

z Error Code A2-2 (Drive motor drive circuit board overheating abnormality)
Related portion

CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

Drive motor drive circuit

N1
Temperature-sensor

Probable cause:
(1) The power cable and motor cable tightening is defective. (5) Cooling fan defect
(2) Connector contact defect (6) Overheating (continuous overload operation)
(3) Harness defect (7) Drive motor drive circuit defect
(4) Cooling fan clogging (8) Main controller defect

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

Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor cable
loosen.
Do not leave the vehicle standing in a hot place.
Error code A0-1

Operate check of three cooling fans , Please apply the

cooling fan compulsorily by using Active Test. The fans
do not rotate.
[ANL] ACTIVE TEST 2/3 1
FAN OFF → ON

The fans rotate.

Inspection: Temperature check

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

[ANL] I/O TEMP/VOLT 2/4

Record the value of
TDMDB.
2
sec04.book 33 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-33

Turn off the key switch and leave the vehicle standing
for a while (about 30 minutes).
The TDMDB temperature is 73°C or more for both
cooling fans 1 and 2 and it has lowered by 5°C or more
compared to the TDMDB temperature previously
checked.
Inspection: Temperature check
Turn on the key switch and check the value of TDMDB
using the Analyzer menu.

[ANL] I/O TEMP/VOLT 1/4

The TDMDB temperature is
TDMDB: 73°C or more and it has not
Less than lowered by 5°C or more compared
73°C to the TDMDB temperature
previously checked.

Drive motor drive circuit defect

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
Jp

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN112, CN113 and CN114
connectors and check the harnesses for their continuities.
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug. Either
2. Disconnect the CN112, CN113 and CN114 connectors. 48V type: Excluding approx. 48V
3. Connect the battery plug and turn on the key switch. 36V type: Excluding approx. 36V
4. Forcibly turn on the cooling fans, using Active Test.
[ANL]ACTIVE TEST 2/3 Main controller defect
FAN OFF → ON
5. Check each connector for its voltage at the Fan ON.
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
48V type: Approx. 48V
36V type: Approx. 36V
Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN112 and disconnect the CN113 and CN114. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 1 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 1.
The fans rotate.

3
sec04.book 34 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-34

Jp

Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN113 and disconnect the CN112 and CN114. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 2 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 2.

The fans rotate.

Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN114 and disconnect the CN112 and CN113. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 3 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 3.

The fans rotate.

Connector contact defect

Inspection 1: Harness check

Perform this check with the battery plug and the CN101, CN102, CN112, 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 CN112-1 Continuity
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN102-1 to CN112-2 Continuity
CN102-2 to CN113-2 Continuity
CN102-1 to CN114-2 Continuity
CN101-4 to P1 Continuity
CN101-3 to CN102-1 No ontinuity
CN101-3 to CN102-2 No ontinuity
CN102-1 to CN102-2 No ontinuity
sec04.book 35 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-35

z Error Code A2-3 (Pump motor drive circuit board overheating abnormality)
Related portion

CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

Pump motor drive circuit

N1
Temperature-sensor

Probable cause:
(1) The power cable and motor cable tightening is defective. (5) Cooling fan defect
(2) Connector contact defect (6) Overheating (continuous overload operation)
(3) Harness defect (7) Drive motor drive circuit defect
(4) Cooling fan clogging (8) Main controller defect

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

Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor cable
loosen.
Do not leave the vehicle standing in a hot place.
Error code A0-2

Operate check of three cooling fans , Please apply the

The fans
cooling fan compulsorily by using Active Test.
do not rotate.
1
[ANL] ACTIVE TEST 2/3
FAN OFF → ON

The fans rotate.

Inspection: Temperature check

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

[ANL] I/O TEMP/VOLT2/4

Record the value of
TDMDB.

2
sec04.book 36 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-36

Turn off the key switch and leave the vehicle standing
for a while (about 30 minutes).
The TDMDB temperature is 73°C or more for both
cooling fans 1 and 2 and it has lowered by 5°C or more
compared to the TDMDB temperature previously
checked.
Inspection: Temperature check
Turn on the key switch and check the value of TDMDB
using the Analyzer menu.

[ANL] I/O TEMP/VOLT 1/4

The TDMDB temperature is
TDMDB: 73°C or more and it has not
Less than lowered by 5°C or more compared
73°C to the TDMDB temperature
previously checked.

Pump motor drive circuit defect

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
Jp

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN112, CN113 and CN114
connectors and check the harnesses for their continuities.
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug. Either
2. Disconnect the CN112, CN113 and CN114 connectors. 48V type: Excluding approx. 48V
3. Connect the battery plug and turn on the key switch. 36V type: Excluding approx. 36V
4. Forcibly turn on the cooling fans, using Active Test.
[ANL]ACTIVE TEST 2/3 Main controller defect
FAN OFF → ON
5. Check each connector for its voltage at the Fan ON.
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
48V type: Approx. 48V
36V type: Approx. 36V
Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN112 and disconnect the CN113 and CN114. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 1 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 1.
The fans rotate.

3
sec04.book 37 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-37

Jp

Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN113 and disconnect the CN112 and CN114. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 2 defect
4. Forcibly turn on the cooling fans, using Active Test
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 2.

The fans rotate.

Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN114 and disconnect the CN112 and CN113. not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 3 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 3.

The fans rotate.

Connector contact defect

Inspection 1: Harness check

Check each harness for its continuity.
Perform this check with the battery plug and the CN101, CN102, CN112, 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 CN112-1 Continuity
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN102-1 to CN112-2 Continuity
CN102-2 to CN113-2 Continuity
CN102-1 to CN114-2 Continuity
CN101-4 to P1 Continuity
CN101-3 to CN102-1 No ontinuity
CN101-3 to CN102-2 No ontinuity
CN102-1 to CN102-2 No ontinuity
sec04.book 38 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-38

z Error Code A3-1 (Battery connection incorrect )

Related portion

F5
P1 CN130-4 CN104-1(41, B48V)

Main
controller

Battery

N1

Probable cause:
(1) Set voltage defect.
(2) The voltage in the B48V line after the F5 fuse is above the set voltage.
(3) Main controller defect.

Error code A3-1

Turn off the key switch and disconnect the battery plug.
A3-1 error does not occur. Plug contact defect or incorrect
Then, connect the battery plug correctly, turn back on
connection of battery
the key switch to check for errors.

A3-1 error occurs.

Inspection 1: Check of the set voltage

NG
Set voltage defect
[OPT] 36V YES/NO

OK

48V type: Less than 65V

Inspection: Check of battery voltage 36V type: Less than 48V
Mmain controller defect
[ANL] I/O TEMP/VOLT 3/4

48V type: 65V or more

36V type: 48V or more
A
sec04.book 39 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-39

48V type:Less than 65 V

Check of battery voltage 36V type:Less than 48 V
Main controller defect
P1[+]←→N1[-]

48V type:65 V or more

36V type:48 V or more
Check the battery, and replace it with a regular battery if necessary.

Inspection 1: ICheck of set voltage

Check [OPT] 1.OPTIONSET 36V setting.

(See page 3-58)

Vehicle specification Standard

36V type YES
48V type NO
sec04.book 40 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-40

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

Related portion

CN103-6 (51, LS-) CN92-1

Main
Seat switch
controller

CN104-18 (67, SDM) CN92-2

Probable cause:
(1) Connector contact defect (3) Harness defect
(2) Seat switch defect (4) Main controller defect

Error code A5-1

1. Disconnect the battery plug, disconnect the CN92

connector, and visually check inside the connector
and the caulked portion of its wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
2. Connect the CN92 connector, connect the battery
plug, and then turn on the key switch without sitting in
the seat.

Inspection: Check of seat switch condition

SDM: 0
Connector contact defect
Check the value of SDM, using the Analyzer menu.
[ANL] I/O TRAVELING 2/5

SDM: 1

Inspection: Check of seat switch condition

1. Turn off the key switch and disconnect the battery
plug. SDM: 0
Seat switch defect
2. Disconnect the CN92 connector , connect the battery
plug, and turn on the key switch.
3. Check the value of SDM, using the Analyzer menu.
[ANL] I/O TRAVELING 2/5

SDM: 1

Inspection 1:
1. Turn off the key switch and disconnect the battery NG
plug. Harness defect
2. Disconnect the CN103, CN104 and CN92 connectors
and check the harnesses for their continuities.

OK

Main controller defect

sec04.book 41 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-41

Inspection 1: Check each harness for its continuity.

Before this check, turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and
CN92 connectors, visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN103-6 to CN92-1 Continuity
CN103-18 to CN92-2 Continuity
CN92-1 to CN92-2 No continuity
sec04.book 42 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-42

z Error Code A6-3 (Tilt lever switch abnormality)

Related portion

Tilt lever switch

CN102-23 (61,SWTR) CN9-3

CN102-22 (62,SWTF) CN9-1

Main
controller CN103-6 (51,LS-) CN9-2

CN9-4

Probable cause:
(1) The battery plug is connected while the tilt lever is being operated.
(2) Connector contact defect
(3) Tilt lever switch defect
(4) Tilt lever switch installation portion defect.
(5) Tilt lever switch harness defect
(6) Main controller defect

The A6-3 error may occur if the battery plug is connected while the tilt lever is being operated.
Error code A6-3

1. Disconnect the battery plug, disconnect the CN9

connector, and visually check inside the connector
A6-3 error does not
and the caulked portion of its wire for defects.
occur.
(Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN9 connector, connect the battery
plug, and turn on the key switch to see if an error
occurs.

A6-3 error occurs.

A6-3 error
1. Disconnect the CN9connector. does not occur. • Tilt lever switch defect
2. Connect the battery plug and turn on the key switch.
• Tilt lever switch installation portion defect.
Check the error code.

A6-3 error occurs.

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery
NG
plug. Harness defect
2. Disconnect the CN102 and CN103 connectors and
check the harnesses for their continuities.

OK

Main controller defect

sec04.book 43 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-43

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN9, CN102and CN103 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

CN102-23 to CN9-3 Continuity
CN102-22 to CN9-1 Continuity
CN103-6 to CN9-2 Continuity
CN103-6 to CN9-4 Continuity
CN102-23 to CN103-6 No continuity
CN102-22 to CN103-6 No continuity
CN102-22 to CN102-23 No continuity
sec04.book 44 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-44

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

Related portion

MB F1 P4

P3

Battery CN104-2 (44, VBMB)

CN130-5
F6

Drive motor Main

drive circuit controller

Pump motor drive

circuit

Probable cause:
(1) Cable or connector contact defect
(2) Improper installation of F1 or F6 fuse
(3) F1 or F6 fuse open
(4) F6 fuse holder defect
(5) Harness or cable defect
(6) Main controller defect
sec04.book 45 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-45

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.
1. Turn off the key switch and disconnect the battery
plug, and visually check the following terminals for
loose bolts: drive motor drive circuit positive terminal,
pump motor drive circuit positive terminal, contactor
panel P4 terminal, drive motor drive circuit negative
terminal, pump motor drive circuit negative terminal A8-1 error does not occur.
and contactor panel N1 terminal. Caution: Before Improper fastening of terminals
starting the job, measure the voltage between
positive terminal and GND; if there is any voltage,
insert a resistor at approx. 100Ω between + and GND
to discharge the capacitor.
2. Connect the battery plug and turn on the key switch
to check for errors.

A8-1 error occurs.

48V type:
All motor drive circuits
Inspection: Check of supply voltages to drive motor
Approx. 48 V
drive circuit and pump motor drive circuit. Drive motor drive circuit defect
1. Measure the voltage between the positive and Pump motor drive circuit defect
36V type:
negative terminals of each drive circuit.
All motor drive circuits
Approx. 36 V

0V

Inspection: Check of installation of F1 fuse

1. Turn off the key switch and disconnect the battery
plug. A8-1 error does not occur.
F1 fuse installation defect
2. Visually check if the F1 fuse is installed properly.
3. Connect the power cable, connect the battery plug,
and then turn on the key switch.

A8-1 error occurs.

Inspection: Check of F1 fuse

1. Turn off the key switch and disconnect the battery NG (∞ Ω)
plug. F1 fuse open
2. Remove the F1 fuse and measure the resistance
between its both ends with a circuit tester.

OK (0 Ω)

Motor drive circuit defect (*)

Motor drive circuit defect (*)

Turn off the key switch and disconnect the battery plug, 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
Negative terminal: [+] probe
}
Motor drivers are defective if their resistance measured is 10 Ω or less.
sec04.book 46 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-46

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.
1. Before this check, disconnect the battery plug,
disconnect the CN130 connector, and visually check
inside the connector and the caulked portion of its
wire for defects. (Refer to BEFORE A8-2 error does not occur.
Connector contact defect
TROUBLESHOOTING.)
2. Connect the CN130 connector, connect the battery
plug, and then turn on the key switch to check for
errors.

A8-2 error occurs.

Inspection: Check of installation of F6 fuse

1. Turn off the key switch and disconnect the battery
plug. A8-2 error does not occur.
F6 fuse installation defect
2. Visually check if the F6 fuse is installed properly.
3. Connect the battery plug and turn on the key switch
to check for errors.

A8-2 error occurs.

Inspection: Check of VBMBSL voltage

VBMBSL: Less than 25 V
Identify the causes of CB1 to CB5.
Check the value of VBMBSL, using the Analyzer menu.
[ANL] I/O TEMP/VOLT 3/4

VBMBSL: More than 25 V

Inspection: Check of F6 fuse

1. Turn off the key switch and disconnect the battery NG (∞ Ω)
plug. F6 fuse open
2. Remove the F6 fuse and measure the resistance
between its both ends with a circuit tester.

OK (0 Ω)

Inspection: Check of F6 fuse holder

1. Turn off the key switch and disconnect the battery
NG (∞ Ω)
plug.
F6 fuse holder defect
2. Disconnect the CN130 connector and measure the
terminals (CN130-5 and P3 terminal) , on the F6 fuse
side with the F6 fuse installed in the fuse holder.

OK (0 Ω)

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN104, CN130 connector and P3
terminal and check the harnesses for their
continuities.

OK

Main controller defect

sec04.book 47 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-47

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN130, CN104 connectors and P3 terminal disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
Note:Tighten the P3 terminal surely.

Portions to be checked Standard

CN104-2 to CN130-5 Continuity
CN130-5 (fuse side) to P3 terminal Continuity
CN104-2 to N1 No continuity
CN130-5 (fuse side) to N1 No continuity
sec04.book 48 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-48

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

Related portion

F7 P3
CN102-3 (19, VBMBSL) CN130-6

Main
controller
CN102-4 (19, VBMBSL)

Probable cause:
(1) Connector contact defect (5) F7 fuse holder defect
(2) MB contactor defect (6) Harness defect
(3) F7 fuse installation defect (7) Main controller defect
(4) 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.
1. Before this check, disconnect the battery plug,
disconnect the CN130 connector, and visually check
inside the connector and the caulked portion of its
wire for defects. (Refer to BEFORE A9-2 error does not occur.
Connector contact defect
TROUBLESHOOTING.)
2. Connect the CN130 connector, connect the battery
plug, and then turn on the key switch to check for
errors.

A9-2 error occurs.

Inspection: Check of installation of F7 fuse

1. Turn off the key switch and disconnect the battery
plug. A9-2 error does not occur.
F7 fuse installation defect
2. Visually check if the F7 fuse is installed properly.
3. Connect the battery plug and turn on the key switch
to check for errors.

A9-2 error occurs.

Inspection: Check of VBMB voltage

VBMB: Less than 25 V
Identify the causes of CB1 to CB5.
Check the value of VBMB, using the Analyzer menu.
[ANL] I/O TEMP/VOLT 3/4

VBMB: 25 V or more

A
sec04.book 49 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-49

Inspection: Check of F7 fuse

1. Turn off the key switch and disconnect the battery
NG (∞ Ω)
plug. F7 fuse open
2. Remove the F7 fuse and measure the resistance
between its both ends with a circuit tester.

OK (0 Ω)

Inspection: Check of F7 fuse holder

1. Turn off the key switch and disconnect the battery
plug. NG (∞ Ω)
F7 fuse holder defect
2. Disconnect the CN130 connector and measure the
terminals (CN130-6 and P3), on the F6 and F7 fuse
box side with the F7 fuse installed in the fuse box.

OK (0 Ω)

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN102, CN130 connectors and P3
terminal, and check the harnesses for their
continuities.

OK

Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN130, CN102 connectors and P3 terminal disconnected.
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
Note:Tighten the P3 terminal surely.

Portions to be checked Standard

CN102-3 to CN130-6 Continuity
CN102-4 to CN130-6 Continuity
CN130-6 (fuse side) to P3 terminal Continuity
CN102-3 to N1 No continuity
CN102-4 to N1 No continuity
CN130-6 (fuse side) to N1 No continuity
sec04.book 50 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-50

z 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.

sec04.book 51 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-51

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

Drive motor drive circuit

Temperature sensor

Probable cause:
Drive motor drive circuit defect

Error code AA-2

* If AA-2 is displayed, the drive motor drive circuit is defective, so replace it.
sec04.book 52 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-52

z 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.
sec04.book 53 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-53

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

Related portion

CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2

CN113-1
Main
controller
Cooling fan 2
CN102-2 (99,FNDC1) CN113-2

CN114-1

Cooling fan 3
CN114-2

Probable cause:
(1) Connector contact defect
(2) Cooling fan defect
(3) Harness defect
(4) Main controller defect

Error code AB-1

1. Turn off the key switch and disconnect the battery

plug, disconnect the CN112, CN113 and CN114
connectors, and visually check inside the connector
and the caulked portion of its wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
2. Connect the CN112, CN113 and CN114 connectors, All cooling fans rotate.
Connector contact defect
connect the battery plug, turn on the key switch,
forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the
three cooling fans rotate.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON

One of the cooling fans stops.

Inspection: Check of cooling fan 1

1. Turn off the key switch and disconnect the battery
plug, disconnect the CN112, CN113 and CN114
connectors, and then connect the battery plug and
turn on the key switch. AB-1 error occurs.
B
2. Forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the error
code after two minutes.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON

AB-1 error does not occurs.

A
sec04.book 54 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-54

Inspection: Check of cooling fan 1

1. Turn off the key switch and disconnect the battery
plug, connect the CN112 connector, disconnect the
CN113 and CN114 connectors, and then connect the
battery plug and turn on the key switch. Stop cooling fan 1.
Cooling fan 1 defect
2. Forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check if
cooling fan 1 rotates.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON Check the cooling fan 2
Cooling fan 1 rotates. sequentially.

Inspection: Check of cooling fan 2

1. Turn off the key switch and disconnect the battery
plug, connect the CN113 connector, disconnect the
CN112 and CN114 connectors, and then connect the Stop cooling fan 2.
battery plug and turn on the key switch. Cooling fan 2 defect
2. Forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check if
cooling fan 2 rotates.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON Check the cooling fan 3
Cooling fan 2 rotates. sequentially.

Inspection: Check of cooling fan 3

1. Turn off the key switch and disconnect the battery
plug, connect the CN114 connector, disconnect the
CN112 and CN113 connectors, and then connect the
battery plug and turn on the key switch. Stop cooling fan 3.
Cooling fan 3 defect
2. Forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check if
cooling fan 3 rotates.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON

Cooling fan 3 rotates.

Main controller defect

sec04.book 55 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-55

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN113 and CN114
connectors and check the harnesses for their
continuities.

OK

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

CN101-3 to CN112-1 Continuity
CN101-3 to CN113-1 Continuity
CN101-3 to CN114-1 Continuity
CN102-1 to CN112-2 Continuity
CN102-1 to CN114-2 Continuity
CN102-2 to CN113-2 Continuity
CN101-3 to CN102-1 No continuity
CN101-3 to CN102-2 No continuity
CN102-1 to CN102-2 No continuity
sec04.book 56 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-56

z Error Code AC-1 (Semiconductor switch abnormality)

Related portion

MB
P2
P1
F5
CN104-1 (41,B48V)

CN101-4 (41,VBBT)

N1 Main
Pump motor drive CN111-1 CN103-4 (42,KYSAT) controller
circuit

Drive motorr CN110-1

drive circuit

Probable cause:
(1) Drive motor drive circuit harness defect
(2) Pump motor drive circuit harness defect
(3) Drive motor drive circuit defect
(4) Pump motor drive circuit defect
(5) Main controller defect
sec04.book 57 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-57

Error code AC-1

Inspection: Harness check

1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN103, CN110 and CN111
connectors and check the harnesses for their
continuities.

OK

Remove the F1 fuse.

Inspection: Check of Main controller

Connect the CN103 connector, connect the battery AC-1 error occurs.
Main controller defect
plug, and then turn on the key switch to check for
errors.

AC-1 error does not occur.

Inspection: Check of pump motor drive circuit

Connect the CN103 and CN111 connectors, connect AC-1 error occurs.
Pump motor drive circuit defect
the battery plug, and then turn on the key switch to
check for errors.

Inspection: Check of drive motor drive circuit

Disconnect CN111, connect CN110, connect the battery
plug, and then turn on the key switch to check for
errors.

Check pump motor drive circuit

Defect in sections where AC-1 error occurs during
drive motor drive circuit check

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN103, CN111 and CN110 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

CN103-4 to N1 No continuity
CN103-4 to CN111-2 Continuity
CN103-4 to CN110-2 Continuity
sec04.book 58 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-58

z Error Code AD-1, -2, -5, -6 (Main controller (CAN) communication

abnormality)
Related portion

CN103-4 (KYSAT) CN110-1

CN103-11 (CAN1H) CN110-11

CN103-12 (CAN1L) CN110-12

Main CN103-5 (N2,N2) CN110-8 Drive motor

controller drive circuit
CN103-4 (N2,N2) CN110-9

CN103-5 (N2,N2) CN110-10

CN103-6 (N2,N2)

CN111-1

CN111-11

CN111-12

CN111-10 Pump motor

drive circuit
CN111-8(152,SETP)

CN111-9(152,0SETP)

Probable cause:
(1) Wrong motor driver type
(2) Connector contact defect
(3) Harness defect
(4) Motor drive circuit defect

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

sec04.book 59 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-59

Error code AD-1, -2, -5, -6

Detach the battery plugs and check that an 8FBCU Motor driver other than
motor driver is installed. Especially if the motor driver 8FBCU installed
Wrong motor driver type
has just been replaced, check that a different model
motor driver hasn’t been installed.
8FBCU motor
driver installed
1. Turn off the key switch and disconnect the battery
plug and visually check inside the CN110 and
CN111connectors and the caulked portions of their
wires for defects. (Refer to BEFORE AD-1, AD-2,
TROUBLESHOOTING.) AD-5, AD-6
Connector contact defect
2. Connect all the connectors, connect the battery plug, None of these error codes
and then turn on the key switch to check for errors. are displayed.
Especially if a motor drive circuit was replaced
immediately before the error occurred, check if the
connector is connected correctly.
AD-2 or AD-6 is displayed.
(*1: Record the error that has occurred.)
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN103, CN104, CN110 and CN111
connectors and check the harnesses for their
continuities.

OK

Check of battery voltage

1. Turn off the key switch, and then connect the CN103
and CN104 connectors. At that time, leave the Less than 15 V
Main controller defect
CN110 and CN111 connectors disconnected.
2. Turn on the key switch and measure the voltage
between CN110-1 and N2.

15 V or more

Motor drive circuit defect

Error that was recorded in *1

AD-2: Drive motor drive circuit defect
AD-6: Pump motor drive circuit defect

Applicable model
28·30·32
Applicable model
20·25·H25
Note: Part numbers are subject to change without notice.
sec04.book 60 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-60

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN103, CN104, 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

CN110-8 to CN110-10 Continuity AD-1,2
CN110-9 to CN110-10 No continuity AD-1,2
CN103-4 to CN110-1 Continuity AD-1,2
CN103-11 to CN110-11 Continuity AD-1,2
CN103-12 to CN110-12 Continuity AD-1,2
CN110-1 to CN110-11 No continuity AD-1,2
CN110-1 to CN110-12 No continuity AD-1,2
CN110-11 to CN110-12 No continuity AD-1,2
CN111-10 to CN111-9 No continuity AD-5.6
CN111-8 to CN111-9 Continuity AD-5.6
CN103-4 to CN111-1 Continuity AD-5.6
CN103-11 to CN111-11 Continuity AD-5.6
CN103-12 to CN111-12 Continuity AD-5.6
CN111-1 to CN111-11 No continuity AD-5.6
CN111-1 to CN111-12 No continuity AD-5.6
CN111-11 to CN111-12 No continuity AD-5.6
CN103-4 to CN103-5 No continuity AD-2,6
CN103-11 to CN103-5 No continuity AD-2,6
CN103-12 to CN103-5 No continuity AD-2,6
sec04.book 61 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-61

z 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.

sec04.book 62 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-62

z Error Code C0-2 (Drive motor power-circuit short)

Related portion

P7
U

Drive P8
V Drive motor
motor
drive
circuit P9
W

Probable cause:
(1) Drive motor defect (3) Drive motor drive circuit defect
(2) 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.

1. Turn off the key switch and disconnect the battery plug and visually
C0-2 error
check the fastened or caulked portions of the motor cables for
does not occur.
defects. (Refer to BEFORE TROUBLESHOOTING.) Improper fastening of motor cable
2. Connect the cables, connect the battery plug, and then turn on the
key switch to check for errors.
C0-2 error occurs.
Inspection: (Check of motor drive circuits)
1. Turn off the key switch and disconnect the battery plug. C0-2 error
2. Disconnect the three motor cables from the drive circuit and occurs.
Drive motor drive circuit defect
insulate the terminals of the cables disconnected.
3. Connect the battery plug and turn on the key switch.
4. Check if the C0-2 error occurs.
C0-2 error does not occur.
Inspection 1: (Check of motor cables)
1. Turn off the key switch and disconnect the battery plug.
NG
2. Disconnect the motors cables from both the motor and the motor Motor cable defect
drive circuit.
3. Check the motor cables for its continuity.
OK
Inspection: (Check of motor drive circuit) *1
1. Replace the drive motor drive circuit with the drive pump drive C0-2 error
circuit or the pump motor drive circuit. occurs.
Drive motor defect
2. Connect the battery plug and turn on the key switch.
3. Check the error code that is displayed. (Ignore the error codes 32-1,
32-3.)
E0-2 error
occurs.
Drive motor drive circuit defect
(Note: Drive circuit that is originally the drive motor drive circuit before replacement)
sec04.book 63 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-63

*1 If the error codes C0-2, C0-4 and E0-2 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 defect
2. Check the Drive motor. (See page 5-5)

OK

Drive motor drive circuit defect

Inspection 1: Continuity check of motor cables

Check the cables for its continuity.
Turn off the key switch and 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
sec04.book 64 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-64

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

Drive motor drive circuit

Current sensor

Probable cause:
Drive motor drive circuit defect

Error code C1-1

* If C1-1 is displayed, the drive motor drive circuit is defective, so replace it.
sec04.book 65 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-65

z Error Code C1-2 (Drive motor current sensor over current)

Related portion

P7
U
Drive
motor V P8 Drive
drive motor
circuit
P9
W

Probable cause:
(1) Drive motor defect
(2) Motor cable defect
(3) Drive 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.
Turn the key switch from OFF to ON, to check for C0-2 error occurs.
Proceed to identify the cause of C0-2.
errors.

C0-2 No error occurs.

1. Turn off the key switch and disconnect the battery

plug and visually check the fastened or caulked C1-2
portions of the motor cables for defects. (Refer to No error occurs.
Improper fastening of motor cable
BEFORE TROUBLESHOOTING.)
2. Connect the cables, connect the battery plug, and
then turn on the key switch to check for errors.

C1-2 error occurs.

Inspection 1: (Check of motor cables)

1. Turn off the key switch and disconnect the battery
plug. NG
Drive motor cable defect
2. Disconnect the motors cables from both the motor
and the motor drive circuit.
3. Check the motor cables for its continuity.

OK

Inspection 2: (Check motor drive circuit)*1

1. Turn off the key switch and disconnect the battery
plug.
C1-2 error occurs.
2. Replace the drive motor drive circuit with the pump Drive motor defect
motor drive circuit.
3. Connect the battery plug, and turn on the key switch.
4. Check the error code. (Disregard 32-1 & 32-3)

E1-2 error occurs.

Drive motor drive circuit defect

(Note: Drive circuit that is originally the drive motor drive circuit before replacement)
sec04.book 66 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-66

*1 If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
motor drive circuits.
Inspection: (Motor check)
1. Turn off the key switch and disconnect the battery NG
Drive motor defect
plug.
2. Check the drive motor.

OK

Drive motor drive circuit defect

Inspection 1: Continuity check of motor cables

Check the cables for its continuity.
Turn off the key switch and 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
sec04.book 67 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-67

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

Related portion

CN110-4 (86, STDM+) CN50-2

Drive motor Drive motor

drive circuit Temperature
CN110-5 (87, STDM) CN50-1 sensor

Probable cause:
Overheating (continuous overload operation)

Do not leave the vehicle standing in a hot place.

Error code C2-1

Inspection: Temperature check

Turn on the key switch.

[ANL] I/O TEMP/VOLT 1/4

Record the value of TDM.

Turn off the key switch and leave the vehicle standing The TDM temperature is 110° C or more for both the
for a while (about 30 minutes). drive motor temperature sensor and it has lowered by 5°
C or more compared to the TDM temperature previously
checked.
Inspection: Temperature check
Turn on the key switch.

[ANL] I/O TEMP/VOLT 1/4

TDM: The TDM temperature is 110° C The TDM (R) temperature is 110° C or
less or more and it has not lowered more and it has not lowered by 5° C or
than by 5° C or more compared to the more compared to the TDM
110° C TDM temperature previously temperature previously checked.
checked.
Proceed to identify the cause of C2-2.

Proceed to identify the cause of C2-2.

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.)
sec04.book 68 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-68

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

Related portion

CN110-4 (86, STDM+) CN50-2

Drive motor Drive motor

drive circuit Temperature
CN110-5 (87, STDM) CN50-1 sensor

Probable cause:
(1) Connector contact defect (3) Drive motor temperature sensor harness defect
(2) Drive motor temperature sensor defect (4) Drive motor drive circuit defect

Error code C2-2

1. Turn off the key switch and disconnect the battery

plug and visually check inside the CN50 connector
C2-2 error
and the caulked portions of their wires for defects.
does not occur.
(Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN50 connector, connect the battery
plug, and then turn on the key switch to check for
errors.

C2-2 error occurs.

Inspection 1: (Check of temperature sensor unit)

1. Turn off the key switch and disconnect the battery
NG
plug. Temperature sensor defect
2. Disconnect the CN50 connector and check the
temperature sensor as a single unit.

OK

Inspection 2: (Harness check)

1. Turn off the key switch and disconnect the battery
NG
plug. Harness defect
2. Disconnect the CN110 and CN50 connectors and
check the harnesses for their continuities.

OK

Drive motor drive circuit defect

sec04.book 69 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-69

Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN50-2 and CN50-1)
Standard value: Approx. 245 Ω and 600 kΩ
* Resistance change (It is a standard as for the following value).

Resistance
Temperature
(CN50-2⇔CN50-1)
20° C Approx. 13 kΩ
80° C Approx. 1.75 kΩ
100° C Approx. 1 kΩ

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect the CN110 and CN50 connectors, 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

CN110-5 to CN50-2 Continuity *1
CN110-6 to CN50-1 Continuity *1
CN50-1 to CN50-2 No continuity

*1: Connect CN50-1 and CN50-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN110-5 and CN110-6.
sec04.book 70 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-70

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

abnormality)
Related portion

Drive motor drive circuit

Temperature sensor

TH101

Probable cause:
Drive motor drive circuit defect

Error code C3-1

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

sec04.book 71 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-71

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

CN101-27 (53, VRA1+) CN29-5

CN102-30 (52, VRA1) CN29-4

CN101-22 (50, VRA-) CN29-6

Main Accelerator
controller CN101-26 (55, VRA2+) CN29-1 sensor

CN102-32 (54, VRA2) CN29-3

CN101-32 (51, POT-) CN29-2

Probable cause:
(1) Connector contact defect (4) Main controller defect
(2) Accelerator sensor defect (5) Accelerator fully open/fully closed matching error
(3) Accelerator sensor harness defect

Error code C4-1, -2, -3, -4, -5

1. Turn off the key switch and disconnect the battery

plug, and visually check if the accelerator senor is
installed correctly, and also check inside the CN29
connector and the caulked portion of its wire for C4-1, -2, -3, -4, -5
defects. (Refer to BEFORE TROUBLESHOOTING.) No error occurs. Improper installation of acceleration sensor
2. Connect the CN29 connector, connect the battery Connector contact defect
plug, turn on the key switch, and depress and release
the accelerator pedal to check if an error occurs. (No
error code must be displayed when the accelerator is
operated.)*
C4-1, -2, -3, -4 or -5
error occurs.
Inspection 1: Check of accelerator sensor
1. Turn off the key switch and disconnect the battery
NG
plug. Accelerator sensor defect
2. Disconnect the CN29 connector and measure the
resistance of the accelerator sensor.

OK

Inspection 2: Harness check

1. Turn off the key switch and disconnect the battery
NG
plug. Harness defect
2. Disconnect the CN101 and CN102 connectors and
check the harnesses for their continuities.

OK

Main controller defect

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

sec04.book 72 ページ ２０１０年４月２３日 金曜日 午後２時４３分

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 CN29 disconnected and CN101 and CN102 connected.
(1) Measuring the resistance of the accelerator sensor
Standard (on sensor side):
CN29-5 to CN29-6 1.8 to 3.5 kΩ
CN29-1 to CN29-2 (Open state)

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

Standard (on sensor side):
CN29-4 to CN29-6 The resistance must increase as the
CN29-3 to CN29-2 potentiometer is rotated.

Inspection 2: Check each harness for its continuity.

Perform this check with the battery plug, CN29, CN101 and CN102 disconnected.
visually check inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.
{ : Items to be checked
C4
Portions to be checked Standard
1 2 3 4 5 6
CN101-27 to CN29-5 Continuity { − − − { − *1
CN102-30 to CN29-4 Continuity { − − − − − *1
CN101-22 to CN29-6 Continuity − − { − { − *3
CN101-26 to CN29-1 Continuity − { − − { − *2
CN102-32 to CN29-3 Continuity − { − − − − *2
CN101-32 to CN29-2 Continuity − − − { { − *4
CN29-5 to CN29-6 No continuity { − − − − −
CN29-5 to CN29-2 No continuity { − − − − −
CN29-4 to CN29-6 No continuity { − − − { −
CN29-4 to CN29-2 No continuity { − − − { −
CN29-4 to CN29-5 No continuity − − { − { −
CN29-4 to CN29-1 No continuity − − { − { −
CN29-1 to CN29-6 No continuity − { − − − −
CN29-1 to CN29-2 No continuity − { − − − −
CN29-3 to CN29-6 No continuity − { − − { −
CN29-3 to CN29-2 No continuity − { − − { −
CN29-3 to CN29-5 No continuity − − − { { −
CN29-3 to CN29-1 No continuity − − − { { −
CN102-30 to CN102-32 No continuity − − − − { −
sec04.book 73 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-73

*1: Connect CN29-5 and CN29-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-27 and CN102-30.
*2: Connect CN29-1 and CN29-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-26 and CN102-32.
*3: Connect CN29-6 and CN29-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-22 and CN102-30.
*4: Connect CN29-2 and CN29-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-32 and CN102-32.

Inspection 3: Perform matching.

(See page 3-62)
sec04.book 74 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-74

z Error Code C8-1 (Drive motor speed (rotation) sensor open)

Related portion

CN110-2 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-6 (79, SSD1) CN155-2 CN51-1
Drive motor
drive circuit CN155-5 CN52-2
N1
- Rotation
sensor 2
CN110-7 (80, SSD2) CN155-3 CN52-1

Probable cause:
(1) Connector contact defect (4) Rotation sensor 2 defect
(2) Rotation sensor harness defect (5) Drive motor drive circuit defect
(3) 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.
1. Turn off the key switch and disconnect the battery plug and visually check
inside the CN155 connector and the caulked portions of their wires for
No error occurs.
defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN155 connector, connect the battery plug, and then turn on the
key switch to check for errors.
An error occurs.
Inspection 1: (Harness check)
Between
1. Turn off the key switch and disconnect the battery plug. NG
CN110 and CN155
2. Disconnect the CN110 and CN155 connectors and check the harnesses for
Harness defect
their continuities.
OK
Inspection: (Check of motor drive circuits)
Other than
1. Turn off the key switch and disconnect the battery plug.
12 to 16 V
2. Disconnect the CN155 connector and connect the CN110 connector.
3. Connect the battery plug and turn on the key switch.
4. Measure the voltage between CN155-1 and N1.
12 to 16 V
Inspection: (Check of error code)
1. Turn off the key switch and disconnect the battery plug.
C8-1 error
2. Disconnect the CN155 connector.
occurs.
3. Connect CN155-3 to CN155-5, and CN155-1 to CN155-2 on the wire harness
side through 09232-13130-71 in order to short them.
4. Connect the battery plug and turn on the key switch.
5. Check the error code that appears.
C8-2 error occurs. Drive motor drive circuit defect

1
sec04.book 75 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-75

Inspection: (Check of motor drive circuits) At least one of the

1. Turn off the key switch and disconnect the battery plug. resistances is not
2. Measure the resistance between CN155-2 and N1 and that between CN155-3 approx. 100 Ω. Drive motor drive
and N1. circuit defect

Both the resistances are approx. 100 Ω.

Between
Inspection 2: (Harness check)
CN155 and CN51
1. Turn off the key switch and disconnect the battery plug. NG
or between
2. Disconnect the CN155, CN51 and CN52 connectors and check the harnesses
CN155 and CN52
for their continuities.
Harness defect

OK

Inspection: (Check of rotation sensor)

1. Turn off the key switch and disconnect the battery plug.
2. Connect the CN155, CN51 and CN52 connectors.
3. Connect the battery plug and turn on the key switch to display the error code
C8-1.
4. Check the value of SSD, using the Analyzer menu.

[ANL] I/O TRAVELING 5/5

SSD: 0.2 or less/0.4 to 1.4 SSD: 0.4 to 1.4/0.2 or less SSD: 0.2 or less/0.2 or less

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.
Turn off the key switch and disconnect the battery plug, disconnect CN110 and CN155, visually check inside
each connector and the caulked portion of each wire for defects and then check the CN110 and CN155
harnesses.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN110-2 to CN155-1 Continuity *1
CN110-2 to CN155-5 Continuity *2
CN110-6 to CN155-2 Continuity *1
CN110-7 to CN155-3 Continuity *2
CN110-2 to CN110-7 No continuity
CN110-2 to CN110-6 No continuity
CN110-7 to CN110-6 No continuity

*1: Connect CN155-2 to CN155-1 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-2 to CN110-6.
*2: Connect CN155-3 to CN155-5 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-2 to CN110-7.
sec04.book 76 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-76

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN155, CN51 and CN52, visually check
inside each connector and the caulked portion of each wire for defects and then check the CN155 and CN51
harnesses and the CN155 to CN52 harnesses. (Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN155-1 to CN51-2 Continuity *3
CN155-2 to CN51-1 Continuity *3
CN155-5 to CN52-2 Continuity *4
CN155-3 to CN52-1 Continuity *4
CN155-3 to CN155-5 No continuity
CN155-3 to CN155-2 No continuity
CN155-3 to CN155-1 No continuity
CN155-5 to CN155-2 No continuity
CN155-5 to CN155-1 No continuity
CN155-2 to CN155-1 No continuity

*3: Connect CN51-1 to CN51-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN155-1 to CN155-2.
*4: Connect CN52-1 to CN52-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN155-5 to CN155-3.
sec04.book 77 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-77

z Error Code C8-2 (Drive motor speed (rotation) sensor short)

Related portion

CN110-2 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-6 (79, SSD1) CN155-2 CN51-1
Drive motor
drive circuit CN155-5 CN52-2
N1
- Rotation
sensor 2
CN110-7 (80, SSD2) CN155-3 CN52-1

Probable cause:
(1) Connector contact defect (4) Rotation sensor 2 defect
(2) Rotation sensor harness defect (5) Drive motor drive circuit defect
(3) 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.
1. Disconnect the battery plug and visually check inside the CN155 connector
and the caulked portions of their wires for defects. (Refer to BEFORE
No error occurs.
TROUBLESHOOTING.) Connector contact defect
2. Connect the CN155 connector, connect the battery plug, and then turn on the
key switch to check for errors.
An error occurs.
Inspection 1: (Harness check)
Between
1. Turn off the key switch and disconnect the battery plug. NG
CN110 and CN155
2. Disconnect the CN110 and CN155 connectors and check the harnesses for
Harness defect
their continuities.
OK
Inspection: (Check of motor drive circuits)
12 to 16 V
1. Turn off the key switch and disconnect the battery plug.
Other than
2. Disconnect the CN155 connector and connect the CN110 connector.
3. Connect the battery plug and turn on the key switch.
4. Measure the voltage between CN155-1 and N1.
12 to 16 V
Inspection: (Check of error code) C8-2 error
1. Turn off the key switch and disconnect the battery plug. occurs.
2. Disconnect the CN155 connector.
3. Connect the battery plug and turn on the key switch.
4. Check the error code that appears.
C8-1 error occurs. Drive motor drive circuit defect

1
sec04.book 78 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-78

Inspection: (Check of motor drive circuits) At least one of the

1. Turn off the key switch and disconnect the battery plug. resistances
2. Measure the resistance between CN155-2 and N1 and that between CN155-3 is not approx. 100 Ω. Drive motor drive
and N1. circuit defect

Both the resistances are approx. 100 Ω.

Between
Inspection 2: (Harness check)
CN155 and CN51
1. Turn off the key switch and disconnect the battery plug. NG
or between
2. Disconnect the CN155, CN51 and CN52 connectors and check the harnesses
CN155 and CN52
for their continuities.
Harness defect

OK

Inspection: (Check of rotation sensor)

1. Turn off the key switch and disconnect the battery plug.
2. Connect the CN155, CN51 and CN52 connectors.
3. Connect the battery plug and turn on the key switch to display the error code
C8-2.
4. Check the value of SSD, using the Analyzer menu.

[ANL] I/O TRAVELING 5/5

SSD: 1.5 or less/0.4 to 1.4 SSD: 0.4 to 1.4/1.5 or less SSD: 1.5 or more/1.5 or more

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.
Turn off the key switch and disconnect the battery plug, disconnect CN110 and CN155, visually check inside
each connector and the caulked portion of each wire for defects and then check the CN110 and CN155
harnesses.
(Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN110-2 to CN155-1 Continuity *1
CN110-2 to CN155-5 Continuity *2
CN110-6 to CN155-2 Continuity *1
CN110-7 to CN155-3 Continuity *2
CN110-2 to CN110-7 No continuity
CN110-2 to CN110-6 No continuity
CN110-7 to CN110-6 No continuity

*1: Connect CN155-2 to CN155-1 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-2 and CN110-6.
*2: Connect CN155-3 to CN155-5 on the CN109 side through 09232-13130-71 and check if there is continuity
between CN110-2 and CN110-7.
sec04.book 79 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-79

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN155, CN51 and CN52, visually check
inside each connector and the caulked portion of each wire for defects and then check the CN155 and CN51
harnesses and the CN155 to CN52 harnesses. (Refer to BEFORE TROUBLESHOOTING.)

Portions to be checked Standard

CN155-1 to CN51-2 Continuity *3
CN155-2 to CN51-1 Continuity *3
CN155-5 to CN52-2 Continuity *4
CN155-3 to CN52-1 Continuity *4
CN155-3 to CN155-5 No continuity
CN155-3 to CN155-2 No continuity
CN155-3 to CN155-1 No continuity
CN155-5 to CN155-2 No continuity
CN155-5 to CN155-1 No continuity
CN155-2 to CN155-1 No continuity

*3: Connect CN51-1 to CN51-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN155-1 to CN155-2.
*4: Connect CN52-1 to CN52-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN155-5 to CN155-3.
sec04.book 80 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-80

z Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality)

Related portion

MB
P1 P3 F1 P4

F7
CN130-6 CN102-3 (19, VBMBSL)

CN102-4 (19, VBMBSL)

F6
CN130-5 CN104-2 (44, VBMB)
Main
F5 controller
CN130-4 CN104-1 (41, B48V)

CN101-4 (41, VBBT)

CN130-1 CN104-9 (2, CBAT-)

MB
contactor CN130-2 CN104-3 (1, CBAT+)

Probable cause:
(1) Connector contact defect
(2) MB contactor defect
(3) Harness defect
(4) Fuse defect
(5) Main controller defect
sec04.book 81 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-81

Error code CB-1

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

CB-1
Disconnect and then connect the battery plug again, and turn on the No error occurs
Check the state of the battery.
key switch to see if an error occurs.

CB-1
An error occurs.
No actuation
Check if the MB contactor actuation sound is heard when the key sound
Identify the cause of CB-3.
switch is turned on.

Actuation sound

Inspection: Check of F6, F7 fuse

1. Turn off the key switch and disconnect the battery plug. ∞Ω F6 fuse defect
2. Remove the F6 and F7 fuses and measure the resistance between F7 fuse defect
their both ends with a circuit tester.

0Ω

Inspection: Check of F6 and F7 fuse holders

1. Install the F6 and F7 fuses and disconnect the CN130 connector
∞Ω F6 fuse holder defect
from the fuse holder.
F7 fuse holder defect
2. Measure the resistance between P3 and CN130-5 and that
between P3 and CN130-6 (fuse holder side).

0Ω

Inspection 1: Harness check NG

Harness defect
Disconnect the CN130, CN102, CN104 connectiors and P3 terminal.

OK

Inspection: Check of voltage

1. Connect all the connectors, connect the battery plug, and then turn
on the key switch.
2. Measure the voltage between both ends on the contact side of the
contactor. (Refer to the figure)

30 V or more
MB contactor defect
P1

P3

Less than 30 V

Main controller defect

sec04.book 82 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-82

Error code CB-2

If the error codes AD-5 and -6, E1-1 and -2, E0-2, 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, E0-2, ,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.

Use the device as it is.

Disconnect and then connect the battery plug again, turn on the key CB-2
(There are cases where the
switch and wait for 5 seconds. After that, turn off the key switch and No error occurs.
residual charge cannot be
wait for 5 seconds. Then back on the key switch to see if an error
discharged for reasons of
occurs.
another error.)

CB-2 error occurs.

The contactor
opens.
Check if the MB contactor opens when the key switch is turned off. A

The contactor does not open.

Inspection: Check of MB contactor

The contactor does
1. Turn off the key switch and disconnect the battery plug.
not open.
2. Measure the voltage between P4 and N1 of the contactor to see MB contactor defect
that it is 3 V or less.
3. Visually check the conditions of the contacts of the MB contactor.

The contactor opens.

Identify the cause of CB-3.

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 V or more

Pump motor drive circuit defect

sec04.book 83 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-83

Error code CB-3, -5

1. Disconnect the battery plug and visually check inside the CN130
CB-3, -5
connector and the caulked portions of their wires for defects. (Refer
No error occurs.
to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN130 connector, connect the battery plug, and then
turn on the key switch to check for errors.
CB-3 or CB-5
An error occurs.
Inspection: Check of MB contactor coil
1. Turn off the key switch and disconnect the battery plug.
NG
2. Disconnect the CN130 connector and measure the resistance of MB contactor defect
the MB contactor coil (resistance between CN130-1 and CN130-2).
Standard value: Approx. 28 Ω: 20°C

OK

Inspection 2: Harness check

NG
Disconnect the CN104 and CN130 connectors and check the Harness defect
harnesses for their continuities.

OK

Main controller defect

sec04.book 84 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-84

Error code CB-4

Disconnect the battery plug and visually check inside the CN130
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 CN130 connector and measure the resistance of
the MB contactor coil (resistance between CN130-1 and CN130-2).
Standard value: Approx. 28 Ω: 20°C

Inspection 2: Harness check

Disconnect the CN104 and CN130 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 CN130, CN102, CN104 connectors and P3 terminal
disconnected, visually check inside each connector and the caulked portion of each wire for defects.
Refer to BEFORE TROUBLESHOOTING.
Note:Tighten the P3 terminal surely.

Portions to be checked Standard Point

CN130-6 to CN102-3 Continuity CB-1
CN130-6 to CN102-4 Continuity CB-1
CN130-5 to CN104-2 Continuity CB-1
CN130-6 (fuse side) to P3 terminal Continuity CB-1
CN130-5 (fuse side) to P3 terminal Continuity CB-1
CN130-5 (fuse side) to N1 No continuity CB-1
CN130-5 to N1 No continuity CB-1
CN130-6 (fuse side) to N1 No continuity CB-1
CN130-6 to N1 No continuity CB-1

Inspection 2: Check each harness for its continuity.

Before this check, disconnect the battery plug, disconnect the CN104 and CN130 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

CN130-1 to CN104-9 Continuity CB-3
CN130-2 to CN104-3 Continuity CB-3
CN130-1 to CN136-2 No continuity CB-4, 5
CN130-1 to N1 No continuity CB-3
CN130-2 to N1 No continuity CB-3
CN130-1 to P1 No continuity CB-4
CN130-1 to P4 No continuity CB-4
sec04.book 85 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-85

z Error Code CB-6 (MB contactor panel overheating abnormality)

Related portion

CN131-1 CN103-7 (307,STCB+)

MB contactor
Temperature- CN131-2 CN101-18 (308,STCB) Main
sensor controller

Probable cause:
Overheating (continuous overload operation)

If CB-2, 4 or 5 is also displayed, perform troubleshooting with priority given to CB-2, 4 or 5.

Do not leave the vehicle standing in a hot place.
Take adequate care when testing, as the parts may be hot.
sec04.book 86 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-86

Error code CB-6

Inspection: Temperature check

Turn on the key switch.

[ANL] I/O TEMP/VOLT 1/4

Record the value of TCMB

Turn off the key switch and leave the vehicle standing
for a while (about 30 minutes).
The TCMB temperature is 130°C or more
and it has lowered by 5°C or more
compared to the TCMB temperature
Inspection: Temperature check
previously checked.
Turn on the key switch.

[ANL] I/O TEMP/VOLT 1/4

The TCMB temperature is 130°C or more and it has not
TCMB:
lowered by 5°C or more compared to the TCMB temperature
less than130°C
previously checked.

Proceed to identify the cause of CB-7

Turn off the key switch and disconnect the battery plug,
and check the terminals for loose bolts in the contactor
panel (See the “CONTACTOR PANEL ASSY
:REASSEMBRY”). NG Terminal bolt tightening defect.
Disconnect the CN131 connector, and visually check Connector contact defect
inside the connector and the caulked portion of its wire
for defects.
(Refer to BEFORE TROUBLESHOOTING.)

OK

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.)
sec04.book 87 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-87

z Error Code CB-7 (MB contacter Temperature-sensor bnormality)

Related portion

CN131-1 CN103-7 (307,STCB+)

MB contactor
Temperature- CN131-2 CN101-18 (308,STCB) Main
sensor controller

Probable cause:
(1) Connector contact defect
(2) MB contacter Temperature-sensor defect
(3) MB contacter Temperature-sensor harness defect
(4) Main controller defect

Error code CB-7

1. Turn off the key switch and disconnect the battery

plug, disconnect the CN131connector, and visually
check inside the connector and the caulked portion of CB-7 error does
its wire for defects. not occur
Connector contact defect
(Refer to BEFORE TROUBLESHOOTING.)
2. Connect the CN131 connector, connect the battery
plug, and then turn on the key switch to check for
errors.
E0-2 error does not occur
Inspection 1:(Check of temperature-sensor as a single
unit)
1. Turn off the key switch and disconnect the battery NG
Temperature-sensor defect
plug.
2. Disconnect the CN131and check the temperature-
sensor as a single unit.
E1-2 error occur
Inspection 2: (Harness check)
1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN131
connectors and check the harnesses for their
continuities.
OK
Main controller defect

Inspection 1: Check of temperature-sensor as a single unit

Check item
Temperature-sensor resistance (on sensor side:CN131-2 and CN131-1)
Standard value: Approx. 12kΩ: at 20°C (5kΩ ~ 28kΩ at 0 to 40°C)
sec04.book 88 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-88

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN101, CN103 and CN131 connectors,
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

CN131-1 ~ CN103-7 Continuity *1
CN131-2 ~ CN101-18 Continuity *1
CN103-7 ~ CN101-18 No continuity

*1: Connect CN103-71 and CN101-18 on the harness side through 09232-13130-71 and check if there is
continuity between CN131-1 and CN131-2.
sec04.book 89 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-89

z Error Code CC-1,-2,-3,-4,-5,-6,-7,-8 (CPU error)

Related portion

Drive motor
drive circuit

Probable cause:
Drive motor drive circuit defect

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

* If CC is displayed, the drive motor drive circuit is defective, so replace it.

sec04.book 90 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-90

z Error Code E0-2 (Pump motor drive power circuit short)

Related portion

P14
P4 U
+
Pump
motor P15
Pump
V
drive motor
circuit
N2 P16
- W

Probable cause:
(1) Pump motor drive circuit defect (3) Pump motor drive circuit defect
(2) 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.
* 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 N2 and start operation after it has lowered below 3 V.

1. Disconnect the battery plug and visually check the fastened or

E0-2 error
caulked portions of the motor cables for defects. (Refer to BEFORE
does not occur.
TROUBLESHOOTING.) Improper fastening of motor cable
2. Connect the cables, connect the battery plug, and then turn on the
key switch to check for errors.
E0-2 error occurs.
Inspection: (Check of motor drive circuits)
1. Turn off the key switch and disconnect the battery plug. E0-2 error
2. Disconnect the three motor cables from the drive circuit and occurs.
Pump motor drive circuit defect
insulate the terminals of the cables disconnected.
3. Connect the battery plug and turn on the key switch.
4. Check if the E0-2 error occurs.
E0-2 error does not occur.
Inspection 1: (Check of motor cables)
1. Turn off the key switch and disconnect the battery plug.
NG
2. Disconnect the motors cables from both the motor and the motor Motor cable defect
drive circuit.
3. Check the motor cables for its continuity.
OK
Inspection: (Check of motor drive circuit) *1
1. Turn off the key switch and disconnect the battery plug.
E0-2 error
2. Replace the pump motor drive circuit with the drive motor drive
occurs.
circuit. Pump motor defect
3. Connect the battery plug and turn on the key switch.
4. Check the error code that is displayed. (Ignore the error codes 32-1,
32-2 and 32-3.)
C0-2 error
occurs.
Pump motor drive circuit defect
(Note: Drive circuit that is originally the drive motor drive circuit before replacement)
sec04.book 91 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-91

*1 If the error codes C0-2 and E0-2 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. Pump motor drive circuit defect
2. Check the pump motor. (See page 5-14)

OK

Pump motor drive circuit defect

Inspection 1: Continuity check of motor cables

Check the cables for its continuity.
Turn off the key switch and 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
sec04.book 92 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-92

z 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.
sec04.book 93 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-93

z Error Code E1-2 (Pump motor current sensor over current)

Related portion

P4 P14
+ U
Pump
motor P15 Pump
V
N2 drive motor
- circuit P16
W

Probable cause:
(1) Pump motor defect
(2) Pump motor cable defect
(3) 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.
* 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 N2 and start operation after it has lowered below
3V.
Error code E1-2

Turn the key switch from OFF to ON to check for E0-2 E0-2 error occur
Proceed to identify the cause of E0-2
error.

E0-2 error does not occur

Turn off the key switch and disconnect the battery plug
and visually check the fastened or caulked portions of
E1-2 error
the motor cables for defects. (Refer to BEFORE
does not occur
TROUBLESHOOTING) Improper fastening of motor cable
After installing the cables, connect the battery plug and
turn the key switch ON. Sit in the seat and perform a
load handling operation (lift or tilt), checking for errors.

E1-2 error occur

Inspection 1: (Check of motor cables)

1. Turn off the key switch and disconnect the battery
plug. NG
Motor cable defect
2. Disconnect the motor cables from both the motor and
motor drive circuit.
3. Check motor cables for its continuity.

OK

1
sec04.book 94 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-94

Inspection: (Check of motor drive circuit)*1

1. Replace the pump motor drive circuit with the drive
motor drive circuit. E1-2 error occur
Pump motor defect
2. Connect the battery plug and turn on the key switch.
3. Check the error code that is displayed. (Ignore the
error codes 32-1 and 32-2)

C1-2 error occur

Pump motor drive circuit defect

(Note: Drive circuit that is originally the drive motor drive
circuit before replacement)

*1 If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
motor drive circuit.
Inspection: (Motor check)
1. Turn off the key switch and disconnect the battery NG
Pump motor defect
plug.
2. Check the pump motor. (See page 5-14)

OK

Pump motor drive circuit defect

Inspection 1: Continuity check of motor cables

Check the cables for its continuity.

Turn off the key switch and 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
sec04.book 95 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-95

z Error Code E2-1 (Pump motor temperature sensor increase abnormality)

Related portion

CN111-4 (88, STPM+) CN41-2

Pump motor Pump motor

drive circuit Temperature
CN111-5 (89, STPM) CN41-1 sensor

Probable cause:
Overheating (continuous overload operation)

Do not leave the vehicle standing in a hot place.

Error code E2-1

Inspection: Temperature check

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

[ANL] I/O TEMP/VOLT 2/4

Record the value of TPM.

Turn off the key switch and leave the vehicle standing
for a while (about 30 minutes).
The TPM temperature is 101°C or more and it has
lowered by 5°C or more compared to the TPM
temperature previously checked.
IInspection: Temperature check
Turn on the key switch and check the value of TPM
using the Analyzer menu.

[ANL] I/O TEMP/VOLT 2/4

TPM: The TPM temperature is 101°C or
Less than more and it has not lowered by 5°C or
101°C more compared to the TPM
temperature previously checked.

Proceed to identify the cause of E2-2.

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.)
sec04.book 96 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-96

z Error Code E2-2 (Pump motor temperature sensor abnormality)

Related portion

CN111-4 (88, STPM+) CN41-2

Pump motor Pump motor

drive circuit Temperature
CN111-5 (89, STPM) CN41-1 sensor

Probable cause:
(1) Connector contact defect
(2) Pump motor temperature sensor defect
(3) Pump motor temperature sensor harness defect
(4) Pump motor drive circuit defect

Error code E2-2

1. Turn off the key switch and disconnect the battery

plug and visually check inside the CN41 connector
E2-2 error
and the caulked portions of their wires for defects.
doen not occurs.
(Refer to BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN41 connector, connect the battery
plug, and then turn on the key switch to check for
errors.

E2-2 error occurs.

Inspection 1: (Check of temperature sensor unit)

1. Turn off the key switch and disconnect the battery
NG
plug. Temperature sensor defect
2. Disconnect the CN41 connector and check the
temperature sensor as a single unit.

OK

Inspection 2: (Harness check)

1. Turn off the key switch and disconnect the battery
NG
plug. Harness defect
2. Disconnect the CN111 and CN41 connectors and
check the harnesses for their continuities.

OK

Pump motor drive circuit defect

sec04.book 97 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-97

Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN41-2 and CN41-1)
Standard value Approx. 245 Ω and 600 kΩ
* Resistance changes (It is a standard as for the following value).

Resistance
Temperature
(CN50-2⇔CN50-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ
100°C Approx. 1 kΩ

Inspection 2: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug and the CN111 and CN41 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

CN111-4 to CN41-2 Continuity *1
CN111-5 to CN41-1 Continuity *1
CN41-1 to CN41-2 No continuity

*1: Connect CN41-1 and CN41-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN111-4 and CN111-5.
sec04.book 98 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-98

z Error Code E3-1 (Pump motor drive power circuit temperature sensor
abnormality)
Related portion

Pump motor
drive circuit

Temperature sensor

Probable 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.
sec04.book 99 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-99

z Error Code E8-1 (Pump motor speed (rotation) sensor open)

Related portion

P4 CN111-2 (81, SSP+) CN42-2

+
Pump motor Rotation
drive circuit sensor
N2 CN111-6 (82, SSP1) CN42-1
-

Probable cause:
(1) Connector contact defect (3) Rotation sensor defect
(2) Rotation sensor harness defect (4) 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.
* 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 N2 and start operation after it has lowered below 3 V.

1. Disconnect the battery plug and visually check inside the CN42 connector and the
No error
caulked portions of their wires for defects. (Refer to BEFORE
occurs.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN42 connector, connect the battery plug, and then turn on the key
switch to check for errors.
An error occurs.
Inspection 1: (Harness check)
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN111 and CN42 connectors and check the harnesses for their
continuities.
OK
Inspection: (Check of motor drive circuits)
1. Turn off the key switch and disconnect the battery plug. Other than
2. Disconnect the CN42 connector and connect the CN111 connector. 12 to 16 V Pump motor drive circuit
3. Connect the battery plug and turn on the key switch. defect
4. Measure the voltage between CN42-2 and N2.
12 to 16 V
Inspection: (Check of error code)
1. Turn off the key switch and disconnect the battery plug. E8-1 error
2. Disconnect the CN42 connector. occur. Pump motor drive circuit
3. Using SST 09232-13240-71, connect the CN42-1 and CN42-2. defect
4. Connect the battery plug and turn on the key switch.
5. Check the error code that appears.
E8-2 error occurs.
Inspection: (Check of motor drive circuits) Other than
1. Turn off the key switch and disconnect the battery plug. Approx.
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). 100 Ω 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 CN42-1 and N2 on the SST side.
Approx. 100 Ω
Rotation sensor defect
sec04.book 100 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-100

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN42, 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

CN111-2 to CN42-2 Continuity *1
CN111-6 to CN42-1 Continuity *1
CN111-2 to CN111-6 No continuity

*1: Connect CN42-1 and CN42-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN111-2 and CN111-6.
sec04.book 101 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-101

z Error Code E8-2 (Pump motor speed (rotation) sensor short)

Related portion

P4 CN111-2 (81, SSP+) CN42-2

+
Pump motor Rotation
drive circuit sensor
N2 CN111-6 (82, SSP1) CN42-1
-

Probable cause:
(1) Connector contact defect (3) Rotation sensor defect
(2) Rotation sensor harness defect (4) 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.
* 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 N2 and start operation after it has lowered below 3 V.

1. Turn off the key switch and disconnect the battery plug and visually check inside
No error
the CN42 connector and the caulked portions of their wires for defects. (Refer to
occurs.
BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN42 connector, connect the battery plug, and then turn on the key
switch to check for errors.
An error occurs.
Inspection 1: (Harness check)
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN111 and CN42 connectors and check the harnesses for their
continuities.
OK
Inspection: (Check of motor drive circuits)
1. Turn off the key switch and disconnect the battery plug. Other than
2. Disconnect the CN42 connector and connect the CN111 connector. 12 to 16 V Pump motor drive circuit
3. Connect the battery plug and turn on the key switch. defect
4. Measure the voltage between CN42-2 and N2.
12 to 16 V
Inspection: (Check of error code)
1. Turn off the key switch and disconnect the battery plug. E8-2 error
2. Disconnect the CN42 connector. occurs. Pump motor drive circuit
3. Using SST 09232-13240-71, connect the CN42-1 and CN42-2. defect
4. Connect the battery plug and turn on the key switch.
5. Check the error code that appears.
E8-1 error occurs.
Inspection: (Check of motor drive circuits) Approx.
1. Turn off the key switch and disconnect the battery plug. 100 Ω
2. Disconnect 09232-13130-71 from the CN42 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 CN42-1 and N2 on the SST side.
Approx. 100 Ω
Rotation sensor defect
sec04.book 102 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-102

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN42, 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

CN111-2 to CN42-2 Continuity *1
CN111-6 to CN42-1 Continuity *1
CN111-2 to CN111-6 No continuity

*1: Connect CN42-1 and CN42-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN111-2 and CN111-6.
sec04.book 103 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-103

z 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.

sec04.book 104 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-104

z Error Code EE-1, -2 (Display → Main controller communication error)

Related portion

CN103-3 (14, DGND) CN27-4

CN103-14 (16, D7V) CN27-5

Main
Display
controller CN103-11 (145, CAN1H) CN27-16

CN103-12 (146, CAN1L) CN27-15

Probable cause:
(1) Connector contact defect
(2) Harness defect
(3) Display defect
(4) Main controller defect

Error code EE-1, 2

* Identify the cause of F1-1 or F1-2.

sec04.book 105 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-105

z Error Code F1-1, -2 (Main controller → Display communication error)

Related portion

CN103-11 (145,CAN1H) CN27-16 (145, CAN1H)

Main
Multi-display
controller
CN103-12 (146,CAN1L) CN27-15 (146, CAN1L)

Probable cause:
(1) Connector contact defect (3) Main controller defect
(2) Harness defect (4) Display defect

Error code F1-1, F1-2

Turn off the key switch and disconnect the battery plug and visually
check inside CN103 to CN27 connectors and the caulked portion of
each wire for defects.
No error occurs.
(Refer to BEFORE TROUBLESHOOTING) Connector contact defect

Connect the connector, connect the battery plug and turn on the key
switch, and if an error occurs.

An error occurs. If the version of at least one motor drive circuit is

displayed
Inspection 1:
Main controller defect
Check the version information on the I/O monitor.
If the version of a motor drive
circuit is not displayed:
Inspection 2:
NG Harness (between CN103 and
Disconnect the CN103 and CN27 connectors and check the
CN27) defect
harnesses for their continuities.

OK

Display defect (*1)

*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.

Turn off the key switch and disconnect the battery plug, disconnect the CN27 and CN103 connectors and check
the harnesses for their continuities.

Portions to be checked Standard

CN103-11 to CN27-16 Continuity (Approx. 0 Ω)
CN103-12 to CN27-15 Continuity (Approx. 0 Ω)
CN27-15 to CN27-16 No continuity (Not 0 Ω)
sec04.book 106 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-106

z 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.

sec04.book 107 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-107

z Error Code FF-1, -2 (Power supply circuit over current)

Related portion

CN103-14 (16,D7V) CN27-5

DISPLAY
CN103-3 (14, DGND) CN27-4
Main
controller CN103-13 (311, SSTR+) CN3-1

Steering-wheel
angle sensor
CN103-6 (51, LS-) CN3-2

Probable cause:
(1) Connector contact defect
(2) Display or steering angle sensor defect
(3) Harness defect
(4) Main controller defect

Error code FF-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN27 connector and visually check inside the connector and the A screen is displayed.
caulked portion of its wire for defects. (Refer to BEFORE
Connector contact defect
TROUBLESHOOTING)
2. Connect the connector, connect the battery plug, and then turn on
the key switch to see if a screen is displayed.

No screen is displayed.

Inspection: Check of display

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN27. Approx. 7 V
3. Connect the battery plug and turn on the key switch. Display defect
4. Measurement of voltage
Measure the voltage between the CN27-5 and CN27-4 connectors
on the harness side.

0V

Inspection 1: Harness check

NG
1. Turn off the key switch and disconnect the battery plug.
Harness defect
2. Disconnect the CN103 connector and check the harnesses for their
continuities.

OK

Main controller defect

sec04.book 108 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-108

Inspection 1: Check each harness for its continuity.

Disconnect the battery plug, disconnect the CN27 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

CN103-14 to CN27-5 Continuity
CN103-3 to CN27-4 Continuity
CN27-5 to CN27-4 No continuity

Error code FF-2

1. Disconnect the battery plug, disconnect the CN3 connector, and

visually check inside the connector and the caulked portion of its FF-2 error does not occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN3 connector, connect the battery plug, and then turn
on the key switch to check for errors.

FF-2 error occurs.

Inspection: Check of steering angle sensor

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN3. Approx. 15 V
3. Connect the battery plug and turn on the key switch. Steering angle sensor defect
4. Measurement of voltage
Measure the voltage between the CN3-1 and CN3-2 connectors on
the harness side.

0V

Inspection 2: Harness check

NG
1. Turn off the key switch and disconnect the battery plug.
Harness defect
2. Disconnect the CN103 connector and check the harnesses for their
continuities.

OK

Main controller defect

Inspection 2: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN3 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 CN3-1 Continuity
CN103-6 to CN3-2 Continuity
CN3-1 to CN3-2 No continuity
sec04.book 109 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-109

z Error Code 32-1 (Drive motor drive circuit EEPROM abnormality)

Related portion

CN110-8 (151, 0SETD)

Drive motor drive circuit CN110-9 NC

CN110-10 (151, 0SETD2)

Probable cause:
(1) Connector contact defect
(2) Drive motor drive circuit harness defect
(3) Drive motor drive circuit 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-5 or 6 is also displayed, perform troubleshooting with priority given to AD-5 or 6.

Error code 32-1

1. Disconnect the battery plug, disconnect the CN110 connector, and

32-1
visually check inside the connector and the caulked portion of its
error does not occur. Drive motor drive circuit
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.
32-1
error occurs.
Drive motor drive circuit defect
sec04.book 110 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-110

z Error Code 32-3 (Pump motor drive circuit EEPROM abnormality)

Related portion

CN111-8 (152, 0SETP)

Pump motor drive circuit CN111-9 (152, SETP)

CN111-10 NC

Probable cause:
(1) Connector contact defect
(2) Pump motor drive circuit harness defect
(3) Pump motor drive circuit defect

*: When a drive motor drive circuit is installed as a pump motor drive circuit, the 32-3 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.

If AD-1 or 2 is also displayed, perform troubleshooting with priority given to AD-1 or 2.

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)
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
sec04.book 111 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-111

z Error code 52-1,-2,-3 Yaw rate sensor abnornality

Related portion

CN104-13 (321,SYR+) CN34-1

CN103-27 (322,SYR) CN34-3
Main contoroller Yaw rate sensor
CN104-11 (323,SYR-) CN34-2

Probable cause:
(1) Connector contact defect
(2) Yaw rate sensor harness defect
(3) Yaw rate sensor defect
(4) Main controller defect
Error code 52-1

1. Disconnect the battery plug, disconnect the CN34 connector, and

visually check inside the connector and the caulked portion of its 52-1error does
wire for defects. (Refer to BEFORE TROUBLESHOOTING) not occur.
Connector contact defect
2. Connect the CN34 connector, connect the battery plug, turn on the
key switch, and then raise the lift from its lowermost to uppermost
position to see if an error occurs.

52-1error occurs

Inspection: Check of the yaw rate sensor

1. Turn off the key switch and disconnect the battery plug. 52-2error
2. Disconnect the CN34 connector and connect CN34-1 to CN34-2 on occurs.
Yaw rate sensor defect
the harness side through SST 09232-13130-71.
3. Connect the the battery plug, and then turn on the key switch to
check for errors.

52-1error occurs

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN103 and CN104 connectors and check the
harnesses for their continuities.

OK

Main controller defect

sec04.book 112 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-112

Error code 52-2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN34 connector, and visually check inside the connector and 52-2,-3error
the caulked portion of its wire for defects. (Refer to BEFORE does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN34 connector, connect the battery plug and turn on
the key switch to check for erroes.

52-2,-3error occurs

Inspection: Check of the yaw rate sensor.

52-1error
1. Turn off the key switch and disconnect the battery plug.
occurs.
2. Disconnect the CN34 connector. Yaw rate sensor defect
3. Connect the the battery plug, and then turn on the key switch to
check for errors.

52-2,-3error occurs

Inspection 2: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN103 and CN104 connectors and check the
harnesses for their continuities.

OK

Main controller defect

Inspection 1,2: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect CN34, CN103 and CN104 and perform the
check without connecting SST.

Portions to be checked Standard Point

CN104-13 to CN34-1 Continuity 52-1 *1
CN103-27 to CN34-3 Continuity 52-1 *1
CN104-11 to CN34-2 Continuity 52-2,-3 *2
CN34-1 to CN34-2 No continuity 52-1
CN34-1 to CN34-3 No continuity 52-2,-3
CN34-2 to CN34-3 No continuity 52-1,-3

*1: Connect CN34-1 and CN34-3 on the harness side through 09230-13700-71 and check if there is continuity
between CN104-13 and CN103-27.
*2: Connect CN34-3 and CN34-2 on the harness side through 09230-13700-71 and check if there is continuity
between CN103-27 and CN104-11.
sec04.book 113 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-113

z Error Code 54-1,-2,-3,-4 (Swing lock solenoid abnormality)

Related portion

CN103-1 (327, SLSW+) CN43-1

CN103-2 (328, SLSW-) CN43-2

CN103-5 (N2, N2)

Main Swing lock
controller CN104-4 (N2, N2) solenoid

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect
(2) Swing lock solenoid harness defect
(3) Swing lock solenoid defect
(4) 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

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN43 connector, and visually check inside the connector and 54-1
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN43 connector, connect the battery plug, and then
turn on the key switch to see if an error occurs.
54-1 error occurs. 54-4
error occurs. Track down the
Check if the 54-4 error has also occurred.
cause of the 54-4 error.
54-4 error does not occur.
Inspection: Check of swing lock solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN43 connector and measure the resistance of the
swing lock solenoid
(Resistance between CN43-1 and CN43-2).
Standard value: 4 to 11 Ω (approx. 6 Ω at 20°C )

Inspection 1: Harness check

Disconnect the CN103 and CN104 connectors and check the
harnesses for their continuities.

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
Main controller defect
sec04.book 114 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-114

Error code 54-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN43 connector, and visually check inside the connector and 54-2
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN43 connector, connect the battery plug, and then
turn on the key switch to check for errors.
54-2 error occurs.
54-3
Check if the 54-3 error has also occurred. error occurs. Track down the
cause of the 54-3 error.
54-3 error does not occur.
Inspection: Check of swing lock solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN43 connector and measure the resistance of the NG
Swing lock solenoid defect
swing lock solenoid
(Resistance between CN43-1 and CN43-2).
Standard value: 4 to 11 Ω (approx. 6 Ω at 20°C )
OK
Inspection 1: Harness check
NG
Disconnect the CN103 and CN104 connectors and check the Harness defect
harnesses for its continuities.
OK
Main controller defect

Error code 54-3

Turn off the key switch and disconnect the battery plug, disconnect the
CN43 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of swing lock solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN43 connector and measure the resistance of the
swing lock solenoid
(Resistance between CN43-1 and CN43-2).
Standard value: 4 to 11 Ω (approx. 6 Ω at 20°C )

Inspection 1: Harness check

Disconnect the CN103 and CN104 connectors and check the
harnesses for its continuities.

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
Main controller defect
sec04.book 115 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-115

Error code 54-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN43 connector, and visually check inside the connector and
the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
2. Connect the CN43 connector, connect the battery plug, and then
turn on the key switch.

Forcibly turn off the output of the swing lock solenoid, using Active 54-4
Test, to see if an error occurs. error does not occur.
Connector contact defect
[ANL] ACTIVE TEST 1/3 SWING SOL
54-4 error occurs.
Inspection: Check of swing lock solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN43 connector and measure the resistance of the NG
Swing lock solenoid defect
swing lock solenoid
(Resistance between CN43-1 and CN43-2).
Standard value: 4 to 11 Ω (approx. 6 Ω at 20°C )
OK
Inspection 1: Harness check
NG
Disconnect the CN103 and CN104 connectors and check the Harness defect
harnesses for its continuities.
OK
Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN43, 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 CN43-1 Continuity 54-4 *
CN103-2 to CN43-2 Continuity 54-4 *
CN103-1 to CN104-4 No continuity 54-4
CN103-2 to CN104-4 No continuity 54-4
CN43-1 to CN43-2 No continuity 54-1,2,3,4
CN43-2 to P1 No continuity 54-1,2,3,4
CN43-2 to P4 No continuity 54-1,2,3,4

* Connect the CN43 connector and measure the resistance between CN103-1 and CN103-2, to see if it falls
between 4 and 11 Ω (approx. 6 Ω at 20°C )
sec04.book 116 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-116

z Error Code 61-1,-2 (Load sensor abnormality)

Related portion

CN104-12 (58, SPLF+) CN7-1

CN103-29 (59, SPLF) CN7-2

Main
Load sensor
controller
CN101-32 (51, POT-) CN7-3

Probable cause:
(1) Connector contact defect
(2) Load sensor defect
(3) Load sensor harness defect
(4) Main controller defect

Error code 61-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN7 connector, and visually check inside the connector and the 61-1
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN7 connector, connect the battery plug, and then turn
on the key switch to check for errors.
61-1 error occurs.
Inspection: Check of load sensor
1. Turn off the key switch and disconnect the battery plug. 61-2
2. Disconnect the CN7 connector and connect CN7-1 to CN7-2 on the error occurs.
Load sensor defect
harness side through SST09230-13700-71.
3. Connect the battery plug and turn on the key switch.
Check the error code.
61-1 error occurs.
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for its continuities.
OK
Main controller defect
sec04.book 117 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-117

Error code 61-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN7 connector, and visually check inside the connector and the 61-2
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN7 connector, connect the battery plug, and then turn
on the key switch to check for errors.
61-2 error occurs.
Inspection: Check of load sensor
61-1
1. Turn off the key switch and disconnect the battery plug.
error occurs.
2. Disconnect the CN7 connector. Lord sensor defect
3. Connect the battery plug and turn on the key switch.
Check the error code.
61-2 error occurs.
Inspection 2: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.
OK
Main controller defect

Inspection 1, 2: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN7, 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 CN7-1 Continuity 61-1 *1
CN103-29 to CN7-2 Continuity 61-1 *1
CN101-32 to CN7-3 Continuity 61-2 *2
CN7-3 to CN7-2 No continuity 61-1
CN7-3 to CN7-1 No continuity 61-1
CN7-2 to CN7-1 No continuity 61-2

*1: Connect CN7-1 and CN7-2 on the harness side through 09230-13700-71 and check
if there is continuity between CN104-12 and CN103-29.
*2: Connect CN7-2 and CN7-3 on the harness side through 09230-13700-71 and check
if there is continuity between CN103-29 and CN101-32.
sec04.book 118 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-118

z Error Code 62-1,-2 (Tilt angle sensor abnormality)

Related portion

CN101-20 (57, VRTA+) CN26-1

CN103-17 (56, VRTA) CN26-2

Main Tilt angle
controller sensor
CN101-32 (51, POT-) CN26-3

Probable cause:
(1) Connector contact defect
(2) Tilt angle sensor defect
(3) Tilt angle sensor harness defect
(4) Main controller defect

Error code 62-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN26 connector, and visually check inside the connector and 62-1
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN26 connector, connect the battery plug, and then
turn on the key switch to check for errors.
62-1 error occurs.
Inspection: Check of tilt angle sensor
1. Turn off the key switch and disconnect the battery plug. 62-2
2. Disconnect the CN26 connector and connect CN26-1 and CN26-2 error occurs.
Tilt angle sensor defect
on the harness side through 09232-13130-71.
3. Connect the battery plug and turn on the key switch.
Check the error code.
62-1 error occurs.
Inspection 1: Harness check
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.
OK
Main controller defect
sec04.book 119 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-119

Error code 62-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN26 connector, and visually check inside the connector and 62-2
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN26 connector, connect the battery plug, and then
turn on the key switch to check for errors.
62-2 error occurs.
Inspection: Check of tilt angle sensor
62-1
1. Turn off the key switch and disconnect the battery plug.
error occurs.
2. Disconnect the CN26 connector. Tilt angle sensor defect
3. Connect the battery plug and turn on the key switch.
Check the error code.
62-2 error occurs.
Inspection 2: Harness check
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.
OK
Main controller defect

Inspection 1, 2: Check each harness for its continuity.

Turn off the key switch and 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

CN101-20 to CN26-1 Continuity 62-1 *1
CN103-17 to CN26-2 Continuity 62-1 *1
CN101-32 to CN26-3 Continuity 62-2 *2
CN26-3 to CN26-2 No continuity 62-1
CN26-3 to CN26-1 No continuity 62-1
CN26-2 to CN26-1 No continuity 62-2

*1: Connect CN26-1 and CN26-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-20 and CN103-17
*2: Connect CN26-2 and CN26-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-17 and CN101-32
sec04.book 120 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-120

z Error Code 63-1,-2,-3 (Tilt switch abnormality)

Related portion
Tilt switch
CN102-23 (61,SWTR) CN9-3

CN102-22 (62,SWTF) CN9-1

Main
controller CN103-6 (51,LS-) CN9-2

CN9-4

Probable cause:
(1) Connector contact defect
(2) Tilt switch adjustment defect.
(3) Tilt switch defect
(4) Tilt switch harness defect
(5) Main controller defect

Error code 63-1, -2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN9 connector, and visually check inside the connector and the A6-3
caulked portion of its wire for defects. error occurs. Track down the cause of the
(Refer to BEFORE TROUBLESHOOTING) A6-3 error.
2. Connect the CN9 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
A6-3 error does not occur.
63-1
• Tilt switch defect
error occurs.
Operate the tilt lever and check the error code. • Tilt switch installation portion
defect.
63-1 error does not occur.
[ANL] I/O M.HANDLING 6/8
Use the analyzer to check the values for the SWTF (forward tilt switch) Either switch
and SWTR (backward tilt switch). displaying “1”
Check the status of the switches when the tilt lever is operated in
either direction and returned to center.
Both switches displaying “0” after
OK
operation repeated several times

Stored in diagnosis memory

Memory 63-1 Memory 63-2, 63-3

The forward and backward tilt The tilt lever has been turned ON
lever switches turned ON at te for two minutes or more in the
same time in the past. past.(Normal)
(Check and adjustment of eath
switch installation)
sec04.book 121 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-121

z Error Code 64-1,-2,-3,-4 (Lift lower lock solenoid abnormality)

Related portion

CN101-1 (3, SOLLU+) CN8-1

CN102-16 (4, SLLL-) CN8-2

CN103-5 (N2, N2)

Main Lift lock
controller CN104-4 (N2, N2) solenoid

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect
(2) Lift lock solenoid harness defect
(3) Lift lock solenoid defect
(4) Main controller defect

If the 64-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code 64-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN8 connector, and visually check inside the connector and the 64-4
caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 64-4 error.
2. Connect the CN8 connector, connect the battery plug, and then turn
on the key switch to check for errors.
No error occurs.
64-1
error does not occur.
Lower the lift to see if an error occurs. Connector contact defect

64-1 error occurs.

Inspection: Check of lift lock solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN8 and measure the resistance of the
lift lock solenoid
(Resistance between CN8-1 and CN8-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

Portion where a problem was found during a check of the lift lock solenoid or its harness.
Main controller defect
sec04.book 122 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-122

Error code 64-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN8 connector, and visually check inside the connector and the 64-3
caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 64-3 error.
2. Connect the CN8 connector, connect the battery plug, and then turn
on the key switch to check for errors.
No error occurs. 64-2
error does not occur.
Lower the lift to see if an error occurs. Connector contact defect

64-2 error occurs.

Inspection: Check of lift lock solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN8 and measure the resistance of the NG
Lift lock solenoid defect
lift lock solenoid
(Resistance between CN8-1 and CN8-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )
OK
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.
OK
Main controller defect

Error code 64-3

Turn off the key switch and disconnect the battery plug, disconnect the
CN8 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of lift lock solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN8 and measure the resistance of the
lift lock solenoid
(Resistance between CN8-1 and CN8-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

Portion where a problem was found during a check of the lift lock solenoid or its harness.
Main controller defect
sec04.book 123 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-123

Error code 64-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN8 connector, and visually check inside the connector and the 64-4
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN8 connector, connect the battery plug, and then turn
on the key switch to check for errors.
64-4 error occurs.
Inspection: Check of lift lock solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN8 and measure the resistance of the NG
Lift lock solenoid defect
lift lock solenoid
(Resistance between CN8-1 and CN8-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )
OK
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.
OK
Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN8, 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 CN8-1 Continuity 64-4 *
CN102-16 to CN8-2 Continuity 64-4 *
CN101-1 to CN104-4 No continuity 64-4
CN102-16 to CN104-4 No continuity 64-4
CN8-2 to CN8-1 No continuity 64-1,2,3,4
CN8-2 to P1 No continuity 64-1,2,3,4
CN8-2 to P4 No continuity 64-1,2,3,4

* Connect the CN8 connector and measure the resistance between CN101-1 and CN102-16 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C )
sec04.book 124 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-124

z Error Code 65-1,-2,-3,-4 (Tilt control solenoid abnormality)

Related portion

CN101-2 (6, SLTFB+) CN14-1

CN102-19 (7, SLTFL-) CN14-2

CN103-5 (N2, N2)

Main
Tilt solenoid
controller CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect
(2) Tilt control solenoid defect
(3) Tilt control solenoid harness defect
(4) Main controller defect

If the 65-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code 65-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN14 connector, and visually check inside the connector and 65-4
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 65-4 error.
2. Connect the CN14 connector, connect the battery plug, and then
turn on the key switch to check for errors.
No error occurs. 65-1
error does not occur.
Tilt the mast forward to check again if an error occurs. Connector contact defect

65-1 error occurs.

Inspection: Check of tilt control solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN14 and measure the resistance of the
tilt control solenoid
(Resistance between CN14-1 and CN14-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

Portion where a problem was found during a check of the tilt control solenoid or its harness.
Main controller defect
sec04.book 125 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-125

Error code 65-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN14 connector, and visually check inside the connector and 65-3
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 65-3
2. Connect the CN14 connector, connect the battery plug, and then
turn on the key switch to check for errors.
No error occurs. 65-2
error does not occur.
Tilt the mast forward to check again if an error occurs. Connector contact defect

65-2 error occurs.

Inspection: Check of tilt control solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN14 and measure the resistance of the NG
Tilt control solenoid defect
tilt control solenoid
(Resistance between CN14-1 and CN14-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )
OK
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.
OK
Main controller defect

Error code 65-3

Turn off the key switch and disconnect the battery plug, disconnect the
CN14 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of tilt control solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN14 and measure the resistance of the
tilt control solenoid
(Resistance between CN14-1 and CN14-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

Portion where a problem was found during a check of the tilt control solenoid or its harness.
Main controller defect
sec04.book 126 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-126

Error code 65-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN14 connector, and visually check inside the connector and 65-4
the caulked portion of its wire for defects. (Refer to BEFORE error not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN14 connector, connect the battery plug, and then
turn on the key switch to check for errors.
65-4 error occurs.
Inspection: Check of tilt control solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN14 and measure the resistance of the NG
Tilt control solenoid defect
tilt control solenoid
(Resistance between CN14-1 and CN14-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )
OK
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.
OK
Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN14, 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

CN101-2 to CN14-1 Continuity 65-4 *
CN102-19 to CN14-2 Continuity 65-4 *
CN101-2 to CN104-4 No continuity 65-4
CN102-19 to CN104-4 No continuity 65-4
CN14-2 to CN14-1 No continuity 65-1,2,3,4
CN14-2 to P1 No continuity 65-1,2,3,4
CN14-2 to P4 No continuity 65-1,2,3,4

* Connect the CN14 connector and measure the resistance between CN101-2 and CN102-19 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C)
sec04.book 127 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-127

z Error Code 66-1 (Outside matching value range for tilt angle error)
Related portion

Main
controller

Probable cause:
(1) The tilt horizontal angle matching value is outside the specified matching range.
(2) The forward tilt angle matching value is outside the specified matching range.
(3) 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 66-1error does not occur.
the load sensor. Use the device as it is.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION / MACHING
After the completion of
matching,
66-1 error occurs.
Main controller defect
sec04.book 128 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-128

z Error Code 67-1 (Lifting height switch open)

Related portion
Vmast, mast height: ~H2500

CN102-10 (51, LS-)

Main CN104-22 (90, SH1)
controller
CN103-24 (91, SH2-1)
N.C.

Others:

Lifting height
CN102-10 (51, LS-) CN96-1 switch

CN104-22 (90, SH1) CN96-2

Main
controller
CN103-24 (91, SH2-1) CN96-3

Probable cause:
(1) Connector contact defect (3) Lifting height switch defect
(2) Harness defect (4) Main controller defect

Error code 67-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN96 connector, and visually check inside the connector and
67-1
the caulked portion of its wire for defects. (Refer to BEFORE
error does not occur.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN95 connector, connect the battery plug, turn on the
key switch, and then raise the lift from its lowermost to uppermost
position to see if an error occurs.
67-1 error occurs.
Inspection: Check of lifting switch input value
Turn on the key switch and check the value of SH using the Analyzer SH: 000
1
menu.
[ANL] I/O M.HANDLING 2/8
SH: Other than 000
Inspection: Check of lifting switch input value
1. Lower the lift to its lowermost position.
2. Turn off the key switch and disconnect the battery plug.
SH: 000
3. Disconnect the CN96 connector. Lifting height switch defect
4. Turn on the key switch and check the value of SH using the
Analyzer menu.
[ANL] I/O M.HANDLING 2/8
SH: Other than 000
A
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4-129

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
Main controller defect

Is the lifting height switch equipped? NO

2

YES

Lifting height switch arm is released.

Inspection: Check of mast lifting height (High lifting height)
Visually check the state of the lifting switch when an error is detected. 3

Lifting height switch arm is held.

(Low lifting height)
Inspection: Check of the lifting height switch as a single unit.
1. Keep the conditions under which the error occurs.
2. Turn off the key switch and disconnect the battery plug.
NG
3. Disconnect the CN96. Lifting height switch defect
4. Check for continuity on the switch side.
CN96-1 to CN96-2 Continuity
CN96-1 to CN96-3 Continuity
OK
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
Main controller defect

Inspection 2: Harness check

NG
Disconnect the CN102, CN103 and CN104 connectors and check the Harness defect
harnesses for their continuities.
OK
Main controller defect
sec04.book 130 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-130

Inspection: Check of the lifting height switch as a single unit.

1. Keep the conditions under which the error occurs.
2. Turn off the key switch and disconnect the battery plug.
NG
3. Disconnect the CN96 connector. Lifting height switch defect
4. Check for continuity on the switch side.
CN96-1 to CN96-2 No continuity
CN96-1 to CN96-3 Continuity
OK
Inspection 1: Harness check
NG
Disconnect the CN102,103 and CN104 connectors and check the Harness defect
harnesses for their continuities.
OK
Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN96, 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 CN96-1 Continuity
CN104-22 to CN96-2 Continuity
CN103-24 to CN96-3 Continuity
CN96-1 to CN96-2 No continuity
CN96-1 to CN96-3 No continuity
CN96-2 to CN96-3 No continuity

Inspection 2: Check each harness for its continuity.

Perform this check with the 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 CN104-22 Continuity
CN104-22 to CN103-24 No continuity
CN103-24 to CN102-10 No continuity
sec04.book 131 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-131

z Error Code 68-1,-2,-3 (Lifting height sensor abnormality)

Related portion

CN101-32 (51, POT-) CN97-1

CN101-24 (219, VRH+) CN97-2

Main Lifting height
controller sensor
CN103-28 (220, VRH) CN97-3

Probable cause:
(1) Lifting height sensor defect
(2) Connector contact defect
(3) Lifting height sensor harness defect
(4) Main controller defect

Error code 68-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN97 connector, and visually check inside the connector and
68-1 error does not
the caulked portion of its wire for defects. (Refer to BEFORE
occur.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN97 connector, connect the battery plug, and then
turn on the key switch to check how the vehicle operates and if an
error occurs.
68-1 error occurs.
Inspection: Check of lifting height sensor as a single unit
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect CN97 and connect CN97-2 to CN97-3 on the harness 68-2 error occurs.
Lifting height sensor defect
side through 09238-13130-71.
3. Connect the battery plug and turn on the key switch.
Check the error code.
68-1 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.
OK
Main controller defect
sec04.book 132 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-132

Error code 68-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN97 connector, and visually check inside the connector and
68-2
the caulked portion of its wire for defects. (Refer to BEFORE
error does not occur.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN97 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.
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 CN97 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.
OK
Main controller defect

Error code 68-3

Visual check of lifting height sensor

• Is the wire broken? NG
Lifting height sensor defect
• Is the wire wound around or pulled out of the reel correctly when the
lift is raised to or lowered from an elevated position?
OK
1. Turn off the key switch and disconnect the battery plug, disconnect
the CN97 connector, and visually check inside the connector and
the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
2. Connect the CN97 connector, connect the battery plug, and then
turn on the key switch.

Inspection: Check of lifting height sensor input value

Raise the lift to an elevated position.
Change in VRH value:
Then, further raise the lift by 1 m from this position and check the
0.5 or more Normal
change in the value of VRH at that time.
(Connector contact defect)
Turn on the key switch and check the value of VRH using the Analyzer
menu.
[ANL] I/O M.HANDLING 2/8
Change in VRH value:
Less than 0.5
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.
OK
Main controller defect
sec04.book 133 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-133

Inspection 1: Harness continuity/shorts

Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN97, CN101 and CN103 and perform the
check without connecting SST.

Portions to be checked Standard Point

CN101-24 to CN97-2 Continuity 68-1, 3 *1
CN103-28 to CN97-3 Continuity 68-1, 3 *1
CN101-32 to CN97-1 Continuity 68-2, 3 *2
CN97-1 to CN97-3 No continuity 68-1, 3
CN97-2 to CN97-1 No continuity 68-1, 3
CN97-3 to CN97-2 No continuity 68-2, 3

*1: Connect CN97-2 and CN97-3 on the harness side through 09238-13130-71 and check if there is continuity
between CN101-24 and CN103-28.
*2: Connect CN97-3 and CN97-1 on the harness side through 09238-13130-71 and check if there is continuity
between CN103-28 and CN101-32.
sec04.book 134 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-134

z Error Code 71-1,-2,-3 (Tire angle sensor abnormality)

Related portion

CN101-23 (316, VRTRA+) CN94-3

CN102-31 (317, VRTRA) CN94-2

Main Tire angle
controller sensor
CN102-26 (51, POT-) CN94-1

Probable cause:
(1) Connector contact defect
(2) Tire angle sensor harness defect
(3) Tire angle sensor defect
(4) Tire angle sensor joint, rear axle link system defect
(5) Main controller defect

Error code 71-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN94 connector, and visually check inside the connector and
71-1
the caulked portion of its wire for defects. (Refer to BEFORE
error does not occur.
TROUBLESHOOTING) 71-1 error occurs.
2. Connect the CN94 connector, connect the battery plug, and then
turn on the key switch to check how the steering operates and if an
error occurs.
71-1 error occurs.
Inspection: Check of tire angle sensor
1. Turn off the key switch and disconnect the battery plug. 71-2
2. Disconnect the CN94connector and connect CN94-3 and CN94-2 error occurs.
Tire angle sensor defect
on the harness side.
3. Connect the battery plug and turn on the key switch to check the
error code.
71-1 error occurs.
Inspection: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the battery plug and the CN101 and CN102 connectors
and check the harness for their continuities.
OK
Main controller defect
sec04.book 135 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-135

Error code 71-2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN94 connector, and visually check inside the connector and
71-2, 71-3
the caulked portion of its wire for defects. (Refer to BEFORE
error does not occur.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN94 connector, connect the battery plug, and then
turn on the key switch to check how the steering operates and if an
error occurs.
71-2 or 71-3 error occurs.
Inspection: Check of tire angle sensor
71-1
1. Turn off the key switch and disconnect the battery plug. Tire angle sensor defect
error occurs.
2. Disconnect the CN94 connector. Tire angle sensor installation
3. Connect the battery plug and turn on the key switch to check the portion defect.
error code.
71-2 error occurs or
no error occurs.
Inspection 2: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101 and CN102 connectors and check the
harnesses for their continuities.
OK
Main controller defect

Inspection 1, 2: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug and the CN94, 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 CN94-3 Continuity 71-1 *1
CN102-31 to CN94-2 Continuity 71-1 *1
CN102-26 to CN94-1 Continuity 71-2 *2
CN94-1 to CN94-2 Continuity 71-1
CN94-1 to CN94-3 Continuity 71-1
CN94-2 to CN94-3 Continuity 71-2

*1: Connect CN94-3 and CN94-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-23 and CN102-31.
*2: Connect CN94-1 and CN94-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN110-26 and CN110-31.
sec04.book 136 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-136

z Error Code 72-1,-2,-3,-4 (Steering-wheel angle sensor abnormality)

Related portion

CN103-13 (311, SSTR+) CN3-1

CN104-30 (312, SSTR1) CN3-3

Main CN104-31 (313, SSTR2) CN3-4 Steering

controller angle sensor
CN104-24 (314, SSTRC) CN3-5

CN102-10 (51, LS-) CN3-2

Probable cause:
(1) Connector contact defect
(2) Steering angle sensor harness defect
(3) Steering angle sensor defect
(4) 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. Turn off the key switch and disconnect the battery plug, disconnect
the CN3 connector, and visually check inside the connector and the 72-1
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN3 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.
Inspection: Checking the state, turning the steering wheel
Turn on the key switch and check the value of SSTR using the SSTR: 1**
Analyzer menu. (* represents either 0 or 1.)
[ANL] I/O STEERING 1/1
SSTR: 0**
(* represents either 0 or 1.)
A
Turn off the key switch, disconnect the battery plug and disconnect the
CN3 connector. After that, connect CN3-2 to CN3-3 (on the main
harness side) through 09232-13130-71 to short them, and then
connect the battery plug and turn on the key switch.

B
sec04.book 137 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-137

SSTR: 1**
Inspection: Checking the state, turning the steering wheel (* represents either 0
Turn on the key switch and check the value of SSTR using the or 1.) Steering angle sensor
Analyzer menu. defect
[ANL] I/O STEERING 1/1
SSTR: 0**
(* represents either 0 or 1.)
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.
OK
Main controller defect

Disconnect the CN104 connector and disconnect the CN3 connector.

Connect the battery plug and turn on the key switch.

SSTR: 0**
Inspection: Checking the state, turning the steering wheel
(* represents either 0
or 1.)
Turn on the key switch and check the value of SSTR using the Steering angle sensor defect
Analyzer menu.
[ANL] I/O STEERING 1/1

SSTR: 1**
(* represents either 0 or 1.)
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.
OK
Main controller defect
sec04.book 138 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-138

Error code 72-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN3 connector, and visually check inside the connector and the 72-2
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING.)
2. Connect the CN3 connector, connect the battery plug, turn on the
key switch, and turn the steering wheel to see if an error occurs.
72-2 error occurs
Inspection: Checking the state, turning the steering wheel
SSTR: *1*
Turn on the key switch and check the value of SSTR using the (* represents either 0
Analyzer menu. or 1.)
[ANL] I/O STEERING 1/1
SSTR: *0* C
(* represents either 0 or 1.)
Turn off the key switch, disconnect the battery plug and disconnect the
CN3 connector. After that, connect CN3-2 to CN3-4 (on the main
harness side) through 09232-13130-71 to short them, and then
connect the battery plug and turn on the key switch.

SSTR: *1*
Inspection: Checking the state, turning the steering wheel
(* represents either 0
or 1.)
Turn on the key switch and check the value of SSTR using the Steering angle sensor defect
Analyzer menu.
[ANL] I/O STEERING 1/1

SSTR: *0*
(* represents either 0 or 1.)
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.
OK
Main controller defect

Disconnect the CN104 connector and disconnect the CN3 connector.

Connect the battery plug and turn on the key switch.
SSTR: *0*
Inspection: Checking the state, turning the steering wheel (* represents either 0
Turn on the key switch and check the value of SSTR using the or 1.) Steering angle sensor
Analyzer menu. defect
[ANL] I/O STEERING 1/1
SSTR: *1*
(* represents either 0 or 1.)
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.
OK
Main controller defect
sec04.book 139 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-139

Error code 72-3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN3 connector, and visually check inside the connector and the 72-3
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN3 connector, connect the battery plug, turn on the
key switch, and turn the steering wheel to see if an error occurs.
72-3 error occurs.
Inspection: Checking the state, turning the steering wheel SSTR: **1
Turn on the key switch and check the value of SSTR using the (* represents either 0
Analyzer menu. or 1.)
[ANL] I/O STEERING 1/1
SSTR: **0 E
(* represents either 0 or 1.)
Turn off the key switch, disconnect the battery plug and disconnect the
CN3 connector. After that, connect CN3-2 to CN3-5 (on the main
harness side) through 09232-13130-71 to short them, and then
connect the battery plug and turn on the key switch.
SSTR: **1
Inspection: Checking the state, turning the steering wheel (* represents either 0
Turn on the key switch and check the value of SSTR using the or 1.)
Steering angle sensor defect
Analyzer menu.
[ANL] I/O STEERING 1/1
SSTR: **0
(* represents either 0 or 1.)
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.
OK
Main controller defect
sec04.book 140 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-140

Turn off the key switch and disconnect the CN104 connector and
disconnect the CN3 connector.
Connect the battery plug and turn on the key switch.

Inspection: Checking the state, turning the steering wheel SSTR: **0
Turn on the key switch and check the value of SSTR using the (* represents either 0 or 1.)
Analyzer menu. Steering angle sensor defect
[ANL] I/O STEERING 1/1
SSTR: **1
(* represents either 0 or 1.)
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.
OK
Main controller defect

Error code 72-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN3 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE 72-4
TROUBLESHOOTING) error does not occur.
Connector contact defect
2. Connect the CN3 connector, connect the battery plug, turn on the
key switch, and turn the steering wheel to see if an error occurs.
(If the steering wheel cannot be turned easily, perform this check
with the direction switch in the Forward or Reverse position.)
72-4 error occurs.
Inspection: Check of sensor supply voltage
1. Turn off the key switch and disconnect the battery plug. Approx. 15 V
2. Disconnect the CN3 connector.
3. Connect the battery plug and turn on the key switch.
4. Check the supply voltage to the sensor.
CN3-1 ⇔ CN3-2
Approx. 0 V
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
2. Disconnect the CN104 connectors and check the harnesses for
their continuities.
OK Main harness defect
Main controller defect

Turn off the key switch, disconnect the battery plug, and then connect CN3.
Connect the battery plug and turn on the key switch.

Track down the cause of 72-1 (SSTR1).

Proceed to identify the cause of 72-2 (SSTR2).
sec04.book 141 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-141

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect CN3, 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

CN104-30 to CN3-3 Continuity 72-1 *1
CN104-31 to CN3-4 Continuity 72-2 *2
CN104-24 to CN3-5 Continuity 72-3 *3
CN103-13 to CN3-1 Continuity 72-4 *4
CN102-10 to CN3-2 Continuity 72-4 *4
CN3-1 to CN3-3 No continuity 72-1
CN3-1 to CN3-4 No continuity 72-2
CN3-1 to CN3-5 No continuity 72-3
CN3-2 to CN3-3 No continuity 72-1
CN3-2 to CN3-4 No continuity 72-2
CN3-2 to CN3-5 No continuity 72-3
CN3-1 to CN3-2 No continuity 72-1,2,3,4

*1: Connect CN3-1 and CN3-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-13 and CN104-30.
*2: Connect CN3-1 and CN3-4 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-13 and CN104-31.
*3: Connect CN3-1 and CN3-5 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-13 and CN104-24.
*4: Connect CN3-1 and CN3-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-13 and CN102-10.
sec04.book 142 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-142

z Error Code 73-1,-2,-3,-4 (Steering knob synchronizer solenoid abnormality)

Related portion

CN102-7 (329, SLS+) CN37-1

CN102-14 (330, SLS-) CN37-2

CN103-5 (N2, N2)

Main Steering knob
controller CN104-4 (N2, N2) synchronizer
solenoid
CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect (3) Knob position compensation solenoid defect
(2) Knob position compensation solenoid harness defect (4) Main controller defect

If the 73-3 error occurs, disconnect the battery plug immediately and track down the cause of it.

Error code 73-1

1. Turn off the key switch and disconnect the battery plug,
disconnect the CN37 connector, and visually check inside the 73-4
connector and the caulked portion of its wire for defects. (Refer to error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) 73-4 error.
Connect the CN37 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.
No error occurs.
73-1
Using Active Test, forcibly turn on the output of the knob position
error does not occur.
compensation solenoid to see if an error occurs. Connector contact defect
[ANL] ACTIVE TEST 1/3 STEERING SOL

73-1 error occurs.

Inspection: Check of knob position compensation solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN37 and measure the resistance of
the knob position compensation solenoid
(Resistance between CN37-1 and CN98-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

Disconnect the CN102, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
Main controller defect
sec04.book 143 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-143

Error code 73-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN37 connector, and visually check inside the connector and 73-3
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of
TROUBLESHOOTING) the 73-3 error.
Connect the CN37 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
No error occurs.

Using Active Test, forcibly turn on the output of the knob position
73-2
compensation solenoid to see if an error occurs. Connector contact
error does not occur.
defect
[ANL] ACTIVE TEST 1/3 STEERING SOL

73-2 error occurs.

Inspection: Check of knob position compensation solenoid
1. Turn off the key switch and disconnect the battery plug.
Knob position
2. Disconnect CN37 and measure the resistance of the knob position NG
compensation solenoid
compensation solenoid
defect
(Resistance between CN37-1 and CN37-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )
OK
Inspection 1: Harness check
NG
Disconnect the CN102, CN103 and CN104 connectors and check the Harness defect
harnesses for their continuities.
OK
Main controller defect

Error code 73-3

Turn off the key switch and disconnect the battery plug, disconnect the
CN37 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of knob position compensation solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect CN37 and measure the resistance of the knob position
compensation solenoid
(Resistance between CN37-1 and CN37-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

Disconnect the CN102, CN103 and CN104 connectors and check the
harnesses for their continuities.

Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
Main controller defect
sec04.book 144 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-144

Error code 73-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN37 connector, and visually check inside the connector and 73-4
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
Connect the CN37 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
73-4 error occurs.
Inspection: Check of knob position compensation solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN37 and measure the resistance of the NG Knob position compensation
knob position compensation solenoid solenoid defect
(Resistance between CN37-1 and CN37-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )
OK
Inspection 1: Harness check
NG
Disconnect the CN102, CN103 and CN104 connectors and check the Harness defect
harnesses for their continuities.
OK
Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN37, 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

CN102-7 to CN37-1 Continuity 73-4 *
CN102-14 to CN37-2 Continuity 73-4 *
CN102-7 to CN104-4 No continuity 73-4
CN102-14 to CN104-4 No continuity 73-4
CN37-1 to CN37-2 No continuity 73-1,2,3,4
CN37-2 to P1 No continuity 73-1,2,3,4
CN37-2 to P4 No continuity 73-1,2,3,4

* Connect the CN37 connector and measure the resistance between CN102-7 and CN102-14 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C).
sec04.book 145 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-145

z 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-FUNCTION does not occur.
correctly.
DISPLAY / MUSK FUCTION / MACHING
Use the device as it is.
After the completion of matching,
74-1 error occurs.
Main controller defect
sec04.book 146 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-146

z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer

abnormality-Conventional lever)
Related portion

CN101-25 (28, VRL+) CN47-4

CN103-26 (20, VRL1) CN47-3

Main Lift lever
controller CN103-18 (21, VRL2) CN47-2 potentiometer

CN102-26 (51, POT-) CN47-1

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:
(1) Connector contact defect
(2) Lift lever potentiometer harness defect
(3) Lift lever potentiometer defect
(4) Main controller defect

Error code H1-1, -2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN47 connector, and visually check inside the connector and H1-1, -2, -3 error does
the caulked portion of its wire for defects. (Refer to BEFORE not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN47 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
H1-1, -2 or -3 error
One of these errors occurs.
H1-1 error occurs and
Inspection: Check of lift lever potentiometer
H1-2, H2-3 error does
1. Turn off the key switch and disconnect the battery plug.
not occur.
2. Disconnect the lift lever potentiometer connector (CN47) . A
3. Connect the battery plug and turn on the key switch.
Check the error code.

H1, -2 or -3 error
One of these errors occurs.
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101,CN102 and CN103 connectors and check
the harnesses for their continuities.

OK

Main controller defect

sec04.book 147 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-147

H1-2 error Inspection: Check of lift lever potentiometer

does not 1. Turn off the key switch and disconnect the battery
occur. plug.
2. Connect the CN47-3 to CN47-4 on the herness side
through SST 09230-13700-71.
3. Connect the battery plug and turn on the key switch.
Check the error code.

H1-2 error occurs.

Inspection: Check of lift lever potentiometer

1. Turn off the key switch and disconnect the battery
plug.
H1-2 error occurs.
2. Disconnect the CN47 connector. Lift lever
3. Connect the CN47-2 to CN47-4 on the herness side potentiometer defect
through SST 09230-13700-71.
4. Connect the battery plug and turn on the key switch.
Check the error code.

H1-2 error does not occur.

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN101,CN102 and CN103
connectors and check the harnesses for their
continuities.

OK

Main controller defect

sec04.book 148 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-148

Error code H1-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN47 connector, and visually check inside the connector and H1-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN47 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

H1-4 error occurs.

Inspection: Check of lift lever potentiometer

1. Turn off the key switch and disconnect the battery plug.
2. Check if the lift lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the lift lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY /MUSK FUCTION /
MACHING

NG

Lift lever potentiometer defect

Error code H1-5

Matching of the lift lever potentiometer After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / MUSK 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.
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN47, CN101, CN102 and CN103 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING)
{ : Items to be checked
H1
Portions to be checked Standard
1 2 3 4 5
CN101-25 to CN47-4 Continuity { − − − −
CN103-26 to CN47-3 Continuity { − − − −
CN103-18 to CN47-2 Continuity { − − − −
CN102-26 to CN47-1 Continuity − { − − −
CN47-2 to CN47-1 No continuity { − { − −
CN47-3 to CN47-1 No continuity { − { − −
CN47-2 to CN47-4 No continuity − { { − −
CN47-3 to CN47-4 No continuity − { { − −
CN47-4 to CN47-1 No continuity { − { − −
CN47-2 to CN47-3 No continuity − − { − −
sec04.book 149 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-149

z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer abnormality-Mini lever)
Related portion

CN101-25 (28, VRL+) CN79-4

CN103-26 (20, VRL1) CN79-3

Main Lift lever
controller CN103-18 (21, VRL2) CN79-2 potentiometer

CN102-26 (51, POT-) CN79-1

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:
(1) Connector contact defect
(2) Lift lever potentiometer harness defect
(3) Lift lever potentiometer defect
(4) Main controller defect

Error code H1-1, -2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN79 connector, and visually check inside the connector and H1-1, -2, -3 error does
the caulked portion of its wire for defects. (Refer to BEFORE not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN79 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
H1-1, -2 or -3 error
One of these errors occurs.
Inspection: Check of lift lever potentiometer
1. Turn off the key switch and disconnect the battery plug. H2-1, -2 or -3 error One
2. Replace the lift lever potentiometer connector (CN79) with the tilt of these errors occurs. Lift lever potentiometer
lever potentiometer connector (CN80). H1-4, H2-4 can be defect
3. Connect the battery plug and turn on the key switch. ignored.
Check the error code.
H1-1, -2 or -3 error
One of these errors occurs.
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101,CN102 and CN103 connectors and check
the harnesses for their continuities.

OK

Main controller defect

sec04.book 150 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-150

Error code H1-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN79 connector, and visually check inside the connector and H1-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN79 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

H1-4 error occurs.

Inspection: Check of lift lever potentiometer

1. Turn off the key switch and disconnect the battery plug.
2. Check if the lift lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the lift lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY /MUSK FUCTION /
MACHING

NG

Lift lever potentiometer defect

Error code H1-5

Matching of the lift lever potentiometer After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / MUSK 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.
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN79, CN101, CN102 and CN103 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING)
{ : Items to be checked
H1
Portions to be checked Standard
1 2 3 4 5
CN101-25 to CN79-4 Continuity { − − − −
CN103-26 to CN79-3 Continuity { − − − −
CN103-18 to CN79-2 Continuity { − − − −
CN102-26 to CN79-1 Continuity − { − − −
CN79-2 to CN79-1 No continuity { − { − −
CN79-3 to CN79-1 No continuity { − { − −
CN79-2 to CN79-4 No continuity − { { − −
CN79-3 to CN79-4 No continuity − { { − −
CN79-4 to CN79-1 No continuity { − { − −
CN79-2 to CN79-3 No continuity − − { − −
sec04.book 151 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-151

z Error Code H2-1, -2, -3, -4, -5 (Tilt lever potentiometer abnormality)
Related portion

CN101-28 (29, VRT+) CN80-4

CN102-23 (22, VRT1) CN80-3

Main Tilt lever
controller CN102-22 (23, VRT2) CN80-2 potentiometer

CN102-26 (51, POT-) CN80-1

If the lever was removed for a check, be sure to perform matching after installing it.
The H2-4 error may occur if the key switch is turned on while the tilt lever is being operated.

Probable cause:
(1) Connector contact defect
(2) Tilt lever potentiometer harness defect
(3) Tilt lever potentiometer defect
(4) Main controller defect

Error code H2-1, -2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN80 connector, and visually check inside the connector and H2-1, -2, -3
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN80 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.
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 (CN80) with the lift occurs.
Tilt lever potentiometer defect
lever potentiometer connector (CN79). H1-4, H2-4
3. Connect the battery plug and turn on the key switch. can be ignored.
Check the error code.
H2-1, -2 or -3 error
One of these errors occurs.
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101 and CN102 connectors and check the
harnesses for their continuities.

OK

Main controller defect

sec04.book 152 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-152

Error code H2-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN80 connector, and visually check inside the connector and H2-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN80 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

H2-4 error occurs.

Inspection: Check of tilt lever potentiometer

1. Turn off the key switch and disconnect the battery plug.
2. Check if the tilt lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the tilt lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY /MUSK FUCTION /
MACHING

NG

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-FUNCTION DISPLAY / 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.
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN80, 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 CN80-4 Continuity { − − − −
CN102-23 to CN80-3 Continuity { − − − −
CN102-22 to CN80-2 Continuity { − − − −
CN102-26 to CN80-1 Continuity − { − − −
CN80-2 to CN80-1 No continuity { − { − −
CN80-3 to CN80-1 No continuity { − { − −
CN80-2 to CN80-4 No continuity − { { − −
CN80-3 to CN80-4 No continuity − { { − −
CN80-4 to CN80-1 No continuity { − { − −
CN80-2 to CN80-3 No continuity − − { − −
sec04.book 153 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-153

z Error Code H3-1, -2, -3, -4, -5 (Attachment 1 lever potentiometer

abnormality)
Related portion

CN101-29 (30, VRAT1+) CN48-4

CN102-21 (24, VRA11) CN48-3

Main Attachment 1
controller CN102-20 (25, VRA12) CN48-2 lever
potentiometer
CN102-26 (51, POT-) CN48-1

If the lever was removed for a check, be sure to perform matching after installing it.
The H3-4 error may occur if the key switch is turned on while the attachment 1 lever is being operated.
* The mini lever specification changes CN48 in CN81 and CN47 is changed into CN79.

Probable cause:
(1) Connector contact defect (3) Attachment 1 lever potentiometer defect
(2) Attachment 1 lever potentiometer harness defect (4) Main controller defect

Error code H3-1, -2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN48 connector, and visually check inside the connector and H3-1, -2, -3 error does
the caulked portion of its wire for defects. (Refer to BEFORE not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN48 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
H3-1, -2 or -3 error
One of these errors occurs.
Inspection: Check of attachment 1 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 attachment 1 lever potentiometer connector (CN48) occurs. Attachment 1 lever
with the lift lever potentiometer connector (CN47). H1-4, H3-4 can be potentiometer defect
3. Connect the battery plug and turn on the key switch. ignored.
Check the error code.
H3-1, -2 or -3 error
One of these errors occurs.
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101 and CN102 connectors and check the
harnesses for their continuities.

OK

Main controller defect

sec04.book 154 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-154

Error code H3-4

• Attachment 1 operation stop. (Conventional Lever)

• Load handling stop. (Mini Lever/Joystick Lever)
1. Turn off the key switch and disconnect the battery plug, disconnect
the CN48 connector, and visually check inside the connector and H3-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN48 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

H3-4 error occurs.

Inspection: Check of attachment 1 lever potentiometer

1. Turn off the key switch and disconnect the battery plug.
2. Check if the attachment 1 lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the attachment 1 lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION /
MACHING

NG

Attachment 1 lever potentiometer defect

Error code H3-5

After the completion of matching,

Matching of the attachment 1 lever potentiometer. Matching has been made
H3-5 error does not occur.
Refer to MULTI-FUNCTION DISPLAY / MUSK correctly.
FUCTION / MACHING Use the device as it is.

After the completion of

matching, H3-5 error
occurs.
Main controller defect

Inspection 1: Check each harness for its continuity.

Perform this check with the battery plug and the CN48, CN101 and CN102 connectors disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING)
{ : Items to be checked
H3
Portions to be checked Standard
1 2 3 4 5
CN101-29 to CN48-4 Continuity { − − − −
CN102-21 to CN48-3 Continuity { − − − −
CN102-20 to CN48-2 Continuity { − − − −
CN102-26 to CN48-1 Continuity − { − − −
CN48-2 to CN48-1 No continuity { − { − −
CN48-3 to CN48-1 No continuity { − { − −
CN48-2 to CN48-4 No continuity − { { − −
CN48-3 to CN48-4 No continuity − { { − −
CN48-4 to CN48-1 No continuity { − { − −
CN48-2 to CN48-3 No continuity − − { − −
sec04.book 155 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-155

z Error Code H4-1, -2, -3, -4, -5 (Attachment 2 lever potentiometer

abnormality)
Related portion

CN101-30 (31, VRAT2+) CN49-4

CN102-29 (26, VRA21) CN49-3

Main Attachment 2
controller CN102-28 (27, VRA22) CN49-2 lever
potentiometer
CN102-26 (51, POT-) CN49-1

If the lever was removed for a check, be sure to perform matching after installing it.
The H4-4 error may occur if the key switch is turned on while the attachment 2 lever is being operated.
* The mini lever specification changes CN49 in CN82 and CN47 is changed into CN79.

Probable cause:
(1) Connector contact defect (3) Attachment 2 lever potentiometer defect
(2) Attachment 2 lever potentiometer harness defect (4) Main controller defect

Error code H4-1, -2, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN49 connector, and visually check inside the connector and H4-1, -2, -3 error does
the caulked portion of its wire for defects. (Refer to BEFORE not occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN49 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 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 attachment 2 lever potentiometer connector (CN49) occurs. Attachment 2 lever
with the lift lever potentiometer connector (CN47). H1-4, H4-4 can be potentiometer defect
3. Connect the battery plug and turn on the key switch. ignored.
Check the error code.
H4-1, -2 or -3 error
One of these errors occurs.
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101 and CN102 connectors and check the
harnesses for their continuities.

OK

Main controller defect

sec04.book 156 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-156

Error code H4-4

• Attachment 2 operation stop. (Conventional Lever)

• Load handling stop. (Mini Lever/Joystick Lever)
1. Turn off the key switch and disconnect the battery plug, disconnect
the CN49 connector, and visually check inside the connector and H4-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN49 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

H4-4 error occurs.

Inspection: Check of attachment 2 lever potentiometer

1. Turn off the key switch and disconnect the battery plug.
2. Check if the attachment 2 lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the attachment 2 lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION /
MACHING

NG

Attachment 2 lever potentiometer defect

Error code H4-5

Matching of the attachment 2 lever potentiometer. After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / 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.
Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN49, CN101 and CN102 connectors disconnected, visually check inside each
connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING)
{ : Items to be checked
H4
Portions to be checked Standard
1 2 3 4 5
CN101-30 to CN49-4 Continuity { − − − −
CN102-29 to CN49-3 Continuity { − − − −
CN102-28 to CN49-2 Continuity { − − − −
CN102-26 to CN49-1 Continuity − { − − −
CN49-2 to CN49-1 No continuity { − { − −
CN49-3 to CN49-1 No continuity { − { − −
CN49-2 to CN49-4 No continuity − { { − −
CN49-3 to CN49-4 No continuity − { { − −
CN49-4 to CN49-1 No continuity { − { − −
CN49-2 to CN49-3 No continuity − − { − −
sec04.book 157 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-157

z Error Code H5-1, -2, -3, -4, -5, -6 (Lift PUSH/PULL solenoid abnormality)
Related portion

CN101-5 (9, SLLA2+) CN11-5

Lift push
CN101-16 (11, SLPS-) CN11-1 solenoid

CN10-5
Lift pull
CN101-17 (10, SLPL-) CN10-1 solenoid
Main
controller
CN103-5 (N2, N2)

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect (4) Lift pull solenoid harness defect
(2) Lift push solenoid harness defect (5) Lift pull solenoid defect
(3) Lift push solenoid defect (6) 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

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H5-6 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H5-6 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs
H5-1, H5-3 error does
Push and hold down the lift lever and pull and hold it up for more than not occur.
Connector contact defect
1 second each to check if an error occurs.

H5-1 or H5-3 error occurs.

Inspection: Check of lift solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the
resistance of the lift solenoid.
(CN10-5 to CN10-1, CN11-5 to CN11-1).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the lift solenoid or its harness.
Main controller defect
sec04.book 158 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-158

Error code H5-2, -4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H5-5 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H5-5 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H5-2, H5-4 error does
Push and hold down the lift lever and pull and hold it up for more than not occur.
Connector contact defect
1 second each to check if an error occurs.

H5-2 or H5-4 error occurs.

Inspection: Check of lift solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the NG
Lift solenoid defect
resistance of the lift solenoid.
(CN10-5 to CN10-1, CN11-5 to CN11-1).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Error code H5-5

Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector
and the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of lift solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the
resistance of the lift solenoid.
(CN10-5 to CN10-1, CN11-5 to CN11-1).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the lift solenoid or its harness.
Main controller defect
sec04.book 159 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-159

Error code H5-6

1. Turn off the key switch and disconnect the battery plug,
disconnect the CN10 and CN11 connectors, and visually check H5-6 error does not
inside the connector and the caulked portion of its wire for defects. occur.
Connector contact defect
(Refer to BEFORE TROUBLESHOOTING)
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

H5-6 error occurs.

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.

Inspection: Check of lift solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the NG
Lift solenoid defect
resistance of the lift solenoid.
(CN10-5 to CN10-1, CN11-5 to CN11-1).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN10, CN11, 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 CN10-5 Continuity H5-6 *1
CN101-17 to CN10-1 Continuity H5-6 *1
CN101-5 to CN11-5 Continuity H5-6 *2
CN101-16 to CN11-1 Continuity H5-6 *2
CN101-5 to CN104-4 No continuity H5-6
CN101-17 to CN104-4 No continuity H5-6
CN101-16 to CN104-4 No continuity H5-6
CN10-5 to CN10-1 No continuity H5-1, 2, 3, 4, 5, 6
CN11-5 to CN11-1 No continuity H5-1, 2, 3, 4, 5, 6
CN10-1 to P1 No continuity H5-1, 2, 3, 4, 5, 6
CN10-1 to P4 No continuity H5-1, 2, 3, 4, 5, 6
CN11-1 to P1 No continuity H5-1, 2, 3, 4, 5, 6
CN11-1 to P4 No continuity H5-1, 2, 3, 4, 5, 6

*1: Connect CN10 to the solenoid and measure the resistance between CN101-5 and CN101-17
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C ).
*2: Connect CN11 to the solenoid and measure the resistance between CN101-5 and CN101-16
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C ).
sec04.book 160 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-160

z Error Code H6-1, -2, -3, -4, -5, -6 (Tilt PUSH/PULL solenoid abnormality)
Related portion

CN101-6 (32, SLTA1+) CN11-6

Tilt push
CN101-13 (34, STPS-) CN11-2 solenoid

CN10-6
Tilt pull
CN101-12 (33, STPL-) CN10-2 solenoid
Main
controller CN103-5 (N2, N2)

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect (4) Tilt pull solenoid harness defect
(2) Tilt push solenoid harness defect (5) Tilt pull solenoid defect
(3) Tilt push solenoid defect (6) Main controller defect

If the H6-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code H6-1, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H6-6 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H6-6 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H6-1, H6-3 error does
Push and hold down the tilt lever and pull and hold it up for more than not occur.
Connector contact defect
1 second each to check if an error occurs.

H6-1 or H6-3 error occurs.

Inspection: Check of tilt proportional solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the
resistance of the tilt solenoid.
(CN10-6 to CN10-2, CN11-6 to CN11-2).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the tilt solenoid or its harness.
Main controller defect
sec04.book 161 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-161

Error code H6-2, -4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H6-5 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H6-5 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H6-2, H6-4 error does
Push and hold down the tilt lever and pull and hold it up for more than not occur. Connector contact defect
1 second each to check if an error occurs.

H6-2 or H6-4 error occurs.

Inspection: Check of tilt proportional solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the NG
Tilt solenoid defect
resistance of the tilt solenoid.
(CN10-6 to CN10-2, CN11-6 to CN11-2).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Error code H6-5

Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector
and the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of tilt proportional solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the
resistance of the tilt solenoid.
(CN10-6 to CN10-2, CN11-6 to CN11-2).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the tilt solenoid or its harness.
Main controller defect
sec04.book 162 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-162

Error code H6-6

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the H6-6 error does not
connector and the caulked portion of its wire for defects. (Refer to occur.
Connector contact defect
BEFORE TROUBLESHOOTING)
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

H6-6 error occurs.

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.

Inspection: Check of tilt proportional solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors and measure the NG
Tilt solenoid defect
resistance of the tilt solenoid.
(CN10-6 to CN10-2, CN11-6 to CN11-2).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN10, CN11, 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 CN10-6 Continuity H6-6 *1
CN101-12 to CN10-2 Continuity H6-6 *1
CN101-6 to CN11-6 Continuity H6-6 *2
CN101-13 to CN11-2 Continuity H6-6 *2
CN101-6 to CN104-4 No continuity H6-6
CN101-12 to CN104-4 No continuity H6-6
CN101-13 to CN104-4 No continuity H6-6
CN10-6 to CN10-2 No continuity H6-1, 2, 3, 4, 5, 6
CN11-6 to CN11-2 No continuity H6-1, 2, 3, 4, 5, 6
CN10-2 to P1 No continuity H6-1, 2, 3, 4, 5, 6
CN10-2 to P4 No continuity H6-1, 2, 3, 4, 5, 6
CN11-2 to P1 No continuity H6-1, 2, 3, 4, 5, 6
CN11-2 to P4 No continuity H6-1, 2, 3, 4, 5, 6

*1: Connect CN10 to the solenoid and measure the resistance between CN101-6 and CN101-12
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C ).
*2: Connect CN11 to the solenoid and measure the resistance between CN101-6 and CN101-13
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C ).
sec04.book 163 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-163

z Error Code H7-1, -2, -3, -4, -5, -6 (Attachment 1 PUSH/PULL solenoid
abnormality)
Related portion

CN101-6 (32, SLTA1+) CN11-7

Attachment 1
CN101-11 (37, SA1PS-) CN11-3 push solenoid

CN10-7
Attachment 2
CN101-10 (36, SA1PL-) CN10-3 push solenoid
Main
controller CN103-5 (N2, N2)

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect (4) Attachment 1 pull solenoid harness defect
(2) Attachment 1 push solenoid harness defect (5) Attachment 1 pull solenoid defect
(3) Attachment 1 push solenoid defect (6) Main controller defect

If the H7-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code H7-1, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H7-6 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H7-6 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H7-1, H7-3 error does
Push and hold down the attachment 1 lever and pull and hold it up for not occur.
Connector contact defect
more than 1 second each to check if an error occurs.

H7-1 or H7-3 error occurs.

Inspection: Check of attachment 1 solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors.
Measure the resistance of attachment 1 solenoid
(CN10-7 to CN10-3, CN11-7 to CN11-3).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the attachment 1 solenoid or its harness.
Main controller defect
sec04.book 164 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-164

Error code H7-2, -4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H7-5 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H7-5 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H7-2, H7-4 error does
Push and hold down the attachment 1 lever and pull and hold it up for not occur.
Connector contact defect
more than 1 second each to check if an error occurs.

H7-2 or H7-4 error occurs.

Inspection: Check of attachment 1 solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors. NG Attachment 1
Measure the resistance of attachment 1 solenoid solenoid defect
(CN10-7 to CN10-3, CN11-7 to CN11-3).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Error code H7-5

Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector
and the caulked portion of its wire for defects.
(Refer to BEFORE TROUBLESHOOTING)

Inspection: Check of attachment 1 solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors.
Measure the resistance of attachment 1 solenoid
(CN10-7 to CN10-3, CN11-7 to CN11-3).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the attachment 1 solenoid or its harness.
Main controller defect
sec04.book 165 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-165

Error code H7-6

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the H7-6 error does not
connector and the caulked portion of its wire for defects. (Refer to occur.
Connector contact defect
BEFORE TROUBLESHOOTING)
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

H7-6 error occurs.

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.

Inspection: Check of attachment 1 solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors. NG Attachment 1
Measure the resistance of attachment 1 solenoid solenoid defect
(CN10-7 to CN10-3, CN11-7 to CN11-3).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN10, CN11, 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 CN10-7 Continuity H7-6 *1
CN101-10 to CN10-3 Continuity H7-6 *1
CN101-6 to CN11-7 Continuity H7-6 *2
CN101-11 to CN11-3 Continuity H7-6 *2
CN101-6 to CN104-4 No continuity H7-6
CN101-10 to CN104-4 No continuity H7-6
CN101-11 to CN104-4 No continuity H7-6
CN10-7 to CN10-3 No continuity H7-1, 2, 3, 4, 5, 6
CN11-7 to CN11-3 No continuity H7-1, 2, 3, 4, 5, 6
CN10-3 to P1 No continuity H7-1, 2, 3, 4, 5, 6
CN10-3 to P4 No continuity H7-1, 2, 3, 4, 5, 6
CN11-3 to P1 No continuity H7-1, 2, 3, 4, 5, 6
CN11-3 to P4 No continuity H7-1, 2, 3, 4, 5, 6

*1: Connect CN10 to the solenoid and measure the resistance between CN101-6 and CN101-10
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C ).
*2: Connect CN11 to the solenoid and measure the resistance between CN101-6 and CN101-11
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C ).
sec04.book 166 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-166

z Error Code H8-1, -2, -3, -4, -5, -6 (Attachment 2 PUSH/PULL solenoid
abnormality)
Related portion

CN101-5 (9, SLLA2+) CN11-8

Attachment 2
CN101-15 (40, SA2PS-) CN11-4 push solenoid

CN10-8
Attachment 2
CN101-14 (39, SA2PL-) CN10-4 pull solenoid
Main
controller CN103-5 (N2, N2)

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect (4) Attachment 2 pull solenoid harness defect
(2) Attachment 2 push solenoid harness defect (5) Attachment 2 pull solenoid defect
(3) Attachment 2 push solenoid defect (6) Main controller defect

If the H8-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code H8-1, -3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the
Track down the
connector and the caulked portion of its wire for defects. (Refer to H8-6 error occurs.
cause of the H8-6
BEFORE TROUBLESHOOTING.)
error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H8-1, H8-3
Push and hold down the attachment 2 lever and pull and hold it up for No error occurs Connector contact
more than 1 second each to check if an error occurs. defect
H8-1 or
H8-3 error occurs.
Inspection: Check of attachment 2 solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors.
Measure the resistance of attachment 2 solenoid
(CN10-8 to CN10-4, CN11-8 to CN11-4).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the attachment 2 solenoid or its harness.
Main controller defect
sec04.book 167 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-167

Error code H8-2, -4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN10 and CN11 connectors, and visually check inside the H8-5
connector and the caulked portion of its wire for defects. (Refer to error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H8-5 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.

No error occurs.
H8-2, H8-4
Push and hold down the attachment 2 lever and pull and hold it up for error occurs
Connector contact defect
more than 1 second each to check if an error occurs.

H8-2 or H8-4 error occurs.

Inspection: Check of attachment 2 solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors. NG
Attachment 2 solenoid defect
Measure the resistance of attachment 2 solenoid
(CN10-8 to CN10-4, CN11-8 to CN11-4).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

OK

Main controller defect

Error code H8-5

Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector
and the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of attachment 2 solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors.
Measure the resistance of attachment 2 solenoid
(CN10-8 to CN10-4, CN11-8 to CN11-4).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for their continuities.

Portion where a problem was found during a check of the attachment 2 solenoid or its harness.
Main controller defect
sec04.book 168 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-168

Error code H8-6

1. Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector H8-6
and the caulked portion of its wire for defects. (Refer to BEFORE No error occurs
Connector contact defect
TROUBLESHOOTING.)
2. Connect the CN10 and CN11 connector, connect the battery plug, and
turn on the key switch to see if an error occurs.
H8-6 error occurs.
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.
Inspection: Check of attachment 2 solenoid
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN10 and CN11 connectors. NG Attachment 2
Measure the resistance of attachment 2 solenoid solenoid defect
(CN10-8 to CN10-4, CN11-8 to CN11-4).
Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
OK
Inspection 1: Harness check
1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check the
harnesses for their continuities.
OK
Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN10, CN11, 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 CN10-8 Continuity H8-6 *1
CN101-14 to CN10-4 Continuity H8-6 *1
CN101-5 to CN11-8 Continuity H8-6 *2
CN101-15 to CN11-4 Continuity H8-6 *2
CN101-5 to CN104-4 No continuity H8-6
CN101-14 to CN104-4 No continuity H8-6
CN101-15 to CN104-4 No continuity H8-6
CN10-8 to CN10-4 No continuity H8-1, 2, 3, 4, 5, 6
CN11-8 to CN11-4 No continuity H8-1, 2, 3, 4, 5, 6
CN10-4 to P1 No continuity H8-1, 2, 3, 4, 5, 6
CN10-4 to P4 No continuity H8-1, 2, 3, 4, 5, 6
CN11-4 to P1 No continuity H8-1, 2, 3, 4, 5, 6
CN11-4 to P4 No continuity H8-1, 2, 3, 4, 5, 6

*1: Connect CN10 to the solenoid and measure the resistance between CN101-5 and CN101-14 to see if it falls
between 6 and 12 Ω (approx. 7 Ω at 20°C).
*2: Connect CN11 to the solenoid and measure the resistance between CN101-5 and CN101-15 to see if it falls
between 6 and 12 Ω (approx. 7 Ω at 20°C).
sec04.book 169 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-169

z Error Code HB-1, -2, -3, (Solenoid power supply circuit over current)
Related portion

F7
CN130-6 (19, F7)

CN102-5 (17, SOLCOM) CN132-8 (17, SOLCOM)

CN132-6 (19, VBMBSL)
CN102-6 (17, SOLCOM)
RY1
CN102-13 (335, RY1) CN132-4 (335, RY1) CN132-2 (97, FAN+)

CN101-3 (97, FAN+)

CN101-5 (9, SLLA2+) CN11-5

Lift PUSH
CN101-16 (11, SLPS-) CN11-1 solenoid

CN101-17 (10, SLPL-) CN10-5

Lift PULL
CN10-1 solenoid

CN101-6 (32, SLTA1+) CN11-6

Tilt PUSH
CN101-13 (34, STPS-) CN11-2 solenoid

CN101-12 (33, STPL-) CN10-6

Tilt PULL
Main
CN10-2 solenoid
controller
CN11-7
ATT1 PUSH
CN101-11 (37, SA1PS-) CN11-3 solenoid

CN101-10 (36, SA1PL-) CN10-7

ATT1 PULL
CN10-3 solenoid

CN11-8
ATT2 PUSH
CN101-15 (40, SA2PS-) CN11-4 solenoid

CN101-14 (39, SA2PL-) CN10-8

ATT2 PULL
CN103-5 (N2, N2) CN10-4 solenoid

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

sec04.book 170 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-170

Probable cause:
(1) Connector contact defect
(2) Harness defect
(3) RY1 defect
(4) Main controller defect

Error code HB-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN132 connector, and visually check inside the connector and HB-1 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN132 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.

HB-1 error occurs.

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102 and CN132 connectors and check
the harnesses for their continuities.

OK

Relay defect (*1)

*1 If the symptom persists after replacement of the relay, there should be any other problems,
so replace the Main controller.

Error code HB-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN132, CN10 and CN11 connectors, and visually check inside HB-2 error does not
the connector and the caulked portion of its wire for defects. occur.
Connector contact defect
(Refer to BEFORE TROUBLESHOOTING)
2. Connect the CN132, CN10 and CN11 connector, connect the
battery plug, and turn on the key switch to see if an error occurs.

HB-2 error occurs.

Inspection 2: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103, CN104, CN10 and CN11
connectors and check the harnesses for their continuities.

OK

Main controller defect

sec04.book 171 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-171

Error code HB-3

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN132 connector, and visually check inside the connector and HB-3 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN132 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.

HB-3 error occurs.

Inspection 3: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN102 and CN132 connectors and check the
harnesses for their continuities.

OK

Inspection: Relay check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector CN132, check the relay and measure its NG
Relay defect
resistance on the primary side
(resistance between CN132-4 and CN132-2).
Standard value: 100 to 320 Ω (aprox. 180 Ω at 20°C)

OK

Main controller defect

Inspection 1: Check each harness for its continuity.

With the battery plug and the CN101, CN102, and CN132 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

CN102-13 to CN132-4 Continuity HB-1
CN101-3 to CN132-2 Continuity HB-1
CN102-5 to CN132-8 Continuity HB-1
CN102-6 to CN132-8 Continuity HB-1
CN132-6 to CN130-6 Continuity HB-1
sec04.book 172 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-172

Inspection 2: Check each harness for its continuity.

With the battery plug and the CN101, CN102, CN103, CN104, CN10 and CN11 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

CN102-5 to CN104-4 No continuity HB-2
CN102-6 to CN104-4 No continuity HB-2
CN101-5 to CN104-4 No continuity HB-2
CN101-6 to CN104-4 No continuity HB-2
CN101-16 to CN104-4 No continuity HB-2
CN101-17 to CN104-4 No continuity HB-2
CN101-13 to CN104-4 No continuity HB-2
CN101-12 to CN104-4 No continuity HB-2
CN101-11 to CN104-4 No continuity HB-2
CN101-10 to CN104-4 No continuity HB-2
CN101-15 to CN104-4 No continuity HB-2
CN101-14 to CN104-4 No continuity HB-2

Inspection 3: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN102 and CN132 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

CN132-4 to P1 No continuity HB-3
CN132-4 to P4 No continuity HB-3
CN132-4 to CN132-2 No continuity HB-3
sec04.book 173 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-173

z Error Code HC-1, -2, -3, -4, (Unload valve solenoid abnormality)
Related portion

CN101-1 (3, SOLLU+) CN13-1

CN102-17 (5, SLUL-) CN13-2

CN103-5 (N2, N2)

Main Unload valve
controller CN104-4 (N2, N2) solenoid

CN104-5 (N2, N2)

CN104-6 (N2, N2)

Probable cause:
(1) Connector contact defect (3) Unload valve solenoid defect
(2) Unload valve solenoid harness defect (4) Main controller defect

If the HC-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
0

Error code HC-1

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN13 connector, and visually check inside the connector and
the caulked portion of its wire for defects. (Refer to BEFORE HC-4 error occurs. Track down the cause of the
TROUBLESHOOTING) HC-4 error.
2. Connect the CN13 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

No error occurs.
HC-1 error does not
Lower the lift to see if an error occurs. occur. Connector contact defect

HC-1 error occurs.

Inspection: Check of unload valve solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN13 connector and measure the resistance of the
unload valve solenoid
(Resistance between CN13-1 and CN13-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

Portion where a problem was found during a check of the unload valve solenoid or its harness
Main controller defect
sec04.book 174 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-174

Error code HC-2

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN13 connector, and visually check inside the connector and
the caulked portion of its wire for defects. (Refer to BEFORE HC-3 error occurs. Track down the cause of the
TROUBLESHOOTING) HC-3 error.
2. Connect the CN13 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.

No error occurs.
HC-2 error does not
occur.
Lower the lift to see if an error occurs. Connector contact defect

HC-2 error occurs.

Inspection: Check of unload valve solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN13 connector and measure the resistance of the NG
Unload valve solenoid defect
unload valve solenoid
(Resistance between CN13-1 and CN13-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

OK

Main controller defect

Error code HC-3

Turn off the key switch and disconnect the battery plug, disconnect the
CN13 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

Inspection: Check of unload valve solenoid

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN13 connector and measure the resistance of the
unload valve solenoid
(Resistance between CN13-1 and CN13-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

Portion where a problem was found during a check of the unload valve solenoid or its harness
Main controller defect
sec04.book 175 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-175

Error code HC-4

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN13 connector, and visually check inside the connector and HC-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
Connector contact defect
TROUBLESHOOTING)
2. Connect the CN13 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 CN13 connector and measure the resistance of the NG
Unload valve solenoid defect
unload valve solenoid
(Resistance between CN13-1 and CN13-2).
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C )

OK

Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
check the harnesses for their continuities.

OK

Main controller defect

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN13, 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 CN13-1 Continuity HC-4 *
CN102-17 to CN13-2 Continuity HC-4 *
CN101-1 to CN104-4 No continuity HC-4
CN102-17 to CN104-4 No continuity HC-4
CN13-2 to CN13-1 No continuity HC-1, 2, 3, 4
CN13-2 to P1 No continuity HC-1, 2, 3, 4
CN13-2 to P4 No continuity HC-1, 2, 3, 4

* Connect the CN13 connector and measure the resistance between CN101-1 and CN102-17 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C).
sec04.book 176 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-176

z Error Code G5-1, -2, -3, -4, -5, -6 (Shock sensor abnormality)
Related portion

CN103-8 (300, IPL+) CN39-3

CN103-30 (301, IPL1) CN39-2

Shock sensor 1
CN101-32 (51, POT-) CN39-1
Main
controller CN40-3

CN103-19 (302, IPL2) CN40-2

Shock sensor 2
CN40-1

Probable cause:
(1) Connector contact defect
(2) Shock sensor harness defect
(3) Shock sensor defect
(4) Main controller defect

Error code G5-1 or G5-4 (For G-5-4, read the numbers in brackets, which refer to the corresponding error code,
connector number, etc.)

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN39 [CN40] connectors, and visually check inside the G5-1 [G5-4]
connector and the caulked portion of its wire for defects. (Refer to error does not occur.
BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN39 [CN40] connector, connect the battery plug, and
turn on the key switch to see if an error occurs.

G5-1 [G5-4] error occurs.

Inspection: Check of shock sensor 1 [shock sensor 2]

1. Turn off the key switch and disconnect the battery plug. G5-2 [G5-5]
2. Disconnect the CN39 [CN40] connector and connect the CN39-3 to error occurs. Shock sensor 1
CN39-2 [CN40-3 to CN40-2] on the harness side through [shock sensor 2] defect
09232-13130-71.
3. Connect the battery plug and turn on the key switch.
Check the error code.

G5-1 [G5-4] error occurs.

Inspection 1: Harness check

NG
1. Turn off the key switch and disconnect the battery plug.
Harness defect
2. Disconnect the CN101 and CN103 connectors and check the
harnesses for their continuities.

OK

Main controller defect

sec04.book 177 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-177

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.)

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN39 [CN40] connectors, and visually check inside the G5-2 [G5-5]
connector and the caulked portion of its wire for defects. (Refer to error does not occur.
Connector contact defect
BEFORE TROUBLESHOOTING)
2. Connect the CN39 [CN40] connector, connect the battery plug, and
turn on the key switch to see if an error occurs.

G5-2 [G5-5] error occurs.

Inspection: Check of shock sensor 1 [shock sensor 2]

G5-1 [G5-4]
1. Turn off the key switch and disconnect the battery plug.
error occurs. Shock sensor 1
2. Disconnect the CN39 [CN40] connector.
[shock sensor 2] defect
3. Connect the battery plug and turn on the key switch.
Check the error code.

G5-2 [G5-5] error occurs.

Inspection 1: Harness check

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.

OK

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.)

1. Turn off the key switch and disconnect the battery plug, disconnect
the CN39 [CN40] connectors, and visually check inside the G5-3 [G5-6]
connector and the caulked portion of its wire for defects. (Refer to error does not occur.
Connector contact defect
BEFORE TROUBLESHOOTING)
2. Connect the CN39 [CN40] connector, connect the battery plug, and
turn on the key switch to see if an error occurs. (after one minute)

G5-3 [G5-6] error occurs.

Inspection: Check of shock sensor 1 [shock sensor 2]

G5-1 [G5-4]
1. Turn off the key switch and disconnect the battery plug.
error occurs. Shock sensor 1
2. Disconnect the CN39 [CN40] connector.
[shock sensor 2] defect
3. Connect the battery plug and turn on the key switch.
Check the error code.

G5-1 [G5-4] error does not occur.

Inspection 1: Harness check

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.

OK

Main controller defect

sec04.book 178 ページ ２０１０年４月２３日 金曜日 午後２時４３分

4-178

Inspection 1: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect CN39 [CN40], 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

CN103-8 to CN39-3 Continuity G5-1 *1
CN103-30 to CN39-2 Continuity G5-1 *1
CN101-32 to CN39-1 Continuity G5-2, -3 *2
CN39-2 to CN39-1 No continuity G5-1
CN39-3 to CN39-1 No continuity G5-1
CN39-3 to CN39-2 No continuity G5-2, -3
CN103-8 to CN40-3 Continuity G5-4 *3
CN103-19 to CN40-2 Continuity G5-4 *3
CN101-32 to CN40-1 Continuity G5-5, -6 *4
CN40-2 to CN40-1 No continuity G5-4
CN40-3 to CN40-1 No continuity G5-4
CN40-3 to CN40-2 No continuity G5-5, -6

*1: Connect CN39-2 and CN39-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-30 and CN103-8.
*2: Connect CN39-1 and CN39-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-32 and CN103-30
*3: Connect CN40-2 and CN40-3 on the harness side through 09232-13130-71 and check if there is continuity
between CN103-8 and CN103-19.
*4: Connect CN40-2 and CN40-1 on the harness side through 09232-13130-71 and check if there is continuity
between CN101-32 and CN103-19.
 sec04.book
ourWHEN NO ERROR CODE IS DISPLAYED
Probable causes of problems for which no error code is displayed
Note:
179 ページ

If an error code is displayed or the spanner light is on, be sure to perform checks with priority given to it.
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Emergency switch main body (with
Emergency switch) – • Release the emergency switch.
: Switch is held down.
２０１０年４月２３日

Check the battery voltage.

Battery
: Battery plug is disconnected. • Charge the Battery
金曜日

: Low voltage
Check the battery voltage.
Key switch main body
: Open failure
Emergency switch main body (with • Check the switch, and replace it if
Emergency switch) necessary.
午後２時４３分

: Open failure – • Check the harness and repair or

Key switch harness replace it if necessary.
: Wire breakage, short circuit or • Replace the F5 fuse.
Although the key switch or ten-key leakage (harness, connector or F5
operation is turned on, power is not fuse)
Power-supply supplied. Numeric keypad harness (with PIN
related control (The multifunction screen does not • Check the harness and repair or
code entry) –
appear, and the vehicle does not replace it if necessary.
: 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
4-179
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-180
Display power supply and ground
harness (with PIN code entry)
180 ページ

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)
２０１０年４月２３日

related control
Display power supply or ground
harness
金曜日

: 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
午後２時４３分

: 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.)
(EZ 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)
 sec04.book
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.
181 ページ

Matching screen.
: No agreement with the vehicle state
Check the brake switch voltage, using
Brake switch main body Analyzer.
• Check the switch and replace it if
: Open failure : Direction switch in neutral, drive
necessary.
Brake switch harness fully closed
• Check the harness and repair or
: Wire breakage, short circuit, Fully open and close the brake
replace it if necessary.
２０１０年４月２３日

leakage (harness or connector) cylinder valve to check the change

in voltage.
Check the seat switch, using Analyzer.
金曜日

Seat switch main body : Direction switch in neutral, drive • Check the seat and replace it if
: 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, connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
午後２時４３分

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
The vehicle does not run. • Check the drive motor, and repair or
Traveling : Seizure or dragging of drive motor front wheels off the ground, rotate
(The drive motor does not 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)
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.
Main controller
– • Replace the main controller.
: Internal failure
4-181
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-182
Pump motor rotation sensor main body
: Internal failure Check the voltage of the drive motor
182 ページ

• 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)
Load handling cannot be performed
２０１０年４月２３日

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.
金曜日

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.
Pump • Check the pump, and repair or
: Seizure replace it if necessary.
午後２時４３分

–
Pump motor • Check the pump motor, and repair or
: Seizure replace it if necessary.
Main controller
– • Replace the Main controller.
Load handling : Internal failure
and power Main body of load handling lever
steering potentiometer
: Internal failure Measure the voltage of the load
Only load handling cannot be Installation of load 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 load handling lever forward
replace it if necessary.
switch operation.) Load handling lever potentiometer and backward to check the change
harness in voltage.
: Wire breakage, short circuit,
leakage (harness or connector)
Main body of tilt forward/backward
switch (Conventional lever)
: Internal failure
Check the tilt forward/backward
Only load handling cannot be Installation of tilt forward/backward
switch, usingAnalyzer. • Check the switch and replace it
performed. switch
: Seated in the seat Operate the tilt ifnecessary.
(The pump motor operates normally : Installation portion is broken or
lever forward to backward position • Check the harness and repair
during steering operation and direction damaged.
to check the switch turns on and off orreplace it if necessary.
switch operation.) Tilt forward/backward switch
normary.
harness
: Wire breakage, short circuit,
leakage (harness or connector)
 sec04.book
Control
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
: Load handling lever in neutral
183 ページ

: 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 (Conventional lever) • Check the oil control valve, and
Only load handling cannot be : Seizure of or leakage from unload repair or replace it if necessary.
performed. valve • Check the unload valve solenoid
–
２０１０年４月２３日

(The pump motor operates normally Harness of unload valve solenoid and replace it if necessary.
during steering operation and direction : Wire breakage, short circuit, • Check the harness and repair or
switch operation.) leakage (harness or connector) replace it if necessary.
金曜日

Pump • Check the pump, and repair or

: Leak replace it if necessary.
–
Load handling Priority valve • Check the priority valve, and repair
and power : Leak, seizure or replace it if necessary.
午後２時４３分

steering Main controller

– • Replace the main controller.
: Internal failure
Only lowering is impossible. If a current flows, turn on the lowering
Lowering lock valve • Check the lowering lock valve, and
(Other load handling operations, lock solenoid using Active Test to
: Seizure (internal damage) rapair or replace it if necessary.
including raising, are possible.) lower the fork.
Only forward tilting is impossible.
If a current flows, turn on the tilt control
(Other load handling operations, Tilt control valve • Check the tilt control valve, and
solenoid using Active Test to lower the
including backward tilting, are : Seizure (internal damage) repair or replace it if necessary.
fork.
possible.)
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, connector) replace it if necessary.
it turns on and off normally.
4-183
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-184
Main body of steering angle sensor
: Internal damage
184 ページ

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,
The steering is heavy. leakage (harness or connector)
(The pump motor operates normally Pump • Check the pump, and repair or
２０１０年４月２３日

Load handling during material handling.) : Leak replace it if necessary.

and power Priority valve • Check the priority valve, and repair
–
steering : Leak, seizure or replace it if necessary.
金曜日

PS valve • Check the PS valve, and repair or

: Leak, seizure replace it if necessary.
Main controller
– • Replace the Main controller.
: Internal failure
午後２時４３分

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. FUNCTION DISPLAY")
(OCV WAY)
Backup buzzer main body
• Check the backup buzzer and
: Internal damage
replace it if necessary.
Backup buzzer harness –
• Check the harness and repair or
: Wire breakage, short circuit or leakage
replace it if necessary.
(harness, connector or F5 fuse)
Auxiliary equipment relay main body
• Check the auxiliary equipment relay
: Open failure
The backup buzzer (option) does not and replace it if necessary.
Auxiliary equipment relay harness –
sound. • Check the harness and repair or
: Wire breakage, short circuit,
replace it if necessary.
leakage (harness or connector)
Auxiliary Backup relay main body (EZ pedal)
• Check the backup relay and replace
equipment : Open failure
it if necessary.
Backup relay harness –
• Check the harness and repair or
: Wire breakage, short circuit.
replace it if necessary.
leakage (harness or connector)
Main controller (EZ pedal)
• 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)
 sec04.book
Control
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
185 ページ

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 backup buzzer (option) does not Backup relay main body (EZ pedal)
• Check the backup relay and replace
stop sounding. : Short circuit
it if necessary.
Backup relay harness –
• Check the harness and repair or
２０１０年４月２３日

: Short circuit, leakage (harness or

replace it if necessary.
connector)
Main controller (EZ pedal)
金曜日

– • Replace the main controller.

: Internal failure
Backup light main body
: Internal breakage, burnout of light • Check the backup light and replace
Auxiliary bulb it if necessary.
–
午後２時４３分

equipment Backup 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.
The backup light (option) does not go Auxiliary equipment relay harness –
• Check the harness and repair or
on. : Short circuit, leakage (harness or
replace it if necessary.
connector)
Backup relay main body (EZ pedal)
• Check the backup relay and replace
: Open failure
it if necessary.
Backup relay harness –
• Check the harness and repair or
: Short circuit, leakage (harness or
replace it if necessary.
connector)
Main controller (EZ pedal)
– • Replace the main controller.
: Internal failure
4-185
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-186
Backup light main body
• Check the backup light and replace
: Internal breakage,
186 ページ

it if necessary.
Backup 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
: Short circuit
and replace it if necessary.
Auxiliary equipment relay harness –
Auxiliary The backup light (option) does not go • Check the harness and repair or
２０１０年４月２３日

: Short circuit, leakage (harness or

equipment out. replace it if necessary.
connector)
Backup relay main body (EZ pedal)
金曜日

• Check the backup relay and replace

: Short circuit
it if necessary.
Backup relay harness –
• Check the harness and repair or
: Short circuit, leakage (harness or
replace it if necessary.
connector)
午後２時４３分

Main controller (EZ pedal)

– • Replace the main controller.
: Internal failure
Display setting
: OPS operation notification buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
disabled screen. FUNCTION DISPLAY")
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. FUNCTION DISPLAY")
Buzzer-related The traveling OPS return-to-neutral (OPS BUZZER)
control 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-
disabled screen. FUNCTION DISPLAY")
The load 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.
 sec04.book
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
Analyzer.
187 ページ

Parking brake switch main body

(The switch can also be checked by
: Short circuit • Check the switch, and adjust or
checking if the parking indicator on the
Installation of parking brake switch replace it if necessary.
display goes on and out.)
: Switch is held down. • Check the harness and repair or
: Direction switch is in neutral.
Parking brake switch harness replace it if necessary.
The parking brake lever release Operate the parking brake lever
: Short circuit (harness or connector)
reminder does not sound. lever to see if the switch turns on
and off normally.
２０１０年４月２３日

Check that the built-in buzzer sounds a

Display • If the buzzer does not sound,
short beep when the direction switch
金曜日

: Built-in buzzer is broken. replace the display.

(microswitch) is pressed.
Main controller
– • Replace the main controller.
: Internal failure
Check the parking brake switch, using
午後２時４３分

Analyzer.
Parking brake switch main body
(The switch can also be checked by
: Open failure • Check the switch, and adjust or
checking if the parking indicator on the
Buzzer-related Installation of parking brake switch replace it if necessary.
When the vehicle runs with the parking display goes on and out.)
control : Switch is off. • Check the harness and repair or
brake lever released, the parking : Direction switch is in neutral.
Parking brake switch harness replace it if necessary.
brake release reminder sounds. Operate the parking brake lever to
: Wire breakage (harness, connector)
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. FUNCTION DISPLAY")
(PKB BUZZER)
Check the parking brake switch, using
The parking brake lever reminder does Parking brake switch main body Analyzer.
not sound. (The switch can also be checked by
: Open failure • Check the switch, and adjust or
checking if the parking indicator on the
Installation of parking brake switch replace it if necessary.
display goes on and out.)
: Switch is off. • Check the harness and repair or
: Direction switch is in neutral.
Parking brake switch harness replace it if necessary.
Operate the parking brake lever to
: Wire breakage (harness, connector)
see if the switch turns on and off
normally.
4-187
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-188
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.
188 ページ

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.
The parking brake lever reminder does
Check that the built-in buzzer sounds a
not sound. 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.
２０１０年４月２３日

: Internal failure
Parking brake switch main body Check the parking brake switch, using
金曜日

Buzzer-related : Short circuit Analyzer. • Check the switch, and adjust or

control Installation of parking brake switch : Direction switch is in neutral. replace it if necessary.
: Switch is held down. Operate the parking brake lever to • Check the harness and repair or
Parking brake switch harness see if the switch turns on and off replace it if necessary.
: Short circuit (harness or connector) normally.
午後２時４３分

Although the parking brake lever is

Check the seat switch, using Analyzer.
pulled up, the parking brake reminder
Seat switch main body : Direction switch in neutral, drive • Check the seat switch and replace it
does not stop sounding.
: Open failure fully closed if necessary.
Seat switch harness Check if the switch turns on and off • Check the harness and repair or
: Wire breakage (harness, connector) 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. FUNCTION DISPLAY")
(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. : In 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. FUNCTION DISPLAY")
set.
 sec04.book
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 automatic lifting stop position is
189 ページ

position setting screen. FUNCTION DISPLAY")

not set.
Height selector switch main body
: Open failure, short circuit
Mechanical detection unit of height Check the height selector switch,
Although the height selector switch is • Check the height selector switch,
selector switch using Analyzer.
pressed, the automatic lifting stop and adjust or replace it if necessary.
: Gap in detection unit is improperly : Vehicle stopped
position cannot be selected. • Check the harness and repair or
２０１０年４月２３日

adjusted. Operate the height selector switch

replace it if necessary.
Height selector switch harness to see if it turns on and off normally.
: Wire breakage, short circuit
金曜日

(harness or connector)
Main controller
– • Replace the main controller.
: Internal failure
If the loading conditions, the tilt angle
午後２時４３分

of the mast, etc at that time are

different from those when the lifting – –
height was set, the fork stop position
Height selector may not agree with the set position.
(option) Lifting height sensor main body
: Dragging or improper winding of wire Check the lifting sensor voltage, using
Installation of lifting height sensor Analyzer.
• Check the sensor and replace it if
The fork stop position is far away from : Breakage of sensor installation : In NL
necessary.
the lifting height set position (100 mm portion, breakage of wire routing Raise and lower the lift to its
• Check the harness and repair or
or more). portion uppermost (relief) and lowermost
replace it if necessary.
Lifting height sensor harness positions to check the change in the
: Wire breakage, short circuit, voltage.
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. FUNCTION DISPLAY")
: 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.
Display setting
Shock sensor The shock detection function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Shock detection function disabled
(option) screen does not appear. screen. FUNCTION DISPLAY")
(SHOCK SENSOR)
4-189
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-190
Way in which the vehicle collides
: The degree of shock that the shock
190 ページ

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.
２０１０年４月２３日

Display setting
• Change the setting (see "MULTI-
: A too large (improper) value is set –
Although shock is applied, the shock FUNCTION DISPLAY")
for shock detection.
金曜日

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
午後２時４３分

its voltage changes.

Shock sensor harness replace it if necessary.
(Compare the voltages of sensors 1
: Wire breakage, short circuit,
and 2.)
leakage (harness or connector)
Shock sensor
Main controller
(option) – • Replace the main controller.
: 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 damage (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
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
One of the following matching
• Change the setting.
operations is not performed.
191 ページ

• Tire straight running angle matching

* If accelerator pedal fully closed and
• Forward tilt limit angle matching
fully open matching is finished by
• Tilt horizontal angle matching
[Diagnostic mode indicator] simply performing fully closed
Multifunction • Tilt no-load matching Check the matching value on the
Although no error code is displayed, matching and fully open matching in
display • Accelerator pedal fully closed Matching screen.
the diagnostic mode indicator is left on. this order, the setting will not be
matching
saved.
• Accelerator pedal fully open
２０１０年４月２３日

matching
* The same goes for brake pedal fully
• Mini-lever neutral voltage matching
closed and fully open matching.
金曜日

• Tire diameter data

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 : In NL replace it if necessary.
午後２時４３分

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.
The correct tilt angle is not displayed. leakage (harness or connector)
Tilt angle sensor leveling matching
Check the matching value on the
value • Perform matching again.
Multifunction Matching screen.
: No agreement with the vehicle state
display
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.
4-191
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-192
• Check the tires and replace them if
Tire specification necessary.
192 ページ

–
: 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
２０１０年４月２３日

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.
金曜日

connector)
Check the load sensor voltage, using
Load sensor main body Analyzer.
• Check the sensor and replace it if
: Internal damage : In NL
necessary.
Load sensor harness Raise and lower the lift to its
午後２時４３分

• 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. : In 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
The vehicle lacks stability during normally.
traveling.
Swing lock Yaw rate sensor main body Check the sensor voltage, using
(The swing mechanism does not lock • Check the sensor and replace it if
: Internal failure Analyzer.
easily or at all during traveling.) necessary.
Yaw rate sensor harness : Vehicle stopped
• Check the harness and repair or
: Wire breakage, short circuit, Check the sensor voltage approx.
replace it if necessary.
leakage (harness or connector) 2.5V.
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
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
• Check the lock cylinder, and repair
Lock cylinder main body Check the lock cylinder, using Active
or replace it if necessary.
193 ページ

: 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
２０１０年４月２３日

: Internal damage : 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
金曜日

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 lifting height switch, and
: In NL
午後２時４３分

detected. replace it if necessary.

The swing mechanism always locks Raise and lower the lift to its
Lifting switch harness • Check the harness and repair or
Swing lock during traveling or load handling, uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
or it locks frequently. to see if the switch turns on and off
(harness or connector)
normally.
Yaw rate sensor main body Check the sensor voltage, using
• Check the sensor and replace it if
: Internal failure Analyzer.
necessary.
Yaw rate sensor harness : Vehicle stopped
• Check the harness and repair or
: Wire breakage, short circuit, Check the sensor voltage approx.
replace it if necessary.
leakage (harness or connector) 2.5V.
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
4-193
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-194
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
194 ページ

Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is : In 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)
２０１０年４月２３日

Tilt angle sensor leveling matching

Check the matching value on the
value • Perform matching again.
Matching screen.
: No agreement with the vehicle state
金曜日

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
: Load handling lever in neutral necessary.
without stopping in a horizontal fork leveling switch
午後２時４３分

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, connector)
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 : In NL 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
 sec04.book
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.
195 ページ

• Check the sensor and replace it if

: Internal damage : In 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.
２０１０年４月２３日

: No agreement with the vehicle state Matching screen.

Main controller
– • Replace the main controller.
: Internal failure
金曜日

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 : In NL replace it if necessary.
午後２時４３分

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
(Mini Lever / Joystick Lever) Check the load sensor voltage, using
When tilted forward for leveling, the Load sensor main body Analyzer.
fork does not stop automatically in a • Check the sensor and replace it if
: Internal breakage : In NL
horizontal position. necessary.
Load sensor harness Raise and lower the lift to its
(When tilted forward for leveling, the • Check the harness and repair or
: Wire breakage, short circuit, uppermost (relief) and lowermost
fork stops where it is when the replace it if necessary.
leakage (harness or connector) positions to check the change in the
automatic fork leveling switch is voltage.
pressed.)
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
: In 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.
: Internal failure
4-195
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-196
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,
196 ページ

Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is : In 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)
(Mini Lever / Joystick Lever)
２０１０年４月２３日

Tilt angle sensor leveling matching

When the fork is tilted backward for Check the matching value on the
value • Perform matching again
leveling, it does not stop automatically Matching screen.
: No agreement with the vehicle state
金曜日

in a horizontal position.
(The fork tilts to its backward tilt limit Main body of automatic fork leveling
without stopping in a horizontal switch
Check the automatic fork leveling
position.) : Open failure
switch, using Analyzer. • Check the switch, and replace it if
Mechanical detection unit of automatic
: Load handling lever in neutral necessary.
fork leveling switch
午後２時４３分

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, connector)
Tilt control Main controller
– • Replace the main controller.
: Internal failure
(Mini Lever / Joystick Lever)
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 : In 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
 sec04.book
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
197 ページ

Check the automatic fork leveling

: Open failure
switch, using Analyzer. • Check the switch, and replace it if
Mechanical detection unit of automatic
: Load 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, connector)
２０１０年４月２３日

Check the tilt control valve, using • Check the oil control valve, and
Oil control valve
Active Test. repair or replace it if necessary.
金曜日

: 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
午後２時４３分

Lifting height switch main body Analyzer.

• Check the switch, and replace it if
: Low lifting height is always detected. : In NL
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
: Load 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 connector)
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.
4-197
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-198
Check the lifting height switch, using
Lifting height switch main body
Analyzer.
198 ページ

: A high lifting height is always • Check the switch, and replace it if

: In NL
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.
２０１０年４月２３日

: Internal failure
Display setting
Check the set value on the Option Set • Change the setting
: Forward tilting speed setting
金曜日

screen. (see "MULTI-FUNCTION DISPLAY")

(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. : In NL
Tilt control mast forward tilting speed is not necessary.
午後２時４３分

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
: In NL
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.
Knob position The knob is displaced from its normal damaged. fully closed • Check the harness and repair or
compensation position to a certain position. Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
control (10° or more from the straight running : Wire breakage, short circuit, the change in voltage.
(OPT) 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
 sec04.book
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
199 ページ

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
２０１０年４月２３日

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
金曜日

: 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
午後２時４３分

idles (heavy).

Knob position The road surface is inclined. – –

compensation Main controller
– • Replace the main controller.
control : Internal failure
(OPT) 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)
4-199
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-200
Check the knob position compensation
valve, using Active Test.
200 ページ

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
Knob position The knob is displaced from its normal compensation solenoid to check
harness necessary.
compensation position. how the steering system operates.
: Wire breakage, short circuit, • Check the harness and repair or
control (The knob position is not constant Forcibly ON ... Steering idles (light).
leakage (harness or connector) replace it if necessary.
Forcibly OFF ... Steering does not
２０１０年４月２３日

(OPT) during straight running.)

idles (heavy).
PS cylinder system link is defective. • Check the cylinder, and repair or
金曜日

–
: Eccentric pin or kingpin is defective replace it if necessary.
Main controller
– • Replace the main controller.
: Internal failure
Check the seat switch, using Analyzer.
午後２時４３分

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 load 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 load 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.
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Oil control valve (Conventional Lever)
• Check the oil control valve, and
: Seizure of or leakage from load
201 ページ

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 load handling OPS does not Harness of load handling proportional
OPS • Check the unload valve solenoid
operate. valve solenoid
and replace it if necessary.
Harness of unload valve solenoid
• Check the harness and repair or
: Wire breakage, short circuit,
２０１０年４月２３日

replace it if necessary.
leakage (harness or connector)
Main controller
金曜日

– • 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 damage : In NL
necessary.
Load sensor harness Raise and lower the lift to its
午後２時４３分

• 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. FUNCTION DISPLAY")
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 FSV or FV 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.
4-201
 sec04.book
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems

4-202
When the lift is raised to its uppermost
position, the load sensor cannot
202 ページ

distinguish this situation from a

situation in which a heavy load is
carried, because, in that situation, a
relief pressure remains in the lift
Lift relief pressure detected. –
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
２０１０年４月２３日

possible to perform operation because

the relief pressure is discharged when
金曜日

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.
午後２時４３分

• Check the sensor and replace it if

: Internal damage : 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
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. : In 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. FUNCTION DISPLAY")
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. FUNCTION DISPLAY")
actual vehicle state.
Main controller
– • Replace the main controller.
: Internal failure
 sec04.book
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.
203 ページ

: A high lifting height is always • Check the switch, and replace it if

: In NL
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.
２０１０年４月２３日

: Internal failure
control (option)
Display setting • Change the setting (see "MULTI-
Check the set value.
: Maximum speed limit is set very low. FUNCTION DISPLAY")
金曜日

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. FUNCTION DISPLAY")
or not.
actual vehicle state.
午後２時４３分

Main controller
– • Replace the main controller.
: Internal failure
4-203
sec05.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-1

MOTOR
5

Page
DRIVE MOTOR ................................................................. 5-2
GENERAL.......................................................................... 5-2
SPECIFICATIONS.............................................................. 5-2
COMPONENTS.................................................................. 5-3
REMOVAL·INSTALLATION ............................................... 5-4
DISASSEMBLY·INSPECTION·REASSEMBLY ................. 5-6
PUMP MOTOR .................................................................. 5-9
5
GENERAL.......................................................................... 5-9
SPECIFICATIONS............................................................ 5-10
COMPONENTS................................................................ 5-11
REMOVAL·INSTALLATION ............................................. 5-12
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 5-13
sec05.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-2

DRIVE MOTOR
5

GENERAL

SPECIFICATIONS
Vehicle model 8FBCU20·25
8FBCU28·30·32
Item 8FBCHU20
Type Three phase AC Three phase AC
Nominal voltage V 21/28 22/29
Rated output kW 10.8/14.8 13.2/18.0
Dimensions mm φ276 × 275 φ276 × 315
(outside diameter × length) (in) (10.87 × 10.83) (10.87 × 12.40)
Weight kg (lb) 127 (280) 145 (320)
Insulation class F F
sec05.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-3

COMPONENTS
1401

GP
CL

CL 01

CL

FX
43
GF CL

5
CL

1401-192

1401

AQ
AQ
BD BD

AQ AQ
AT
BD FV
AF
AT AD 60 41 AF
AF
20A AX
CH AX AX
BD
AU HN
ER
EE
BJ
BJ BJ
22
AX
AS 01
20B

20
AT
AW
20C
AT
EW
AT
18
AW AT
AT

49

1401-190
sec05.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-4

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 29.2 ~ 43.8
(298 ~ 447)
[21.5 ~ 32.3]

Removal Procedure

1 Remove the front axle ASSY W/drive motor ASSY. (See page 6-5)
2 Put match marks between the drive unit case and stator ASSY. [Point 1]
3 Loosen the through bolt and remove the drive motor. [Point 2]

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec05.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-5

Point Operations
Match mark
[Point 1]
Disassembly:
Put match mark on the drive unit case and stator ASSY.

Reassembly:
Align match mark when reassembling these parts.

[Point 2]
Removal⋅Installation:
Wave washer Carefully operate so as not to drop the rotor ASSY.

Installation:
(1) Never fail to install the wave washer on the bearing
face of the rotor ASSY. It is recommended to apply a
small amount of MP grease in order to prevent the 5
washer from falling.
(2) Apply the molybdenum disulfide grease at the splined
portion of the rotor shaft.
(3) Carefully operate so as not to damage the oil seal lip
surface.
sec05.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-6

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf-cm) [ft-lbf]

T = 5 (51) [3.69]

T = 5 (51) [3.69]
2
T = 23.7 (242) [17.49]
4
5

3
7

T = 13 (133) [9.59] 10

8
T = 5 (51) [3.69] 9

Disassembly Procedure
1 Remove the temperature sensor clamp.
2 Remove the sensor cover.
3 Remove the revolution sensor.
4 Remove the revolution sensor gear.
5 Remove the snap ring.
6 Remove the bolt.
7 Remove the terminal bracket and end plate.
8 Remove the end frame. [Point 1]
9 Remove the rotor ASSY.
10 Remove the bearing. [Point 2]
11 Inspect the stator ASSY. [Point 3]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

sec05.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-7

Point Operation
SST(1)
[Point 1]
SST(2)
Disassembly:
Use the SST to remove the end frame.
SST 09950-76014-71 (09950-40011) ...(1)
09140-10920-71............................(2)

[Point 2]
Removal:
Check the bearing of the rotor ASSY.
SST If abnormal noise or damage is found, replace the
bearing.
SST 09950-76014-71
(SST 09950-40011)

Installation:
SST 09700-30200-71

SST

[Point 3]
Inspection:
(1) Measure the insulation resistance of the stator ASSY.

Measurement terminals:
Between the terminals and body
Standard: 1 MΩ or more

(2) Check continuity between terminals.

Measurement terminals: U-V, V-W, W-U

Standard: 0 Ω
sec05.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-8

(3) Measure the resistance of the thermo-sensor.

Measurement terminals:
Both terminals of temperature sensor connector
Standard: Approx. 11 ~ 15 kΩ
(at 20°C [68°F])
sec05.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-9

PUMP MOTOR
GENERAL
sec05.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-10

SPECIFICATIONS
Vehicle model
All models
Item
Type Three phase AC
Nominal voltage V 21/27
Rated output kW 11.3/15.1
Dimensions mm φ220 × 282
(outside diameter × length) (in) (8.66 × 11.10)
Weight kg (lb) 47 (104)
Insulation class H
sec05.book 11 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-11

COMPONENTS
1401

01

AE
AB AE
AE
AE AB
AB AE
AE
AE
AB
AE CO
CO
CO

45
1402-166

1401

41

01B

BF

21 42

22 01
AZ
BJ
AX
01B
AT AZ
EH
GN
EY AQ GN
AZ CR
GN
23 CR
AU AU CR
AC CW DX
CG AU
AT AU
AZ
BS AC
BS
AC

AC
BS
BS
1402-167
sec05.book 12 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-12

REMOVAL·INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

5
6

Insulator (4PCS.):
T = 30.0 ~ 122.0
(306 ~ 1244)
[22.1 ~ 90.0]

Removal Procedure

1 Disconnect the battery plug.

2 Remove the side cover RH.
3 Disconnect the wiring and connector.
4 Disconnect the oil pump from the pump motor ASSY.
5 Remove the pump motor ASSY W/mounting bracket.
6 Remove the pump motor ASSY from the mounting bracket.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec05.book 13 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-13

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 3.0 ~ 7.0
(36 ~ 71)
[2.2 ~ 5.2]

10

T = 14.2 ~ 33.2
(145 ~ 339) 8 9
[10.5 ~ 24.5]

T = 7.8 ~ 18.2
(80 ~ 186) 11
[5.8 ~ 13.4] 6
T = 3.0 ~ 7.0
(36 ~ 71)
2 5 [2.2 ~ 5.2]
4 3

T = 17.2 ~ 22.8
(175 ~ 232)
7 [12.7 ~ 16.8]

Disassembly Procedure

1 Remove the temperature sensor clamp .

2 Remove the sensor cover.
3 Remove the speed sensor.
4 Remove the pickup gear.
5 Remove the snap ring.
6 Remove the bolt.
7 Remove the housing set bolt.
8 Remove the end bracket. [Point 1]
9 Remove the rotor ASSY.
10 Remove the bearing. [Point 2]
11 Inspect stator ASSY. [Point 3]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

sec05.book 14 ページ ２０１０年４月２３日 金曜日 午前１１時５７分

5-14

SST (1)
Point Operations
[Point 1]
SST (2)
Disassembly
Use the SST to remove the end bracket.
SST 09950-76014-71(09950-40011).... (1)
09140-10920-71 ........................... (2)

[Point 2]
SST (1)
Disassembly:
Use the SST to remove the bearing.
SST 09950-76014-71(09950-40011) ....(1)
09950-76018-71(09950-60010) ....(2)

SST (2)

[Point 3]
Inspection:
1. Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and body
Standard: 1 MΩ or more

2. Check continuity between motor cables.

Measurement terminals: U-V, V-W, W-U
Standard: 0 Ω

3. Measure the resistance of the thermo-sensor.

Measurement terminals:
Both terminals of temperature sensor
connector
Standard: 11 to 15 kΩ (at 20°C)
sec06.book 1 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-1

DRIVE UNIT
6

Page
GENERAL .......................................................................... 6-2
SPECIFICATIONS ............................................................ 6-3
COMPONENTS ................................................................. 6-3
DRIVE UNIT ASSY ........................................................... 6-5
REMOVAL·INSTALLATION ............................................... 6-5
DISASSEMBLY·INSPECTION·REASSEMBLY ................. 6-8
DIFFERENTIAL CASE ASSY...................................... 6-11
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 6-11
6
sec06.book 2 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-2

GENERAL
6

B
Third axis
(Pinion shaft) C D
Second axis First axis
(Counter shaft) (Motor input shaft)

X-X

A
Fourth axis
(Axle shaft)
D X

X A C
B
sec06.book 3 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-3

SPECIFICATIONS
Model
All models
Item
Number of teeth of motor
23
shaft gear
Large: 92
Number of teeth of idle gear
Small: 43
Number of teeth of pinion Large: 84
gear Small: 12
Number of teeth of
53
differential gear
Total reduction gear ratio 34.512
Drive unit oil quantity
l (US gal)
6.0(1.58)
Differential oil quantity
l (US gal)

COMPONENTS 6
4101

Refer to
FIG.3305

02

02

AB
20

48A
46
46A 48

48A
48
48
48A

48 46A
46
48A

4101-262
 sec06.book

6-4
4 ページ

BJ

AG

53A
AV
AM
２０１０年４月２３日

AZ
30[RH] AH AP
BM
金曜日

Refer to
57 FIG.1401
午後２時１３分

AO
AA BR
AF
EA 57A
51B
51
AW AW 52B 51A
BP Refer to 57A 52
4101-02

AX
32B
32A AW
52A
32B
32A
53B AR
53

EA
AF BM
AH
BP
AX

3305-037
3305
sec06.book 5 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-5

DRIVE UNIT ASSY

REMOVAL·INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

13

T = 235 ~ 294
(2400 ~ 3000)
[173.6 ~ 217.1]

T = 98 ~ 127
(1000 ~ 1300)
[72 ~ 94]
11 12
T = 235 ~ 294
(2400 ~ 3000)
[173.6 ~ 217.1] 15
T = 28.5~ 42.7 16
6
(291 ~ 435)
[21.0 ~ 31.5] 10
14

T = 167 ~ 225
(1700 ~ 2300)
[123 ~ 166]

T = 108 ~ 137
T = 98 ~ 127 15 (1100 ~ 1400)
(1000 ~ 1300) [79.6 ~ 101.3]
[72 ~ 94]

T = 108 ~ 137
16 (1100 ~ 1400)
[79.6 ~ 101.3]
sec06.book 6 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-6

Removal Procedure
1 Remove the mast ASSY. (See page 13-4)
2 Remove the battery. (See page 1-5)
3 Drain drive unit oil. [Point 1]
4 Jack up the vehicle, and remove the front wheels. [Point 2]
5 Drain brake fluid, and disconnect the brake piping.
6 Remove the toe board (front and rear), lower panel and instrument panel LH.
7 Disconnect the parking brake wire.
8 Disconnect the wiring from the drive motor ASSY.
9 Disconnect the drive motor speed sensor connector and temperature sensor connector.
10 Use a garage jack and support the front axle ASSY W/drive motor. [Point 3]
11 Remove the front axle bracket set bolt. (through bolts)
12 Remove the front axle bracket set bolt. (reamer bolts) [Point 4]
13 Hoist the front side of the vehicle and move the vehicle backward. [Point 5]
14 Remove the drive motor ASSY. (See page 5-4)
15 Remove the front axle shaft.
16 Remove the front axle hub W/axle bracket and axle housing.

Installation Procedure

The installation prosedure is the reverse of the removal procedure.

Note:
After the end of installation, perform air bleeding from the brake system (See page 10-13) and
parking brake inspection adjustment (See page 10-19)

Point Operations
[Point 1]
Installation:
After installation, fill hypoid gear oil to the specified level.

A A = Within 15 mm (0.6 in)

[Point 2]
Removal⋅Installation:
Jack up the vehicle and support both sides of the front
frame with wooden blocks.
sec06.book 7 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-7

[Point 3]
Removal:
Support the differential with a garage jack.

[Point 4]
Removal:
Use the SST to remove the reamer bolts in the illustrated
positions.

LH RH

Removal:
SST 09310-23320-71

SST

[Point 5]
Removal⋅Installation:
Wind a fiber rope on the front side of the over head guard.
sec06.book 8 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-8

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 82 ~ 123
3 T = (836 ~ 1254)
T = [60.5 ~ 90.7]

3 2

1
3

T = 82 ~ 123
T = (836 ~ 1254) 4
T = [60.5 ~ 90.7]

Disassembly Procedure

1 Remove the drive unit cap and lock nut. [Point 1]

2 Erect the housing with the gear case cover LH on the upper side, remove the gear case cover LH.
[Point 2]
3 Remove the reduction gears No.1, 2 and 3. [Point 3]
4 Face the drive unit gear case cover RH upward, and remove the gear case cover RH. [Point 4]
5 Remove differential ASSY W/reduction gear shaft No.1.

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

sec06.book 9 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-9

Point Operations
[Point 1]
Disassembly⋅Reassembly:
Set the SST on the spline of the input shaft, and remove
SST
the lock nut.
Take care not to give harm on the oil seal when setting
SST.
SST 09330-21440-71
Tightening torque T = 167 ~ 225 N⋅m
(1700 ~ 2300 kgf⋅cm) [123 ~ 166 ft⋅lbt]
Reassembly:
Use a punch and caulk the lock nut securely (at 2 places).

[Point 2]
Disassembly:
Use a service bolt and remove the gear case cover LH.
Service bolt: M14 × 1.5

Reassembly:
Apply liquid gasket (08826-76002-71 (08826-00090)) on
the surface to be in contact with the gear case cover LH.

[Point 3]
Disassembly:
As a bearing exists on the nut side end of reduction gear
No.3, remove the gear by pulling it up while tapping the
nut side end with a hammer.

Reduction gear No.3

Reassembly:
Install reduction gear No.1 with the bearing seal facing the
motor.
sec06.book 10 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-10

[Point 4]
Reassembly:
Apply liquid gasket (08826-76002-71 (08826-00090)) on
the surface to be incontact with the gear case cover RH.
sec06.book 11 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-11

DIFFERENTIAL CASE ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 127 ~ 176.5
T = (1300 ~ 1800)
T = [94.1 ~ 130.2] 3

T = 43.1 ~ 53.9
T = (440 ~ 550)
3 T = [17.3 ~ 21.7]
2
1

Disassembly Procedure

1 Remove the differential case bearings. [Point 1]

2 Remove the differential upper case. [Point 2]
3 Remove the side gear and pinion gear. [Point 3]
Remove the ring gear. [Point 4]
sec06.book 12 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-12

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
SST (1)
Disassembly:
SST 09950-76014-71 ............ (1)
SST (2)
(SST 09950-40011)
SST 09950-76018-71 ............ (2)
(SST 09950-60010)

Reassembly:
Install the side bearing.

1. Use the SST and install the side bearing up to the

end face of the case.
SST SST 09370-10410-71

2. Use an appropriate tool and hammer to drive the

bearing fully in.

[Point 2]
Disassembly⋅Reassembly:
Match mark Check the match mark.

Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on
the threaded portion of the set bolt.

[Point 3]
Inspection:
Measure the differential pinion inside diameter.

Standard: 22.12 mm (0.8709 in)

Limit: 22.22 mm (0.8748 in)
sec06.book 13 ページ ２０１０年４月２３日 金曜日 午後２時１３分

6-13

Inspection:
Measure the spider outside diameter.

Standard: 22.00 mm (0.8661 in)

Limit: 21.75 mm (0.8563 in)

Inspection:
Measure the side gear thrust washer thickness.

Standard: 1.6 mm (0.063 in)

Limit: 1.3 mm (0.051 in)

Inspection:
Measure the pinion gear thrust washer thickness.

Standard: 1.6 mm (0.063 in)

Limit: 1.0 mm (0.039 in)
Reassembly:
Install the side gear thrust washer with its oil groove facing
the tooth flank.

Reassembly:
Apply chassis grease (molybdenum disulfide grease) on
Grease application
both sides of the spider pinion thrust washer before
reassembly.

[Point 4]
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on
the threaded portion of the set bolts. Tighten them
gradually first in the diagonal order, and finally tighten
them in the circular order to the specified torque.

T = 127.5 ~ 176.5 N⋅m

T = (1300 ~ 1800 kgf⋅cm)
T = [94.1 ~ 130.2 ft⋅lbf]
sec06.book 14 ページ ２０１０年４月２３日 金曜日 午後２時１３分
sec07.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-1

FRONT AXLE
7

Page
GENERAL .......................................................................... 7-2
SPECIFICATIONS ............................................................ 7-4
COMPONENTS ................................................................. 7-4
FRONT AXLE SHAFT·AXLE HUB ............................... 7-6
REMOVAL·INSTALLATION ............................................... 7-6
FRONT AXLE BRACKET·AXLE HOUSING .............. 7-9
REMOVAL·INSTALLATION ............................................... 7-9

7
sec07.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-2

GENERAL
20⋅25 Model

7
sec07.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-3

28~32 Model

7
sec07.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-4

SPECIFICATIONS
Model
All models
Item
Front axle type Full-floating
Suspension type Fixed to frame

COMPONENTS
20⋅25 model 4201

Refer to AB
3305-BP CT 43[RH]
44[LH] AA

BT
FS
AJ
AJ
DA 43B AA
41A 41E
41

41B 41B
41G

BP

AD
AF 49 41D 40
40C
40B
41J

40A
4201-340
sec07.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-5

28~32 model 4201

CT
43[RH]
44[LH]
AB

BT
FS AA
AJ
Refer to AJ
3305-BP
43A
AA
DA
41E 41G

AD
41A AF
AC
41B
41D
40C

41 41B
49 40
BP
40B
41J 7
41A
4201-342
sec07.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-6

FRONT AXLE SHAFT·AXLE HUB

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

30⋅32 model only T = 166.7 ~ 205.9 (1700 ~ 2100) [123.0 ~ 151.9]

T = 294.2 ~ 588.4
(3000 ~ 6000)
[217.1 ~ 434.1]

8 5
T = 2.0 ~ 3.9
7 (20 ~ 40)
[1.45 ~ 2.89]

T = 98.1 ~ 127.5
9
(1000 ~ 1300)
6 [72.4 ~ 94.1]
4

Removal Procedure

1 Drain drive unit oil. [Point 1]

2 Jack up the vehicle and remove front wheel.
3 Remove the front axle shaft. [Point 2]
4 Remove the axle shaft oil seal. [Point 3]
5 Remove the bearing lock nut and plate. [Point 4]
6 Remove the outer bearing roller and front axle hub. [Point 5]
7 Remove the oil seal and inner bearing roller. [Point 6]
8 Remove the bearing outer race. [Point 6]
9 Remove the hub bolt.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec07.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-7

Point Operations
[Point 1]
Installation:
Fill Hypoid gear oil to the specified level after installation.

A A = within 15 mm (0.059 in)

[Point 2]
Removal⋅Installation:
Carefully operate so as not to damage the oil seal by
contact with the axle shaft.

[Point 3]
Removal:
SST 09320-23000-71

SST

Installation:
SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST 09950-76020-71 ............(2)
(SST 09950-70010)

SST (2) SST (1)

[Point 4]
Removal⋅Installation:
SST 09509-76003-71
(SST 09509-55030)

SST
sec07.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-8

Installation:
Adjust the front axle hub starting force.
1. Install the plate.
2. Fully tighten the bearing lock nut, and rotate the hub
by 4 to 5 turns to run in the bearing.
3. Return the bearing lock nut by 1/12 to 1/6 turn (30 to
60°), and rotate the hub by 4 to 5 turns again.
4. Set a spring scale on a hub bolt, and measure the
starting force.
Standard:
25.5 ~ 72.6 N (2.6 ~ 7.4 kgf) [5.7 ~ 16.3 lbf]
5. If the standard is not satisfied, adjust the degree of
bearing lock nut tightening for adjustment.
6. Install the nut lock screw.
Coat thread tightener (08833-76002-71 (08833-
00080)), on the nut lock screw before tightening.

[Point 5]
Installation:
Fill MP grease in the hub before installing the front axle
hub.
Installation:
SST 09370-10410-71

SST

[Point 6]
Removal:
SST (2) Use a screwdriver or the like to remove the oil seal.
Removal:
Use a brass bar to remove the bearing.
Installation:
SST 09950-76019-71 ............(1)
SST (1) (SST 09950-60020)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
sec07.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-9

FRONT AXLE BRACKET·AXLE HOUSING

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 167 ~ 225 (1700 ~ 2300) [123 ~ 166]

4
3

T = 108 ~ 137 (1100 ~ 1400) [79.6 ~ 101.3]

T = 137 ~ 196 (1400 ~ 2000) [101.3 ~ 144.7]

Removal Procedure

1 Remove the front axle W/drive motor ASSY. (See page 6-5)
2 Remove the front axle shaft and axle hub. (See page 7-6)
3 Remove the brake ASSY. [Point 1]
4 Remove the front axle bracket and O-ring.
5 Remove the axle housing and O-ring.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
Apply grease on the O-ring before installation.
sec07.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時３１分

7-10

Point Operation
[Point 1]
Installation:
Sealing agent Apply sealing agent (08826-76001-71 (08826-00080)) on
the mating surfaces of the brake backing plate and front
axle bracket before installation.
Installation:
Apply locking agent (08833-76001-71 (08833-00070)) on
the set bolts before tightening.
sec08.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-1

REAR AXLE
8

Page
GENERAL .......................................................................... 8-2
SPECIFICATIONS ............................................................ 8-4
COMPONENTS ................................................................. 8-5
REAR AXLE ASSY .......................................................... 8-7
REMOVAL·INSTALLATION ............................................... 8-7
STEERING KNUCKLE .................................................. 8-10
REMOVAL·INSTALLATION ............................................. 8-10
REAR AXLE CYLINDER .............................................. 8-15
REMOVAL·INSTALLATION ............................................. 8-15
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 8-17
8
sec08.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-2

GENERAL
8
sec08.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-3

Rear Axle Cylinder

8
sec08.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-4

SPECIFICATIONS
Rear axle type Elliot type
Rear axle suspension type Center-supported right-left rocking type
Toe-in mm (in) 0 (0)
Camber degree 1.5°
Wheel alignment
Caster degree 0°
King pin angle 0°
8FBCU20 model : 1790 (70.5)
8FBCU25 : 1800 (70.9)
8FBCHU25 : 1940 (76.4)
Minimum turning radius (outermost) mm (in)
8FBCU28 model : 1845 (72.6)
8FBCU30 model : 1960 (77)
8FBCU32 model : 2000 (78.7)
Cylinder type Double acting
Piston rod outside 20⋅25 model : 40.0 (1.575)
Rear axle cylinder diameter mm (in) 28 ~ 32 model : 50.0 (1.969)
20⋅25 model : 70.0 (2.756)
Cylinder bore mm (in)
28 ~ 32 model : 76.0 (2.992)
sec08.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-5

COMPONENTS
4301

JN BQ
JM BQ

GJ BQ 16
GJ
JN
GJ JO EC

EC EC
GV

EC JL
BQ

GJ EF

4301-268 8

4301

CF

GU

DN

DN

20A CL

EJ

GC

20A
CL

20B 01

EJ

GC
4301-267
sec08.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-6

4301

42K=(INCL. )

CG AU
EQ
HJ

20

JC 42
Refer to
4302-01 BX

DY
42C
EK

AC 42A
Refer to
AC FIG.4407
40[RH]
41[LH]
BR 44A
BR
DG 42E
AC
DG
47[UPPER] 42C
42B 44F
CK
CP CK

CK CP
CK 44E
45
JS 47[LOWER]
DV JS
DV 44B
44H
44G

4301-270

4302
BB

BC
(RUST PROOF)
01
AK

BH BT 46 01K=(INCL. )
44
AB BS
AX AC
BT 45
AD

BS

BB

BC
BA

AD 46 (RUST PROOF)
21 44
BT
AX
AC AB
BT
AK

BH
4302-047
sec08.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-7

REAR AXLE ASSY

REMOVAL·INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

8 7
3
6

T= 128~175 (1310~1780) [94.8~128.8]

Removal Procedure

1 Chock the front wheels.

2 Jack up the vehicle and remove rear wheels. (See removal procedure steps 2 to 4 in steering knuckle
removal-installation section on page 8-10.)
3 Remove the swing crank rod pin (lower) of swing lock cylinder. [Point 1]
4 Disconnect the rear axle cylinder hose.
5 Support the rear axle ASSY with a garage jack.
6 Remove the rear axle ASSY. [Point 2]
7 Remove the center pin bushing. [Point 3]
8 Remove the rear axle damper. (Lifting height 5000 mm (198 in) or above)

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
After installation, add grease through each grease fitting. Add molybdenum disulfide grease at the
rear axle beam center pins (two places) and swing lock cylinder crank rod pin. Use MP grease to
other grease fittings.
sec08.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-8

Upper Point Operations

[Point 1]
Rod
Installation:
Install the rod with its chamfered side down.

Chamfering
Lower

Make sure that the upper and lower sides of the rod pin
are positioned correctly. (The upper and lower grooves
are in different locations.)

Rod

Rear viaw

[Point 2]
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: 0.7 mm (0.028 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:
0.6⋅1.2⋅2.3⋅3.0⋅3.5⋅4.0⋅4.5 and 5.0 mm
(0.024⋅0.047⋅0.091⋅0.118⋅0.138⋅0.157⋅0.177 and
0.197 in)

Removal:
Draw different match marks on the rear axle bracket caps
front and rear to prevent confusion.

Installation:
Match mark Install after aligning the match mark.
sec08.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-9

[Point 3]
Inspection:
Inspect the inside diameter of the rear axle center pin
bushing.

Limit: 52.0 mm (2.047 in)

Installation:
Apply molybdenum disulfide grease to the bushing before
installation.

Installation:
Install the bushing by aligning the grease groove in the
bushing with the grease fitting position.

Grease
groove
sec08.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-10

STEERING KNUCKLE
REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

9
7

11

12
T = 49.0 ~ 73.5 (500 ~ 750)
10 T = [36.2 ~ 54.3]

11 9
3

2
11
5
T = 35 ~ 52
T = (357 ~ 530) 6 5
T = [25.8 ~ 38.4] T = 44.1 ~ 53.9
T = (450 ~ 550)
T = [32.6 ~ 39.8] 4

Removal Procedure

1 Jack up the vehicle.

2 Remove the hub cap. [Point 1]
3 Remove the castle nut and claw washer. [Point 2]
4 Remove the outer bearing and rear wheel. [Point 3]
5 Remove the bearing outer race from the rear wheel. [Point 4]
6 Remove the inner bearing roller and oil seal. [Point 5]
7 Disconnect the tie rod (on the knuckle side). [Point 6]
8 Remove the king pin cover.
9 Remove the king pin lock bolt and king pin. [Point 7]
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seal and needle roller bearing. [Point 8]
12 Remove the bushing from the steering knuckle. [Point 9]

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
After installation, add MP grease through grease fittings.
sec08.book 11 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-11

Point Operations
[Point 1]
Installation:
Fill MP grease 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:
Adjust the rear wheel starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a
torque of 15 to 32 N⋅m (150 to 330 kgf⋅cm) [10.9 to
23.9 ft⋅lbf].
3. Rotate the hub by 3 to 5 turns to run in the bearing.
Claw washer

4. Set a spring scale at the outer periphery of the wheel,

and measure the starting force.
Standards:
9.8 ~ 29 N (1.0 ~ 3.0 kgf) [2.2 ~ 6.6 lbf]

Note:
Wind a rope around a wheel 2 or 3 times to prevent the
rope from slipping on the wheel.

5. If the standard is not satisfied, adjust the degree of

castle nut tightening for adjustment.
6. Install a new cotter pin.

[Point 3]
Installation:
Fill MP grease in the hub and knuckle spindle.
sec08.book 12 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-12

Installation:
Install the rear wheel and outer bearing.
SST 09370-20270-71

SST

[Point 4]
SST (2) Removal:
SST (1) Use a brass bar and remove the bearing outer race.

Installation:
SST 09950-76019-71 ................ (1)
(SST 09950-60020)
SST 09950-76020 ..................... (2)
(SST 09950-70010)

[Point 5]
SST
Removal:
SST 09950-76014-71
(SST 09950-40011)

Installation:
Install the oil seal and inner bearing roller.
1. Use the SST and install the oil seal.
SST 09370-10410-71

SST

2. Use the SST and install the inner bearing roller.

SST 09370-20270-71

SST
sec08.book 13 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-13

[Point 6]
Seal cone
washer Installation:
To install the end pin lock nut, install the seal cone washer
in the direction shown in the figure and tighten to a
specified torque.

T = 49.3 ~ 73.5 N·m (500 ~ 750 kgf-cm)

Seal cone [36.2 ~ 54.3 ft-lbf]
washer

[Point 7]
Inspection:
Measure the king pin outside diameter.

Limit: 27.8 mm (1.094 in)

Installation:
Punch mark
Before installation, check the positional relationships
between the punch mark on top of the king pin and the
king pin lock bolt.

Lock bolt

Installation:
Measure the steering knuckle starting force.
1. 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.
2. Set a spring scale at the tip end of the knuckle
spindle, and measure the starting force.
Standard: 19.3 N (2.0 kgf) [4.4 lbf] or less

3. If the standard is exceeded, check the king pin for

bend, the needle bearing for damage and axle beam
for deformation.

Spacer thickness: 3.0, 3.5, 4.0 and 4.5 mm

(0.118, 0.138, 0.157 and
0.177 in)

4. Tighten the lock nut for the king pin lock bolt.
sec08.book 14 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-14

[Point 8]
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 (2) SST 09950-76018-71 ......... (1)
(SST 09950-60010)
SST (1)
SST 09950-76020-71 ......... (2)
(SST 09950-70010)

Installation:
Install the needle roller bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
0 mm Check the needle roller bearing press-fitting surface,
(0 in) pressing direction and installation depth.
SST 09950-76018-71 ......... (1)
(SST 09950-60010)
SST 09950-76020-71 ......... (2)
(SST 09950-70010)
4 mm
(0.16 in)
2. Install the dust seal.
3. Use the SST and install the oil seal.
SST 09950-76018-71 ......... (1)
(SST 09950-60010)
SST 09950-76020-71 ......... (2)
(SST 09950-70010)

Press-fitting direction

[Point 9]
Bushing Installation:
Drive in the bushing to the specified depth as shown in the
1.3 mm (0.051 in)
illustration.

(1.3 mm (0.051 in))

sec08.book 15 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-15

REAR AXLE CYLINDER

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 166.7 ~ 215.8 (1700 ~ 2200)

T = [123.0 ~ 159.1]
3

2
4 5

T = 49.0 ~ 73.5 (500 ~ 750) [36.2 ~ 54.3]

Removal Procedure

1 Jack up the vehicle.

2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder. [Point 3]
5 Remove the bushing from the piston rod. [Point 4]

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec08.book 16 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-16

Point Operations
Seal cone
washer
[Point 1]
Installation:
To install the end pin lock nut, install the seal cone washer
in the direction shown in the figure and tighten to a
specified torque.

Seal cone T = 49.0 ~ 73.5 N·m (500 ~ 750 kgf-cm)

washer [36.2 ~ 54.3 ft-lbf]

[Point 2]
Installation:
Install the fitting in the illustrated direction.

20° 20°

[Point 3]
Bushing
Installation:
1.3 mm (0.051 in)
Drive in the bushing to the specified depth as shown in the
illustration.

(1.3 mm (0.051 in))

sec08.book 17 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-17

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 29.2 ~ 38.0 1 4
T = (298 ~ 387)
T = [21.5 ~ 28.0]
2

3
1

T = 29.2 ~ 38.0
T = (298 ~ 387)
T = [21.5 ~ 28.0]

Disassembly Procedure

1 Remove the through bolt.

2 Remove the piston rod guide.
3 Remove the piston rod. [Point 1]
4 Inspect the cylinder. [Point 2]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note:
Coat hydraulic oil before reassembly.
sec08.book 18 ページ ２０１０年４月２３日 金曜日 午前１１時２９分

8-18

Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.

Limit:
20·25 model : 39.92 (1.5717 in)
28 ~ 32 model: 49.92 (1.9654 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:
Operate carefully to avoid scalding.
[Point 2]
Inspection:
Measure the rear axle cylinder bore.

Limit:
20⋅25 model: 70.35 mm (2.7697 in)
28 ~ 32 model: 76.35 mm (3.0059 in)
sec09.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-1

STEERING
9

Page
GENERAL .......................................................................... 9-2
SPECIFICATIONS ............................................................ 9-4
COMPONENTS ................................................................. 9-4
STEERING WHEEL·MAST JACKET ........................... 9-7
REMOVAL·INSTALLATION ............................................... 9-7
DISASSEMBLY·INSPECTION·REASSEMBLY ................. 9-9
HYDROSTATIC STEERING VALVE ASSY .............. 9-10
TROUBLESHOOTING ..................................................... 9-10
REMOVAL·INSTALLATION ............................................. 9-11
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 9-12
RELIEF PRESSURE
INSPECTION·ADJUSTMENT ................................... 9-16 9
sec09.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-2

GENERAL
9

Steering wheel

Combination switch
RH:Turn signal light switch
LH:Direction lever

Parking brake release lever

Adjusting lever for tilt steering

Parking brake wire

Parking brake pedal

12
°

Movable range for tilt steering

sec09.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-3

Hydrostatic Steering Valve

1 9 2 5 4 6 7

1. Neutral position spring

2. Housing
3. Check valve
4. Spool
5. Sleeve
6. Cardan shaft
7. Gear rim
8. Gear wheel (rotor)
9. Relief valve

L R

P T LS
sec09.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-4

SPECIFICATIONS
Model
20⋅25 28⋅30⋅32
Item
Steering wheel diameter mm (in) 300 (11.8)
Steering wheel play (at idling) mm (in) 20 ~ 50 (0.79 ~ 1.97)
Power steering type Hydrostatic steering
Type (manufacturer) OSPC (Danfoss)
Delivery cm3 (in3)/rev 90 (5.49) ←
Hydrostatic steering Rated flow rate
valve 12 (3.2) ←
l (US gal)/min
Relief set pressure
7.2 (73) [1038] 7.8 (80) [1138]
MPa (kgf/cm2) [psi]

COMPONENTS
4501

(STEERING KNOB)
01

48
Refer to
4502-CQ
01

4501-074
sec09.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-5

4502

CQ

Refer to
4501-01

GQ

CR
FU

GP

EC
KZ
EZ
37

FS
AI
GR

AX

AB

BN
20
JL
CR
4502-286

9
4507

AT
55A
BJ 55
AZ
BJ 42
AX

GD
43
BJ

53 54
CD MQ
GE 55A
BJ
AU DB
AS
AU
CI
CK
AS
DB

EA BJ CA
BZ
GU FO
AU
GG
CQ HA
BH
CQ
KY
CI 42 BC
CQ EP HA
EI 77
FN
BZ 43

Refer to
FIG.4302

KN

DE

4507-324
sec09.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-6

4503

CE

AQ

01

4503-078
sec09.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-7

STEERING WHEEL·MAST JACKET

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 24.5 ~ 45.5
(250 ~ 464)
[18.1 ~ 33.6]

T = 29.8 ~ 38.8
(304 ~ 398)
[22.0 ~ 28.6]

6
4
8
T = 7.2 ~ 16.7
(73 ~ 171)
[5.3 ~ 12.4]

7
T = 0.9 ~ 1.10
(9.2 ~ 11.2)
[0.7 ~ 0.81]

T = 35.2 ~ 52.8
(359 ~ 538)
[26.0 ~ 39.0] 3

Removal Procedure

1 Disconnect the battery plug.

2 Remove the steering wheel. [Point 1]
3 Remove the parking brake release lever.
4 Remove the steering column cover (upper and lower).
5 Disconnect the combination switch connector.
6 Remove the combination switch.
7 Remove the tilt lock mechanism and tilt steering lock release lever. [Point 2]
8 Remove the steering valve set bolt and keep the valve free.
9 Remove the mast jacket ASSY from steering valve.
sec09.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-8

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
• Apply MP grease on each sliding portion of the tilt lock mechanism and tilt steering lick release
lever.
• Fill MP grease at the coupling between the tilt steering shaft and steering valve.

Point Operations
SST [Point 1]
Removal:
SST 09950-76003-71
(SST 09950-50012)

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]
Installation:
Install so that the tilt lever and column cover lines make an
angle of ± 20 degrees.
20°

20°
sec09.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-9

DISASSEMBLY·INSPECTION·REASSEMBLY
1
3

4
2

Disassembly Procedure

1 Remove the snap ring.

2 Remove the steering shaft.
3 Remove the bearing.
4 Remove the turn signal switch bracket.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec09.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-10

HYDROSTATIC STEERING VALVE ASSY

TROUBLESHOOTING
Phenomenon Estimated cause Corrective action
• The steering valve drive shaft is installed incorrectly or Inspect and correct or replace.
The steering wheel cannot
damaged.
be rotated.
• The piping is damaged. Replace.
• The tire inflating pressure is low. Adjust the inflating pressure.
• The oil pressure does not rise. Inspect and adjust the relief pressure.
The steering wheel is • The high and low pressure pipes are connected Inspect and correct.
heavy. reversely.
• The power steering cylinder rod is bent or the piston is Inspect and correct or replace.
sticking.
• The high and low pressure pipes are connected Inspect and correct.
reversely.
The oil pressure does not • The relief valve is faulty or not closed. Inspect and correct.
rise. • The oil pump function is degraded or the oil volume is Inspect and correct or replace.
insufficient.
• The power steering cylinder piston packing is damaged. Replace.
• The tire inflating pressure is low. Adjust the inflating pressure.
The steering wheel does • The steering valve spool does not move smoothly. Correct or replace the steering valve
not return properly. ASSY.
• The steering knuckle sliding motion is improper. Add the lubricant or correct.
• The steering valve spool does not move smoothly. Correct or replace the steering valve
The steering wheel does ASSY.
not return to the neutral • The steering valve drive shaft is damaged. Replace the steering valve ASSY.
position when released. • The centering spring is damaged. Replace.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
• Oil moves in the steering valve. Replace the steering valve ASSY.
• The steering valve spool is not moving correctly. Correct or replace the steering valve
The play is excessive and
ASSY.
the vehicle wobbles.
• Air is sucked from the piping. Inspect and correct or replace.
• The steering shaft is defective. Inspect and correct or replace.
• Oil moves in the steering valve. Replace the steering valve ASSY.
• The relief valve is not functioning correctly. Inspect and correct.
The steering wheel in the • Air is sucked from the piping. Inspect and correct or replace.
idling state is heavy. • The piping is blocked (crushed or clogged). Inspect and correct or replace.
• The end cap set screw is tightened to an excessive Tighten uniformly to the specified
torque. torque.
The steering wheel
• The steering valve drive shaft is installed incorrectly. Inspect and correct.
shimmies.
The tires are steered
opposite to the steering • The cylinder piping is connected reversely. Inspect and correct.
wheel operated direction.
• The relief valve is defective. Correct, inspect the pressure, and
Abnormal noise is adjust.
generated. • Air is sucked from the piping. Inspect and correct or replace.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
sec09.book 11 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-11

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 29.8 ~ 38.8 (304 ~ 396) [22.0 ~ 28.6]

2 1

2
3 4

Removal Procedure
1 Remove the steering column cover.
2 Disconnect the piping.
3 Remove the steering valve ASSY.
4 Remove the steering valve spacer.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec09.book 12 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-12

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf-cm) [ft-lbf]

T = 40 ~ 60 (408 ~ 612) [29.5 ~ 44.3]

5
6

3
5

4 4

T = 24 ~ 36 (245 ~ 367) [17.7 ~ 26.6]

Disassembly Procedure

1 Remove the end cover. [Point 1]

2 Remove the gear wheel set, cardan shaft and distributor plate. [Point 2]
3 Remove the check valve.
4 Remove the sleeve W/spool and bearing. [Point 3]
5 Remove the O-ring, kin-ring and dust seal ring. [Point 4]
6 Remove the rerief valve. [Point 5]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note:
Wash each part with clean hydraulic oil before assembly.
sec09.book 13 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-13

Point Operations
[Point 1]
Disassembly:
Put a match mark.
Reassembly:
Align the match marks.

Disassembly:
When removing each set bolts, carefully operate so as not
to lose the steel ball.
Reassembly:
Put a steel ball in the illustrated position before installing
each set bolts.
Reassembly:
As one out of seven set bolts is a bolt with pin, install it in
Steel ball the correct position.

[Point 2]
Reassembly:
Pay attention to the following points at the time of
Parallel 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 carden shaft down into the bore so that the
Parallel
slot is parallel with the connection flange.

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 at the time of reassembly.
sec09.book 14 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-14

[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.)

Chamfering

Sleeve

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.

O-ring [Point 4]
Reassembly:
Install the kin-ring and O-ring correctly.

Note:
For SST No. SJ150-9000-11, please inquire at the nearest
SAUER DANFOSS service shop.
Kin-ring
sec09.book 15 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-15

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.
sec09.book 16 ページ ２０１０年４月２３日 金曜日 午前１１時２６分

9-16

RELIEF PRESSURE
SST
INSPECTION·ADJUSTMENT
1. Install a pressure gauge on the P port of the steering
valve.
(1) Disconnect the hose from the P port and connect the
adapter.
SST 09450-23320-71
(2) Install the pressure gauge.
Plug size: PT1/8

2. When the steering wheel is rotated beyond the end,

relief state is obtained. Read the pressure on the
pressure gauge at the time.

Standard:
MPa (kg/cm2) [psi]
20⋅25 model 7.2
+0.5
0 (73
+5
0 ) [1038
+70
0 ]
28 ~ 32 model 7.8
+0.5
0 (80
+5
0 ) [1138
+70
0 ]

3. If the standard is not satisfied, remove the steering valve

and make adjustment by turning the steering valve
adjusting screw.
sec11.book 1 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-1

BODY
11

Page
COMPONENTS ............................................................... 11-2
BATTERY HOOD ASSY ............................................... 11-6
REMOVAL·INSTALLATION ............................................. 11-6
COUNTERWEIGHT ........................................................ 11-7
REMOVAL·INSTALLATION ............................................. 11-7
DRIVER’S SEAT ............................................................. 11-8
REMOVAL·INSTALLATION ............................................. 11-8
FUSE .................................................................................. 11-9
FUSE MOUNTING POSITION ......................................... 11-9
NAMES (APPLICABLE PORTIONS) AND
CAPACITIES.................................................................. 11-9

11
sec11.book 2 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-2

COMPONENTS
11

5101
(EXPORT SPEC)
AY
SW GV GV
BG IA
FV
MZ IA HI
JV BG HI
GV AY
GV
AB

MZ IA
XH
CV IA
MY
XH
CV
71 BX
CG
JB
NA
DB

SD CG BX SW
VS
EV PK
LI
LI LI BG
DB
SD
GM VS
CI EV
LILI NB

XH
FV
CV
30
XH
AB
FY
AF
FF CV
BW MY
AG AB
5101-697

5201

EL FT
PL
AB AC
DI DS
EL AD JA 20
DI
QK
AE CT
BQ
GV
DQ PF
AC
MJ UR
DS AB
PF TS

MDAW FA
HM

BB
GY UN
SD BO HN

DR
56
RY KW
32 LE
WB

LE
FO PZ
LE LE
NZ

RZ

5201-386
sec11.book 3 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-3

5201

EL

BQ
DQ
MJ

EL
PL
AB AC FT
DI DS
AD JA 20
DI
QK
AE CT
GV
PF
DS AC
UR AB
PF TS

MDAW FA
HM

BB UX
GY
SD BO UX
HN
HN
DR
56 56
RY KW
32
PZ
LE LE
PZ
FO RZ
LE NZ

LE

5201-387

5301

60

11
AH
13 CC
CC BV
KO
CC

KM 23

CC AA
AW KL

AA KL
81
CC AA
38
BV
28 CC

MI[LH] FE

56
CE

MI[RH]
CE
BW 30

CE
BW

CE

31
CE
5301-477
sec11.book 4 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-4

5301

78

NJ

34

5301-478

5301

(ORANGE BELT)

47

47

CX GY GY
BG
01 GY

EA
(ORANGE BELT)
26 26

FM
GY GY
BG BG

5308-418
sec11.book 5 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-5

5401

20

DT
KJ
BH KU BN
CP

CP
BE

5401-465

5401

(RR PILLAR GRIP) (EXTINGUISHER)

[20,25,28] [H25,30,32]
PL 11
GN AJ DZ
AE
AJ

CA
RT RT
KH KH
KH 14
VQ
VQ

CA

RT
RT
KH KH
KH
(2-MIRROR)
(PENCIL/TAPE HDR)
31

FM
CO

FO
KM
32
CG

RB
CO

DV

FM

5401-467
sec11.book 6 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-6

BATTERY HOOD ASSY

REMOVAL·INSTALLATION

Removal Procedure
1 Remove the cownterweight. (See page 11-7)
2 Remove the driver’s seat. (See page 11-8)
3 Remove the damper stay cover.
4 Open the battery hood and disconnect the damper stay.
5 Close the battery hood and remove the battery hood set pin.
6 Remove the battery hood ASSY.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec11.book 7 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-7

COUNTERWEIGHT
REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

3 T = 500 ~
(5099 ~)
[368.9 ~]
2

Removal Procedure
1 Remove the rear pillar cover and temporarily hoist the counterweight slinging with a wire rope.
2 Remove the drawbar, and remove the counterweight set bolt.
3 Remove the counterweight.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
See page 0-20 for the weight of the counterweight.
sec11.book 8 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-8

DRIVER’S SEAT
REMOVAL·INSTALLATION

Removal Procedure
1 Open the seat stand.
2 Disconnect the seat switch connector.
3 Remove the driver’s seat set nuts.
4 Remove the driver’s seat. [Point 1]

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Point Operation
[Point 1]
Inspection:
Push on the seat cushion and cheak continuity of the seat
switch.
Standard seat switch: Between CN92-1 and CN92-2
Free : OFF (∞Ω)
Push : ON (0Ω)
sec11.book 9 ページ ２０１０年４月２３日 金曜日 午後１２時４分

11-9

FUSE
FUSE MOUNTING POSITION
All fuses are installed on the contactor panel.

Contactor panel

F1
F4

F5

F6

F7

Contactor panel

NAMES (APPLICABLE PORTIONS) AND CAPACITIES

F1 For drive 600A F6 For controller 10A
F4 For lamps 10A F7 For controller 10A
F5 For control circuit 10A

Caution for fuse replacement

Always disconnect the battery plug and discharge CO (overall capacitor) by connection between P4 and
N1 with a resistance of about 100Ω before replacing any fuse.
sec11.book 10 ページ ２０１０年４月２３日 金曜日 午後１２時４分
sec10.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-1

BRAKE
10

Page
GENERAL ........................................................................ 10-2
SPECIFICATIONS .......................................................... 10-4
COMPONENTS ............................................................... 10-5
FRONT BRAKE............................................................... 10-8
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 10-8
BRAKE AIR BLEEDING ............................................. 10-13
BRAKING FORCE
INSPECTION·ADJUSTMENT ................................. 10-13
BRAKE MASTER CYLINDER ................................... 10-14
REMOVAL·INSTALLATION ........................................... 10-14
DISASSEMBLY·INSPECTION·REASSEMBLY ............. 10-15
PARKING BRAKE ........................................................ 10-17
REMOVAL·INSTALLATION ........................................... 10-17
10
PARKING BRAKE INSPECTION·
ADJUSTMENT ............................................................ 10-18
RELEASE LEVER CABLE ADJUSTMENT ........... 10-18
BRAKE PEDAL INSPECTION·ADJUSTMENT..... 10-19
sec10.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-2

GENERAL
Front Brake
10

Wheel Cylinder
sec10.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-3

Parking Brake

10
sec10.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-4

Master Cylinder

SPECIFICATIONS
Model
All models
Item
Foot brake type Hydraulic internal expanding duo servo brake
Parking brake type Internal expanding mechanical brake
Brake drum inside diameter mm (in) 310 (12.2)
Brake lining material Resin mold (asbestos-free)
Brake lining dimensions 5.7 × 60 × 343
Thickness × width × length mm (in) (0.22 × 2.36 × 13.5)
Wheel cylinder bore mm (in) 28.5 (1.12)
Brake master Bore mm (in) 19.05 (0.75)
cylinder Stroke mm (in) 30 (1.18)
Applicable oil SAE J-1703-DOT-3
sec10.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-5

COMPONENTS
Front Brake
4715

01

02 4715-135

Brake Master Cylinder

4702 10

AP
BD
AP Refer to
FIG.4701
CZ

11
DH
43A
AM DH

01
43A
43

4702-126A
sec10.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-6

Reservoir
4702
11

45

48

4702-127

Brake Pipe
4702

Refer to
FIG. 4702

LM
22

07

AF
23

AF

AE
20

4714-323
sec10.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-7

Parking Brake
4601

BW

BZ
15
CD

BW 67

15
24[RH] 24[LH]
AR
JT

37
GZ

JT
GZ

4601-221

Brake Pedal
l

4701
10

EL

43 GR

AA
20A
20

20A AB
AF
AZ BW
AK 40

CR
GV
Refer to
4702-DH

Refer to
4702-01

4701-254
sec10.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-8

FRONT BRAKE
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf-cm) [ft-lbf]

4
11

T = 17.7 ~ 26.5 (180 ~ 270)

T = [13.0 ~ 19.5]

12

8 3
6

Brake backing plate set bolt T = 137 ~ 196 (1400 ~ 2000) [101.3 ~ 144.7]

Disassembly Procedure

1 Drain brake fluid.

2 Remove the front axle hub. (See page 7-6)
3 Remove the shoe hold down spring and cup. [Point 1]
4 Remove the anchor to shoe spring and shoe guide plate. [Point 2]
5 Remove the cable and cable guide.
6 Remove the lever strut. [Point 3]
7 Remove the adjuster spring and adjusting screw. [Point 4]
8 Disconnect the parking brake cable. [Point 5]
9 Remove the brake shoe. [Point 6]
10 Disconnect the brake pipe.
11 Remove the wheel cylinder ASSY. [Point 7]
12 Remove the backing plate. [Point 8]
13 Inspect the front axle hub (brake drum). [Point 9]
sec10.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-9

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Check that the brake lining and brake drum interior surface are free from grease or oil before
installation.
• Before reassembly, decrease the brake drum outside diameter for installation to approx. 1 mm
(0.04 in) less than the drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (See page 10-13) and braking force inspection (See
page 10-18).
Point Operations
[Point 1]
Disassembly⋅Reassembly:
SST SST 09510-31960-71

Inspection:
Measure the free length of the hold down spring.

Standard: 25.5 mm (1.004 in)

Reassembly:
Apply liquid packing (08826-76001-71 (08826-00080)) on
the shoe hold down pin and the contact surface on the
back side of the backing plate to eliminate any clearance.

[Point 2]
SST
Disassembly:
SST 09717-76001-71
(SST 09717-20010)
sec10.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-10

Inspection:
Measure the free length of the anchor to shoe spring.

Standard: On the side of lining W/pin

139.3 mm (5.484 in)
On the side of lining L/pin
121.8 mm (4.795 in)
Limit: No clearance between coil turns

Reassembly:
SST SST 09718-76001-71
(SST 09718-20010)

[Point 3]
Inspection:
Measure the free length of the strut to shoe spring.

Standard: 29.8 mm (1.173 in)

[Point 4]
Inspection:
Measure the free length of the adjuster spring.

Standard: 126.0 mm (4.961 in)

Limit: No clearance between coil turns

Reassembly:
Apply grease on the adjusting screw threaded portion and
fill grease in the cap.
Reassembly:
Tie a wire to the free end of the adjuster spring and set by
pulling with a screwdriver.
sec10.book 11 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-11

[Point 5]
Reassembly:
Apply liquid packing (08826-76001-71 (08826-00080)) on
the parking brake cable outlet in the backing plate to
eliminate any clearance.

[Point 6]
Inspection:
Measure the brake lining thickness.

Standard: 5.7 mm (0.224 in)

Limit: 1.0 (0.039 in)

Reassembly:
Before brake shoe installation, apply grease on illustrated
portions of the backing plate (6 places in contact with the
shoe rim and the anchor pin).

[Point 7]
Inspection:
Measure the clearance between the wheel cylinder and
piston.

Limit: 0.125 mm (0.00492 in)

Reassembly:
Apply liquid packing (08826-76001-71 (08826-00080)) to
backing plate fitting portion of the wheel cylinder and on
whole periphery of the set bolts to eliminate any
clearance.
sec10.book 12 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-12

[Point 8]
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070))
on the set bolts before reassembly.

Bolt length
L = 40 mm (1.57 in)

Reassembly:
Apply liquid packing (08826-76001-71 (08826-00080)) on
the backing plate surface in contact with the front axle
bracket to eliminate any clearance.
Sealing
agent

[Point 9]
Inspection:
Measure the brake drum inside diameter.

Standard: 310 mm (12.20 in)

Limit: 312 mm (12.28 in)
sec10.book 13 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-13

BRAKE AIR BLEEDING

Note:
Add brake fluid to the reservoir tank during air bleeding
to prevent it from becoming insufficient.
Perfrom air bleeding by two operators.
1. Bleed air from the brake master cylinder.
(1) Depress the brake pedal several times to compress
the air in the piping, and hold that state.
Breather (2) Loosen the breather plug to discharge air in the piping
plug
with the brake fluid, and tighten the plug immediately
before the fluid stops to run out.
(3) Repeat steps (1) and (2) above until no air bubbles
are seen in the discharged brake fluid.
2. Bleed air from wheel cylinders RH and LH.
(1) Operate as described in step 1 above for each of the
RH and LH side at a time.
3. Add brake fluid to the specified level.
(1) Add brake fluid through the filter provided at the
reservoir tank.
(2) Add brake fluid up to the staged portion in the
reservoir tank.

BRAKING FORCE INSPECTION·ADJUSTMENT

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)
Initial speed of braking km/h (mph) Max.speed
Braking distance m (ft) 5.0 (16.4) or less
2. Adjust the braking force.
(1) Repeat traveling in the forward and reverse directions to adjust the brake shoe clearance.
The adjusting screw adjusts the clearance automatically when the brake pedal is depressed in
reverse traveling.
(2) If the braking force is insufficient, adjuster malfunction, lining contact defect, foreign matter
adhesion on the lining or brake fluid leakage is assumed. Remove and inspect the brake drum.
(3) When the brake shoe is replaced with a new one, repeat traveling in the forward and reverse
directions for running in.
sec10.book 14 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-14

BRAKE MASTER CYLINDER

REMOVAL·INSTALLATION
4

Removal Procedure

1 Remove the toe board (front and rear) and lower panel.
2 Disconnect the brake side hose from the reservoir tank and drain brake fluid.
3 Disconnect the piping.
4 Remove the push rod clevis pin.
5 Remove the brake master cylinder.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
After installation, perform brake pedal adjustment (See page 10-19) and air bleeding (page 10-13).
sec10.book 15 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-15

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf-cm) [ft-lbf]

1
2

3
5

T = 52.0 ~ 82.4
T = (530 ~ 840)
T = [38.3 ~ 60.8]

Disassembly Procedure

1 Turn the boot up and remove the snap ring.

2 Remove the push rod. [Point 1]
3 Remove the piston. [Point 2]
4 Remove the pin and the fluid inlet elbow.
5 Remove the outlet plug and valve.

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

sec10.book 16 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-16

Point Operations
[Point 1]
Reassembly:
Temporarily set the push rod length to the illustrated
dimension, and make readjustment after installation.

128 mm (5.04 in)

[Point 2]
Reassembly:
Apply rubber grease on the piston cup and whole
periphery of the cup before reassembly.
sec10.book 17 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-17

PARKING BRAKE
REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 0.9 ~ 1.10
(9.2 ~ 11.2)
[0.7 ~ 0.81]

T = 9.1 ~ 16.9
T = (93 ~ 172)
T = [6.7 ~ 12.5]

Removal Procedure

1 Disconnect the battery plug.

2 Remove the tilt steering lock release lever.
3 Remove the column cover.
4 Remove the instrument panel LH.
5 Remove the lower panel.
6 Remove the parking brake release cable from the mast jacket.
7 Remove the parking brake ASSY.

Reassembly Procedure

The reassembly procedure is the reverse of the removal procedure.

sec10.book 18 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-18

PARKING BRAKE INSPECTION·

ADJUSTMENT
1. Check the parking brake cable set position.

# Standard:
A = 0 ~ 2 mm (0 ~ 0.08 in)

(QT4* 2. Apply chassis grease on the portions indicated by

(QT.*
arrows.
3. Inspect and adjust the parking brake pedal operating
force.
(1) Push the probe of a push-pull tester vertically into the
center of the brake pedal.
(2) Measure the operating force.

Standard:
270 ~ 310 N (27.5 ~ 31.6 kgf) [60.7 ~ 69.7lbf]

(3) If the operating force is out of the standard range,

release the parking brake and make adjustment at the
adjusting portion.

Clockwise turn: Increase the operating force.

Counterclockwise turn: Decrease the operating force.

RELEASE LEVER CABLE ADJUSTMENT

1. Adjust the play of the release lever to 0 to 5 mm (0 to 0.2
in) at the tip of the lever using the release cable
adjusting nut.

#FLWUVKPIPWV

4GNGCUG
NGXGT
sec10.book 19 ページ ２０１０年４月２３日 金曜日 午前１１時２３分

10-19

BRAKE PEDAL INSPECTION·ADJUSTMENT

Stopper bolt protrusion

Brake master cylinder

Push rod

B
Reference valve

(5.08 ~ 5.28 in)

C

129 ~ 134 mm

A
Floor mat
D

Toe board

1. Inspect brake pedal height A. (From toe board to top of pedal)

Standard: A = 139 ~ 144 mm (5.47 ~ 5.67 in) (with pedal pad)

If the standard is not satisfied, make adjustment by changing the stopper bolt protrusion.

2. Inspect brake pedal play B.

Standard: B = 5 ~ 9 mm (0.2 ~ 0.35 in)

If the standard is not satisfied, make adjustment by changing the master cylinder push rod length.

3. Check master cylinder push rod play C with the brake pedal in the above state.

Standard: C = 1 ~ 2 mm (0.04 ~ 0.08 in)

4. After the adjustment, fully depress the brake pedal and inspect the pedal height D.

Standard: D = 84 mm (3.31 in) or more

sec10.book 20 ページ ２０１０年４月２３日 金曜日 午前１１時２３分
sec12.book 1 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-1

MATERIAL HANDLING SYSTEM

12

Page
HYDRAULIC SYSTEM DIAGRAM ............................. 12-2
COMPONENTS ............................................................... 12-3
RETURN FILTER·SUCTION FILTER ......................... 12-7
REMOVAL·INSTALLATION ............................................. 12-7
NATURAL DROP TEST ................................................ 12-8
NATURAL FORWARD TILT TEST ............................. 12-8
OIL LEAK TEST.............................................................. 12-9
LIFT CYLINDER .............................................................. 12-9
TILT CYLINDER............................................................... 12-9

12
sec12.book 2 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-2

HYDRAULIC SYSTEM DIAGRAM

12

Lift Cylinder
Mini Lever

Steering ECU
Valve

Load Oil Control Valve

Solenoid
Valve Oil Control Valve

Oil Tank

Tilt Cylinder
Steering
Valve Return

Return Filter
Steering
Valve Suction Filter
Load Sensing
Oil Pump
Pump
Priority Motor
Valve

Power Steering Cylinder

sec12.book 3 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-3

COMPONENTS
6801

28

Refer to
FIG.4507

EH

Refer to
BM FIG.6705
30
NN
19A 51A
32

11
51
51A US
EG
Refer to PM
AT 6701-01

20A
55A
55A 20
AD
BG

BL 55

CL GU
10A

10
AU
DE
6801-742A

6801

45 12
AC

45
34
AC

45

35 AC
BQ

EJ 34

45
AC

35

35
34
34 35

6801-743
sec12.book 4 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-4

6801
FSV, QFV, V
PE
JN
KQ
BR

AB

BR

FSV, QFV, V (OIL FULL, RUST PROOF)

PE
JN
KQ
AM

AG

AM
AM

HC

6801-744

V 6802

GS
CO

50 GS

50
CO

CO

Refer to
6801-PE
GS
GS

CO
BB
76

AC
Refer to
6801-32 DJ 6802-727
sec12.book 5 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-5

FV 6802

AB

30

BA

AN

41

76

BB
DO

48

AC

DJ

6802-729

FSV 6802
AA

AD
20

AK

12
GL
BL 40
EQ
NV

GS

GH
50
GS

CO NP

GH

39 CO

DH
48
CO AR

CZ
BH

Refer to GS CO
6801-32 30

GS
AC BB 50
76
DJ
Refer to
6801-PE
6802-728
sec12.book 6 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-6

QFV 6802

EP
AR 32
NB AG 41
20
GS
28

GL

CO BA
33

GS
CO CO
42

50 CO

CO

50
DJ
Refer to CO
AC 6801-CZ

GS
GS

GB
BB
31

6802-726
sec12.book 7 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-7

RETURN FILTER·SUCTION FILTER

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T=9.8 ~ 14.7
(100 ~ 150)
[7.2 ~ 10.9]

Removal Procedure

1 Drain hydraulic oil.

2 Remove the toe board (front and rear).
3 Disconnect the hose.
4 Remove the tank cover W/return filter.
5 Remove the return filter.
6 Remove the suction filter.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec12.book 8 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-8

NATURAL DROP TEST

1. Set the mast vertical with the standard load on the fork.
Lift the fork by 1 to 1.5 m (40 to 59 in), and turn the key
switch to OFF.

2. Draw datum lines on the inner and outer masts, and

measure the drop in 15 minutes.

Limit: 45 mm (1.77 in)

NATURAL FORWARD TILT TEST

1. Set the mast vertical with standard load on the fork. Lift
the fork by about 50 cm (19.7 in) and turn the key switch
to OFF.

2. Measure the tilt cylinder rod extension in 15 minutes.

Natural forward tilt amount
Model
mm (in)
ALL 15 (0.59) or less
sec12.book 9 ページ ２０１０年４月２３日 金曜日 午後１２時２分

12-9

OIL LEAK TEST

LIFT CYLINDER

1. Set the mast vertical with the standard load on the fork.
Lift the fork by 1 to 1.5 m (40 to 59 in).

2. Slowly tilt the mast fully forward, and turn the key switch
to OFF.

3. After 5 minutes, disconnect the oil control valve to oil

tank hose. Place a measuring cylinder under the elbow
and measure the amount of oil leaking in one minute.

Standard (at lift port): 8 cm3 (0.49 in3) or less

Note:
If the natural drop is big even though the oil leak
amount is within the standard, the lift cylinder
packing is defective.

TILT CYLINDER

1. Set the mast in the vertical position with standard load

on the fork. Lift the fork by about 50 cm (19.7 in) and
turn the key switch to OFF.

2. After 5 minutes, disconnect the oil control valve to oil

tank hose. Place a measuring cylinder under the elbow
and measure the amount of oil leaking in one minute.

Standard (total for lift and tilt):

16 cm3 (0.98 in3) or less

3. The leak amount at the tilt port is equal to the remainder

when you subtract the lock amount at the lift port from
the total leak amount of the lift and tilt cylinder.

Note:
If the natural forward tilt is even though the oil leak
amount is within the standard, either the tilt lock
valve or the tilt cylinder packing is defective.
sec12.book 10 ページ ２０１０年４月２３日 金曜日 午後１２時２分
sec13.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-1

MAST
13

Page
V MAST ASSY................................................................. 13-2
COMPONENTS................................................................ 13-2
REMOVAL·INSTALLATION ............................................. 13-4
REMOVAL·INSTALLATION (W/LIFT BRACKET) ........... 13-7
MAST DISASSEMBLY·INSPECTION REASSEMBLY .... 13-9
LIFT BRACKET DISASSEMBLY·
INSPECTION·REASSEMBLY ....................................... 13-11
MAST ADJUSTMENT (V MAST)..................................... 13-13
MAST ROLLER REMOVAL·INSTALLATION .................. 13-18
CHAIN................................................................................ 13-19
INSPECTION ................................................................... 13-19
REASSEMBLY (V·FV·FSV) ............................................. 13-19
REASSEMBLY (QFV) ...................................................... 13-20
ADJUSTMENT ................................................................. 13-21
FV·FSV MAST ASSY ..................................................... 13-22
COMPONENTS................................................................ 13-22
MAST ADJUSTMENT (FV·FSV)...................................... 13-26
13
QFV MAST ASSY ........................................................... 13-30
COMPONENTS................................................................ 13-30
MAST ADJUSTMENT (QFV) ........................................... 13-31
STANDARD FOR SELECTING
AN OVERSIZE ROLLER ............................................ 13-33
LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) .................. 13-34
V·FSV·QFV MAST ........................................................... 13-34
FV MAST.......................................................................... 13-35
sec13.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-2

V MAST ASSY
13

COMPONENTS
6101

30A 30
40A
41

40

41A

21

AD
AD

CK

20B 20B
DW

LI
AM BH

20

6101-625

20⋅25 model 6301

22

02 20
(BACKREST LESS)
DD

BF BF
BB (20D,RUSTROOF)

BF
BG

6301-780
sec13.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-3

6302

40 40A

AD
AD
AD

20

AE
BS

6302-567

13
sec13.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-4

REMOVAL·INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

11

10

T = 76.8 ~ 115.2
4
(783 ~ 1175)
[56.7 ~ 85.0]

T = 84 ~ 156
(857 ~ 1591)
[62.0 ~ 115.1]

Removal Procedure

1 Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 1]
3 Remove the chain wheel. [Point 2]
4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until the lift bracket comes off
from the inner mast, and slowly run the vehicle backward to move away from the lift bracket.)
5 Remove the toe board (front and rear).
6 Disconnect the fork height switch connector.
7 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure in the lift cylinder.)
8 Slightly hoist the mast.
9 Remove the mast support cap. [Point 3]
10 Remove the tilt cylinder front pin. [Point 4]
11 Remove the mast ASSY.
sec13.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-5

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 on the tilt cylinder front pin.
• Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift
cylinder is replaced. (See page 13-34)
• Adjust the chain tension after installation. (See page 13-19)
• When the mast is replaced, perform SAS matching after installation. (See section 3)
Point Operations

SST [Point 1]
Removal-Installation:
SST 09630-23600-71

[Point 2]
SST
Removal:
If the fitting is hard, use the SST for removal.
SST 09950-76014-71
(SST 09950-40011)

[Point 3]
Removal:
Make a match mark.
13
Installation
Align the match mark.

Match mark

[Point 4]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate and lock bolt. Match marks, however,
are unnecessary when the mast or mast ASSY is replaced
since mast tilt angle adjustment is to be done after the
replacement.
sec13.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-6

Removal:
SST 09810-20172-71

SST
sec13.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-7

REMOVAL·INSTALLATION (W/LIFT BRACKET)

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 76.8 ~ 115.2
(783 ~ 1175)
[56.7 ~ 850]

2
T = 84 ~ 156
(857 ~ 1591)
[62.0 ~ 115.1] 7

Removal Procedure

1 Set the mast vertical.

2 Remove the fork. (See page 13-4)
3 Remove the toe board (front and rear).
4 Disconnect the wiring of the fork height switch.
5 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift
cylinder.)
6 Slightly hoist the mast.
7 Remove the mast support cap. [Point 1]
8 Remove the tilt cylinder front pin. [Point 2]
9 Remove the mast ASSY W/lift bracket.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec13.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-8

Note:
• Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease on the tilt cylinder front pin.
• Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either
lift cylinder is replaced. (See page 13-34)
• When the mast is replaced, perform SAS matching after installation. (See section 3)

Point Operations
[Point 1]
Removal:
Make a match mark.

Installation:
Align the match mark.

Match mark

[Point 2]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate and lock bolt. Match marks, however,
are unnecessary when the mast or mast ASSY is replaced
since mast tilt angle adjustment is to be done after the
replacement.

Removal:
SST 09810-20172-71

SST
sec13.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-9

MAST DISASSEMBLY·INSPECTION REASSEMBLY

1
2

8 7

Disassembly Procedure

1 Remove the fork height switch.

2 Disconnect the overflow hose and high pressure hose.
3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]
4 Remove each cylinder support. [Point 2]
5 Remove each cylinder bottom set bolt.
6 Remove each lift cylinder.
7 Slide the inner mast in the lowering direction, and remove the lift rollers.
8 Remove the mast strip. [Point 3]
9 Remove the outer mast.

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

sec13.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-10

Point Operations
Shim
[Point 1]
Disassembly:
Shim adjustment has been made at the lift cylinder rod
end for prevention of cylinder uneven motion between the
left and right sides. Take a note on which side the shim
adjustment is made and the number of shims in use.

[Point 2]
Disassembly:
Take a note on the number of cylinder support shims in
use.
Shim

Reassembly:
Make cylinder support shim adjustment if the mast or
either cylinder is replaced.
With the cylinder rod end inserted to the inner mast, insert
shims between the cylinder support and outer mast to
eliminate the clearance. The shim thickness should be
slightly greater than the clearance.

[Point 3]
Inspection:
Measure the mast strip thickness.

Thickness limit: A = 2.7 mm (0.106 in)

A
B = 1.3 mm (0.051 in)

B
sec13.book 11 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-11

LIFT BRACKET DISASSEMBLY·INSPECTION·REASSEMBLY

T = N⋅m (kgf⋅cm) [ft⋅lbf]

3
2

STD:
T = 138 ~ 322
T = (1407 ~ 3283)
T = [101.8 ~ 237.6]
RUST PROOF SPEC:
T = 98 ~ 182
T = (999 ~ 1856)
T = [72.3 ~ 134.3]
sec13.book 12 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-12

Disassembly Procedure

1 Remove lift rollers. [Point 1]

2 Remove side rollers. [Point 2]
3 Remove the back rest.

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71
(SST 09950-40011)

SST

[Point 2]
Front side
Reassembly:
The side chamfered with larger radius of the roller shall
Rounded face the front side of the vehicle.
chamfering
sec13.book 13 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-13

MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast
1. Inner mast roller clearance adjustment

Inner mast

Outer mast

Bring into contact

Inner mast rollers

Bring into
contact
A

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

Inspect and adjust the inner mast rollers.
(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, measure the clearance
between the roller side face on the opposite side and
outer mast at the point where they are the closest.

Standard: A = 0 ~ 0.6 mm (0 ~ 0.024 in)

If the standard is not satisfied, make adjustment by

changing the shim thickness. Distribute shims equally
Shims to the rollers on the left and right side. (See page 13-
18 for the mast roller removal and installation.)

Shim thickness: 0.25·0.5 and 1.0 mm

(0.010·0.020 and 0.039 in)

(3) After the adjustment, check that the inner mast moves
smoothly in the outer mast.
sec13.book 14 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-14

2. Outer mast roller clearance adjustment

Outer mast rollers

Bring into contact

Outer mast
Inner mast

Bring into
B contact

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

Inspect and adjust the outer mast rollers.
(2) Shift the outer mast to one side to bring the roller into
contact with the inner mast, measure the clearance
between the roller side face on the opposite side and
inner mast at the point where they are the closest.

Standard: B = 0 ~ 0.6 mm (0 ~ 0.024 in)

If the standard is not satisfied, make adjustment by

changing the shim thickness. Distribute shims equally
Shims to the rollers on the left and right side.
(See page 13-18 for the mast roller removal and
installation.)

Shim thickness: 0.25·0.5 and 1.0 mm

(0.010·0.020 and 0.039 in)

(3) After the adjustment, check that the inner mast moves
smoothly in the outer mast.
sec13.book 15 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-15

Roller Adjustment at Lift Bracket

100 mm (3.94 in)

Middle and lower Outer mast

F, G lift roller
Lift
bracket
Contact here
Inner mast
H
Side roller

Measure with contacting Position of lift bracket during

this rolling surface middle lift rollers inspection

100 mm (3.94 in)

Contact here

Outer mast
F,G

Lift Inner mast

bracket

Position of lift bracket during

upper and lower lift rollers inspection

(1) Hoist the lift bracket to the specified position.

Bring the center of the middle lift rollers in the lift bracket
to 100 mm (3.94 in) below the top of the inner mast.
(2) Remove side rollers.
(3) Inspect and adjust the middle lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: F = 0 ~ 0.6 mm (0 ~ 0.024 in)

If the standard is not satisfied, make adjustment by

changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.
Shim thickness: 0.25·0.5 and 1.0 mm
(0010·0.020 and 0.039 in)
(4) Lower the lift bracket to the specified position.
Bring the center of the upper lift rollers in the lift bracket to
100 mm (3.94 in) below the top of the inner mast.
sec13.book 16 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-16

(5) Inspect and adjust the lower lift rollers.

Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: G = 0 ~ 0.6 mm (0 ~ 0.024 in)

If the standard is not satisfied, make adjustment by

changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(6) Install side rollers.
(7) Inspect and adjust the side rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the side roller
clearance at the position on the opposite side where the
Shims
roller side is closest to the mast.
Standard: H = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the side roller shaft shim thickness. Distribute
shims equally to the rollers on the right and left side.
Refer to ("Lift bracket dissassembly and reassembly",
page 11-18. Also, shim replacement is possible on the
vehicle)
Shim thickness: 0.25·0.5 and 1.0 mm
(0.010·0.020 and 0.039 in)
(8) After the adjustment, check that the lift bracket moves
smoothy along the overall length of the mast.
sec13.book 17 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-17

Mast Strip Adjustment

1. Mast strip clearance adjustment

Roller

Inner mast

Bring into contact

Outer mast

Outward

Note: The strip is of tapered shape, thicker side of the

Note: width must be placed outward.

(1) Lower the inner mast fully.

Inspect and adjust the clearance between the mast
strip and the inner mast.
(2) With the inner mast in contact with the outer mast
roller, measure the clearance between the mast strip
and inner mast.

Standard: J = 0 ~ 1.0 mm (0 ~ 0.039 in)

If the standard is not satisfied, make adjustment by

changing the shim thickness.
Shim

Shim thickness: 0.5 and 1.0 mm

(0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth

movement.
sec13.book 18 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-18

MAST ROLLER REMOVAL·INSTALLATION

1. Remove the lift bracket.

(Refer to page 13-4, procedure 1 to 4.)
2. Jack up the vehicle, and support tires with wooden
blocks. Check the front and rear tires.
3. Remove the lift cylinders. (See page 14-10)

4. Remove mast rollers.

(1) Remove wooden blocks under the inner mast, and
lower the hoisted inner mast slowly until mast rollers
appear.
(2) Support the bottom of the inner mast with wooden
blocks.
(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims.

5. The installation procedure is the reverse of the removal
Shims procedure.
sec13.book 19 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-19

CHAIN
SST INSPECTION
1. Inspect the chain elongation according to the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement line varies with the chain
type, set the corresponding line on the chain as
illustrated.

(2) Check the number of the chain to be inspected, and

check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, change the chain.
Chain Link Pitch Standard (V⋅FV⋅FSV⋅QFV)
Model Pitch mm (in) Type Chain No.
20⋅25 model
QFV inner and 19.05 (0.7500) BL634 60
middle chain
28∼32 model 25.4 (1.0) BL823 80
QFV outer chain 25.4 (1.0) BL834 80

Note:
• Perform measurement without removing the chain
from the vehicle.
• Inspect elongation over the entire chain length since it
may be localized.
REASSEMBLY (V·FV·FSV)
1. Installing direction
Applicable mast FV: Lift bracket
V: Lift bracket FSV: Inner mast
and portion FSV: Lift bracket

Center of Outside of Rear of

vehicle vehicle vehicle

Cotter pin Cotter pin Cotter pin

Sketch

Install the chain with the cotter pin facing Install the chain with the cotter pin facing Install the chain with the cotter pin facing
the center of the vehicle center side. the center of the vehicle outside. the center of the vehicle rear side.

2. Chain adjusting nut tightening order

(1) Tighten nuts A and B. T =53 ~ 85 N⋅m (540 ~ 867 kgf⋅cm) [39.1 ~ 62.7 ft⋅lbf]
(2) Tighten nut C.
V: Outer mast
Applicable mast FV: Front cylinder (28~32 mode)
FV: Front cylinder (20⋅25 model) FSV: Outer mast
and portion FSV: Front cylinder (28~32 mode)
FSV: Front cylinder (20⋅25 model)

Clamp
C
Sketch
B B B
A A A
sec13.book 20 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-20

REASSEMBLY (QFV)
1. Installing direction
As shown in the table below.
2. Chain adjusting nut tightening order
(1) Tighten nuts A and B.
(2) Tighten nut C.
T = N⋅m (kgf⋅cm) [ft⋅lbf]
Outer chain Middle chain Inner chain
Clamp
Clamp Lower C Front
middle cylinder
Hard lock nut
Outer mast
mast

B B Nut B Nut

A Nut A Nut
A

T = 98.0 ~ 147.0 (1000 ~ 1500) T = 53 ~ 85 (540 ~ 867) T = 53 ~ 85 (540 ~ 867) [39.1 ~ 62.7]
T = [72.35 ~ 108.5] [39.1 ~ 62.7]

← Center of truck ← Outside of truck

Hard lock nut Cotter pin
Upper
middle Inner mast
C
mast

Lift bracket
B
A
Installation side of split pin is outward of the
truck center.
T = 98.0 ~ 147.0 (1000 ~ 1500) Installation side of split pin is at center side
T = [72.35 ~ 108.5] of the truck.

Chain connection
Middle chain Outer chain

Inner chain

Inner
Upper Middle
Lower Middle
Outer
sec13.book 21 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-21

ADJUSTMENT
1. Incline the mast backwards and fully lower the forks.
2. Set the forks vertically and adjust the chain with the adjusting nut to remove slack in it.
3. Check that the chain tension is equal on the left and right side.
4. Check the chain for twist.
5. Check that the fork height is the standard.
6. With the fork raised fully, check that the lift bracket stopper at the innermast upper beam is not in contact with the
lift bracket.

7. After adjusting the chain, check that the distance from the
center of the roller at the lower part of the lift bracket to the
Inner mast bottom end of the inner mast is within the range below.
A = 15 ~ 20 mm (0.59 ~ 0.79 in)

FORK

REMOVAL
1. Set the fork at approx. 20 cm (7.9 in) above the ground.
2. Place a wooden block under the cutout portion of the fork rail.
3. Unlock the fork by lifting the fork stopper pin and shift the fork
blades, one at a time, to the center.
4. Slowly lower the forks and remove them.

INSTALLATION
The installation procedure is the reverse of the removal procedure.

INSPECTION
1. Inspect misalignment of the fork tip ends.
Limit: 10 mm (0.39 in)
If the limit is exceeded, inspect individual fork for bend,
looseness of the fork installation part and lift bracket finger bar
distortion.
sec13.book 22 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-22

FV·FSV MAST ASSY

COMPONENTS
FV 6101

30A 30
40A 41

40
41A

21

AP
AD

AH JB
53
AJ
LI
AI
AM BH

AD
6101-628 20

FSV: 20, 25, H25 6101

31A 31
42A

42

22 41
30A 30 21

40A

40 41A
CK
HX

AD
AD 43
20B

20B
LI
43A AM BH

6101-626
20
sec13.book 23 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-23

FSV: 28, 30, 32 6101

30A 30 HX
42A CK

42

30A 30
40A 21

41
40

22 41A
AD
AD

20B
43
LI
AM BH
43A 6101-627
20

FV: 20, 25, H25 6302

41A AQ
41
BV
CM

41A

21
45
41

AD
AD 21
AD

BS AD
AD
AD

AE

BS

AE
6302-570
sec13.book 24 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-24

FV: 28, 30, 32 6302

41A AQ
41
BV
CM
41A
21
45
41 21

21A
AD

BS

21A
AD
AE

BS

AE
6302-571

FSV: 20, 25, H25 6302

42A
41A
41 AQ
BV
42
CM AC
41A AN
AD AQ
21 AD
45
41
21
AD
AD 22
AD

AD
AD
AD
BS

AE

BS
BS

AE

6302-568
AE
sec13.book 25 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-25

FSV: 28, 30, 32 6302

42
41A AQ
41 42A
BV AN
CM AC
AQ
41A
AD
21
45 AD

41
22
21A
AD
21

BS

21A
AD
AE

BS

BS
AE

6302-569
AE
sec13.book 26 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-26

MAST ADJUSTMENT (FV·FSV)

Lift Roller Adjustment at Mast
1. Inner mast roller (FV·FSV) and middle mast lower roller (FSV) clearance adjustment

Bring into contact

Position where the

roller is the closest
FSV mast
FV mast
Inner mast
Inner mast Outer mast

Outer mast Middle mast

These rollers These rollers

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Adjust the inner mast rollers (FV·FSV) and the middle mast lower rollers (FSV). Shift the inner mast (or
middle mast) to one side to bring the roller into contact with the middle mast (or outer mast). Measure the
clearance between the roller side face on the opposite side and middle mast (or outer mast) at the point
where they are the closest.
Standard: A = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check that mutual mast movement is smooth.
sec13.book 27 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-27

2. Outer mast roller (FV·FSV) and middle mast upper roller (FSV) clearance adjustment

Bring into Bring into

contact contact

Bring into
contact
B
Position where the
roller is the closest
FV FSV
These rollers

These rollers

Middle mast

Outer mast Outer mast

Inner mast
Inner mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Adjust the outer mast rollers (FV·FSV) and the middle mast upper rollers (FSV). Shift the outer mast (or
middle mast) to one side to bring the roller into contact with the middle mast (or inner mast). Measure the
clearance between the roller side face on the opposite side and middle mast (or inner mast) at the point
where they are the closest.
Standard: B = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check that mutual mast movement is smooth.
sec13.book 28 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-28

Lift/Side Roller Adjustment at Lift Bracket

1. FV mast·FSV mast

C Lower lift roller 100 mm (3.94 in)

Contact here
D
Side roller

Measure with contacting Outer mast

this rolling surface Lift
bracket

Inner mast
Contact here

FV
28 ~ 32
C

Outer mast Outer mast

Outer mast
Middle mast Middle mast

Lift Inner mast Lift Inner mast Lift Inner mast

bracket bracket bracket

FSV FSV FV
20·25 28 ~ 32 20·25

(1) Raise the lift bracket to the uppermost position for the FSV mast (20·25) and FSV, and bring the center of
the upper lift roller to approx.100 mm (3.94 in) below the top of the inner mast for the FV mast (other than
20·25).
(2) Inspect and adjust the lower lift rollers.
Shift the lift bracket to one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.
Standard: C = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Inspect and adjust the side rollers.
Shift the lift bracket to one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) After the adjustment, check that the lift bracket moves smoothly over the entire length of the mast.
sec13.book 29 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-29

Mast Strip Adjustment

1. Mast strip clearance adjustment

FV mast Roller
Inner mast

Bring into contact

Outer mast

E
FSV mast Middle mast
Roller
Bring into contact

Inner mast

Outer mast
E

(1) Lower the inner (or middle) mast fully.

(2) Inspect and adjust the clearance between the mast strip and the mast.
FV Mast: With the inner mast in contact with the outer mast rollers, measure the clearance between the
mast strip and the mast.
FSV Mast: With the inner (or middle) mast in contact with the middle mast upper rollers (or outer mast
rollers), measure the clearance between the mast strip and the mast.
Standard: E = 0 ~ 1.0 mm (0 ~ 0.039 in)
If the standard is not satisfied, make adjustment by changing the shim thickness.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check the mast for smooth movement.
sec13.book 30 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-30

QFV MAST ASSY

COMPONENTS
6101
31A 31
42A
30A 30 31
31A
40A 42A
22 42
[UPPER]
40 42

21

AD AH
41

AD 22 43 AI
[LOWER]
41A
43
43A
20B
43A
LI
AM BH

20 6101-629

6302

42
DB 42A
49
49A
41A BV
BG
CM
BG
AV AV
45
41A CU AC
AR AN
41 AN
22
41
21 25

AN
AN
AN
AN
AE 21 AN
AN

BS
AE AD
BS AR
AN
6302-566 AN
AN
sec13.book 31 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-31

MAST ADJUSTMENT (QFV)

Lift Roller Adjustment

The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown:

Channel seen from the top Channel seen from the bottom

0 ~ 0.6 mm
(0 ~ 0.02 in)

100 mm
(3.94 in)

0 ~ 0.6 mm
(0 ~ 0.02 in)
0 ~ 0.6 mm
(0 ~ 0.02 in)

0 ~ 0.6 mm
Overlap
(0 ~ 0.02 in)
450 mm
(17.7 in)
0 ~ 0.6 mm
(0 ~ 0.02 in)

0 ~ 0.6 mm
450 mm
(0 ~ 0.02 in)
(17.7 in)

0 ~ 0.6 mm
(0 ~ 0.02 in)

0 ~ 0.6 mm
450 mm
(0 ~ 0.02 in)
(17.7 in)

Note:
The mast strip & shim adjustment between the mast channels can also be performed in the same
sequence with those of V⋅FV⋅FSV.
sec13.book 32 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-32

Lift Roller Position on Each Upright:

Inner

b b

a
c
c

Upper Lower
middle middle

d d
f f
e

Outer
sec13.book 33 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-33

STANDARD FOR SELECTING AN OVERSIZE ROLLER

The clearance is on The clearance is on 1. Select the mast lower lift rollers and lift bracket upper and
one side both sides lower lift rollers.
A A Select the appropriate rollers from the table below so that the
minimum clearance between the mast or the lift bracket and
the roller is from 0 to 1.0 mm (0 to 0.039 in).
mm (in)
No Outside diameter of the roller
clearance B
107.7 (4.240) 108.2 (4.260)
119.7 (4.713) 120.2 (4.732)
Minimum Minimum
clearance = A clearance = A + B

Upper lift rollers 2. Select the middle lift rollers of the lift bracket.
Select middle lift rollers to correspond to the lift rollers selected
in 1. from the table below. (Use rollers of outer diameters 1 to
1.2 mm (0.04 to 0.047 in) smaller than those of the upper
roller).
mm (in)
Outside diameter of the roller
Upper lift rollers Middle lift rollers
107.7 (4.240) 106.5 (4.193)
Middle lift rollers 108.7 (4.280) 107.7 (4.240)
119.7 (4.713) 118.5 (4.665)
120.7 (4.752) 119.7 (4.713)

Note:
• There is no selection for the upper lift rollers of the outer
mast and middle mast, and for the side roller of the lift
bracket.
• The outer diameter of the selected rollers may be different
between right and left.
sec13.book 34 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-34

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF

UNEVEN LIFTING)
V·FSV·QFV MAST
Note:
• For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner
mast SUB-ASSY
• Perform SAS matching after adjustment. (See section 3)

1. Inspection method
Slowly raise the inner mast, and observe the stopping states of
the left and right cylinder rods at the moment when the inner
mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct this,
add shims to the cylinder that stops first.

2. Adjustment method

SST (1) Remove the left and right cylinder rod end set bolts.
(2) Suspend the inner mast with a hoist, attach the SST to
the outer mast tie beam, and lower the inner mast until it
makes contact with the SST.
SST 09610-22000-71

(3) Place shims on top of the cylinder rod end on the side to
be adjusted, then slowly raise it and insert into the inner
mast.
Shims
Shim thickness: 0.5·1.0·2.0·3.2 mm
(0.020·0.039·0.079·0.126 in)
(4) Reattach the left and right cylinder rod end set bolts.
(5) Remove the SST.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the number of
shims is determined.
sec13.book 35 ページ ２０１０年４月２３日 金曜日 午前１１時１１分

13-35

FV MAST
Note:
• For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner
mast SUB-ASSY
• Perform SAS matching after adjustment. (See section 3)

1. Inspection method
Slowly raise the inner mast, and observe the stopping states of
the left and right cylinder rods at the moment when the inner
mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. In this case, it
is necessary to make a shim adjustment.

2. Adjustment method

SST (1) Remove the left and right cylinder rod end set bolts.
(2) Suspend the inner mast with a hoist, attach the SST to
the outer mast tie beam, and lower the inner mast until it
makes contact with the SST.
SST 09610-22000-71

(3) Place shims on LH of the cylinder rod end, then slowly

raise the cylinder rod end into the inner mast.
Shim thickness: 0.5·1.0·2.0·3.2 mm
Shims
(0.020·0.039·0.079·0.126 in)
(4) Reattach the left and right cylinder rod end set bolts.
(5) Remove the SST.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the number of
shims is determined.
Çñ

Set bolts

Shims

Inner mast

Cylinder rod end LH Cylinder rod end RH

sec13.book 36 ページ ２０１０年４月２３日 金曜日 午前１１時１１分
sec14.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-1

CYLINDER
14

Page
LIFT CYLINDER (V)·REAR LIFT CYLINDER
(FV·FSV·QFV) ............................................................... 14-2
GENERAL........................................................................ 14-2
SPECIFICATIONS............................................................ 14-4
COMPONENTS................................................................ 14-5
REMOVAL·INSTALLATION ........................................... 14-10
DISASSEMBLY·INSPECTION·REASSEMBLY ............. 14-12
SAFETY DOWN VALVE .............................................. 14-14
FRONT LIFT CYLINDER (FV·FSV·QFV) ................ 14-15
GENERAL...................................................................... 14-15
SPECIFICATIONS.......................................................... 14-15
COMPONENTS.............................................................. 14-16
REMOVAL·INSTALLATION ........................................... 14-17
DISASSEMBLY·INSPECTION·REASSEMBLY ............. 14-18
TILT CYLINDER ............................................................ 14-20
GENERAL...................................................................... 14-20
SPECIFICATIONS.......................................................... 14-20
COMPONENTS.............................................................. 14-21
14
REMOVAL·INSTALLATION ........................................... 14-22
DISASSEMBLY·INSPECTION·REASSEMBLY ............. 14-24
MAST FORWARD BACKWARD
TILTING ANGLE ADJUSTMENT
(PREVENTION OF UNEVEN TILTING)....................... 14-26
sec14.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-2

LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV·QFV)

14

GENERAL
Lift Cylinder

Rear Lift Cylinder (FV)

RH

LH
sec14.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-3

Rear Lift Cylinder (FSV)

Rear Lift Cylinder (QFV)

RH

LH

14
sec14.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-4

SPECIFICATIONS
Lift Cylinder (V)
Model
20⋅25 28 ~ 32
Item
Cylinder type Single-acting ←
Cylinder bore mm (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter mm (in) 40.0 (1.58) 45.0 (1.77)
Piston seal type U packing ←
Rod seal type U packing ←
Others Built-in safety down valve (LH)

Rear Lift Cylinder (FV)

Model
20⋅25 28 ~ 32
Item
Cylinder type Single-acting ←
Cylinder bore mm (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter mm (in) 34.9 (1.37) 40.0 (1.57)
Rod seal type U packing ←
Others Built-in safety down valve (LH)

Rear Lift Cylinder (FSV)

Model
20⋅25 28 ~ 32
Item
Cylinder type Single-acting ←
Cylinder bore mm (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter mm (in) 40.0 (1.58) 45.0 (1.77)
Piston seal type U packing ←
Rod seal type U packing ←
Others Built-in safety down valve (RH)

Rear Lift Cylinder (QFV)

Model
All models
Item
Cylinder type Single-acting type
Cylinder bore mm (in) 63 (2.48)
Piston rod outside diameter mm (in) 50 (1.97)
Rod seal type U packing
Others Built-in safety down valve (LH)
sec14.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-5

COMPONENTS
Lift Cylinder (V)
6503

CJ

AI

02
BP

01 DG

DY CR
CP
CL
CS AW

6503-288

V: 20⋅25,H25 6503
02[LH] 01[RH]

02K=(INCL. ) 01K=(INCL. )

AG
02K=(INCL. ) AE

33
AG 42

AE AD
14
33
42 23
22

AD 21 20

AA
AB

6503-284
sec14.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-6

V: 28⋅30⋅32 6503
02[LH] 01[RH]

01K=(INCL. )

02K=(INCL. )
AG
AE

AG
33
AE 42

AD

33
42 23
22

AD 21 20

AA
AC
AA
AB AC
AB

6503-285

Rear Lift Cylinder

FV 6503

CJ

AI

BP

DG CR
CP

AW
DY

CL
CS

6503-290
sec14.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-7

FSV 6503

AI
DV

CJ
02

01
BP
DG CR
CP
DY
AW
CS

CL

6503-289

QFV 6503
sec14.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-8

FV 6503

02[LH] 01[RH]

AX
CZ
41 CZ
AX
22

21 20

02K 41

23
01K

40

6503-287

FSV: 20⋅25,H25 6503

02[LH] 01[RH]

02K=(INCL. ) 01K=(INCL. )

AG

AG AE

33
AE 42

AD

33
42
AD
23 21 22 20

AA
AB
AA
AB

6503-255
sec14.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-9

FSV: 28⋅30⋅32 6503

02[LH] 01[RH]

01K=(INCL. )

02K=(INCL. ) AG
AE

AG 42
33

AE AD

33
42
23 21 22 20
AD

AA
AC
AA
AB AC
AB

6503-256

QFV 6503
sec14.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-10

REMOVAL·INSTALLATION

10

Removal Procedure

1 Set the mast vertical and lower the fork fully.

2 Remove the lift cylinder rod end set bolt.
3 Hoist the inner mast by slinging with a wire and disconnect the end of each lift cylinder rod. [Point 1]
4 Hoist the inner mast further so that the lift cylinder ASSY can be removed toward the front of the
vehicle.
5 Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer
mast.
6 Remove the hose cover.
7 Disconnect the low pressure hose and high pressure hose.
8 Remove the lift cylinder bottom end set bolt.
9 Remove the lift cylinder support. [Point 2]
10 Remove the lift cylinder ASSY.
sec14.book 11 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-11

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
After installing the lift cylinder, follow the steps below.
• Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal functioning.
• Check the hydraulic oil level and add if insufficient.
• Inspect lift cylinders for uneven lifting, and make necessary adjustment. (See page 13-34)

Point Operations
[Point 1]
Removal:
Shim adjustment is made at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH. Take
notes on the cylinder where adjustment is made and the
number of shims used.

[Point 2]
Installation:
Temporarily fasten the cylinder support here, and
Shim eliminate any clearance between the cylinder support and
outer mast by shim insertion after connecting the rod end.
(Use shim (s) slightly thicker than the clearance.)
sec14.book 12 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-12

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

*
2
*: Tightening torque

20·25 28~25
models models

200~300 284.4~421.7
V (2039~3059) (2900~4300)
[147.6~221.3] [209.8~311.0]
203~271 237~305
FV (2073~2764) (2419~3110)
[150~200] [209.8~311.0]
200~300 284.4~421.7
FSV (2039~3059) (2900~4300)
[147.6~221.3] [209.8~311.0]
340~440 340~440
QFV (3467~4487) (3467~4487) 3
[250.8~324.6] [250.8~324.6]

4
1

Disassembly Procedure
1 Remove the safety down valve. (V·FV·QFV:LH, FSV:RH)
2 Remove the cylinder cover. [Point 1]
3 Remove the piston rod. [Point 2]
4 Remove seals on the piston side. [Point 3]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion.

• Apply MP grease all around the inner surface of the

1/3 to 1/2 of circumference
cylinder cover (including the packing, dust seal, and
bushing). After installation, wipe off any excess grease.
2 ridges
• Apply sealant (08833-76002-71 (08833-00080)) to the
cylinder cover on the part shown in the illustration and
2 to 3 ridges
reassemble it.
sec14.book 13 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-13

Point Operations
[Point 1]
SST Disassembly•Reassembly:
If the cylinder cover is a U-groove type, use the SST.
SST 09620-10100-71

[Point 2]
Inspection:
Measure the piston rod outside diameter.
Unit: mm (in)
Vehicle model Standard Limit
20·25 40 (1.575) 39.92 (1.5717)
V
28 ~ 32 45 (1.77) 44.92 (1.7685)
20·25 34.9 (1.37) 34.82 (1.3708)
FV
28 ~ 32 40 (1.575) 39.92 (1.5717)
20·25 40 (1.575) 39.92 (1.5717)
FSV
28 ~ 32 45 (1.77) 44.92 (1.7685)
QFV ALL 50 (1.97) 49.92 (1.9654)

Inspection:
Measure the bend of the piston rod.
Limit: 2.0 mm (0.079 in)

Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
Cylinder rod 20·25: SST 09652-26600-71
28 ~ 32: SST 09653-26600-71

Cylinder

[Point 3]
Inspection:
Measure the lift cylinder bore.
Unit: mm (in)
Vehicle model Standard Limit
V·FV· 20·25 50 (1.97) 50.20 (1.9764)
FSV 28 ~ 32 55 (2.17) 55.35 (2.1791)
QFV ALL 63 (2.48) 63.35 (2.4909)
sec14.book 14 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-14

SAFETY DOWN VALVE

V·FSV·FV mast QFV mast

A B

Except QFV mast QFV mast

sec14.book 15 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-15

FRONT LIFT CYLINDER (FV·FSV·QFV)

GENERAL
FSV·QFV

FV

SPECIFICATIONS
Vehicle model FV·FSV QFV
Item 20·25 28 ~ 32 ALL
Cylinder type Single acting Single acting Single acting
Cylinder bore mm (in) 75.0 (2.95) 85.0 (3.35) 75.0 (2.95)
Piston rod outside diameter mm (in) 50.8 (2.00) ← ←
Piston seal type U packing ← ←
Rod seal type U packing ← ←
Others Built-in safety down valve
sec14.book 16 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-16

COMPONENTS
Front Lift Cylinder (FV·FSV)
6502

01

AL

AL

6502-151

Front Lift Cylinder (QFV)

6502

01

AL

AL

6502-152
sec14.book 17 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-17

REMOVAL·INSTALLATION
Removal Procedure

1 Remove the lift bracket W/fork.

2 Disconnect the pipng.
3 Remove the front lift cylinder.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
After installing the lift cylinder, follow the steps below.
• Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
• Check the hydraulic oil level, and add if insufficient.
• Adjust the lift chain tension equally on the left and right side.
sec14.book 18 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-18

DISASSEMBLY·INSPECTION·REASSEMBLY
Front Lift Cylinder (FV⋅FSV⋅QFV) T = N⋅m (kgf⋅cm) [ft⋅lbf]

FV FSV⋅QFV

* *
7 7
2 3 2 3
4 4

1
5 5

6 6

* Cylinder cover

FV/FSV: 20⋅25 model

T = 407 ~ 434 (4150 ~ 4426) [300 ~ 320]
QFV: ALL model
FV/FSV: 28 ~ 32 model T = 461 ~ 488 (4701 ~ 4976) [340 ~ 360]

Disassembly Procedure

1 Remove the safety down valve.

2 Remove the cylinder cover. [Point 1]
3 Remove the cover seals.
4 Remove the piston rod. [Point 2]
5 Remove the wear ring and U packing.
6 Remove the check valve. [Point 3]
7 Remove the cylinder. [Point 4]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

1/3 to 1/2 of circumference • Apply sealant (08833-76002-71 (08833-00080)) to the

cylinder cover on the part shown in the illustration to
reassemble it.
2 ridges • Fill the cylinder with the specified amount of hydraulic oil
through the cylinder top opening before installing the
2 to 3 ridges cylinder cover.
Filling amount cm3 (in3)
Model 20⋅25 28 ~ 32
FV⋅FSV 75 ~ 95 (4.58 ~ 5.80) 110 ~ 145 (6.71 ~ 8.85)
QFV ↑ 75 ~ 95 (4.58 ~ 5.80)
sec14.book 19 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-19

Point Operations
[Point 1]
SST
Disassembly⋅Reassembly:
SST 09620-10100-71

[Point 2]
Inspection:
Measure the piston rod outside diameter.

Standard: 50.8 mm (2.0 in)

Limit: 50.72 mm (1.9969 in)

Inspection:
Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

Check [Point 3]
valve
Reassembly:
Install the check valve so that the arrow will direct
downward of the front lift cylinder.

[Point 4]
Inspection:
Measure the lift cylinder bore.

20⋅25 model, 28 ~ 32 model (QFV)

Standard: 75.0 mm (2.953 in)
Limit: 75.35 mm (2.9665 in)
28 ~ 32 model
Standard: 85.0 mm (3.346 in)
Limit: 85.40 mm (3.3622 in)
sec14.book 20 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-20

TILT CYLINDER
GENERAL

SPECIFICATIONS
Item All models
Cylinder type Double acting type
Cylinder bore mm (in) 70 (2.76)
Piston rod outside diameter mm (in) 30 (1.18)
Piston seal type U packing
Rod seal type U packing
sec14.book 21 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-21

COMPONENTS
6511

(20D, RUST PROOF)

31
CT 31
CT
ED
CZ

CZ

01 (20D, RUST PROOF)

(TILT BOOTS)

01
CI

DK
BZ CH
BZ

32

EH

6511-304

6511
01

01K=(INCL. ) DH
BB
AB

30
DH
42
AC
AE
AF
AL

40
AM 21

AJ AD

20
AI
AP

21B
AP
20A
CA
AN

6511-305
sec14.book 22 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-22

REMOVAL·INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 76.8 ~ 115.2
(783 ~ 1174)
[56.7 ~ 85]

T = 43.2 ~ 72.9
(441 ~ 743)
[31.9 ~ 53.8]
9 6 8

Removal Procedure

1 Remove the toe board and lower panel.

2 Remove the instrument panel.
3 Remove the front piller cover.
4 Hoist the mast slightly.
5 Disconnect the hose.
6 Disconnect the tilt angle sensor link (RH).
7 Remove the tilt cylinder front pin. [Point 1]
8 Remove the tilt cylinder rear pin.
9 Remove the tilt cylinder ASSY.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
• Apply MP grease on the portions for inserting tilt cylinder front and rear pins before installation.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portion of the rear pin set
bolt before tightening.
• After installation, slowly tilt the mast forward and backward a few times to check normal
functioning.
• Check the hydraulic oil level, and add if insufficient.
• After installation, perform SAS matching. (Refer to section 3)
sec14.book 23 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-23

[Point 1]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate and lock bolt. Match marks, however,
are unnecessary when the mast or mast ASSY is replaced
since mast tilt angle adjustment is to be done after the
replacement.

Removal:
SST 09810-20172-71

SST
sec14.book 24 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-24

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N⋅m (kgf⋅cm) [ft⋅lbf]

4
6

T = 225.4 ~ 284.2
1·5 (2300 ~ 2900)
[166.4 ~ 209.8]

T = 284 ~421 3
(2896 ~ 4293)
[210 ~ 311]

Disassembly Procedure

1 Loosen the rod guide. [Point 1]

2 Extract the piston rod W/piston.
3 Remove the tilt cylinder. [Point 2]
4 Remove the piston.
5 Remove the rod guide.
6 Remove the piston rod. [Point 3]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
• Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the rod guide before
reassembly.
• Apply MP grease to front and rear pin insertion portions of the cylinder.
sec14.book 25 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-25

Point Operations
SST [Point 1]
Disassembly⋅Reassembly:
SST 09620-10100-71

[Point 2]
Inspection:
Measure the cylinder bore.

Standard: 70.0 mm (2.756 in)

Limit: 70.35 mm (2.7697 in)

Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
SST 09659-26600-71

Cylinder

Cylinder rod

[Point 3]
Inspection:
Measure the piston rod outside diameter.

Standard: 30.0 mm (1.181 in)

Limit: 29.92 mm (1.1780 in)

Inspection:
Measure the bend of the piston rod.

Limit: 1.0 mm (0.039 in)

sec14.book 26 ページ ２０１０年４月２３日 金曜日 午前１１時５分

14-26

MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF

UNEVEN TILTING)
Note:
Adjust the mast forward and backward tilting angles (to prevent uneven tilting) when the tilt
cylinder and mast ASSY are replaced or overhauled.
After adjustment, perform SAS matching. (Refer to section 3)
1. With the mast in the neutral position, install the stopper with the tilt cylinder pin eccentric direction on
the lower side.

Eccentric
direction

2. Inspect the forward and backward tilt angle and unevenness in tilting at the pin position above.

Standard:
Mast forward tilting angle: Standard set angle -0.6° ~ +1.6°
Mast backward tilting angle: Standard set angle -0.8° ~ +0.6°
Unevenness: 1 mm (0.04 in) or less

3. If the standard is not satisfied, make adjustment by turning the fixation angle of the eccentric pin in
alliance with the stopper bolt hole matching in the stopper plate. To align the hole with the tapped hole
in the tilt bracket, either of two holes in the plate is selective and the plate is reversible on side to find
desirous position.
4. After the adjustment, tighten the stopper set bolt to lock the front pin.
sec15.book 1 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-1

OIL PUMP
15

Page
15

GENERAL ........................................................................ 15-2

SPECIFICATIONS .......................................................... 15-2
COMPONENTS ............................................................... 15-3
OIL PUMP ASSY ............................................................ 15-4
REMOVAL·INSTALLATION ............................................. 15-4
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 15-5
TEST METHOD ............................................................... 15-8

15
sec15.book 2 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-2

GENERAL

SPECIFICATIONS
Model Manufacturer (Model) Pump type Displacement cm3 (in3)/rev
SHIMADZU
All models Single gear 25.8 (1.574)
(TMG1A25A9H5-R935)
sec15.book 3 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-3

COMPONENTS
6701

Refer to
FIG.1402

01

AI

AI

6701-245

6701
01

01K=(INCL. )

15

6701-246
sec15.book 4 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-4

OIL PUMP ASSY

REMOVAL·INSTALLATION

7
T = 74.1 ~ 81.9
2
(756 ~ 835)
T = 24.0 ~ 33.0 [54.7 ~ 60.4]
T = 61.6 ~ 75.6 (245 ~ 337)
(628 ~ 771) [34.0 ~ 36.2]
[45.4 ~ 55.8]

Removal Procedure

1 Disconnect the battery plug.

2 Remove the side cover RH.
3 Drain hydraulic oil.
4 Disconnect the outlet hose.
5 Disconnect the inlet hose.
6 Remove the oil pump ASSY.
7 Remove the fitting.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
• Apply grease (molybdenum disulfide grease) on the pump shaft spline portion before
installation.
• Clean the fitting mounting portion thoroughly to prevent damage to the O-ring.
sec15.book 5 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-5

DISASSEMBLY·INSPECTION·REASSEMBLY

T = N⋅m (kgf-cm) [ft-lbf]

3
2

5
4 T = 46.1 ~ 48.6
(470 ~ 500)
6 [34.0 ~ 36.2]

Disassembly Procedure

1 Put match marks on the cover, body and mounting flange. [Point 1]
2 Remove the cover.
3 Remove the mounting flange.
4 Remove the bushing set and pump gear set. [Point 2] 15
5 Remove the oil seal. [Point 3]
6 Inspect the body. [Point 4]

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
sec15.book 6 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-6

Point Operations
Match marks
[Point 1]
Disassembly:
Provide a match marks between the front cover and body,
and between the rear cover and body.

Reassembly:
Assembly by aligning the match marks.

[Point 2]
Disassembly:
Put match marks on the teeth of the drive and driven
gears.

Reassembly:
Align match marks at the time of reassembly.

Inspection:
Discharge side Inspect the bushing set contact trace.

Standard:
Relatively stronger contact trace on the suction side,
with slight trace on the discharge side.

Suction side
Contact trace

Length Inspection:
Measure the bushing set length.

Limit: 26.411 mm (1.03980 in)

Inspection:
Inside
diameter Inspect the bushing set for wear at the interior surface.

Limit:
Replace if the teflon coating layer is worn out even
locally.
Inspection:
Measure the outside diameter of each gear shaft.

Limit: 18.935 mm (0.74547 in)

Shaft diameter
sec15.book 7 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-7

[Point 3]
Disassembly:
SST 09319-76001-71
(SST 09319-60020)
SST

Reassembly:
SST 09950-76018-71(1)
SST (2) (SST 09950-60010)
SST 09950-76020-71(2)
(SST 09950-70010)
After installation, apply MP grease on the oil seal lip
SST (1) portion.

[Point 4]
Inspection:
Inspect the contact trace on the inner surface of the body
(suction side).
Contact trace
of gear teeth
Limit: Contact trace covers more than half of the
crests circumference.

Discharge side
sec15.book 8 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-8

TEST METHOD
A bench test should be conducted for strict testing, but as it is generally impossible in practical service
operation, install the oil pump on the vehicle and judge the oil pump discharge performance by means of
cylinder operation.
• Check that the battery charge is sufficient by observing the battery charge indicators.
• Check that the oil control valve set relief pressure is as specified.(See page 16-12)
• Measure the lift cylinder full stroke operation time when the hydraulic oil temperature is 50 to 55°C (122
to 131°F), and calculate the lifting speed.

The lifting speed depends slightly on the battery, hydraulic oil temperature and mast adjustment.
The value below is for the case where given conditions are satisfied.

Liffting Speed Table (Approx.value)

Liffting speed mm/sec (fpm)
Model(36V) 8FBCU20 8FBCU25/HU25 8FBCU28 8FBCU30 8FBCU32
No- No- No- No- No-
Mast Mode Loaded Loaded Loaded Loaded Loaded
load load load load load
540 340 540 300 460 280 460 260 460 240
H
(160) (67) (106) (59) (91) (55) (91) (51) (91) (47)
530 330 530 290 450 270 450 250 450 230
Lifting P
(104) (65) (104) (57) (89) (53) (89) (49) (89) (45)
V
520 320 520 280 440 260 440 240 440 220
S
(102) (63) (102) (55) (87) (51) (87) (47) (87) (43)
500 500 500 500 500 500 500 500 500 500
Lowering ALL
(98) (98) (98) (98) (98) (98) (98) (98) (98) (98)
480 320 480 290 400 260 400 250 400 240
H
(94) (63) (94) (57) (79) (51) (79) (49) (79) (47)
470 310 470 280 390 250 390 240 390 230
Lifting P
(93) (61) (93) (55) (77) (49) (77) (47) (77) (45)
FSV
460 300 460 270 380 240 380 230 380 220
S
(91) (59) (91) (53) (75) (47) (75) (45) (75) (43)
450 480 450 480 420 460 420 460 420 460
Lowering ALL
(89) (94) (89) (94) (83) (91) (83) (91) (83) (91)
530 330 530 290 430 270 430 260 430 250
H
(104) (65) (104) (57) (85) (53) (85) (51) (85) (49)
520 320 520 280 420 260 420 250 420 240
Lifting P
(102) (63) (102) (55) (83) (51) (83) (49) (83) (47)
FV
510 310 510 270 410 250 410 240 410 230
S
(100) (61) (100) (53) (81) (49) (81) (47) (81) (45)
420 480 420 480 390 460 390 460 390 460
Lowering ALL
(83) (94) (83) (94) (77) (91) (77) (91) (77) (91)
470 320 470 290 470 290 470 290 470 290
H
(93) (63) (93) (57) (93) (57) (93) (57) (93) (57)
460 310 460 280 460 280 460 280 460 280
Lifting P
(91) (61) (91) (55) (91) (55) (91) (55) (91) (55)
QFV
450 300 450 270 450 270 450 270 450 270
S
(89) (59) (89) (53) (89) (53) (89) (53) (89) (53)
450 510 450 510 450 510 450 510 450 510
Lowering ALL
(89) (100) (89) (100) (89) (100) (89) (100) (89) (100)
sec15.book 9 ページ ２０１０年４月２３日 金曜日 午前１１時４分

15-9

Model(48V) 8FBCU20 8FBCU25/HU25 8FBCU28 8FBCU30 8FBCU32

No- No- No- No- No-
Mast Mode Loaded Loaded Loaded Loaded Loaded
load load load load load
660 450 660 400 590 370 590 350 590 330
H
(130) (89) (130) (79) (116) (73) (116) (69) (116) (65)
650 440 650 390 560 350 560 330 560 320
Lifting P
(128) (87) (128) (77) (110) (69) (110) (65) (110) (63)
V
640 430 640 380 530 330 530 320 530 310
S
(126) (85) (126) (75) (104) (65) (104) (63) (104) (61)
500 500 500 500 500 500 500 500 500 500
Lowering ALL
(98) (98) (98) (98) (98) (98) (98) (98) (98) (98)
620 420 620 390 490 340 490 330 490 320
H
(122) (83) (122) (77) (96) (67) (96) (65) (96) (63)
600 410 600 380 480 330 480 320 480 310
Lifting P
(118) (81) (118) (75) (94) (65) (94) (63) (94) (61)
FSV
580 400 580 370 470 320 470 310 470 300
S
(114) (79) (114) (73) (93) (63) (93) (61) (93) (59)
450 480 450 480 420 460 420 460 420 460
Lowering ALL
(89) (94) (89) (94) (83) (91) (83) (91) (83) (91)
640 430 640 390 530 350 530 340 520 320
H
(126) (85) (126) (77) (104) (69) (104) (67) (102) (63)
630 420 630 380 520 340 520 330 510 310
Lifting P
(124) (83) (124) (75) (102) (67) (102) (65) (100) (61)
FV
620 410 620 370 510 330 510 320 500 300
S
(122) (81) (122) (73) (100) (65) (100) (63) (98) (59)
420 480 420 480 390 460 390 460 390 460
Lowering ALL
(83) (94) (83) (94) (77) (91) (77) (91) (77) (91)
610 440 610 400 610 390 610 390 610 390
H
(120) (87) (120) (79) (120) (77) (120) (77) (120) (77)
580 410 580 380 580 380 580 380 580 380
Lifting P
(114) (81) (114) (75) (114) (75) (114) (75) (114) (75)
QFV
560 400 560 370 560 360 560 360 560 360
S
(110) (79) (110) (73) (110) (71) (110) (71) (110) (71)
450 470 450 510 450 510 450 510 450 510
Lowering ALL
(89) (93) (89) (100) (89) (100) (89) (100) (89) (100)
sec15.book 10 ページ ２０１０年４月２３日 金曜日 午前１１時４分
sec16.book 1 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-1

OIL CONTROL VALVE

16

Page
GENERAL ........................................................................ 16-2
SPECIFICATIONS .......................................................... 16-7
COMPONENTS ............................................................... 16-8
OIL CONTROL VALVE ASSY ................................... 16-10
REMOVAL·INSTALLATION ........................................... 16-10
RELIEF PRESSURE ADJUSTMENT ...................... 16-12
MANUAL DOWN VALVE ............................................ 16-14
CONTROL VALVE LEVER ASSY ............................ 16-15
REMOVAL·INSTALLATION ........................................... 16-15

16
sec16.book 2 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-2

GENERAL
16

Oil Control Valve

X1
X3 X4
X2

X1
X4

X2 X3
sec16.book 3 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-3

X1-X1

Unload solenoid

X2-X2

Lift solenoid

16
sec16.book 4 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-4

X3-X3

Tilt forward solenoid

Tilt limit switch

(Pulling motion detection)
Tilt limit switch
(Pushing motion detection)

X4-X4
sec16.book 5 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-5

Hydraulic Circuit Diagram (Conventional Lever)

T2 R
Unloading valve
P
(Unloading SOL)
OUT

Load check valve

Lift lock valve Flow regulator

(Lift lock SOL) valve

Manual down valve

S
C1

Load check valve

Tilt control valve

(Tilt control SOL)

C2
C3

Load check valve

16

C4
C5

T1
sec16.book 6 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-6

Hydraulic Circuit Diagram (Mini Lever/Joystick Lever)

T2 R1 Gauge port
P

OUT

b1 a1

Lift lock valve

(Lift lock SOL)

Flow regulator valve S

C1
Manual down valve

b2 a2

Tilt control valve

(Tilt control SOL) C2
C3

b3 a3

C4
C5

Decompression
valve
T1 R2
sec16.book 7 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-7

SPECIFICATIONS
Model
All models
Item
Type Add-on type (1-, 2- spool monoblock)
Lift
Relief pressure
& 17800 (181.51) [2573.8]
kPa (kgf/cm2)[psi]
Tilt
Other Built-in lift & tilt lock valves

Lowering Speed Specifications

Unit: mm/sec (fpm)
V mast FV mast FSV mast QFV mast
Model
No load Full load No load Full load No load Full load No load Full load
20 500 (98) 500 (98) 420 (83) 480 (94) 450 (89) 480 (94) 450 (89) 470 (93)
25 ↑ ↑ ↑ ↑ ↑ ↑ ↑ 510 (100)
28 ↑ ↑ 390 (77) 460 (91) 420 (83) 460 (91) ↑ ↑
30 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑
32 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑
sec16.book 8 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-8

COMPONENTS
Conventional Lever
6705

CA 01

50F
BZ LE
BY
KZ
50C
GN

AZ
BT 50A

BV
50C
50B
BV
BU 50E BX
50C
50D
BW

BZ
BZ
6705-D32

Mini Lever/Joystick Lever

6705

CA

BZ BY 50F 01
GN
50C AZ
LE
KZ

50A
BT

50B
BU

50C

BV

50C 50E

BV BX
50D
BW
6705-D37
sec16.book 9 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-9

6705

UJ
RZ
81

QT

UJ

LJ

01

LD

UJ 81

QT

UJ

LJ

6705-D35

6709

20 06 LY LY
40
LY EB
22
EB

66A CZ

40
66A
MV 66A
27
AB
66A 66
AB
MV
AB
MV

30 30
30

LU
LU
LU
30A
30A
6709-493 30A
sec16.book 10 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-10

OIL CONTROL VALVE ASSY

REMOVAL·INSTALLATION
Note:
Operate the control lever and bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the material handling system before starting
removal.

10
T = 14.4 ~ 33.6
3
(147 ~ 343) 10 10
[10.6 ~ 24.8]

10

4, 5

6
7
sec16.book 11 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-11

Removal Procedure

1 Disconnect the battery plug.

2 Remove the toe board (front and rear) and lower panel.
3 Remove the instrument panel RH.
4 Disconnect the connector.
5 Disconnect the lever rod.
6 Remove the control valve lever. (See page 16-15)
7 Remove the harness bracket.
8 Disconnect all the piping and the load sensor connector.
9 Remove the oil control valve ASSY W/ bracket.
10 Remove the oil control valve ASSY.
11 Remove the fitting and load sensor.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
• Apply chassis grease special to the oil control valve lever linkage.
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced.(See section 17)

Point Operations
[Point 1]
Removal ･ Installation
For the removal of the oil control valve ASSY W/ bracker
for over fourth-way, use a hoist.
sec16.book 12 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-12

RELIEF PRESSURE ADJUSTMENT

Note:
• Since the relief valve is structured in two stages, be sure to adjust the lift (hight pressure) side
first and adjust the tilt (low pressure) side then. (If the lift side is normal and tilt side is abnormal
as the result of relief pressure inspection, only the tilt side adjustment can be performed.)
• 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 engine hood.

2. Remove the lower panel and toe board.
3. Install an oil pressure gauge.
Remove the oil-pressure detecting plug installed on the
9/16-18
left side of the oil control valve, and install the oil
UNF
pressure gauge there.

Plug size: 9/16 - 18UNF

Fitting Fitting size: 9/16 - 18UNF × PF1/4
Fitting: 90407-13469-71

4. Set the adjusting screw A and adjusting sleeve B of the

Adjusting screw A
relief valve as described below
Lock nut 1
(1) Loosen lock nut 1. After fully tightening⋅adjusting
Adjusting
screw A once, loosen it by 1 to 2 turns.
sleeve B (2) Loosen the lock nut 2, and position adjusting sleeve B
to the following dimension.

Lock nut 2 a = 27.0 mm (1.06 in)

5. Start the engine, and check for oil leaks and abnormal
noise.

6. Install the toe board.

7. Close the engine hood.

8. Adjust the lift side relief pressure.

(1) Set the seat switch to ON. (Operate by two workers
with onesetting on the seat.)
(2) Operate the lift lever to lift the fork fully.
(3) While running the engine at the maximum speed,
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.
sec16.book 13 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-13

9. Adjust the tilt side relief pressure.

(1) Set the seat switch ON.
(2) Operate the tilt lever to tilt the mast fully backward.
(3) While running the engine at the maximum speed,
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 tighening lock nut 1.
(4) Tighten the lock nut and re-check the oil pressure.

Relief Pressure Standards Unit: kPa (kgf-cm2) [psi]

Lift relief pressure 17800 +490
(181 +5
) [2574 +70
]
0 0 0
sec16.book 14 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-14

MANUAL DOWN VALVE

T = N⋅m (kgf-cm) [ft-lbf]

Lift lock unlocking bolt

T = 3.5 ~ 4.3
(36 ~ 44)
[2.6 ~ 3.2]

Solenoid valve (Lift) Solenoid valve (Tilt)

If the fork does not come down due to a failure of the solenoid valve, for example, the fork can be lowered
manually by operating the lift lever to the down side after loosening the lock nut and the lift lock unlocking
bolt. Always retighten the unlocking bolt after the end of repair. Otherwise, most of the hydraulic oil from
the oil pump is relieved to slow down lifting extremely, resulting in difficulty in load handling.
sec16.book 15 ページ ２０１０年４月２３日 金曜日 午後５時３３分

16-15

CONTROL VALVE LEVER ASSY

REMOVAL·INSTALLATION

1 3

Removal Procedure

1 Remove the instrument panel (RH).

2 Remove the set pin and disconnect the lever rod.
3 Tilt lever: Disconnect the knob switch wiring.
4 Remove the set bolt.
5 Remove the control valve lever. [Point 1]

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
Apply grease at control valve lever link portions.

Point Operation
[Point 1]
Inspection:
Inspect the knob switch for continuity.
sec16.book 16 ページ ２０１０年４月２３日 金曜日 午後５時３３分
sec17.book 1 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-1

SAS FUNCTIONS
17

Page
GENERAL ........................................................................ 17-2
SAS (System of Active Stability) system
configuration ................................................................ 17-2
COMPONENTS ............................................................... 17-4
BEFORE STARTING REPAIR WORK ...................... 17-9
YAW RATE SENSOR ................................................... 17-11
REMOVAL·INSTALLATION ........................................... 17-11
SWING LOCK CYLINDER ......................................... 17-12
REMOVAL·INSTALLATION ........................................... 17-12
TILT ANGLE SENSOR ................................................ 17-14
REMOVAL·INSTALLATION ........................................... 17-14
LOAD SENSOR ............................................................ 17-15
REMOVAL·INSTALLATION ........................................... 17-15
SPEED SENSOR .......................................................... 17-16
REMOVAL·INSTALLATION ........................................... 17-16
MAST LIFTING HEIGHT SWITCH ........................... 17-17
REMOVAL·INSTALLATION ........................................... 17-17
MATCHING ..................................................................... 17-18
STANDARD STATE OF VEHICLE................................. 17-20
CAUTIONS ON MODIFYING VEHICLES ............... 17-21
RENEWAL OF SAS CAUTION LABEL .................. 17-22
17
sec17.book 2 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-2

GENERAL
17

SAS (System of Active Stability) system configuration

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
control rear stabilizer (S) and active mast function control (T).

S: Active Control Rear Stabilizer

T: Active Mast Function Control
Input Output
Control S T S T Control
Sensor/Switch Actuator
1 Height switch ○○ ○ 10 Swing lock cylinder

2 Tilt angle sensor ○ ○ 11 Tilt control valve

14 Main controller

3 Tilt lever switch *1 ○ ○ 12 Tilt electric proportional

valve *2
4 Tilt lever angle sensor *2 ○ ○ 13 Lift lock valve

5 Lift lever angle sensor ○

6 Load sensor ○○
7 Automatic fork leveling
control switch ○
8 Yaw rate sensor ○
9 Vehicle speed sensor *3 ○

*1: Without Mini Lever and Joystick Lever [STD]

*2: With Mini Lever [OPT] or Joystick Lever [OPT]
*3: The vehicle speed is detected by the motor speed sensors via the drive motor drivers.
sec17.book 3 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-3

Conventional Lever [STD]

7

Mini Lever [OPT]/Joystick Lever [OPT]

4,5,7
3,5,11,13
14 6 1
10 8 9
2

11,12,13
14 6
10 8 9

No. Name No. Name

1 Height switch 8 Yaw rate sensor
2 Tilt angle sensor 9 Vehicle speed sensor
3 Tilt lever switch *1 10 Swing lock cylinder
4 Tilt lever angle sensor *2 11 Tilt control valve
5 Lift lever angle sensor 12 Tilt electric proportional valve *2
6 Load sensor 13 Lift lock valve 17
7 Automatic fork leveling control switch 14 Main controller
*1: Without Mini Lever and Joystick Lever [STD]
*2: With Mini Lever [OPT] or Joystick Lever [OPT]
sec17.book 4 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-4

COMPONENTS
Speed sensor (Revolution sensor) 1401
01

AQ
AQ
BD BD

AQ AQ
AT
BD FV
AF
AT AD 60 41 AF
AF
20A AX
CH AX AX
BD
AU HN
ER
EE
BJ
BJ BJ
22
AX
AS
20B

20
AT
AW
20C
AT
EW
AT
18
AW AT
AT

49

1401-190

Main controller 2400

05

AR

AR
AR

AR

2400-234
sec17.book 5 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-5

Yaw rate sensor 5803

EN

47

EN

5803-548

Swing lock cylinder 4301

JN BQ
JM BQ

GJ BQ 16
GJ
JN
GJ JO EC

EC EC
GV

EC JL
BQ

17
GJ EF

4301-268
sec17.book 6 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-6

Lifiting height switch (V) 5803

10

BY

BX 10

BP 64

63
62 AV AU AR
AS

AO

CY

AT
33 AV

CY

5803-542

Lifting height switch (FV) 5803

10

65
64
AZ
DA

BC

BE

AR
AU
AO

AP
AS AV
AV

10
AT
33 CZ

62
AW
EI BV

AX

5803-544
sec17.book 7 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-7

Lifting height switch (FSV) 5803

10

65
64
AZ
DA

BC

BE

AR
AU
AO
10
AP
AS AV
AV

AW
AT
33 CZ
EI
AX 62

BV

5803-543

Lifting height switch (QFV) 5803

10

65
64
AZ
DA

BC

BE

AR
AU
AO

AP
AS AV
AV

10
AT
AW 33 CZ

62

EI
BV
AX

5803-545
sec17.book 8 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-8

Tilt angle sensor 5803

36

CL
BN
BO
11

BL

BW

5803-547

Load sensor 5803

Refer to
FIG.6705

35

5803-546
sec17.book 9 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-9

BEFORE STARTING REPAIR WORK

Before starting SAS repair, fully understand the SAS function.
1. Preparation for repairing
(1) Avoid vehicle washing as far as possible. For cleaning, blow compressed air. If washing with water
is required, avoid water jet washing. Always blow compressed air to remove water after washing.
(2) Transport the main controller in packed state. Keep it packed until installation. Never transport it in
exposed state. Full care should be taken not to drop the controller, allow contact with elsewhere or
impact against it.
(3) If matching is required, park the vehicle in a flat place in advance.
(4) Provide necessary tools and instruments, SST 09230-21440-71, SST 09240-23400-71, and SST
09230-13700-71.

2. During repair work

(1) Never use an impact wrench for removing or installing the main controller. Full care should be
taken not to drop main controller by mistake avoid impact from dropping that may damage parts
inside.
(2) Don’t turn the key switch to ON or OFF carelessly when 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 and up to ten error codes can be stored. Beyond ten, older error codes
will be eliminated sequentially.
(3) During matching, SAS function will stop. Don’t operate the vehicle.
(4) 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 swing lock and causes the vehicle to be tilted
suddenly, leading to great danger.
(5) When the hydraulic piping is disconnected, apply cover to the fitting and hose to prevent the dirt
from entering.
(6) If the oil control valve for manual lowering is loosened, tighten it to a prescribed torque.
(7) Tighten respective set bolts to a prescribed torque.
(8) Respective sensors require no adjustment during installation. Make initialization during matching.
(9) To disconnect a connector, do not pull it by the harness.
(10) When inspecting the harness, carefully operate so as not to damage connector terminals.
(11) The swing lock cylinder must not be disassembled. If disassembled, air enters to make it not
reusable.
(12) Do not apply strong impacts to the frame and head guard to prevent the yaw rate sensor from being
damaged.
(13) 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
sec17.book 10 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-10

3. Temporary measures
If the mast should fail to lower because of some trouble,
it can be lowered manually.
Loosening the illustrated valve on the top of the oil
control valve lowers the mast. Operate the lift lever for
lowering with the manual lowering valve loosened.
After the repair, tighten it appropriately.

T = 32.0 N⋅m (326 kgf⋅cm) [23.6 ft⋅lbf]

Lift unlock bolt
sec17.book 11 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-11

YAW RATE SENSOR

REMOVAL·INSTALLATION
Note:
Take the utmost care so as not to give a shock or impact on the yaw rate sensor. Don’t use an air
impact wrench on controller parts wholly. If dropped, replace with a new one.
T = N⋅m (kgf-cm) [ft-lbf]

T = 3.3 ~ 7.7
(33 ~ 79)
[2.4 ~ 5.7]

T = 1.0 ~ 2.0
(10 ~ 20)
[0.7 ~ 1.5]

Removal Procedure

1 Disconnect the battery plug.

2 Remove the flour mat and toe board No.2.
3 Disconnect the connector.
4 Remove the yaw rate sensor.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec17.book 12 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-12

SWING LOCK CYLINDER

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 19 ~ 37
3 (190 ~ 370)
[13.7 ~ 26.8]

4
5
T = 19 ~ 37
7
(190 ~ 370)
[13.7 ~ 26.8]

Removal Procedure

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

2 Jack up the vehicle until the rear wheels leave the ground.
3 Disconnect the swing lock solenoid connector.
4 Remove the swing lock cylinder crank pin. [Point 1]
5 Remove the swing lock cylinder pin. [Point 2]
6 Remove the swing lock cylinder ASSY W/crank. [Point 3]
7 Remove the swing crank from the swing lock cylinder.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
• 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.
sec17.book 13 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-13

Point Operations
[Point 1]
Removal:
Make match marks on the swing crank and crankpin.

Installation:
Install by aligning the match marks.

[Point 2]
Removal:
SST 09810-20172-71

SST

[Point 3]
Inspection:
Accumulator inspection
1. Remove the plug from the tip end of the accumulator.

2. 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))
L
If the limit value is exceeded, replace the swing lock
cylinder ASSY.
3. After inspection, tighten the plug to be flush with the
end face of the accumulator (do not tighten it
excessively).

Installation:
Install with the mark (protruded portion) at the rod end
facing upside.
sec17.book 14 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-14

TILT ANGLE SENSOR

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

5
T = 7.8 ~ 18.2
(80 ~ 186)
T = [5.8 ~ 13.4]

T = 7.8 ~ 18.2
(80 ~ 186)
T = [5.8 ~ 13.4]

Removal Procedure

1 Remove the toe boards (front and rear).

2 Remove the lower panel.
3 Remove the instrument panel RH.
4 Remove the front piller cover RH.
5 Disconnect the tilt angle sensor link.
6 Disconnect the connector.
7 Remove the tilt angle sensor.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note:
Carry out matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is
adjusted in length or replaced.
sec17.book 15 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-15

LOAD SENSOR
REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

1 Load sensor:
2
T = 22.0 ~ 26.0 (224 ~ 265) [16.2 ~ 19.2]

Removal Procedure

1 Disconnect the connector from the load sensor.

2 Remove the load sensor.

Installation Procedure

Reverse the removal procedure.

Note:
When the load sensor is replaced, proceed with the matching procedure. (Refer to section 3)
sec17.book 16 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-16

SPEED SENSOR
REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

Removal Procedure

1 Remove the cover.

2 Remove the speed sensor.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec17.book 17 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-17

MAST LIFTING HEIGHT SWITCH

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]
V mast

T = 16.2 ~ 37.8 (165 ~ 385)

3 T = [12.0 ~ 27.9]

FV⋅FSV⋅QFV mast

T = 16.2 ~ 37.8 (165 ~ 385) [12.0 ~ 27.9]

Removal Procedure

1 Remove the lower cover.

2 Disconnect the connector.
3 Remove the mast lifting height switch.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

sec17.book 18 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-18

MATCHING
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 used for drive functions, the signal voltage values at accelerator fully released,
accelerator fully closed 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 load-handling lever function is controlled based on the memory of signal
voltage values in the neutral position stored in the controller at the time of shipment. When servicing these
sensors or replacing related parts, MATCHING (updating the sensor signal voltage value 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”. (See page 3-70)

Matching Items and Prerequisite for Implementation

1. Drive
Prerequisite for
No. Indication Description
implementation
Accelerator sensor output value with fully opened
1 ACCEL OFF *1,*2
accelerator position to the controller.
Accelerator sensor output value with fully stepped
2 ACCEL ON *1,*2
accelerator position to the controller.
2. SAS
Prerequisite for
No. Indication Description
implementation
Tilt angle sensor output value with fork in the hori- *1, *3, *4,
1 TILT LEVEL
zontal position to the controller. *7, *8, *9
Tilt angle sensor output value at the forward tilt
*1, *3, *4, *5
2 TILT FWD LIMIT limit position and the load sensor output value with-
*7, *8, *9
out load to the controller.
Tire angle sensor output value while the vehicle is
3 TIRE POSITION *1, *6
traveling straight to the controller.
sec17.book 19 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-19

3. LEVER
Prerequisite for
No. Indication Description
implementation
Lift lever angle sensor output value in the lift lever
1 LEVER1 *1, *10
neutral position is stored in the controller.
Tilt lever angle sensor output value in the tilt lever
2 LEVER2 *1, *11
neutral condition is stored in the controller.
Attachment (1) lever angle sensor output value in
3 LEVER3 the attachment (1) lever neutral position is stored *1, *12
in the controller.
Attachment (2) lever angle sensor output value in
4 LEVER4 the attachment (2) lever neutral position is stored *1, *13
in the controller.
4. TIRE DATA
Prerequisite for
No. Indication Description
implementation
1 TIRE DATA The tire data according to the tire size is stored. *1, *15

Prerequisite content for implementation

*1: When main controller replacement
*2: When removing/installing or replacing accelerator sensor
*3: When removing/installing or replacement tilt angle sensor
*4: When length change or replacement of tilt angle sensor rod
*5: When removing/installing or replacing load sensor
*6: When removing/installing or replacing tire angle sensor or sensor cover
*7: When installing or changing attachment or fork
*8: When removing/installing or replacing mast
*9: When removing/installing or replacing tilt cylinder
*10: When replacing lift lever angle sensor
*11: When replacing tilt lever angle sensor
*12: When replacing attachment (1) lever angle sensor
*13: When replacing attachment (2) lever angle sensor
*14: When replacing multifunction display
*15: When the tire size or type is changed.
sec17.book 20 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-20

STANDARD STATE OF VEHICLE

If the surface on which matching is to be performed is slanted, error occurs to the standard state. Select a
level floor without irregularity for matching.

Note:
The finishing accuracy of the floors for factories, warehouses and buildings in general calls for the
floor inclination to be 0.5° or under. Therefore, matching on these floors is not affected. Don’t
perform matching on a floor that is inclined for over 0.5° for draining purpose.

Fork stop position with automatic leveling and forward

tilting limit position
FV⋅FSV⋅QFV • Set the vehicle in the following condition so as to have the
V
tilt angle sensor signal voltage value stored with the mast
held vertical to the floor surface:Load sensor
No-load standard load
100 mm (3.9 in)

• Set the vehicle in the following condition so as to have the

load sensor signal voltage value stored under no-load
condition:

500 mm (19.7 in) Standard:

• Raise the fork to a height of 500 mm (19.7 in) for the
V mast or raise the rear lift cylinder to a height of
100 mm (3.9 in) for the FV, FSV or QFV mast. Place a
level (goniometer) at a height of 1200 to 1500 mm
(47.2 to 59.1 in) on the front or rear side of the outer
mast and set the mast in the vertical position.
• In the case of a special vehicle with a heavy
attachment (exceeding the additional weight shown
in the table below), adjust the perpendicularity of
the mast with the attachment height at 500 mm (19.7
in), and perform relief at the topmost position.

Note:
• Keep the fork or attachment installed on the vehicle.
• Set the mast vertical from a backward tilted position
(not from the forward tilted position).
• In case of a detachable attachment, keep the
attachment installed on the vehicle.

Additional Weight Table kg (lbs)

Lift height
20 model 25 model 28~32 model
mm (in)
3000 (118) 950 950 1200
or less (2095) (2095) (2646)
3300 (130) 950 950 1200
~ 4000 (157.5) (2095) (2095) (2646)
4300 (169) 700 900 1000
~ 5000 (197) (1544) (1985) (2205)
5500 (216.5) 450 650 800
~ 6000 (236) (992) (1433) (1764)
6500 (256) 300 500 500
~ 7000 (275.5) (662) (1103) (1103)
sec17.book 21 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-21

CAUTIONS ON MODIFYING VEHICLES

H (fork height): mm (in)
No. Content of modification Condition Content of work
1 Mast replacement Between two H2000 (79) s Change the mast.
Change the mast.
Install the lifting height switch.
H2000 (79) Install the mast harness.
↓ Install the rear axle damper.
H2500 (98.5) or above (Lifting height 5000 mm (198 in)
or above)
(See page 8-7)
H2500 (98.5) or above Change the mast.
↓ Remove the lifting height switch.
H2000 (79) Remove the mast harness.
2 Installation/Removal of attachment  Install or remove attachment.
3 Mast installation  Install the mast.
(Mast less spec. model) Install the lifting height switch.
Install the mast harness.

Note:
• Proceed with the alignment (matching) procedure after the above-mentioned modification. (See
page 17-20)
• After modification, replace the caution label affixed on the vehicle with the one matching the
new SAS function.
• When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch,
load sensor, mast harness and other SAS related parts) simultaneously if such parts are
required.
sec17.book 22 ページ ２０１０年４月２３日 金曜日 午前１０時５５分

17-22

RENEWAL OF SAS CAUTION LABEL

The warning instructions on the SAS caution label affixed to each truck must always agree with the SAS
features that particular model owns. You must be strictly careful because the SAS caution label must be
changed to the one with different warning in case that the modification on your side may vary the SAS
features.
Notice that the caution label must be changed in the following cases:

The selective function of the mast forward tilt angle control was switched to either of Validation and
Invalidation.*
(*: See Vol.2 Page 3-58 Option set for the switching method.)

1. Case of Switching “Mast forward tilt control Valid/Invalid.”

Label (1) Label (2)

Valid Invalid

(1) (2)

(1) (2)

Valid Invalid

Label (1) for use on the SINGLE TIRE models Label (2) for use on the SINGLE TIRE models
having the following SAS features: having the following SAS features:
• Equipped with swing lock control • Equipped with swing lock control
• Mast forward tilt angle control “VALID”. • Mast forward tilt angle control “INVALID”.

2. Case of Mast Installation for Mast-Less Spec. models.

When you install the mast to the mastless models, make sure the specification features with the mast
assembled.
Take note that the proper caution label must be chosen to be affixed to the truck.
The proper label can be found from the label numbering (1) - (2) in the illustration.
sec18.book 1 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-1

APPENDIX
18

Page
SST LIST........................................................................... 18-2
SERVICE STANDARDS LIST ..................................... 18-5
WIRING DIAGRAM (Conventional Lever) ............ 18-12
WIRING DIAGRAM
(Mini Lever / Joystick Lever) ................................. 18-13

18
sec18.book 2 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-2

SST LIST
18

Section
Illustration Part No. Part Name
1 5 6 7 8 9 10 13 14 15 17

Puller B set extension

09140-10920-71 O
tool

09310-23320-71 Reamer bolt remover O

09319-76001-71 Output shaft needle

O
(09319-60020) roller bearing remover

09320-23000-71 Bearing remover O

09330-21440-71 Stopper pin O

Front axle bearing

09370-10410-71 O O O
replacer

Drive pinion bearing

09370-20270-71 O
replacer

09450-23320-71 Adapter O

09509-76003-71 Rear wheel bearing

O
(09509-55030) nut wrench

Brake hold down

09510-31960-71 spring remover and O
replacer

09610-22000-71 Inner mast stopper O

sec18.book 3 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-3

Section
Illustration Part No. Part Name
1 5 6 7 8 9 10 13 14 15 17

Cylinder cap remover

09620-10100-71 O
and replacer

09630-23600-71 Deep socket A O

09659-26600-71 Piston rod guide O

Spring pin tool

09700-30200-71 O
remover

09717-76001-71 Brake shoe return

O
(09717-20010) spring remover

09718-76001-71 Brake shoe return

O
(09718-20010) spring replacer

09810-20172-71 Joint pin remover O O

09950-76003-71
Puller C set O
(09950-50012)

09950-76014-71
Puller B set O O O O
(09950-40011)

09950-76018-71
Replacer set O O O O O
(09950-60010)

09950-76019-71
18
Replacer set No.2 O O
(09950-60020)
sec18.book 4 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-4

Section
Illustration Part No. Part Name
1 5 6 7 8 9 10 13 14 15 17

09950-76020-71
Handle set O O O
(09950-70010)

25009-13201-71 Battery hanger O

sec18.book 5 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-5

SERVICE STANDARDS LIST

BATTERY
Specific gravity upon full charge 1.280 [20°C (68°C)]
Specific gravity upon end of discharge 1.150 [20°C (68°C)]
36V 32.0
Discharge end voltage V
48V 42.5
Insulation resistance MΩ 1 or more

DRIVE MOTOR
Insulation resistance MΩ 1 or more
Terminal continuity Ω 0
Temperature sensor resistance kΩ Approx. 11~15
Tightening torque N⋅m (kgf-cm) [ft-lbf]
Revolution sensor gear set bolt Standard 13 (133) [9.59]
Sensor cover Standard 5 (51) [3.69]
Terminal bolt Standard 5 (51) [3.69]
Terminal bracket Standard 23.7 (242) [17.49]
Revolution sensor Standard 5 (51) [3.69]

PUMP MOTOR
Insulation resistance MΩ 1 or more
Terminal continuity Ω 0
Temperature sensor resistance kΩ Approx. 11~15
Tightening torque N⋅m (kgf-cm) [ft-lbf]
Pump motor set nut Standard 32~122 (306~1244) [22.1~90.0]
Revolution sensor gear set bolt Standard 7.8~18.2 (80~186) [5.8~13.4]
Terminal bracket Standard 14.2~33.2 (145~339) [10.5~24.5]
End bracket through bolt Standard 17.2~22.8 (175~232) [12.7~16.8]
Revolution sensor Standard 3.0~7.0 (36~71) [2.2~5.2]

18
sec18.book 6 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-6

DRIVE UNIT
Differential
Standard 22.12 (0.8709)
Differential pinion inside diameter mm (in)
Limit 22.22 (0.8748)
Standard 22.00 (0.8661)
Spider outside diameter mm (in)
Limit 21.75 (0.8563)
Standard 22.00 (0.8661)
Side gear thrust washer thickness mm (in)
Limit 21.75 (0.8563)
Standard 1.6 (0.063)
Pinion gear thrust washer thickness mm (in)
Limit 1.0 (0.039)
Tightening torque N⋅m (kgf-cm) [ft-lbf]
Front axle shaft Standard 98~127 (1000~1300) [72~94]
Drive motor Standard 28.5~42.7 (291~435) [21.0~31.5]
Axle bracket Standard 167~225 (1700~2300) [123~166]
Axle bracket set bolt (through bolt) Standard 235~294 (2400~23000) [173.6~217.1]
Axle bracket set bolt (reamer bolt) Standard 235~294 (2400~23000) [173.6~217.1]
Drive unit cap Standard 82~123 (836~1254) [60.5~90.7]
Gear case cover Standard 82~123 (836~1254) [60.5~90.7]
Ring gear set bolt Standard 127~176.5 (1300~1800) [94.1~130.2]
Differential upper case Standard 43.1~53.9 (440~550) [17.3~21.7]

FRONT AXLE
Front axle shaft · axle hub
Front axle bearing starting force N (kgf) [lbf] Standard 25.5~72.6 (2.6~7.4) [5.7~16.4]
Tightening torque N⋅m (kgf-cm) [ft-lbf]
Hub bolt set nut Standard 166.7~205.9 (1700~2100) [123.0~151.9]
Hub nut Standard 294.2~588.4 (3000~6000) [217.1~434.1]
Front axle shaft Standard 98.1~127.5 (1000~1300) [72.4~94.1]
Brake ASSY set bolt Standard 137~196 (1400~2000) [101.3~144.7]
Axle housing set bolt Standard 108~137 (1100~1400) [79.6~101.3]
sec18.book 7 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-7

REAR AXLE
Rear axle ASSY
Rear axle front to rear clearance mm (in) Standard 0.7 (0.028) or less
Rear axle center pin bushing inside diameter mm (in) Limit 52.9 (2.047)
Steering knuckle
Rear axle wheel starting force N (kgf) [lbf] Standard 9.8~29 (1.0~3.0) [2.2~6.6]
King pin outside diameter mm (in) Limit 27.8 (1.094)
Steering knuckle starting force N (kgf) [lbf] Standard 19.3 (2.0) [4.4]
Rear axle cylinder
Rear axle cylinder piston rod outside 20·25 Limit 39.92 (1.5717)
diameter mm (in) 28~32 Limit 49.92 (1.9654)
Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.020)
20·25 Limit 70.35 (2.7697)
Rear axle cylinder bore mm (in)
28~32 Limit 76.35 (3.0059)
Tightening torque N⋅m (kgf-cm) [ft-lbf]
Axle bracket cap set bolt Standard 128~175 (1310~1780) [94.8~128.8]
King pin lock bolt Standard 44.1~53.9 (450~550) [32.6~39.8]
King pin lock nut Standard 35~52 (357~530) [25.8~38.4]
Steering knuckle tie rod end pin lock nut Standard 49.0~73.5 (500~750) [36.2~54.3]
Rear axle cylinder set bolt Standard 166.7~215.8 (1700~2200) [123.0~159.1]
Rear axle cylinder rod guide set nut Standard 29.2~38.0 (298~387) [21.5~28.0]

STEERING
Hydrostatic steering valve ASSY
20·25 Standard 7.2 (73) [1038]
Relief pressure MPa (kgf/cm2) [psi]
28~32 Standard 7.8 (80) [1138]
Tightening torque N⋅m (kgf-cm) [ft-lbf]
Steering wheel set nut Standard 24.5~45.5 (250~464) [18.1~33.6]
Steering column cover Standard 0.9~1.10 (9.2~11.2) [0.7~0.81]
Steering valve ASSY set bolt Standard 29.8~38.8 (304~398) [22.0~28.6]
Tilt lock bolt Standard 7.2~16.7 (73~171) [5.3~12.4]
Mast jacket set nut Standard 35.2~52.8 (359~538) [26.0~39.0]
Relief valve Standard 40~60 (408~612) [29.5~44.3]
Steering valve end cap set screw Standard 24~36 (245~367) [17.7~26.6]
sec18.book 8 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-8

BRAKE
Front brake
Hold down spring free length mm (in) Standard 25.5 (1.004)
On the side of
Standard 139.3 (5.484)
lining W/pin
Anchor to shoe spring free length
On the side of
mm (in) Standard 121.8 (4.795)
lining L/pin
Limit No clearance between coil turns
Strut to shoe spring free length mm (in) Standard 29.8 (1.173)
Standard 126.0 (4.961)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 5.7 (0.224)
Brake lining thickness mm (in)
Limit 1.0 (0.039)
Wheel cylinder to piston clearance mm (in) Standard 0.125 (0.00492)
Standard 310 (12.20)
Brake drum inside diameter mm (in)
Limit 312 (12.28)
Parking brake
Parking brake cable set position mm (in) Standard 0~2 (0~0.08)
Parking brake operating force N (kgf) [lbf] Standard 270~310 (27.5~31.6) [60.7~69.7]
Brake pedal
Brake pedal height mm (in) Standard 139~144 (5.47~5.67)
Brake pedal play mm (in) Standard 5~9 (0.2~0.35)
Master cylinder push rod play mm (in) Standard 1~2 (0.04~0.08)
Brake pedal depressed height mm (in) Standard 84 (3.31)
Tightening torque N·m (kgf-cm) [ft-lbf]
Wheel cylinder set bolt Standard 17.7~26.5 (180~270) [13.0~19.5]
Brake backing plate set bolt Standard 137~196 (1400~2000) [101.3~144.7]
Outlet plug Standard 52.0~82.4 (530~840) [38.3~60.8]
Parking brake release lever set screw Standard 9.1~16.9 (93~172) [6.7~12.5]

BODY
Tightening torque N·m (kgf-cm) [ft-lbf]
Counterweight set bolt Standard 500~ (5099~ ) [368.9~ ]

MATERIAL HANDLING SYSTEM

Neutral drop test
Neutral drop mm (in) Standard 45 (1.77)
Natural forward tilt test
Natural forward tilt mm (in) Standard 15 (0.59) or less
Oil leak test
Lift cylinder oil leak amount (at tilt port) cm3 (in3) Standard 8 (0.49) or less
Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3) Standard 16 (0.98) or less
sec18.book 9 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-9

MAST
Mast adjustment (V mast)
Inner mast roller clearance mm (in) Standard 0~0.6 (0~0.024)
Outer mast roller clearance mm (in) Standard 0~0.6 (0~0.024)
Middle lift roller clearance mm (in) Standard 0~0.6 (0~0.024)
Lower lift roller clearance mm (in) Standard 0~0.6 (0~0.024)
Side roller clearance mm (in) Standard 0~0.6 (0~0.024)
Mast strip to inner mast clearance mm (in) Standard 0~1.0 (0~0.039)
Mast adjustment (FV·FSV mast)
Inner mast roller clearance mm (in) Standard 0~0.6 (0~0.024)
Middle mast lower roller clearance mm (in) Standard 0~0.6 (0~0.024)
Outer mast roller clearance mm (in) Standard 0~0.6 (0~0.024)
Middle mast upper roller clearance mm (in) Standard 0~0.6 (0~0.024)
Lower lift roller clearance mm (in) Standard 0~0.6 (0~0.024)
Side roller clearance mm (in) Standard 0~0.6 (0~0.024)
Mast strip to mast clearance mm (in) Standard 0~1.0 (0~0.039)
Tightening torque N·m (kgf-cm) [ft-lbf]
Mast support cap set bolt Standard 84~156 (857~1591) [62.0~115.1]
Tilt cylinder front pin Standard 76.8~115.2 (783~1175) [56.7~85.0]
STD 138~322 (1407~3283) [101.8~237.6]
Lift bracket set bolt Rust
98~182 (999~1856) [72.3~134.3]
proof

CYLINDER
Lift cylinder
Standard 40 (1.575)
20·25
Limit 39.92 (1.5717)
V
Standard 45 (1.77)
28~32
Limit 44.92 (1.7685)
Standard 34.9 (1.37)
20·25
Limit 34.82 (1.3708)
FV
Piston rod outside diameter Standard 40 (1.575)
28~32
mm (in) Limit 39.92 (1.5717)
Standard 40 (1.575)
20·25
Limit 39.92 (1.5717)
FSV
Standard 45 (1.77)
28~32
Limit 44.92 (1.7685)
Standard 50 (1.97)
QFV ALL
Limit 49.92 (1.9654)
Piston rod bend mm (in) Limit 2.0 (0.079)
sec18.book 10 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-10

Standard 50 (1.97)
20·25
V·FV· Limit 50.20 (1.9764)
FSV Standard 55 (2.17)
Cylinder bore mm (in) 28~32
Limit 55.35 (2.1791)
Standard 63 (2.48)
QFV ALL
Limit 63.35 (2.4909)
Front lift cylinder (FV·FSV·QFV)
FV· 20·25 Standard 75~95 (4.58~5.80)
Hydraulic oil filling amount FSV 28~32 Standard 110~145 (6.71~8.85)
cm3 (in) 20·25 Standard 75~95 (4.58~5.80)
QFV
28~32 Standard 75~95 (4.58~5.80)
Standard 50.8 (2.0)
Piston rod outside diameter mm (in)
Limit 50.72 (1.9969)
Piston rod bend mm (in) Limit 2.0 (0.079)
Standard 75.0 (2.953)
20·25
FV· Limit 75.35 (2.9665)
FSV Standard 85.0 (3.346)
28~32
Limit 85.40 (3.3622)
Cylinder bore mm (in)
Standard 75.0 (2.953)
20·25
Limit 75.35 (2.9665)
QFV
Standard 75.0 (2.953)
28~32
Limit 75.35 (2.9665)
Tilt cylinder
Standard 70.0 (2.756)
Cylinder bore mm (in)
Limit 70.35 (2.7697)
Standard 30.0 (1.181)
Piston rod outside diameter mm (in)
Limit 29.92 (1.1780)
Piston rod bend mm (in) Limit 1.0 (0.039)
Tightening torque N·m (kgf-cm) [ft-lbf]
20·25 Standard 200~300 (2039~3059) [147.6~221.3]
V
28~32 Standard 284.4~421.7 (2900~4300) [209.8~311.0]
20·25 Standard 203~271 (2073~2764) [150~200]
FV
28~32 Standard 237~305 (2419~3110) [174.8~225.0]
Lift cylinder cover
20·25 Standard 200~300 (2039~3059) [147.6~221.3]
FSV
28~32 Standard 284.4~421.7 (2900~4300) [209.8~311.0]
20·25 Standard 340~440 (3467~4487) [250.8~324.6]
QFV
28~32 Standard 340~440 (3467~4487) [250.8~324.6]
FV·
20·25
FSV Standard 407~434 (4150~4426) [300~320]
Front lift cylinder cover QFV ALL
FV·
28~32 Standard 461~488 (4701~4976) [340~360]
FSV
sec18.book 11 ページ ２０１０年４月２３日 金曜日 午前１０時５２分

18-11

Tilt cylinder front pin Standard 76.8~115.2 (783~1174) [56.7~85.0]

Tilt cylinder rear pin Standard 43.2~72.9 (441~743) [31.9~53.8]
Tilt cylinder piston castle nut Standard 225.4~284.2 (2300~2900) [166.4~209.8]
Tilt cylinder cover Standard 284~421 (2896~4293) [210.0~311.0]

OIL PUMP
Oil pump ASSY
Bushing set length mm (in) Limit 26.411 (1.03980)
Gear shaft outside diameter mm (in) Limit 18.935 (0.74547)
Tightening torque N·m (kgf-cm) [ft-lbf]
Oil pump ASSY set bolt Standard 24.0~33.0 (245~337) [34.0~36.2]
Fitting (High pressure side) Standard 74.1~81.9 (756~835) [54.7~60.4]
Fitting (Low pressure side) Standard 61.6~75.6 (628~771) [45.4~55.8]
Outlet housing set bolt Standard 46.1~48.6 (470~500) [34.0~36.2]

OIL CONTROL VALVE

Oil control valve
Relief set pressure KPa (kgf/cm2) [psi] Lift & Tilt 17800 (181.51) [2573.8]
Tightening torque N·m (kgf-cm) [ft-lbf]
Oil control valve set bolt Standard 14.4~33.6 (147~343) [10.6~24.8]
Lift lock unlocking bolt Standard 3.5~4.3 (36~44) [2.6~3.2]

SAS
Tightening torque N·m (kgf-cm) [ft-lbf]
Yaw rate sensor bracket set bolt Standard 3.3~7.7 (33~79) [2.4~5.7]
Yaw rate sensor set bolt Standard 1.0~2.0 (10~20) [0.7~1.5]
Swing lock cylinder crank pin set bolt Standard 19~37 (190~370) [13.7~26.8]
Swing lock cylinder pin set bolt Standard 19~37 (190~370) [13.7~26.8]
Tilt angle sensor set bolt Standard 7.8~18.2 (80~186) [5.8~13.4]
Tilt angle sensor link Standard 7.8~18.2 (80~186) [5.8~13.4]
Load sensor Standard 22.0~26.0 (224~265) [16.2~19.2]
Mast lifting height switch set bolt Standard 16.2~37.8 (165~385) [12.0~27.9]
sec18.book 12 ページ ２０１０年４月２２日 木曜日 午前１０時７分

18-12
WIRING DIAGRAM (Conventional Lever)
P1 STCB

MB (P3,G) F7
F6
F1 P4
(P1,B) SWK DISCONNECT SW(OPT)
CONTACTOR PANEL F5 (41,Y) (43,O) RYMS
ACCEL
F4 SWD VRA2 LIFT LEVER TILT LEVER ATT1 LEVER ATT2 LEVER
VRL1 VRL2 VRT1 VRT2 VRAT11 VRAT12 VRAT21 VRAT22
PIN CODE ENTRY (OPT)

(101,R)
FAN2 FAN1 FAN3 SH SPB SWBK
VRA1 VRH VRTA VRATA
KEY OFF H/L OFF(OPT) SPLF SYR SIM1 SIM2
SSTR
(105,L)

RYAC

(19, GR)

SYR (322, W)

POT- (51, GR)

W)
(44, BR)

LS- (51, BR)

POT- (51, BR)

(307, G)
(308, O)

VRH (220, O)

VRTA+ (57, SB)

SYR+ (321, O)

VRT1 (22, SB)

VRTRA+ (316, G)
IPL1 (301, R)

R)
(335, Y)

VRH+ (219, P)

SYR- (323, B)

IPL2 (302, V)

B)

VRTRA (317, P)
IPL+ (300, L)

L)
VRA1+ (53, W)

VRT2 (23, W)
FNDC1 (98, O)

(1 , G)

VRL+ (28, O)
VRL1 (20, G)

VRA21 (26, G)

VRA22 (27, O)
FNDC2 (99, R)

VRA1 (52, R)

VRAT2+ (31, R)

SH1 (90, R)
(41, Y)

(97, P)

SOLCOM (17, V)

(2 , V)

VRA2+ (55, V)

VRA- (50, B)

VRTA (56, B)

SPLF (59, Y)

VRL2 (21, P)

VRT+ (29, B)

VRAT1+ (30, Y)
VRA11 (24, V)

SPB (66, V)

SWBK (65, Y)
(47, L)

VRA2 (54, L)

SPLF+ (58, L)

VRA12 (25, L)

SH2-1 (91, L)
BATT

(314,
(313,
(312,
(311,
36V(48V) RYH

VBBT
B48V
VBKY
VBMB
FAN+

SOLCOM

VBMBSL
VBMBSL
CBAT-
CBAT+
STCB+

SSTRC
SSTR2
SSTR1
SSTR+
STCB
RY1
MAIN CONTROLLER
(117,O)

SWH SWST
RYH

(334, P) PSACC+

(3, B) SOLLU+

(6, V) SLTFB+
(32, W) SLTA1+
(9, L) SLLA2+

(37, Y) SA1PS-

(40, SB) SA2PS-

(60, R) PSSW+
(332, R) OACC2

(36, R) SA1PL-

(39, GR) SA2PL-

(327, L) SLSW+
(145, B) CAN1H

(147, Y) CAN2H
(7, G) SLTFL-
(42, R) KYSAT

(146, W) CAN1L

(148, O) CAN2L
(328, Y) SLSW-
(34, P) STPS-

(14, B) DGND
(11, G) SLPS-

(33, O) STPL-
(10, BR) SLPL-

(4, GR) SLLL-

SA

(329, BR) SLS+

(330, P) SLS-

(67, P) SDM
(46, SB) DSR
(68, Y) SLM

(45, G) DSF
(16, GR) D7V

(70, O) STK

(51, BR) LS-

N2
N2
N2
(N2, W) N2
(118,GR)

(111,SB)
(48,P)

EZ PEDAL(OPT)

D7V
DGND
DISPLAY DSF DSR SWS
SWCM SWW RYHL RYTL STK SHS

LEDTKY1
LEDTKY2
IPSTKY1
CAN1H
RYBU

OTKY1
OTKY2
OTKY3
CAN1L
RYF

TGND
ITKY1
ITKY2
ITKY3
H SWBU
(102,SB)

(116,SB)
(104,G)
(115,P)

(160, Y)
(161, R)
(162, G)
(163, O)
(164, L)
(165, V)
(166, P)
(167, W)
(168, SB)
(169, BR)
(110,GR)
(112,SB)

(107,V)

SLPL SLPS STPL STPS SA1PL SA1PS SA2PL SA2PS SLS SLLL SLTFL SLSW
SWHR SWHA LSTL LSTR
RESISTOR JOYSTICK(OPT)

(103,O)
SWF
LCM LW
SWL TEN KEY
12V POWER

(108,BR)
LS (109,B) LBUR LBUL BZ CHI
F8(10A) PIN CODE ENTRY (OPT) EZ PEDAL(OPT)
H T

(121, B)
(123, BR)
LHR LHL LTR LTL LCR LCL

(122, O)
(124, R)
(125, B)

(151, SB)

(152, SB)
BR)

W)
O)

G)

G)

O)
P)

B)

L)
LFLR LFL LFRR LFR

(86,
(87,
(79,
(78,
(80,

(88,
(89,
(82,
(81,
P41 SSD P4 SSP
P7 U P14 U

OUT+
OUT-

IN+
IN-

OSETD
SETD2
KYSAT
CAN1L
CAN1H
STDM+
STDM
SSD1
SSD+
SSD2

KYSAT
CAN1L
CAN1H
OSETP
SETP1

STPM+
STPM
SSP1
SSP+
U U

STPM
STDM
P8 V P15 V
V
P9 W ACMD V
P16 W ACMP

GND
CAN1L
CAN1H
CAN2L
CAN2H
FLPD
PSACC+
W W

(51, BR)
(46, SB)
(45, G)
DC/DC ACMDD ACMDP
N1 N2 DIAGNOSIS
(N1, W)

DSR
DSF

LS-
BATT BATTERY VRA VARIABLE RESISTOR, ACCEL SWBK SWITCH, BRAKE LHL LAMP, HEAD LH
MB CONTACTOR, BATTERY VRL VARIABLE RESISTOR, LIFT SWS SWITCH, SEAT LHR LAMP, HEAD RH
F FUSE VRT VARIABLE RESISTOR, TILT SH SWITCH, HEIGHT LCL LAMP, CLEARANCE LH
VRTA VARIABLE RESISTOR, TILT ANGLE SPB SWITCH, PARKING BRAKE LCR LAMP, CLEARANCE RH
ACMD AC MOTOR, DRIVE VRTRA VARIABLE RESISTOR, TIRE ANGLE LTL LAMP, TAIL LH
ACMP AC MOTOR, PUMP VRAT1 VARIABLE RESISTOR, ATT NO.1 LTR LAMP, TAIL RH
ACMDD AC MOTOR DRIVER, DRIVE VRAT2 VARIABLE RESISTOR, ATT NO.2 STK SWITCH, TILT KNOB LW LAMP, WORKING
ACMDP AC MOTOR DRIVER, PUMP VRH VARIABLE RESISTOR, HEIGHT SHS SWITCH, HEIGHT SELECT LFLR LAMP, FLASHER LH RR
SWD SWITCH, DISCONNECT LFRR LAMP, FLASHER RH RR
SPLF SENSOR, PRESSURE LIFT SLSW SOLENOID, SWING SWHA SWITCH, HORN ARMREST LFL LAMP, FLASHER LH
SSD SENSOR, SPEED, DRIVE SLLL SOLENOID, LIFT LOCK SWHR SWITCH, HORN RR LFR LAMP, FLASHER RH
SSP SENSOR, SPEED, PUMP SLTFL SOLENOID, TILT, FORWORD LOCK SWK SWITCH, KEY LCM LAMP, COMPARTMENT
SSTR SENSOR, STEERING SLS SOLENOID, STEERING SWL SWITCH, LIGHT LSTL LAMP, STOP LH
STDM SENSOR, TEMP DRIVE MOTOR SWF SWITCH, FLASHER LSTR LAMP, STOP RH
STPM SENSOR, TEMP PUMP MOTOR SLPL SOLENOID, LIFT PULL SWH SWITCH, HORN LBUL LAMP, BACK-UP LH
SYR SENSOR, YAWRATE SLPS SOLENOID, LIFT PUSH SWCM SWITCH, COMPARTMENT LIGHT LBUR LAMP, BACK-UP RH
SIM SENSOR, IMPACT STPL SOLENOID, TILT PULL SWW SWITCH, WORKING LAMP LS LAMP, STROBE
STCB SENSOR, TEMP CONTACTOR STPS SOLENOID, TILT PUSH SWST SWITCH, STOP LAMP
SA1PL SOLENOID, ATT1 PULL SWBU SWITCH, BACK-UP RYHL RELAY, HEAD LAMP
DSF DIRECTION SWITCH, FORWARD SA1PS SOLENOID, ATT1 PUSH RYTL RELAY, TAIL LAMP
DSR DIRECTION SWITCH, REVERSE SA2PL SOLENOID, ATT2 PULL RYMS RELAY, MINI LEVER SOLENOID RYF RELAY, FLASHER
BZ BUZZER SA2PS SOLENOID, ATT2 PUSH RYH RELAY, HORN
CHI CHIME RYAC RELAY, ACCESSORY
H HORN RYBU RELAY, BACK-UP
SA SURGE ABSOBER RYKH RELAY, KEY OFF H/L OFF
sec18.book 13 ページ ２０１０年４月２２日 木曜日 午前１０時７分

18-13
WIRING DIAGRAM (Mini Lever / Joystick Lever)
P1 STCB

(P3,G) F7
F6
F1 P4
(P1,B) SWK
CONTACTOR PANEL F5 (41,Y)
ACCEL
F4 VRA2 LIFT LEVER ATT1 LEVER ATT2 LEVER
VRL1 VRL2 VRAT11 VRAT12 VRAT21 VRAT22

(101,R)
PIN CODE ENTRY(OPT)
FAN2 FAN1 FAN3 SH SPB SWBK SWTF SWTR DSF DSR STK
VRA1 VRTA + - + - + - + - + - + - VRATA
KEY OFF H/L OFF (OPT) SPLF SYR SIM1 SIM2
SSTR
(105,L)

GR)
SB)
W)

W)

W)
RYAC

BR)

(51 , BR)
G)
G)
O)

O)

O)
G)

G)

O)

SB)

SB)

(316, G)
R)

R)

R)

R)
(19 , GR)

V)

V)

B)

B)

B)

V)

P)

V)

V)

B)

(317, P)
Y)

Y)

R)
L)

L)

L)

L)

L)

L)
O)
R)
VBMB (97 , P)

W)
(41 , Y)

Y)
B48V (47 , L)
VBKY (44 , BR)

G)

O)
BATT

(99 ,

(98 ,

(2 ,
(1 ,
(307,
(308,

(55 ,
(54 ,

(53 ,
(52 ,
(50 ,

(57 ,
(56 ,

(58 ,

(59 ,

(321,
SYR+ (322,
(323,

(300,

(301,

(302,

(28 ,
(20 ,

(21 ,

(30 ,
(24 ,

(25 ,

VRAT2+ (31 ,
(26 ,

(27 ,

POT- (51 ,
(90 ,

(91 ,

(66 ,

(314,
(313,
(312,
(311,

(65 ,

(61 ,

(62 ,

(45 ,

(46 ,

(70 ,

(51 ,
36V (48V) RYH

VBBT

VRTA

VRTRA
FAN+

FNDC2

VBMBSL
VBMBSL
CBAT-
CBAT+
STCB+
STCB

VRA2+
VRA2

VRA1+
VRA1
VRA-

VRTA+

SPLF+

SPLF

SYR
SYR-

IPL+

IPL1

IPL2

VRL+
VRL1

VRL2

VRAT1+
VRA11

VRA12

VRA21

VRA22

SH1

SH2-1

SPB

SSTRC
SSTR2
SSTR1
SSTR+

SWBK

SWTF

SWTR

DSF

DSR

STK

LS-

VRTRA+

POT-
(107,O)

SWH SWST MAIN CONTROLLER

RYH

PSACC+

SOLLU+

SLTFB+
OACC2

SLSW+
CAN1H

CAN2H
SLTFL-
CAN1L

CAN2L
KYSAT

SLSW-

DGND
SLUL-

SLLL-
SLS+

SLS-

SDM
SA

D7V

LS-
N2
N2
N2
N2
(118,GR)

GR)

BR)
O)
(111,SB)

B)

P)
Y)
R)

P)

W)

R)

B)
W)

BR)

P)

P)

B)

(4 , GR)

V)

G)

L)

Y)
(48,P)

(16 ,
(14 ,

(148,
(147,

(67 ,

(51 ,
(334,
(332,

(N2 ,

(145,
(42 ,

(327,

(328,
(146,

(330,

(5 ,

(3 ,

(6 ,

(7 ,
(329,
EZ PEDAL (OPT)

D7V
DGND
DISPLAY SWS
SWCM SWW RYHL

LEDTKY1
(169, BR) LEDTKY2
L) IPSTKY1
CAN1H

V) OTKY1
P) OTKY2
(167, W) OTKY3
CAN1L
RYF RYBU

TGND
R) ITKY1
G) ITKY2
ITKY3
H SWBU
(102,SB)

(116,SB)

(110,GR)
(104,G)

Y)

O)

(168, SB)
(115,P)
(112,SB)

(107,V)

SLS SLUL SLLL SLTFL SLSW

SWHR LSTL LSTR

(164,
(160,

(165,
(166,
(161,
(162,
(163,
RESISTOR

(103, O)
SWF
LCM LW
SWL TEN KEY
12V POWER
(109, B)
(108,BR)
LS LBUR LBUL BZ CHI
PIN CODE ENTRY (OPT) EZ PEDAL (OPT)
F8 (10A)
H T

B)
BR)
O)

SB)

SB)
LHR LHL LTR LTL LCR LCL

R)
B)

W)
, BR)
, O)

, G)

G)

O)
, P)

, B)

L)
(121,
LFLR LFL LFRR LFL

(124,
(125,

(122,
(123,

(151,

(152,

,
,
,
,
SSD SSP

(86
(87
(79
(78
(80

(88
(89
(82
(81
P41 P4
+ U P7 U + U P14 U

CAN1L

CAN1L
KYSAT

0SETP

KYSAT
OUT+
OUT-

IN+

0SETD
SETD2

CAN1H
STDM+
STDM
SSD1
SSD+
SSD2

SETP1

CAN1H
STPM+
STPM
SSP1
SSP+
STDM
IN-

STPM
V P8 V ACMD V P15 V ACMP
W P9 W P16

CAN1L

CAN2L
GND

CAN1H

CAN2H
FLPD
PSACC+
W W

BR)
G)

SB)
DC/DC - ACMDD - ACMDP

(45 ,

(46 ,

(51 ,
N1 N2 DIAGNOSIS
(N1,W)

DSR
DSF

LS-
BATT BATTERY VRA VARIABLE RESISTOR, ACCEL SWBK SWITCH, BRAKE LHL LAMP, HEAD LH
MB CONTACTOR, BATTERY VRL VARIABLE RESISTOR, LIFT SWS SWITCH, SEAT LHR LAMP, HEAD RH
F FUSE SH SWITCH, HEIGHT LCL LAMP, CLEARANCE LH
VRTA VARIABLE RESISTOR, TILT ANGLE SPB SWITCH, PARKING BRAKE LCR LAMP, CLEARANCE RH
ACMD AC MOTOR, DRIVE VRTRA VARIABLE RESISTOR, TIRE ANGLE SWTF SWITCH, TILT FR LTL LAMP, TAIL LH
ACMP AC MOTOR, PUMP VRAT1 VARIABLE RESISTOR, ATT NO.1 SWTR SWITCH, TILT RR LTR LAMP, TAIL RH
ACMDD AC MOTOR DRIVER, DRIVE VRAT2 VARIABLE RESISTOR, ATT NO.2 STK SWITCH, TILT KNOB LW LAMP, WORKING
ACMDP AC MOTOR DRIVER, PUMP LFLR LAMP, FLASHER LH RR
STCB AC MOTOR DRIVER, PUMP LFRR LAMP, FLASHER RH RR
SPLF SENSOR, PRESSURE LIFT SLSW SOLENOID, SWING LFL LAMP, FLASHER LH
SSD SENSOR, SPEED, DRIVE SLLL SOLENOID, LIFT LOCK SWHR SWITCH, HORN RR LFR LAMP, FLASHER RH
SSP SENSOR, SPEED, PUMP SLTFL SOLENOID, TILT, FORWORD LOCK SWK SWITCH, KEY LCM LAMP, COMPARTMENT
SSTR SENSOR, STEERING SLS SOLENOID, STEERING SWL SWITCH, LIGHT LSTL LAMP, STOP LH
STDM SENSOR, TEMP DRIVE MOTOR SLUL SOLENOID, UNLOAD SWF SWITCH, FLASHER LSTR LAMP, STOP RH
STPM SENSOR, TEMP PUMP MOTOR SWH SWITCH, HORN LBUL LAMP, BACK-UP LH
SYR SENSOR, YAWRATE SWCM SWITCH, COMPARTMENT LIGHT LBUR LAMP, BACK-UP RH
SIM SENSOR, IMPACT SWW SWITCH, WORKING LAMP LS LAMP, STROBE
STCB SENSOR, TEMP CONTACTOR SWST SWITCH, STOP LAMP
SWBU SWITCH, BACK-UP RYHL RELAY, HEAD LAMP
DSF DIRECTION SWITCH, FORWARD RYTL RELAY, TAIL LAMP
DSR DIRECTION SWITCH, REVERSE RYF RELAY, FLASHER
BZ BUZZER RYH RELAY, HORN
CHI CHIME RYAC RELAY, ACCESSORY
H HORM RYBU RELAY, BACK-UP
SA SURGE ABSOBER RYKH RELAY, KEY OFF H/L OFF