Toyota 7FBEF 15-20

TOYOTA 7FBE13, 7FBEF13-20
SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CONTROLLER 2
MULTI-DISPLAY FUNCTIONS 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT & FRONT AXLE 6
REAR AXLE 7
STEERING 8
BRAKE 9
BODY & FRAME 10
MATERIAL HANDLING SYSTEM 11
MAST 12
CYLINDER 13
OIL PUMP 14
OIL CONTROL VALVE 15
SAS FUNCTIONS 16
APPENDIX 17
1
OPS (fr.o.m 2006) 1 18
New Model Features < Tillbaka till Index

0-1
GENERAL
Page Page
VEHICLE EXTERIOR VIEW........... 0-2 HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ............. 0-16 0
VEHICLE MODELS .......................... 0-3
FRAME NUMBER ............................. 0-3 RECOMMENDED LUBRICANT 1
QUANTITY AND TYPES ........... 0-17
HOW TO USE THIS MANUAL ...... 0-4 2
LUBRICATION CHART ................. 0-18
EXPLANATION METHOD ................. 0-4
PERIODIC MAINTENANCE ......... 0-19
3
TERMINOLOGY................................. 0-5
PERIODIC REPLACEMENT OF 4
ABBREVIATIONS .............................. 0-5
PARTS AND LUBRICANTS ..... 0-24
SI UNITS ............................................ 0-6
5
OPERATING TIPS ............................ 0-7 Totaldokument, service.............0-25 6
GENERAL INSTRUCTIONS .............. 0-7 7
JACK-UP POINT ............................... 0-8
8
HOISTING THE VEHICLE ................. 0-9
WIRE ROPE
9
SUSPENSION ANGLE LIST ........ 0-10
10
SAFE LOAD FOR EACH WIRE ROPE
SUSPENSION ANGLE ................. 0-10 11
MEMBER WEIGHTS........................ 0-11 12
TOWING THE VEHICLE .................. 0-11
13
ELECTRICAL PARTS
INSPECTION ................................ 0-12 14
NOTES ON SAS .............................. 0-13 15
STANDARD BOLT & NUT
TIGHTENING TORQUE ............. 0-14
16
BOLT STRENGTH CLASS 17
IDENTIFICATION METHOD ......... 0-14
18
TIGHTENING TORQUE TABLE ...... 0-15
PRECOATED BOLTS ...................... 0-16
0-2
VEHICLE EXTERIOR VIEW

0-3
VEHICLE MODELS
Vehicle model code Load Capacity Vehicle Model Control method Voltage (V)
15 1.5 ton 7FBEF15 AC microcomputer controller 48
16 1.6 ton 7FBEF16 ↑ ↑
18 1.75 ton 7FBEF18 ↑ ↑
20 2.0 ton 7FBEF20 ↑ ↑
0
FRAME NUMBER
1
Vehicle model Punching format Punching position 2
3
7FBEF15 7FBEF15 10011
4
5
7FBEF16
6
7FBEF18 7FBEF20 10011

7
8
7FBEF20 9
Punching position
10
11
12
13
14
15
16
17
18
0-3b
VEHICLE MODELS
Vehicle model code Payload (ton) Vehicle Model Control method Voltage (V)
10 1.0 7FBE10 AC microcomputer controller 48
13 1.25 7FBE13 ↑ ↑
15 1.5 7FBE15 ↑ ↑
18 1.75 7FBE18 ↑ ↑
0
20 2.0 7FBE20 ↑ ↑
1
FRAME NUMBER 2
Vehicle model Drive motor model Punching format Punching position
3
7FBE10
4
7FBE13-50011
7FBE13
5
6
7FBE15 AR09
7
7FBE18-50011
8
7FBE18
9
7FBE20 7FBE20-50011
Punching position
10
11
12
13
14
15
16
17
18
0-4
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
Pattern A: Each step of the operation is explained with its own illustration.
Pattern B: The entire operation is indicated by step numbers in one illustration, followed by
cautions, notes, and point operations.
Example of pattern B
DISASSEMBLY · INSPECTION · REASSEMBLY

Tightening torque unit T=N·m (kgf·cm) [ft·lbf]
• Some step numbers may be
omitted in some illustrations. 4
• When a part requiring 1
2
tightening torque instruction is 3
not indicated in the illustration,
the part name is described in
the illustration frame. 7
5 6
T = 46.1 to 48.1
(470 to 490)
[34.0 to 35.5]
5
9 1
Disassembly Procedure
1 Remove the cover. [Point 1] Operation to be explained
2 Remove the bushing. [Point 2]
3 Remove the gear.
Point Operations
Explanation of operation point with illustration
[POINT 1]
Disassembly:
Make match marks before removing the pump cover
[POINT 2]
Inspection:
Measure the bushing inside diameter.
Limit 19.12 mm (0.7528 in)
0-5
2. How to read component figures (Example)

(1) The component figures use the illustration in the parts
catalog for the vehicle model. Please refer to the catalog 3201
to check the part name. Parts catalog
FIG number
3. Matters omitted from this manual
(1) This manual omits descriptions of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
0
TERMINOLOGY 1
Caution:
Important matters, negligence of which may cause accidents. Be sure to observe them. 2
Note:
Important items, negligence of which may cause accidents, or matters in operating procedure
3
which require special attention.
4
Standard: Value showing the allowable range in inspection or adjustment
Limit: The maximum or minimum value allowed in inspection or adjustment. 5
6
ABBREVIATIONS
Abbreviation Meaning Abbreviation Meaning
7
ASSY Assembly RH Right hand 8
Society of Automotive Engineers
ATT Attachment SAE
(USA) 9
Electronically controlled fully
EHPS
hydraulic power steering
SAS System of active stability 10
FHPS Fully hydraulic power steering SST Special service tool 11
LH Left hand STD Standard
12
L/ Less T= Tightening torque
OPT Option {{T Number of teeth ({{T) 13
O/S Oversize U/S Undersize
14
PS Power steering W/ With
15
16
17
18
0-6
SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify
the various systems of units used in the past for smoother international technical communication.
New Units Adopted in SI
Item New unit Conventional Conversion rate*1 (1 [conventional unit] = X [SI

unit unit])
Force*2 N (newton) kgf 1 kgf = 9.80665 N
Torque*2 N·m kgf·cm 1 kgf·cm = 9.80665 N·m
(Moment)
Pressure*2 Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
↑ ↑ mmHg 1 mmHg = 0.133322 kPa
Revolving speed rpm rpm 1 rpm = 1 r/min
Spring
N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
constant*2
Volume l cc 1 cc = 1 ml
Power W PS system 1 PS = 0.735499 kW
Heat quantity W·h cal 1 kcal = 1.16279 W·h
Specific fuel g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
<Reference>
* 1: X represents the value in SI units as converted from 1 [in conventional units], which can be
used as the rate for conversion between conventional and SI units.
* 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf],
which should be used as the unit of force.
Conversion between Conventional and SI Units
Equation for conversion
Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding
to X in the conversion rate column in
Value in conventional unit = Value in SI unit ÷ Conversion rate the table above
When converting, change the unit of the value in conventional or SI units to the one in the
conversion rate column in the table above before calculation. For example, when converting 100 W
to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate
0.735499.
0-7
OPERATING TIPS
GENERAL INSTRUCTIONS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.
2. Skillful operation
(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure
gauge, etc.) and SSTs before starting operation.
(2) Check the cable color and wiring state before disconnecting any wiring.
(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts
neatly to prevent confusion.
(4) When disassembling and inspecting a precision part such as the control valve, use clean tools and
operate in a clean location.
(5) Follow the specified procedures for disassembly, inspection and reassembly.
(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each
time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling.
(Tighten to the medium value of the specified tightening torque range.) If no tightening torque is
specified, use the value given in the “standard tightening torque table”.
3. Protection of functional parts (battery operated vehicles)
(1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each
connector for any connection failure or imperfect connection.
Failure or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
4. Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or
replacement is necessary for the defect.
5. Waste fluid disposal
Always use a proper container when draining waste fluid from the vehicle.
Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely
affect human health and the environment. Always collect and sort well, and ask specialized companies
for appropriate disposal.
0-8
JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
• When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an
inclined or rough surface.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up
at any other point is dangerous.
• Always support the load of jacked-up vehicle with wooden blocks at specified points.
Supporting the vehicle with the jack only is very dangerous.
• Never, under any circumstances, put any part of the body (including hands and feet) under the
jacked-up vehicle.
Jack-up point
Wooden block or stand

setting points
0-9
HOISTING THE VEHICLE

When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist
by any other attachment section as it is very dangerous.
0-10
WIRE ROPE SUSPENSION ANGLE LIST

Suspension Tension Compression Suspension Suspension Tension Compression Suspension
Angle method Angle method
1.00 1.41
0° 0 time 90° 1.00 time
1 tf
90°
time time
f
1t
2t
1.4
2t
30°
1.04 2.00
30° 0.27 time 120° 1.73 time
tf
time time
1.04
120°
f
2t
2t 2t
1.16 60°
60° 0.58 time
time
tf
6
1.1
2t
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Single-rope Two-rope suspension four-rope suspension
Rope Cutting
suspension
diameter load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] 2337 [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[11690] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
0-11
MEMBER WEIGHTS - 7FBEF15-20

Unit: kg (lbs)
Member Vehicle model Weight
BATTERY ASSY See page 1-2.
Drive motor ASSY All Models Approx. 37 (82)
Pump motor ASSY All Models Approx. 31 (68)
All Models (one side) Approx. 61 (135)
Front axle ASSY W/ drive motor ASSY
All Models (both sides) Approx. 122 (269)
Rear axle ASSY W/ rear axle cylinder ASSY All Models Approx. 50 (110)
7FBEF15 Approx. 483 (1065)
7FBEF16 Approx. 427 (942)
Counterweight
7FBEF18 Approx. 544 (1200)
7FBEF20 Approx. 743 (1638)
Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork, 7FBEF15 to 18 330 (730)
Lifting height 3000 mm (118 in), V mast) 7FBEF20 400 (880)
7FBEF15 1885 (4156)
7FBEF16 1775 (3914)
Vehicle weight (without battery)
7FBEF18 1895 (4178)
7FBEF20 2215 (4884)
TOWING THE VEHICLE

Note the cautions below when towing the vehicle.
1. Lift the rear wheels for towing
2. The traveling speed when towing must not exceed the
maximum traveling speed of the forklift.
3. Before starting towing, always set the key switch to OFF
and the direction switch to the neutral position.
4. Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the
ground due to bouncing.
0-11b
MEMBER WEIGHTS - 7FBE10-20

Unit: kg (lbs)
Member Vehicle model Weight
BATTERY ASSY See P1-2
Drive motor ASSY All Models Approx. 37 (82)
Pump motor ASSY All Models Approx. 31 (68)
Front axle ASSY W/ drive motor ASSY All Models Approx. 122 (269)
Rear axle ASSY W/ rear axle cylinder ASSY All Models Approx. 45 (99)
7FBE10 Approx. 405 (893)
7FBE13 Approx. 598 (1319)
Counterweight 7FBE15 Approx. 697 (1537)
7FBE18 Approx. 853 (1881)
7FBE20 Approx. 1040 (2293)
Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork, 7FBE10 to 7FBE18 330 (730)
Lifting height 3000mm, V mast) 7FBE20 400 (880)
7FBE10 2225 (4906)
7FBE13 2425 (5347)
Vehicle weight 7FBE15 2685 (5920)
7FBE18 2840 (6262)
7FBE20 3155 (6957)
TOWING THE VEHICLE

Note the cautions below when towing the vehicle.
1. Lift the rear wheels for towing
2. The traveling speed when towing must not exceed the
maximum traveling speed of the forklift.
3. Before starting towing, always set the key switch to OFF
and the direction switch to the neutral position.
4. Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the
ground due to bouncing.
0-12
ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers
and relays, to impact.
(2) Never expose electronic parts to high temperature or
moisture.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.
3. Use a circuit tester that matches the object and purpose of measurement.
Analog type: This type is convenient for observing movement during operation and the operating
condition. Measured value is only a reference
Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or
movement.
(1) Difference between results of measurement with analog and digital types
∗ The results of measurements using the analog type and the digital type may be different.
Differences between the polarities of the analog type and the digital type are described below.
1) Analog circuit tester
Example of measurement result
Forward Reverse
Tester range: kΩ range
Analog type
Continuity
Forward
11 kΩ
No continuity
Reverse
∞
2) Digital circuit tester

Example of measurement result
Forward Reverse Tester range: 2 MΩ range
Digital type
No continuity
Forward
1
Continuity
Reverse
2 MΩ
0-13
NOTES ON SAS
1. For the explanations of SAS functions and operation, also see “New Model Feature 7FBEF15 to 20
Pub. No.PE316”.
2. See page 16-7 FOR REPAIR WORK of this repair manual before servicing.
3. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform
necessary matching to ensure proper SAS function (see page 3-60).
4. always be sure to operate the vehicle carefully. Be aware of the difference in control features between
with and without SAS.
5. Many precision valves are used in the SAS oil control valves. When disassembling or replacing
hydraulic parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of
the hydraulic oil is also very important.
6. As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may
cause vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the
electrical parts (auxiliary equipment, optional parts, etc.).
0-14
STANDARD BOLT & NUT TIGHTENING TORQUE

Tightening torque of standard bolts and nuts are not indicated throughout the manual.
Use the charts and table below to judge the standard tightening torque.
1. Find the class of the bolt strength on the table below and then find the bolt tightening torque on the
tightening torque table.
2. The nut tightening torque can be judged from its corresponding bolt type.
BOLT STRENGTH CLASS IDENTIFICATION METHOD
Identification by bolt shape Identification by part No.
Shape and class Class Hexagon head bolt
Hexagon 4 = 4T
Bolt with raised 5 = 5T Part No.
head bolt
or etched 6 = 6T 91611-40625
numeral on head 7 = 7T Length (mm)
Hexagon
bolt 8 = 8T Nominal diameter (mm)
Class
(standard) No mark 4T
Hexagon
No mark 4T
flange bolt
Hexagon Bolt with two

head bolt raised lines on 5T
(standard) head Nominal diameter
Hexagon Bolt with two

raised lines on 6T
flange bolt Length
head
Hexagon Bolt with three
head bolt raised lines on 7T
(standard) head Stud bolt
Hexagon Bolt with four
head bolt raised lines on 8T Part No.
(standard) head 92132-40614
Length (mm)
Nominal diameter (mm)
Welded bolt 4T Class
No mark 4T Nominal diameter
Stud bolt Length
2 mm groove(s)
on one/both 6T
edge(s)
0-15
TIGHTENING TORQUE TABLE

Standard tightening torque
Nominal Hexagon Hexagon

Pitch head bolt
Class diameter flange bolt
mm
mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf

6 1.0 5.4 55 48 in·lbf 5.9 60 52 in·lbf
8 1.25 13 130 9 14 145 10
10 1.25 25 260 19 28 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 75 760 55 83 850 61
16 1.5 113 1150 83   
6 1.0 6.4 65 56 in·lbf 7.5 75 65 in·lbf
8 1.25 16 160 12 18 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 137 1400 101 157 1600 116
6 1.0 7.8 80 69 in·lbf 8.8 90 78 in·lbf
8 1.25 19 195 14 21 215 16
10 1.25 38 400 29 43 440 32
6T
12 1.25 72 730 53 79 810 59
14 1.5 110 1100 80 123 1250 90
16 1.5 170 1750 127 191 1950 141
6 1.0 11 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 103 1050 76
14 1.5 147 1500 108 167 1700 123
16 1.5 226 2300 166   
6 1.0 12 125 9 14 145 9
8 1.25 29 300 22 32 330 24
10 1.25 61 620 45 68 690 50
8T
12 1.25 108 1100 80 123 1250 90
14 1.5 172 1750 127 196 2000 145
16 1.5 265 2700 195 299 3050 221
0-16
PRECOATED BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not replace or restore a precoated bolt as it is in the
following cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
NOTE:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves,
Seal lock agent
retighten it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when
replacing the bolt with a new one)
(2) Completely dry the washed parts by blowing with air.
(3) Apply a specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact
surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or
other damage on the contact surfaces before installation.
2. When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Tightening torque standard N·m (kgf·cm) [ft·lbf] Inside diameter
of screw of hose
Standard Tightening range mm (in)
7/16-20UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16-18UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
3/4-16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15 (0.59)
1·1/16-12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
1·5/16-12UNF 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
PF3/8 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
0-17
RECOMMENDED LUBRICANT QUANTITY AND TYPES

Application Type Capacity
Hypoid gear oil Approx. 0.4 l (0.11 US gal)
Drive unit
(API GL-4, SAE 75W-80W) (Until pouring out from the filler port)
STD: Hydraulic oil (ISO VG32) See “Hydraulic oil level by lifting
Hydraulic oil
Cold storage vehicle: Mobil Aero HFE height” below
MP grease
Chassis parts Molybdenum disulfide grease Appropriate amount
Esso beacon 325
Battery Distilled water Appropriate amount
Hydraulic oil level by lifting height

Unit:l (US gal)
Lifting height V mast FV Mast FSV Mast
To 3000 mm Capacity 14 (3.70) 17 (4.49) 

(118 in) Hydraulic oil level in the tank 12.4 (3.27)
To 4000 mm Capacity 15 (3.96) 19 (5.01) 16 (4.22)

(157.5 in) Hydraulic oil level in the tank 14.2 (3.75)
To 6000 mm Capacity 18 (4.75)  19 (5.01)

(236 in) Hydraulic oil level in the tank 17.2 (4.54)
0-18
LUBRICATION CHART
I
II
III
IV
V
{: Inspection and addition I. Inspection every 8 hours (daily)

z: Replacement II. Inspection every 40 hours (weekly)
A: MP grease III. Inspection every 250 hours (6 weekly)
B: Motor oil IV. Inspection every 1000 hours (6 monthly)
C: Gear oil (SAE 75W-80W) V. Inspection 2000 hours (annual)
D: Hydraulic oil (ISO VG32)
E: Molybdenum disulfide grease
1. Mast strip 8. Steering rack and pinion gear

2. Tilt cylinder front pin 9. Accelerator link
3. Mast support bushing 10. Oil tank
4. Lift chain 11. Tilt steering lock device
5. Drive unit 12. Rear wheel bearing
6. Brake link 13. Rear axle bearing
7. Oil control valve lever pin
0-19
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection·Repair or Replacement if required
M: Measurement·Repair or Adjustment if required
T: Retightening C: Cleaning L: Lubrication
*: For new vehicle *1: Flaw detector
Inspection timing Every 6 Every 3 Every 6 Every 12

weeks months months months
Item Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound abnormality I ← ← ←
Motor Looseness in the connecting parts T ← ← ←
Insulation resistance M ← ←
Charging level (Display) I ← ← ←
Electrolyte level I ← ← ←
Electrolyte specific gravity M ← ← ←
Looseness in the connecting parts I ← ← ←
Battery
Abnormality in the upper portion of the I ← ← ←
battery and/or the case
Insulation resistance M ← ←
Voltage measurement of each battery cell M
after charging
Contact looseness, damage, abrasion I ← ← ←
Operating condition, contamination and I ← ← ←
abrasion of the auxiliary contact
Mounting condition of the arc shooter I
Magnet switch
Operating condition and timing I
Looseness of the coil installation locations I
Mounting condition and looseness of the I
main circuit lead wire
Operating condition and timing I ← ← ←
Micro switch Damage and looseness of installation I ← ← ←
locations
Direction switch Operating condition, damage I ← ← ←
Operating condition I ← ← ←
Controller Interior contamination, damage C ← ← ←
Motor input voltage M
Fuses Looseness of the installation locations I ← ← ←
0-20

Harness deterioration, damage and I ← ← ←
looseness of the clamp
Wiring
(incl. charging Looseness of the connections, taping I ← ← ←
cable) condition
Connecting condition and damage of the I ← ← ←
battery connector
POWER TRANSMISSION SYSTEM
Oil leak I ← ← ←
Drive unit Oil level I ← ← ←
Bolt or nut looseness T
DRIVE SYSTEM
Front axle Damage and deformation I
Damage and deformation I
Rear axle Looseness of rear axle bearing I
Abnormal noise of rear axle bearing I
Tire pressure (OPT) M ← ← ←
Tire crack, damage and abnormal wear I ← ← ←
Tire tread depth M ← ← ←
Metal piece, stone and other foreign matter I ← ← ←
on tire
Wheels Loosening of wheel nut and bolt T ← ← ←
Rim, side ring and disc wheel damage I ← ← ←
Looseness and abnormal noise of front I ← ← ←
wheel bearing
Looseness and abnormal noise of rear I ← ← ←
wheel bearing
STEERING SYSTEM
Play, loosening, looseness I ← ← ←
Steering wheel
Function I ← ← ←
Steering valve
Looseness of the installation locations T ← ← ←
Wheels for Turning angle to left and right I
steering
Power steering Looseness of the installation locations I ← ← ←
Damage of power steering hose I
0-21

BRAKING SYSTEM
Reserve M ← ← ←
Brake pedal
Braking performance I ← ← ←
Operating force and pull margin I ← ← ←
Parking brake
Braking performance I ← ← ←
Looseness and damage I ← ← ←
Rod and cable
Operating condition I ← ← ←
Clearance between disc and pad M ← ← ←
Wear of sliding portion and pad I
Disc wear and damage I
Disc brake
Looseness of the disc installation locations I
Operating condition I
Return spring fatigue I
MATERIAL HANDLING SYSTEM
Damage or wear of fork or stopper pin I ← ← ←
Fork Fork deformation and wear I ← ← ←
Cracks at fork root and welded part of tooth I*1
Deformation and damage of each part and I ← ← ←
crack at welded part
Wear and damage of roller I ← ← ←
Mast and Mast and lift bracket looseness I ← ← ←
lift bracket
Wear and damage of mast support bushing I
Wear and damage of roller pin I
Wear and damage of mast strip I ← ← ←
Chain lubrication I ← ← ←
Deformation, damage and slackness of I ← ← ←
Chain and chain
chain wheel Abnormality of chain anchor bolt I ← ← ←
Wear, damage and revolution of chain I ← ← ←
wheel
Various Abnormality and installation condition of I ← ← ←
attachments each part
0-22

HYDRAULIC SYSTEM
Looseness, deformation and damage of rod I ← ← ←
and rod end
Cylinder operation I ← ← ←
Natural drop and natural forward tilt M ← ← ←
Oil leak and damage I ← ← ←
Cylinder Wear and damage of pin and cylinder I ← ← ←
bearing
Loosening and damage of cylinder T ← ← ←
mounting
Lifting speed M ← ← ←
Uneven movement I ← ← ←
Oil pump Oil leak and abnormal sound I ← ← ←
Oil level and contamination I ← ← ←
Hydraulic oil
tank
Tank and oil strainer cleaning C ←
Hydraulic oil Filter clogging C
filter
Loose linkage I ← ← ←
Control lever
Operation I ← ← ←
Oil control
Safety valve function I ← ← ←
valve
Relief pressure measurement M
Hydraulic hose Oil leakage, deformation and damage I ← ← ←

and piping Looseness T ← ← ←
SAFETY DEVICES, ETC.
Looseness of the installation locations T ← ← ←
Head guard
Deformation, crack and damage I ← ← ←
and backrest
Crack at welded portion I ← ← ←
Lighting system Function and installation condition I ← ← ←
Direction Function and installation condition I ← ← ←
indicator
Horn Function and installation condition I ← ← ←
Backup buzzer Function and installation condition I ← ← ←
Rear view Rear reflection status I ← ← ←

mirror Dirt, damage I ← ← ←
0-23

Instruments Operation I ← ← ←
Loosening and damage of mounting I ← ← ←
Seat Seat belt damage and function I ← ← ←
Deadman seat operation I ← ← ←
Damage and cracks in frame, cross mem- I
Body bers, etc.
Bolts and nuts looseness T
Functions I ← ← ←
Loosening and damage at sensor mounting I ← ← ←
portion
SAS Damage, deformation, oil leakage and loos- I ← ← ←
ened installation of functional parts
Loosening and damage of wire harnesses I ← ← ←
Rusting and corrosion of load sensor I
Others Grease up L ← ← ←
0-24
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

●: Replacement
Every Every Every Every
Replacement cycle
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item
Drive unit gear oil ● ←
Hydraulic oil ● ←
● New
Hydraulic oil filter vehicle initial ● ←
replacement
Rear wheel bearing grease ● ←
●Every
Power steering hose
2 years
●Every
Power steering rubber parts
2 years
●Every
Hydraulic hose
2 years
●Every
Lift chain
3 years
0-25
Totaldokument
Toyota 7FBEF 15-20
Var 500:e timme
Pos Kontroll av: Pos Kontroll av: Pos Kontroll av:
0:0 Grupp 0, Hel maskin 3:0 Grupp 3, Bromsar/hjul 5:9 Fartreglage

0:1 Dörrar/luckor 3:1 Däck/hjul 5:10 Microbrytare
0:2 Motviktsinfästning 3:2 Lufttryck däck 5:11 Kontaktor/kontakter
0:3 Förarskydd/hytt 3:3 Hjulbultar/hjullager 5:12 Säkringar
0:4 Batterilåsning 3:4 Färdbroms, funktion 5:13 Batterivätskenivå
0:5 Skyltar/dekaler 3:5 Parkeringsbroms 5:14 Batteri, smuts/läckage
0:6 Förarmiljö 3:7 Pedallänkage/pedalspel 5:15 Batterianslutningar
0:7 Stol/mattor 5:16 Batteripoler reng./infettning
0:8 Pedalgummin 4:0 Grupp 4, Styrning 5:17 Batterihandskar, kontroll
0:9 Torkare/spolare 4:1 Styrcylinder, kontroll 5:18 Batteri, isolationsprov
0:10 Provkörning test av 4:2 Slangar/rör, läckage
samtliga funktioner 4:3 Styraxel/upphängning 6:0 Grupp 6, Hydraulik
0:11 Smörjning enligt schema 6:1 Slangar/rör, läckage
0:12 SAS system, funktion 5:0 Grupp 5, Elsystem 6:2 Ventilreglage/länkage
5:1 Belysning/körriktningsvisare 6:3 Andningsfilter/ventilatorer
1:0 Grupp 1, Motorer 5:2 Instrument/kontrollampor 6:4 Oljenivå
1:1 Missljud 5:3 Signalhorn
1:2 Fastsättning/infästning 5:4 P-broms-/Backalarm 7:0 Grupp 7, Arbetsfunktion
1:3 Drivmotorer, renblåsning 5:5 Timmätare, avläsning 7:1 Lyftstativ
1:4 Pumpmotor, renblåsning 5:6 Färdväljare 7:2 Gafflar
1:5 Motorer, isolationsprov 5:7 Kablar/anslutningar 7:3 Lyftkedjor
5:8 Transistorpanel 7:4 Laststöd
2:0 Grupp 2, Kraftöverföring 7:5 Lyft-/tiltcylindrar
2:1 Oljenivå
2:2 Fastsättning
Var 1000:e timme tillkommer: Var 2000:e timme tillkommer: 4:0 Grupp 4, Styrning
4:5 Styrlager infettning
2:0 Grupp 2, Kraftöverföring 0:0 Grupp 0, Hel maskin
2:3 Drivväxlar, oljebyte 0:13 Ram, kontroll av sprickor 5:0 Grupp 5, Elsystem
0:14 Bultar/Muttrar, fastsättning 5:19 Batteribelastningsprov
4:0 Grupp 4, Styrning 5:20 Motorström, mätning
4:4 Slangar, kontroll 2:0 Grupp 2, Kraftöverföring
2:4 Drivväxlar, fastsättn./sprickor 6:0 Grupp 6, Hydraulik
6:0 Grupp 6, Hydraulik 6:9 Hydraultryck, kontroll
6:5 Hydraulolja, byte 3:0 Grupp 3, Bromsar/hjul
6:6 Returfilter, byte 3:10 Hjullager infettning 7:0 Grupp 7, Arbetsfunktion
6:7 Sugfilter, rengöring/byte 3:11 Bromsbelägg, slitagekontroll 7:6 Gafflar, gaffeltest
6:8 Andningsfilter, reng./byte
7FBEF 15-20
© BT Svenska AB 04/04
1-1
BATTERY
Page
BATTERY COMPARTMENT AND
REQUIRED WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 0
SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3
BATTERY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
4
REMOVAL · INSTALLATION . . . . . . . . . . . . . . . . . . . . . 1-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 5
6
7
8
9
10
11
12
13
14
15
16
16
18
1-2
BATTERY COMPARTMENT AND REQUIRED WEIGHT

When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
Compartment dimensions mm (in) Minimum required battery

Vehicle model Remarks
weight (with case) Kg (lb)
Length X Width Y Height Z
7FBEF15 630 (24.8) 830 (32.7) 627 (24.7) 830 (1830)
7FBEF16 to 20 738 (29.1) ↑ ↑ 985 (2172)
Compartment dimension Minimum required bat-

mm (in) tery Weight (W/ case) Remarks
Depth X Width Y Height Z kg (lb)
7FBE10·13 451 (17.8) 998 (39.3) 613 (24.1) 520 (1147)
7FBE15·18 551 (21.7) ↑ ↑ 655 (1444)
7FBE20 638 (25.1) ↑ ↑ 655 (1444)
X
th
ng
Le
Height
Z
Y
Width
1-3
SERVICE STANDARDS
Specific gravity 1.280 [20 °C (68 °F)]
Specific gravity 1.150 [20 °C (68 °F)]
Discharge end voltage 48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 1MΩ or more
0
1
DISPLAY
Battery Charge Indicator 2
The battery charge indicator indicates 10 levels of battery
charge on the LCD. 3
3 0 / 9 AM
11: 00
4
S P H
S P H
MENU
Battery Indicate level Low Remaining Battery Charge Warning 6

discharged 10 9 8 7 6 5 4 3 2 1 When the battery charge becomes below the set level, the
state % F E battery charge indicator blinks and the alarm will sound for 7
five seconds after the key switch is set to the ON position.
0 to 10
(exclusive)
{{{{{{{{{{
Battery Overdischarge Warning
8
10 to 20
(exclusive)
− {{{{{{{{{ When the battery charge decreases further below the set
level after the remaining battery charge warning, any attempt
9
20 to 30 at traveling or material handling operation will cause all
(exclusive)
− − {{{{{{{{
charge indicator segments to blink and the alarm to sound to 10
30 to 40 warn the operator.
(exclusive)
− − − {{{{{{{ 11
40 to 50
− − − − {{{{{{
(exclusive) 12
50 to 60
− − − − − {{{{{
(exclusive) 13
60 to 70
− − − − − − {{{{
(exclusive) 14
70 to 80
− − − − − − − {{{
(exclusive) 15
80 to 90
− − − − − − − − {{
(exclusive)
90 to 100
16
− − − − − − − − − {
(exclusive)
100 or more − − − − − − − − − −
16
18
1-4
TROUBLESHOOTING
Plate corrosion Sulfation Plate warpage and ative substance freeing
Improper charging
Long storage Repeated overdischarge/
without operation overcharge
End of life Short circuit
between cells
Excessive charging
Defect of electrolyte
Insufficient current
Defective electrolyte
electrolyte
Overdischarge Excessive ambient
Battery defect
temperature
Crack or
Damaged Improper chipping of cell
separator water supply Imperfect
Overcharge terminal
connection
Deposition of freed Fouled terminal or

active substance connecting plug
at bottom of cell
Short circuit Electrolyte leakage and reduction Loosened or corroded connection

1-5
BATTERY ASSY
REMOVAL · INSTALLATION
0
2 1
2
3
4 4
5
6
7
8
1
9
Removal Procedure
10
1 Disconnect the battery plug.
2 Open the seat stand.
3 Release the steering release lever.
11
4 Remove the battery ASSY. [Point 1]
12
Installation Procedure
The installation procedure is the reverse of the removal procedure. 13
Point Operations 14
[POINT 1]
SST Removal · Installation: 15
SST 25009-13201-71
16
16
18
1-6
INSPECTION
1. Electrolyte inspection
The battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity.If it
cannot be checked clearly, put the electrolyte in a
beaker for inspection.
2. Battery electrolyte specific gravity inspection

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

used.
Equation for converting specific gravity
S20=St+0.0007 (t-20)
S20: Specific gravity at 20 °C
St: Specific gravity at t °C
t: Electrolyte temperature upon measurement (°C)
* How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the
electrolyte port and allow the electrolyte to be
sucked into its outer tube.
(2) Let the hydrometer float correctly without
contact with the outer tube, top or bottom, and
read the scale at the highest point of the
electrolyte surface as illustrated at left when
the bubbles in the electrolyte disappear.
(3) After the measurement, wash the inside and
outside of the hydrometer well with clear
water and store it after wiping water off with
clean cloth.
1-7
3. Insulation resistance inspection

Measure the resistance between the battery and battery
case with an insulation resistance meter
(megohmmeter).
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.
Inspection date Specific Electrolyte Added water
Inspected cell No. Remarks Inspector
and time gravity temperature quantity
2-1
CONTROLLER
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
0
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 1
BEFORE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2
CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . 2-7 3
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
4
MAIN CONTROLLER ASSY . . . . . . . . . . . . . . . . . . . . . 2-26
5
TRAVELING AC DRIVER . . . . . . . . . . . . . . . . . . . . . . . . 2-27
MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL 6
ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
7
CHECK MOTOR INPUT VOLTAGE . . . . . . . . . . . . . . . . 2-30
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
8
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 9
DIRECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 10
REMOVAL • INSTALLATION . . . . . . . . . . . . . . . . . . . . . 2-34
11
DISASSEMBLY • INSPECTION • REASSEMBLY . . . . . 2-36
12
ACCELERATOR POTENTIOMETER
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 13
BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . 2-38 14
MATERIAL HANDLING LEVER SWITCH
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 15
16
17
18
2-2
GENERAL
7FBEF series models are equipped with traveling/material handling controllers that control traveling and
material handling system. They are multi-functional controller that utilize micro computer.
The traveling/material handling controller provides high performance in a wide range by means of inverter
control of the AC motor drive system.
The main controller has a self-diagnosis function that automatically detects any abnormality of the main
drive/pump circuits, accelerator, SAS function or any other sensor and displays the corresponding error
code together with a warning beep.
At the same time, an action such as disabling traveling, disabling material handling or restriction of
traveling speed is automatically taken to ensure safety.
Identification of faulty portion and functional inspection of the main drive/pump circuits, each operating
system and sensors are also possible by setting the display to the analyzer (fault analysis) mode.
See page 3-15 in the “MULTI-DISPLAY FUNCTIONS” section for the diagnosis.
See page 3-26 in the “MULTI-DISPLAY FUNCTIONS” section for the analyzer.
Material handling
Control panel
AC driver
Traveling AC driver
Contactor panel
2-3
SPECIFICATIONS - 7FBEF15-20
All Models
F1 (for drive and pump circuits) 500A
F4 (for lights) 10A
FUSES
F5 (for control circuit) 10A
F6 (SAS, for solenoid) 10A
0
Contactor MB (for power supply) ME251 1
2
SPECIFICATIONS - 7FBE10-20 3
7FBE10·13 7FBE15·18·20 4
F1 (for drive and pump circuits) 450A 500A
5
F4 (for lights) 10A ←
FUSES
F5 (for control circuit) 10A ← 6
F6 (SAS, for solenoid) 10A ← 7
Contactor MB (for power supply) ME251 ←
8
9
10
11
12
13
14
15
16
17
18
2-4
COMPONENTS
2401
2401
2-5
2402
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2-6
BEFORE REPAIR
INSPECTION
1. Insulation resistance measurement

Note:
Always measure before inspecting the traveling/material
handling controller.
(1) Disconnect the battery plug and measure the
resistance between battery plug and body.
Measurement terminals Controller side of battery plug-body

Resistance value depends greatly on the vehicle operating state, place and
Standard: weather.
(Approx. 1MΩ or more)
Some components can be inspected after they are removed from the vehicle, while others can only be
inspected as installed on the vehicle.
The CPU board must be inspected as installed on the vehicle since the battery voltage must be applied.
The explanation here is mainly for inspection of the controller ASSY as removed from the vehicle.
• Overhauling the control panel is rarely necessary. In most cases, failed parts is replaced after finding out
the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to the
figures of configuration and ASSY
• Do not disassemble traveling/material handling controller, as it should be replaced in a form of ASSY.
Caution for part replacement
• Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of
tightening may cause other failure.
• When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connection.
Incorrect connection may cause other failure.
• Always apply new silicon grease when reassembling parts originally coated with silicon grease.
Otherwise, overheating may occur.
• After installation, check that there is no interference of the bar and harness connection with other
portion.
2-7
CONNECTOR INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the board
but check the following items.
• Abnormality in related harnesses
• Looseness of the related connectors
• Bending or damage of connector pin and defective contact of any related connector pin.
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will
be damaged.
Always replace the board after careful inspection.
When the cause of trouble is determined to be in the CPU board or other board, connect SST 09240-
23400-71 or to the corresponding connector pin and measure the applied voltage and resistance. Always
disconnect the battery plug before measuring the resistance.
Caution:
Disconnect the battery plug before connecting or disconnecting CPU board.
Note:
When the CPU or DC/MD board is determined to be the cause of trouble as the result of
troubleshooting, always measure the applied voltage and resistance of each related portion when
replacing.
(1) SST Setting Method
(a) Key switch OFF and battery plug disconnected.
(b) Connect the SST to the corresponding connector pin.
Caution:
As connection of the wrong connector pin may damage normal portions, make sure to confirm the
connector pin number before connecting it to the SST.
Connectors to which SST 09240-24300-71 is applicable

SST09240-23400-71 CPU board: CN101 to CN104
SST09230-13700-71Applicable connector
SST09230-13700-71
CPU board: CN100,CN105
2-8
(2) Measurement method and standard list

How to read the list
Tester probe
Tester probe
Connector pin No.
Connector No. Connector No. Conditions Standard Remarks

CN101-1 CN101-26
Key switch OFF, DSF ON. Approx.0V
(45, DSF) (51, LS-)
Part name
Level No. Conditions for measurement
Main controller
CPU board
CN101 connector basic conditions (battery plug connected, key switch ON) [Standard vehicle]
Connector No.⇔Connector No. Conditions Standard: Remarks
CN101-1 CN101-16 Key switch OFF, DSF ON Approx. 0V
(45, DSF) (51, LS-) key switch OFF, DSF OFF Approx. 5V
CN101-2 CN101-16 Key switch OFF, DSR ON Approx. 0V
(46, DSR) (51, LS-) Key switch OFF, DSR OFF Approx. 5V
CN101-3 CN101-16 Key switch OFF, LSB ON Approx. 5V
(65, LSB) (51, LS-) Key switch OFF, LSB OFF Approx. 0V
CN101-4 CN101-16 Key switch OFF, LSPB ON Approx. 5V
(66, LSPB) (51, LS-) Key switch OFF, LSPB OFF Approx. 0V
CN101-5 CN101-16 Key switch OFF, LSD ON Approx. 0V
(67, LSD) (51, LS-) Key switch OFF, LSD OFF Approx. 5V
CN101-6  Unused 
CN101-7 CN101-16
Unused 
(, OPTO) (51, LS-)
CN101-8 CN101-16
Unused 
(, LEDTK) (51, LS-)
FAN OFF
CN101-9 CN101-16 Approx. 48V
(39, FAN-) (51, LS-) Approx. 0V
FAN ON
FAN OFF
CN101-10 CN101-16 Approx. 48V
(39, FAN-) (51, LS-) Approx. 0V
FAN ON
CN101-11 CN101-16 LSAT1 OFF Approx. 5V
(63, LSAT1+) (51, LS-) LSAT1 ON Approx. 0V
CN101-12
 Unused 
(309, SSTMA)
2-9

CN101-13
 Unused 
(310, SSTMK)
CN101-14
 Unused 
(307, SMTSA)
CN101-15
 Unused 
(308, SMTSK)
CN101-16
  
(51, LS-)
CN101-17 CN101-16 LSTR OFF Approx. 5V
(62, LSTR+) (51, LS-) LSTR ON Approx. 0V
CN101-18 CN101-16 Key switch OFF, SWTK ON Approx. 0V
(70, SWTK) (51, LS-) Key switch OFF, SWTK OFF Approx. 5V
CN101-19 CN101-16 Lift cylinder at the bottom posi-
Approx. 0V
(90, MH1) (51, LS-) tion
Approx. 5V
(91, MH2-1) (51, LS-) tion
CN101-21 CN101-16 Only vehicle with steering syn- Approx. 0V or
(314, STSC) (51, LS-) chronizer Approx. 5V
CN101-22 CN101-16
Unused 
(68, LSAT2+) (51, LS-)
CN101-23 CN101-16 LSTF OFF Approx. 5V
(61, LSTF+) (51, LS-) LSTF ON Approx. 0V
CN101-24 CN101-16 Steering operation (only vehicle Approx. 0V to
(312, STS1) (51, LS-) with steering synchronizer) Approx. 5V
CN101-25   
CN101-26
  
(51, LS-)
CN101-27 CN101-16
Unused 
(71, SWLE) (51, LS-)
CN101-28   
CN101-29   
CN101-31   
CN101-32 CN101-16 LSL OFF Approx. 5V
(60, LSL+) (51, LS-) LSL ON Approx. 0V
CN101-33   
CN101-34 CN101-16
Approx. 0V
(51, POT-) (51, LS-)
2-10
CN101 connector basic conditions (battery plug connected, key switch ON)
[Mini-lever specification vehicle]
CN101-1 CN101-16 Key switch OFF, DSF ON Approx. 0V
(45, DSF) (51, LS-) key switch OFF, DSF OFF Approx. 5V
CN101-2 CN101-16 Key switch OFF, DSR ON Approx. 0V
(46, DSR) (51, LS-) Key switch OFF, DSR OFF Approx. 5V
CN101-3 CN101-16 Key switch OFF, LSB ON Approx. 5V
(65, LSB) (51, LS-) Key switch OFF, LSB OFF Approx. 0V
CN101-4 CN101-16 Key switch OFF, LSPB ON Approx. 5V
(66, LSPB) (51, LS-) Key switch OFF, LSPB OFF Approx. 0V
CN101-5 CN101-16 Key switch OFF, LSD ON Approx. 0V
(67, LSD) (51, LS-) Key switch OFF, LSD OFF Approx. 5V
CN101-6  Unused 
CN101-7 CN101-16
Unused 
(, OPTO) (51, LS-)
CN101-8 CN101-16
Unused 
(, LEDTK) (51, LS-)
FAN OFF
CN101-9 CN101-16 Approx. 48V
(39, FAN-) (51, LS-) Approx. 0V
FAN ON
FAN OFF
CN101-10 CN101-16 Approx. 48V
(39, FAN-) (51, LS-) Approx. 0V
FAN ON
CN101-11 CN101-16
 
(63, LSAT1+) (51, LS-)
CN101-12
 Unused 
(309, SSTMA)
CN101-13
 Unused 
(310, SSTMK)
CN101-14
 Unused 
(307, SMTSA)
CN101-15
 Unused 
(308, SMTSK)
CN101-16
  
(51, LS-)
CN101-17 CN101-16
 
(62, LSTR+) (51, LS-)
CN101-18 CN101-16 Key switch OFF, SWTK ON Approx. 0V
(70, SWTK) (51, LS-) Key switch OFF, SWTK OFF Approx. 5V
Approx. 0V
(90, MH1) (51, LS-) tion
2-11

Approx. 5V
(91, MH2-1) (51, LS-) tion
CN101-21 CN101-16 Only vehicle with steering syn- Approx. 0V or
(314, STSC) (51, LS-) chronizer Approx. 5V
CN101-22 CN101-16
Unused 
(68, LSAT2+) (51, LS-)
CN101-23 CN101-16
 
(61, LSTF+) (51, LS-)
CN101-25   
CN101-26
  
(51, LS-)
CN101-27 CN101-16
Unused 
(71, SWLE) (51, LS-)
CN101-28   
CN101-29   
CN101-31   
CN101-32 CN101-16
 
(60, LSL+) (51, LS-)
CN101-33   
CN101-34 CN101-16
Approx. 0V
(51, POT-) (51, LS-)
CN102 connector basic conditions (battery plug connected, key switch ON)[Standard vehicle]
CN102-1 CN102-22 Key switch OFF, SWAC ON Approx. 0V
(64, SWAC) (51, POT-) Key switch OFF, SWAC OFF Approx. 5V
CN102-2 CN102-22 Key switch OFF, accelerator
0.4V to 3V
(52, POTA) (51, POT-) pedal fully depressed
CN102-3 CN102-22
 
(317, POTH) (51, POT-)
CN102-4 CN102-22 Variation upon changeover
0.5V to 3V
(56, POTTA) (51, POT-) from forward to backward tilting
CN102-5 CN102-22
 0.5V to 4.5V
(59, SPL) (51, POT-)
2-12

CN102-6 CN102-22 LSL OFF Approx. 5V
(60, LSL) (51, POT-) LSL ON Approx. 0V
CN102-7 CN102-22
 
(21, POTL2) (51, POT-)
When the tilt lever is in the neu-
Approx. 5V
CN102-8 CN102-22 tral position
(61, LSTF) (51, POT-) When the tilt lever is in the for-
Approx. 0V
ward tilt position
When the tilt lever is in the neu-
Approx. 5V
CN102-9 CN102-22 tral position
(62, LSTR) (51, POT-) When the tilt lever is in the
Approx. 0V
backward tilt position
CN102-10
CN102-22 LSAT1 OFF Approx. 5V
(63,
(51, POT-) LSAT1 ON Approx. 0V
LSAT1,LSAT2)
CN102-11 CN102-22
 
(25, POTAT12) (51, POT-)
CN102-12 CN102-22
 
(26, POTAT21) (51, POT-)
CN102-13 CN102-22
 
(27, POTAT22) (51, POT-)
CN102-14 CN102-22
 Approx. 4.6V
(53, POTA+) (51, POT-)
CN102-15 CN102-22
 Approx. 4.7V
(316, POTH+) (51, POT-)
CN102-16 CN102-22
 Approx. 4.7V
(57, POTTA+) (51, POT-)
CN102-17 CN102-22
 Approx. 5V
(58, SPL+) (51, POT-)
CN102-18 CN102-22
 
(28, POTL+) (51, POT-)
CN102-19 CN102-22
 
(29, POTT+) (51, POT-)
CN102-20 CN102-22
 
(30, POTAT1+) (51, POT-)
CN102-21 CN102-22
 
(31, POTAT2+) (51, POT-)
CN102-22
  
(51, POT-)
2-13
CN102-1 CN102-22 Key switch OFF, SWAC ON Approx. 0V
(64, SWAC) (51, POT-) Key switch OFF, SWAC OFF Approx. 5V
CN102-2 CN102-22 Key switch OFF, accelerator
0.4V to 3V
(52, POTA) (51, POT-) pedal fully depressed
CN102-3 CN102-22
 
(317, POTH) (51, POT-)
CN102-4 CN102-22 Variation upon changeover
0.5V to 3V
(56, POTTA) (51, POT-) from forward to backward tilting
CN102-5 CN102-22
 0.5V to 4.5V
(59, SPL) (51, POT-)
Lever is in the neutral position
CN102-6 CN102-22 Approx. 1.3V
Change when the lift lever is
(20, POLT1) (51, POT-) 0.5V to 2.2V
tilted forward and backward
CN102-7 CN102-22 Approx. 3.3V
Change when the lift lever is
(21, POTL2) (51, POT-) 2.3V to 4V
CN102-8 CN102-22 Approx. 1.3V
Change when the tilt lever is
(22, POTT1) (51, POT-) 0.5V to 2.2V
CN102-9 CN102-22 Approx. 3.3V
Change when the tilt lever is
(23, POTT2) (51, POT-) 2.3V to 4V
CN102-10 CN102-22 Change when the attachment 1 Approx. 1.3V
(24, POTAT11) (51, POT-) lever is tilted forward and back- 0.5V to 2.2V
ward
Lever in neutral position
CN102-11 CN102-22 Change when attachment 1 Approx. 3.3V
(25, POTAT12) (51, POT-) lever is tilted forward and back- 2.3V to 4V
ward
CN102-12 CN102-22 Change when attachment2 Approx. 1.3V
(26, POTAT21) (51, POT-) lever is tilted forward and back- 0.5V to 2.2V
ward
CN102-13 CN102-22 Change when attachment2 Approx. 3.3V
(27, POTAT22) (51, POT-) lever is tilted forward and back- 2.3V to 4V
ward
CN102-14 CN102-22
 Approx. 4.6V
(53, POTA+) (51, POT-)
2-14

CN102-15 CN102-22
 Approx. 4.7V
(316, POTH+) (51, POT-)
CN102-16 CN102-22
 Approx. 4.7V
(57, POTTA+) (51, POT-)
CN102-17 CN102-22
 Approx. 5V
(58, SPL+) (51, POT-)
CN102-18 CN102-22
 Approx. 4.5V
(28, POTL+) (51, POT-)
CN102-19 CN102-22
 Approx. 4.5V
(29, POTT+) (51, POT-)
CN102-20 CN102-22
 Approx. 4.5V
(30, POTAT1+) (51, POT-)
CN102-21 CN102-22
 Approx. 4.5V
(31, POTAT2+) (51, POT-)
CN102-22
  
(51, POT-)
CN103 connector basic conditions (battery plug connected, key switch ON)[Standard vehicle]
Connector No.⇔ Connector No. Conditions Standard: Remarks
CN103-1
 Immeasurable 
(145, CANH)
CN103-2
(146, CANL)
CN103-3 CN103-12
 Approx. 0V
(147, CANGND) (14, GNDD)
CN103-4 CN103-12 Key switch OFF Approx. 0V
(43, VBKY) (14, GNDD) Key switch ON Approx. 48V
CN103-5 CN103-12
Unused 
(324, SSO+) (14, GNDD)
CN103-6 CN103-12
Unused 
(325, SSO-) (14, GNDD)
CN103-7 CN103-12
 Approx. 48V
(41, VBBT) (14, GNDD)
CN103-8 CN103-12
Unused 
(, CHK15V) (14, GNDD)
CN103-9 CN103-12
Unused 
(, CHK5V) (14, GNDD)
CN103-10 CN103-12
 Approx. 15V
(16, D15V) (14, GNDD)
2-15

CN103-11 CN103-12
Unused 
(, CHK3.3V) (14, GNDD)
CN103-12
  
(14, GNDD)
CN103-13
(144, SMTDK)
CN103-14
(143, SDTMK)
CN103-15
(142, SDTMA)
CN103-16
(141, SMTDA)
CN103-1
(145, CANH)
CN103-2
(146, CANL)
CN103-3 CN103-12
 Approx. 0V
CN103-4 CN103-12 Key switch OFF Approx. 0V
(43, VBKY) (14, GNDD) Key switch ON Approx. 48V
CN103-5 CN103-12
Unused 
(324, SSO+) (14, GNDD)
CN103-6 CN103-12
Unused 
(325, SSO-) (14, GNDD)
CN103-7 CN103-12
 Approx. 48V
(41, VBBT) (14, GNDD)
CN103-8 CN103-12
Unused 
(, CHK15V) (14, GNDD)
CN103-9 CN103-12
Unused 
(, CHK5V) (14, GNDD)
CN103-10 CN103-12
 Approx. 15V
(16, D15V) (14, GNDD)
CN103-11 CN103-12
Unused 
(, CHK3.3V) (14, GNDD)
CN103-12
  
(14, GNDD)
2-16

CN103-13
(144, SMTDK)
CN103-14
(143, SDTMK)
CN103-15
(142, SDTMA)
CN103-16
(141, SMTDA)
CN104 Connector basic conditions (battery plug connected, key switch ON)[Standard vehicle]
CN104-1 CN104-22
Key switch OFF Approx. 48V
(18, B48V) (N2, N2)
CN104-2 CN104-22
(18, B48V) (N2, N2)
CN104-3 CN104-4
Approx. 11V
(3, SOLL+) (4, SOLL-)
CN104-4 CN104-3 Resistance measurement with
Approx. 10Ω
(4, SOLL-) (3, SOLL+) battery plug disconnected
CN104-5 CN104-3
 
(5, SOL a1) (3, SOLL+)
CN104-6 CN104-7
 
(6, SOL2+) (7, SOL a2)
CN104-6 CN104-8
 
(6, SOL2+) (8, SOL b2)
Tilt lever in the neutral position
CN104-6 CN104-22
Tilt lever in the forward or back- Approx. 11V
(6, SOLT+) (7, SOLT-)
ward position
Approx. 10Ω
(7, SOLT-) (6, SOLT+) battery plug disconnected
CN104-8 CN104-6
 
(8, SOL b2) (6, SOL2+)
CN104-9 CN104-22
Approx. 48V
(55, CPR) (N2, N2)
CN104-10 CN104-22
Approx. 48V
(55, CPR) (N2, N2)
CN104-11 CN104-12
 
(9, SOL3+) (10, SOL a3)
CN104-11 CN104-13
 
(9, SOL3+) (11, SOL b3)
2-17

CN104-12 CN104-11
 
(10, SOL a3) (9, SOL3+)
CN104-13 CN104-11
 
(11, SOL b3) (9, SOL3+)
CN104-14 CN104-22
Approx. 48V
(44, VBMB) (N2, N2)
CN104-15 CN104-22
Approx. 48V
(44, VBMB) (N2, N2)
CN104-16 CN104-17
 
(34, SOL4+) (35, SOL a4)
CN104-16 CN104-18
 
(34, SOL4+) (36, SOL b4)
CN104-17 CN104-16
 
(35, SOL a4) (34, SOL4+)
CN104-18 CN104-16
 
(36, SOL b4) (34, SOL b4)
CN104-19 CN104-20 Measurement with (−) probe in
Approx. 11V
(1, MB+) (2, MB-) contact with CN104-20
Approx. 20Ω
(2, MB-) (1, MB+) battery plug disconnected
Measurement with (−) probe in
CN104-21 CN104-28 contact with CN104-28
Approx. 11V
(329, SOLST+) (330, SOLST-) (only vehicle with steering syn-
chronizer)
CN104-22
  
(N2, N2)
CN104-23
  
(N2, N2)
CN104-24 CN104-22
Unused 
(39, FAN-) (N2, N2)
Key switch OFF
CN104-25 CN104-22 Approx. 0V
Key switch ON
(42, KEYSTART) (N2, N2) Approx. 48V
CN104-26 CN104-27
 
(12, SOLP+) (13, SOLP-)
CN104-27 CN104-26
 
(13, SOLP-) (12, SOLP+)
Resistance measurement with
CN104-28 CN104-21 battery plug disconnected
Approx. 10Ω
(330, SOLST-) (329, SOLST+) (only vehicle with steering syn-
chronizer)
2-18
CN104 Connector basic conditions (battery plug connected, key switch ON)
CN104-1 CN104-22
(18, B48V) (N2, N2)
CN104-2 CN104-22
(18, B48V) (N2, N2)
CN104-3 CN104-4 Lever in neutral position Approx. 0V
(3, SOL1+) (4, SOL b1) Change when fork is raised 2V to 8V
CN104-3 CN104-5 Lever in neutral position Approx. 0V
(3, SOL1+) (5, SOL a1) Change when fork is lowered 2V to 8V
Approx. 7Ω
(4, SOL b1) (3, SOL1+) battery plug disconnected
Approx. 7Ω
(5, SOL a1) (3, SOL1+) battery plug disconnected
Amount of change when tilting
CN104-6 CN104-7 Approx. 0V
forward with the lever in the
(6, SOL2+) (7, SOL a2) 2V to 8V
neutral position
Amount of change when tilting
CN104-6 CN104-8 Approx. 0V
backward with the lever in the
(6, SOL2+) (8, SOL b2) 2V to 8V
neutral position
Approx. 7Ω
Approx. 7Ω
CN104-9 CN104-22
Approx. 48V
(55, CPR) (N2, N2)
CN104-10 CN104-22
Approx. 48V
(55, CPR) (N2, N2)
Lever in neutral position Approx. 0V
CN104-11 CN104-12
Change when attachment 1 2V to 8V
(9, SOL3+) (10, SOL a3)
lever is tilted backward
Lever in neutral position Approx. 0V
CN104-11 CN104-13
Change when attachment 1 2V to 8V
(9, SOL3+) (11, SOL b3)
lever is tilted forward
Approx. 7Ω
Approx. 7Ω
CN104-14 CN104-22
Approx. 48V
(44, VBMB) (N2, N2)
2-19

CN104-15 CN104-22
Approx. 48V
(44, VBMB) (N2, N2)
CN104-16 CN104-17 Approx. 0V
Change when attachment 2
(34, SOL4+) (35, SOL a4) 2V to 8V
lever is tilted forward
CN104-16 CN104-18 Approx. 0V
Change when attachment2
(34, SOL4+) (36, SOL b4) 2V to 8V
lever is tilted backward
Approx. 7Ω
Approx. 7Ω
(36, SOL b4) (34, SOL b4) battery plug disconnected
Approx. 11V
(1, MB+) (2, MB-) contact with CN104-20
Approx. 20Ω
(2, MB-) (1, MB+) battery plug disconnected
Measurement with (−) probe in
CN104-21 CN104-28 contact with CN104-28
Approx. 11V
(329, SOLST+) (330, SOLST-) (only vehicle with steering syn-
chronizer)
CN104-22
  
(N2, N2)
CN104-23
  
(N2, N2)
CN104-24 CN104-22
Unused 
(39, FAN-) (N2, N2)
Key switch OFF
CN104-25 CN104-22 Approx. 0V
Key switch ON
(42, KEYSTART) (N2, N2) Approx. 48V

Approx. 11V
(12, SOLP+) (13, SOLP-) contact with CN104-27
Approx. 10Ω
(13, SOLP-) (12, SOLP+) battery plug disconnected
Resistance measurement with
CN104-28 CN104-21 battery plug disconnected
Approx. 10Ω
(330, SOLST-) (329, SOLST+) (only vehicle with steering syn-
chronizer)
2-20
CN105-1 CN104-22 FAN stopped Approx. 48V
(39, FAN-) (N2, N2) FAN ON Approx. 0V
FAN stopped Approx. 48V
CN105-4 CN104-22
FAN ON (depending on the Approx. 1V
(130, FAN1) (N2, N2)
vehicle condition) (Approx. 48V)
CN105-5 CN104-22
(131, FAN2) (N2, N2)
CN105-6 CN104-22
(132, FAN3) (N2, N2)
CN105-7 CN104-22
(133, FAN4) (N2, N2)
CN105-8 CN104-22
(134, FAN5) (N2, N2)
CN105-9 CN104-22
(135, FAN6) (N2, N2)
CN105-10
 Unused 
(, FAN7)
CN105-11
 Unused 
(, CHKG)
2-21
CN107 connector basic conditions (battery plug connected, key switch ON, connector disconnected)
CN107-1 CN107-2
Unused 
(127, FANR+) (128, FANR-)
CN107-2
 Unused 
(128, FANR-)
CN100-1
 Unused 
(, C5V)
CN100-2
 Unused 
(, GNDC)
CN100-3
 Unused 
(, FTXD)
CN100-4
 Unused 
(, FWE)
CN100-5
 Unused 
(, MD1)
CN100-6
 Unused 
(, FRES)
CN100-7
 Unused 
(, FRXD)
CN100-8
 Unused 
(, SELR)
Approx. 20Ω
(55, CPR) (P2, P2) battery plug disconnected
CN26-2
  
(P2, P2)
2-22
Traveling AC driver 2
CN109-10
CN109-1
(82, SSD2-, Approx. 0V
(, CUDIDO)
TD2-)
CN109-2
 Unused 
(, CUDID1)
CN109-3
(145, CANH)
CN109-4
(146, CANL)
CN109-5
 Unused 
(, CANTRD)
CN109-6 CN109-6
Approx. 0V
CN109-7 N2
Approx. 48V
(55, KEYSTART) (N2, N2)
CN109-8
Unused 
(, CUDON)
CN109-10
CN109-9
(78, SSD2-,  Approx. 12V
(75, SSD2+)
TD2-)
CN109-10 CN109-10
(78, SSD2-, (78, SSD2-,  Approx. 0V
TD2-) TD2-)
CN109-10
CN109-11
(78, SSD2-,  0 to 12V
(76, SSD21)
TD2-)
CN109-10
CN109-12
(78, SSD2-,  0 to 12V
(77, SSD22)
TD2-)
CN109-13
 Immeasurable
(78, TD2+)
2-23
CN110-1
 Unused 
(, CUDIDO)
CN110-2
 Unused 
(, CUDID1)
CN110-3
(145, CANH)
CN110-4
(146, CANL)
CN110-5
 Unused 
(, CANTRD)
CN110-6 CN110-6
Approx. 0V
CN110-7 N2
Approx. 48V
CN110-8
 Unused 
(, CUDON)
CN110-10
CN110-9
(78, SSD2-,  Approx. 12V
(80, SSD+)
TD2-)
CN110-10 CN110-10
(83, SSD1-, (83, SSD1-,  Approx. 0V
TD1-) TD1-)
CN110-10
CN110-11
(83, SSD1-,  0 to 12V
(81, SSD11)
TD1-)
CN110-10
CN110-12
(83, SSD1-,  0 to 12V
(82, SSD12)
TD1-)
CN110-13
(88, TD1+)
2-24
Material handling AC driver

CN111-1
 Unused 
(, CUPIDO)
CN111-10
CN111-2
(87, SSP-, Approx. 0V
(87, CUPID1)
TP-)
CN111-3
(145, CANH)
CN111-4
(146, CANL)
CN111-5
 Unused 
(, CANTRD)
CN111-6 CN111-6
Approx. 0V
(147, CANGND) (147, CANGND)
CN111-7 N2
Approx. 48V
CN111-8
 Unused 
(, CUPON)
CN111-10
CN111-9
(87, SSP-,  Approx. 12V
(84, SSP+)
TP-)
CN111-10 CN111-10
(87, SSP-, (87, SSP-,  Approx. 0V
TP-) TP-)
CN111-10
CN111-11
(87, SSP-,  0 to 12V
(85, SSP1)
TP-)
CN111-10
CN111-12
(87, SSP-,  0 to 12V
(86, SSP2)
TP-)
CN111-13
(89, TP+)
Contactor panel ASSY

CN27-1 P1 terminal Battery plug OFF and CN
Approx. 0Ω
(P1, P1) (P1, P1) 27 disconnection
Approx. 0Ω
2-25

Approx. 0Ω
Approx. 0Ω
(101, F4) (P1, P1) 27 disconnection
Approx. 0Ω
Approx. 0Ω
CN136connector basic conditions (battery plug connected, key switch ON)
CN136-1 CN136-2 Battery plug OFF and CN
Approx. 20Ω
(P1, P1) (1, MB+) 136 disconnection
Approx. 11V
(P1, P1) (2, MB-) contact with CN136-1
Approx. 0Ω
Approx. 0Ω
Approx. 0Ω
Approx. 0Ω
2-26
CONTROLLER
MAIN CONTROLLER ASSY
REMOVAL • INSTALLATION
3
2
Removal Procedure
2 Open the battery hood.
3 Remove the main controller cover.
4 Disconnect the wiring of the main controller ASSY.
5 Remove the main controller ASSY.
The installation procedure is the reverse of the removal procedure.
2-27
TRAVELING AC DRIVER
Caution:
Before starting the job, measure the voltage between P3 and N1; if there is any voltage, insert a
resistor at approx. 100Ω between P3 and N to discharge the capacitor.
Removal Procedure
1. Disconnect the battery plug.
2. Open the battery hood.
3. Remove the side cover.
4. Remove the main controller cover.
5. Remove the rear side cover.
6. Remove the controller fan.
7. Disconnect the outer wiring of the traveling AC driver (LH, RH) at the connectors and terminals.
8. Remove the traveling AC driver (LH).
9. Remove the traveling AC driver (RH).
2-28
MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL ASSY

Caution:
Before starting the job, measure the voltage between P3 and N2; if there is any voltage, insert a
resistor at approx. 100Ω between P3 and N to discharge the capacitor.
2
4
Removal Procedure
2. Open the battery hood.
3. Remove the side cover.
4. Remove the main controller cover.
5. Remove the rear side cover.
6. Remove the cooling fan.
7. Disconnect the outer wiring of the material handling AC driver at the connectors and terminals.
8. Remove the material handling AC driver.
9. Remove the contactor panel ASSY.
2-29
INSPECTION
1. Cooling fan (for traveling/material handling AC driver)
Inspection method
Disconnect the fan connector
Portion
Measurement
to be Standard Tester range
terminals
inspected
CN113-1 (7) 
Traveling
CN113-2 (8)
∞Ω Ω×1
Material CN114-1 (9) 
handling CN114-2 (10)
2. MB (power supply contactor)

Inspection method
Disconnect CN134 connector, and measure the
resistance of the MB coil.
Portion
Measurement
terminals
inspected
Approx.
Both terminals of
MB coil 20 Ω (at Ω×1
CN134
20°C)
3. FUSES
Inspection method
F1
Disconnect the fuse and measure the insulation
resistance
Portion
Measurement
terminals
inspected
F4 F6 Both terminals of
F5 FUSES 0Ω Ω×1
fuse
2-30
CHECK MOTOR INPUT VOLTAGE

When traveling or material handling operation seems abnormal, it is possible to accurately judge if the
controller is functioning correctly or not by measuring the motor input voltage.
Drive Motor Input Voltage Measurement
Measuring method Procedure
(1) Disconnect the battery plug.
(2) Jack up the front wheels.
(3) Open the battery hood
(4) Remove the side cover and rear side cover.
(5) Connect the (−) of the analog voltmeter to N1 terminal of traveling AC driver 1 (or 2).
(6) Connect the (+) probe of the voltmeter to P7 (or P71).
(7) Connect the battery plug.
(8) Turn the key switch to ON. Release the parking brake.
(9) Shift the direction switch to the forward (or backward) position.
(10) Depress the accelerator pedal fully and record the voltmeter reading at the time. (Without applying
the brake)
(11) Repeat steps (6) through (10) also for P8 (P81) and P9 (P91).
(12) Repeat steps (5) through (11) also for traveling AC driver2.
(13) Compare voltages measured between N1 and each of P7, P8, P9, P71, P81 and P91 and check
that the difference between the measured voltages meets the standard shown below.
Difference of input voltage at P7, P8, P9, P71, P81, and P91
Standard: 2V or less
B+
CN110
P3 P7 P8 P9 N1
B+
CN109
P3 P71 P81 P91 N1

2-31
Pump Motor Input Voltage Measurement

Measuring method Procedure
(2) Open the battery hood
(3) Remove the side cover and rear side cover.
(4) Connect the (−) probe of an analog voltmeter to the N2 terminal.
(5) Connect the (+) probe of the voltmeter to P14.
(7) Turn the key switch to ON.
(8) Operate the tilt lever to the backward position and record the voltmeter reading in the relief state.
(9) Repeat steps (5) through (8) also for P15 and P16.
(10) Compare voltages measured between N2 and each of P14, P15 and P16 and check that the
difference between the measured voltages meets the standard shown below.
Difference of input voltage at P14, P15 and P16
Standard: 2V or less
Material handling
AC driver
N2 P16 P15 P14 P3
CN111
B+
2-32
REASSEMBLY
Contactor Panel ASSY Reassembly Drawing
T=N·m(kgf·cm)[ft·lbf]
T=11 15
(112 153)
[8.1 11.1]
T=7.8 11.8
(80 120)
[5.79 8.68]
T=7.8 11.8
(80 120)
T=2.3 3.0 [5.79 8.68]
(20 30)
[1.45 2.17]
T=7.8 11.8
(80 120)
T=7.8 11.8 [5.79 8.68]
(80 120)
[5.79 8.68]
T=11 15
T=2.9 3.9 (112 153)
(30 400) [8.1 11.1]
[2.17 2.9]
Caution:
Insulation sheet Be sure to install insulating sheets without fail.
• Failure to install the insulating sheet under the MB
MB contactor will cause a critical failure.
• Check the insulation resistance between the bracket and
each P terminal after controller reassembly.
Standard: 3 MΩ or more
2-33
DISPLAY
If the cause of trouble is judged to exist in the display, measure the voltage at the connector to which
voltage is applied.
CN70
(+) CN70
14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
(-)
1
CN70 connector basic condition (Battery plug connected)
Connector No. ⇔ Connector No. Conditions Standard: Remarks
CN70-14 CN70-30
Approx. 10 to 18V
(16, D15V) (14, GNDD)
2-34
DIRECTION SWITCH
Removal Procedure
2. Remove the steering wheel. [Point 1]
3. Remove the instrument panel.
4. Remove the direction cover (rear and front)
5. Remove the column cover (rear).
6. Disconnect the wiring of the direction switch, lamp switch and key switch.
7. Remove the direction switch.
2-35
Point Operations
[POINT 1]
SST Disassembly:
Use the SST to remove the steering wheel.
SST 09950-76003-71
(09950-50012)
2-36
DISASSEMBLY • INSPECTION • REASSEMBLY
1
5
3
2
1. Remove the cam.
2. Remove the horn contact.
3. Remove the steering angle sensor.
4. Remove the light control valve ASSY.
5. Remove the direction switch ASSY.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-37
ADJUSTMENT
1. Check the ON/OFF condition of the switch (SWAC) by
operating accelerator pedal.
Set screw Measurement terminals 51 − 64
Pedal not oper-
∞Ω
Standard: ated
Pedal operated Continuity
2. Adjustment of Accelerator Potentiometer Installation

(1) Apply Three Bond 1401B to the threaded portion of a
set screw and assembly accelerator ASSY.
(2) Temporarily install the potentiometer.
(3) Check the ON/OFF switching point of the accelerator
switch (SW AC).
When thickness gauge 1.0mm (0.039in) is inserted:
OFF
When thickness gauge 2.0mm (0.079in) is inserted:
ON
(4) After adjusting the switch ON/OFF operation, apply

yellow paint to the head of a set screw.
Set screw CN26 ACCEL
4 3 2 1 1 2 3 4
TAB REC
NO P C J NO P C J
1 51 - E2 1 51 R-W J3
2 64 - IDL 2 64 R CN132-12
3 52 - VTA 3 52 GR CN132-13
4 53 - VC 4 53 R-G CN132-14
2-38
BRAKE SWITCH ADJUSTMENT

For regenerative braking FOOT BRAKE
1. Adjust brake pedal play.
Standard 5 to 9mm (0.20 to 0.35in)
2. Adjust brake rod length.
(See page 9-15)
3. Check continuity of the limit switch for the stop light
when the brake pedal is operated.
For stop lamp
Standard: Not operated: OFF (∞ Ω)

Operated: ON (0Ω)
5~9mm 4. Check that the limit switch for the regenerative brake
(0.20~0.35in)
turns ON (OFF) when the brake pedal is depressed
further (5 to 6mm [0.2 to 0.24in]) from the position
without any play.
Standard: Not operated: ON (0Ω)
5~6mm Operated: OFF (∞ Ω)
(0.20~0.24in)
For regenerative
5. If the standard is not met, adjust by bending each limit
For stop lamp switch bracket.
braking
Limit switch
bracket
PARKING BRAKE
Set screws 1. Check the ON/OFF operation of the parking brake limit
switch.
Standard: Lever returned to original position:
ON (0Ω)
Lever pulled: OFF (∞ Ω)
2. If the standard is not met, adjust the limit switch
installation location.
CN15
LSPB
2-39
MATERIAL HANDLING LEVER SWITCH

CN11(for lift) ADJUSTMENT
1. Operate the material handling lever and check continuity
of the limit switch.
Standard: Lift: CN11-1 CN11-2
Not operated: OFF (∞ Ω)
Operated: ON (0 Ω)
CN87 2. Operate the material handling lever and check that the
limit switch is turned on at dimension A beyond the no-
play position.
A = 5 to 15mm (0.39 to 0.79in)
Lever 3. If the limit switch ON timing does not occur within

looseness dimension A, adjust the limit switch installation location.
A As for the tilt lever operation, adjustment is not necessary, as
A the micro switch is built in the control valve ASSY.
3-1
MULTI-DISPLAY FUNCTIONS
Page
MULTIPLE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
0
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 1
GENERAL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 2
DISPLAY INDICATION LIST. . . . . . . . . . . . . . . . . . . . . . 3-8
3
ABBREVIATIONS DISPLAYED ON THE SCREEN . . . . 3-9
4
GENERAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . 3-10
OPERATING PROCEDURE OF FUNCTION SETTING . 3-11 5
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 6
DIAGNOSIS CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . 3-15
7
MASK FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
8
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
PASSWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 9
OPERATION ON MASK MENU SCREEN . . . . . . . . . . . 3-25 10
ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
11
TUNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
12
OPTION SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
MATCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 13
TIRE CONSTANT SET . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 14
FLÖDESSCHEMA, PROGRAMMERING . . . . . . . . . . . . . . . . . . . 3-65
15
16
17
18
3-2
MULTIPLE DISPLAY
GENERAL
The multiple display indicates various types of vehicle information by switching the screen according to
need.
Display and Buttons
Initial screen upon key switch on
TOYOT A
SAS EQU I P P ED
S P H
S P H
MENU
(1) (2) (3) (4) (8) (9)
3 0 / 9 AM
11: 00
S P H
S P H
MENU
(5) (7) (6) (10)
During traveling Upon error occurrence
10Km / h 1 1 : 0 0 A1 1 A1 2 A1 3
1 2 3 4 5 . Oh
S P H S P H
S P H S P H
MENU MENU
(1) Parking brake ON indicator (6) Power select indicator

(2) 2-speed travel speed set indicator (7) Multiple display area
(3) Diagnosis ON indicator (8) 2-speed travel speed control
(4) Overheat warning indicator (9) Hour meter selector button
(5) Battery charge indicator (10) Power select button
3-3
(1) Parking brake ON indicator

This indicator comes on when the parking brake is activated. If the accelerator pedal is depressed with
the direction lever in the forward or reverse position, beeps sound to warn the operator.
(2) 2-speed travel speed set indicator
Each time the button is pressed, the indicator comes on or goes out. When this indicator is on, 2-speed
travel speed is on to limit the maximum vehicle speed to the set level.
(3) Diagnosis ON indicator
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same
time, the corresponding error code is displayed and buzzer sounds to warn the operator. 0
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to
six error codes are displayed with alternation at intervals of 2 seconds.
On a SAS model vehicle without matching performed for the SAS function, this indicator comes on to
1
warn the service person. Perform matching by referring to the MATCHING section.
(4) Overheat warning indicator 2
If the temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or
pump motor rises beyond the specified level, the overheat warning indicator blinks. At the same time, 3
a buzzer sounds to warn the operator.
When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks. 4
Description
Overheat warning indicator
Indication Overheat section 5
C/R Main controller
6
DCR Traveling AC driver
3 0 / 9 AM
11 : 00
S P H
S P H
MENU
PCR Material handling AC driver 7
DM Drive motor
8
Overheat section PM Pump motor
9
Vehicle Operation Restriction when Overheated
Overheat Description of control 10

Specification Mode
section Primary control Secondary control Tertiary control
11
H
STD · 1. Character indication and indicator blink
Main
controller
Fisherman P 2. Buzzer for 5 seconds 12
spec (OPT) 3. Change to half throttle
S
13
H
STD · 1. Character indication and indicator blink
Traveling
AC driver
Fisherman P 2. Buzzer for 5 seconds 14
spec (OPT) 3. Change to half throttle
S
H
15
Material STD · 1. Character indication and indicator blink
handling Fisherman P 2. Buzzer for 5 seconds 16
AC driver spec (OPT) 3. Restrict material handling output
S
17
18
3-4
Overheat Description of control

Specification Mode
section Primary control Secondary control Tertiary control
1. Character indication 1. Character indication
and indicator blink and indicator blink
H 2. Buzzer for 5 2. Buzzer continues
seconds 3. Change to half
3. Change to S mode throttle
STD
P 1. Character indication
and indicator blink
2. Buzzer continues
3. Change to half
S throttle
Drive motor
1. Character indication
and indicator blink
2. No buzzer
3. Restrict drive output
3. Change to S mode throttle
Fisherman
spec (OPT) 1. Character indication 1. Character indication
P
2. Buzzer for 5 2. Buzzer continues
S 3. Restrict drive output throttle
H
1. Character indication and indicator blink
STD P 2. Buzzer continues
3. Restrict material handling output
S
and indicator blink
2. No buzzer
seconds 3. Restrict material
3. Change to S mode
3. Change to P mode handling output
Pump motor 1. Character indication 1. Character indication
Fisherman
P 2. Buzzer for 5 2. Buzzer continues
spec (OPT)
seconds 3. Restrict material
3. Change to S mode handling output
and indicator blink
S 2. Buzzer continues
3. Restrict material
handling output
3-5
(5) Battery charge indicator

This indicator indicates the remaining battery charge in 10 stages.
A: Low remaining battery charge warning
Low remaining battery charge warning
The battery charge indicator blinks when the remaining
battery charge drops to the set level or below. When the
key switch is turned from OFF to ON in this state, a
3 0 / 9 AM
11 : 00 buzzer sounds for 5 seconds to warn the operator.
S P H
B: Battery overdischarge warning (lift interrupt function)
0
S P H
MENU
When the battery charge decreases further below the

set level after the remaining battery charge warning, any
Number of segments corresponding to attempt at traveling or material handling operation will 1
the remaining battery charge. cause all charge indicator segments to blink and the
alarm to sound to warn the operator. In this case, 2
Battery overdischarge warning material handling during traveling cannot be performed.
Note: 3
The level can be set using TUNING function of the mask
function. (See page 3-46.)
11 : 00 4
3 0 / 9 AM
S P H
S P H
MENU
5
All segments blink.
6
(6) Power select indicator (traveling and material handling)
A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by
pressing the power select button on the GENERAL screen.
7
If all symbols are enclosed, control is performed in the original mode (level set on the POWER
CONTROL LEVEL SETTING screen). 8
(7) Multiple display area
The date and time are normally displayed in this area. This area is also used for various function 9
settings and error code displays of the diagnosis function.
(8) 2-speed travel speed control
Press this button on the GENERAL screen to set the 2-speed travel speed on and off.
10
(9) Hour meter selector button
This button changes displayed items of multi-hour meter function. The built-in function is different on 11
the easy model (standard vehicle) and the all-round model (OPT). (See page 3-7.)
(10) Power select button 12
The button selects S, P or H mode. The selected mode can be changed each time the power select
button is pressed on the GENERAL screen. 13
Press the button and hold it for 2 seconds to set the level of each function.
14
15
16
17
18
3-6
(11) Low temperature warning indicator

Warn the low temperature of the traveling and material handling AC drivers. When the material
handling AC driver temperature becomes low, a buzzer sounds to warn the operator for 5 seconds. At
the same time, it restricts the material handling output.
The low temperature section indication blinks.
Description
Indication Low temperature section
COLD DCR Traveling AC driver
COL D
DCR
AM
11 : 00 COLD PCR Material handling AC driver
S P H
S P H
MENU
Low temperature section
(12) Wheel indicator

The turning direction is displayed by “|” on the multiple display area.
Note:
• Display setting can be set by option setting of mask
3 0 / 9 AM 1 1 : 0 0
function.
〈〈 〈〈 〈〈 | 〉〉 〉〉 〉〉
S P H
• Speedometer can not be displayed when wheel
S P H
MENU
indicator is set to be displayed.
Wheel indicator
In straight traveling state

3 0 / 9 AM 1 1 : 0 0
〈〈 〈〈 〈〈 | 〉〉 〉〉 〉〉
During left turn

3 0 / 9 AM 1 1 : 0 0
〈〈 〈〈 | 〈〈 〉〉 〉〉 〉〉
During right turn

3 0 / 9 AM 1 1 : 0 0
〈〈 〈〈 〈〈 〉〉 | 〉〉 〉〉
SPECIFICATIONS
LCD Dot matrix + fixed display
Buttons Three buttons
Back light LED type that comes on when the key switch is turned to ON
Heater Temperature detection type (provided only on the cold-storage model)
3-7
GENERAL FUNCTION
1. General function can generally been used or seen by the user.
2. Two types of multiple displays are available: the easy model (the standard specification), and the all-
round model (OPT). The display contents vary as follows:
{:Provided :Not provided
Model Easy model All-round model
Function (Standard) (option)
Battery charge indicator { {
Speedometer { {
Status display 2-speed travel speed set indicator { {

function Parking brake ON indicator { {
Power select indicator { {
Wheel indicator  {
Power select { {
Level setting Traveling power control level setting { {

function Material handling power control level setting { {
2-speed travel speed level setting { {
Key ON hour meter { {
Traveling hour meter  {
Material handling hour meter  {
Multi-hour meter Traveling or Material handling hour meter  {

function Odometer  {
Lap time meter  {
Trip meter  {
Calendar · clock { {
Battery overdischarge warning { {
Low remaining battery charge warning { {
Overheat warning { {
Low temperature warning { {
Parking brake ON warning { {
Warning function
Parking brake OFF warning { {
Return to neutral warning { {
Material handling operation lock {*1 {*1
Overspeed alarm  {
Diagnosis display { {
*1: Provided on the vehicle with mini lever (OPT).
3-8
DISPLAY INDICATION LIST
GENERAL screen
Enter password
Press button (3) for 2 sec. or more

To be selected by the user
2-speed travel speed ON/OFF ON or OFF setting of 2-speed travel speed
Switching to hour meter display Checking traveling or material handling system operation time
Power select Power mode selection
To be set by the user
Traveling speed level Setting of 2-speed travel speed level
Speed alarm Traveling speed setting for overspeed alarm
Fine adjustment of each of traveling and material handling power
Power control select
control levels
Clock set Adjustment of indicated time
MASK FUNCTION screen

To be set by dealer or serviceman
DIAG MEMORY Checking past diagnosis error codes stored in memory
I/O MONITOR1 Checking the temperature and voltage of each functional part
I/O MONITOR2 Checking traveling-related sensors
ANALYZER
I/O MONITOR3 Checking material handling and mast control sensors
I/O MONITOR4 Checking steering knob synchronizer and other sensors
ACTIVE TEST Forced ON/OFF test of each switch
TUNING1 Standard function adjustment
TUNING2 LIFTV Lift lever adjustment
TUNING TUNING3 TILTV Tilt lever adjustment
TUNING4 ATT1V ATT 1 lever adjustment
TUNING5 ATT2V ATT 2 lever adjustment
DEMO MODE Enabling simultaneous traveling and material handling before H/M start
H/M START Starting the hour meter count
P/C LOCK Power control lock selection
DESTI Changing display for each destination
B LEVEL
MPH Setting the traveling speed display
C/CNT RES
BATTERY Setting the calculation constant for battery charge indicator
SHOU-TOKU
SEAT P-OFF Setting the operation of the Auto-OFF function in relation to the seat switch
PARKING ERR Setting the parking brake OFF warning
OPTION SET
TILT CONT Setting the mast forward tilt angle restriction
KNOB CONT
TILT F-LIM Setting the mast forward tilt/level function
B-TYPE Setting the battery type
36V
2-WAY VALVE Setting the specification of 2-way mini lever models
4-WAY VALVE Setting the specification of 4-way mini lever models
USA
WHEEL IND Setting the wheel indicator indication
SAS Setting the SAS function
FISHERMAN
TILTL Matching of the tilt/level angle
TILTF Matching of the tilt forward restricted angle
LOAD Matching of the NL load
TIRE Matching of the tire angle sensor forward direction
MATCHING
LIFT Matching of the lift lever neutral position
TILT Matching of the tilt lever neutral position
ATT1 Matching of the ATT1 lever neutral position
ATT2 Matching of the ATT2 lever neutral position
WHEEL DIA WHEEL DIA Setting the tire constant
3-9
ABBREVIATIONS DISPLAYED ON THE SCREEN

Abbreviation Meaning Abbreviation Meaning
A1 Attachment switch 1 SSD2 Drive motor 2 rpm sensor
A2 Attachment switch 2 SSP Pump motor rpm sensor
C/R Controller STS Steering angle sensor
DCR Traveling AC driver STS1 Steering angle sensor 1
DM Drive motor STS2 Steering angle sensor 2
Steering angle sensor for straight
DSF Forward direction switch STSC
traveling
DSR Backward direction switch SWAC Accelerator switch
FAN Cooling fan SWTK Tilt knob switch
H/M Hour meter T Forward and backward tilt switch
Deviation of steering angle knob posi- Traveling AC driver control board
K-DIFF TBD
tion surface temperature
Material handling AC driver control
K-POS Steering angle knob position TBP
board surface temperature
KSOL Steering synchronizer solenoid TD Drive motor temperature
LOAD Material handling hydraulic pressure TEMP CPU board surface temperature
L Lift switch THCD Main drive circuit temperature
LSB Brake switch THCP Main pump circuit temperature
LSD Seat switch TILTF Forward tilt restriction position
MH Lifting height switch TILTL Tilt level position
P/C Power control TIRE Tire angle sensor voltage
PCR Material handling AC driver TP Pump motor temperature
PM Pump motor VB48 Battery voltage
Traveling AC driver power source
POTA Accelerator potentiometer VBBD
voltage
Material handling AC driver power
POTT Tilt angle potentiometer VBBP
source voltage
SPD Main traveling speed VBKS Voltage after key switch
SPL Load sensor VBMB Main controller input voltage
SSD1 Drive motor 1 rpm sensor VBSOL Solenoid power source voltage
3-10
GENERAL FUNCTIONS
Changing Display
Button (1) Button (2)
ï 2-speed travel speed

ON/OFF setting
GENERAL screen
3 0 / 9 AM
11 : 00 ï Hour meter display
S P H
S P H selection
MENU
ï Power control selection
Button (3)
Press button (3)
for 2 seconds or more.
2-SPEED TRAVEL SPEED S P E E D 1 5 8

L E V E L
LEVEL SETTING screen S P H
S P H
MENU
Press button (3)
* This screen is displayed

only on the all-round model.
OVERSPEED ALARM The easy model does not
S P E E D
A L A RM 10Km / h
SETTING screen (OPT) S P H
S P H have this screen.
MENU
Press button (3)
POWER CONTROL
P O WE R S E L E CT
FUNCTION SELECTION Y E S / NO
screen S P H
S P H
MENU
Press button (3)
CLOCK SET FUNCTION CL OCK S E T

YES / NO
SELECTION screen S P H
S P H
MENU Press button (3)

(To GENERAL screen)
*1: OVERSPEED ALARM SETTING screen is displayed only on the all-round model (OPT).
This screen is skipped on the easy model (standard).
*2: Upon returning to the GENERAL screen after moving to each function setting screen, the power select
mode is set to “S”. If necessary, select the desired mode.
If necessary, select the desired mode.
3-11
OPERATING PROCEDURE OF FUNCTION SETTING

GENERAL SCREEN
1. 2-speed travel speed on/off selection
2-speed travel speed indicator Press button (1) for 2-speed travel speed control on/off.
Button (1) The 2-speed travel speed is on if the indicator comes on.
3 0 / 9 AM
11 : 00
S P H
S P H
MENU
2. Hour meter display selection

Press button (2) to select the hour-meter display.
The differences between the displayed contents of the easy model (standard setting) and the all-round
model (optional setting) are as follows:
Easy model (standard)

Button (2)
GENERAL screen G:Trip meter
:
3 0 / 9 AM
11 : 00 T R I P
RE S E T
1 2 3 4 5. 0 k m
SW 2 S E C
S P H S P H
S P H S P H
MENU Press MENU
button (2)
Button (3)
Press button (3)
Press button (2) Press button (2)
(Easy model)
A:Key ON hour meter F:Lap time meter
K E Y ON :
0 . 0 h L A P : 1 2 3 4 5. 0 h
SW 2
S P H
S P H S P H
S P H
MENU
MENU
Press button (2)

Press button (2)
(All-round model)
B:Traveling hour meter D:Traveling or material handling hour meter
C:Material handling hour meter E:Odometer
: 0 . 0 h : 0 . 0 h
: 0 . 0 h ODO : 0 . 0k m
S P H S P H
S P H S P H
MENU
Press MENU
button (2)
ï The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.
ï Press button (3) on each screen to return to the GENERAL screen.
3-12
Model Easy All-round

Description
Function model model
A Key ON hour meter { { Indicates the total key ON time

B Traveling hour meter  { Traveling operation time
C Material handling hour meter  { Material handling operation time
Total time of traveling and material handling
Traveling/material handling operation (when both operations occur at the
D  {
hour meter same time, only operation time of either
operation)
E Odometer  { Total distance traveled
F Lap time meter  { Lap time upon key ON
G Trip meter  { Trip distance
3. Power select mode switching (S, P or H)

Press button (3) on the GENERAL screen to change the
travel/material handling power select mode. When all of
S, P and H are highlighted by squares, the control is
3 0 / 9 AM
11 : 00
S P H
S P H performed in the mode set on the Power Control Level
MENU SETTING screen.
S: Standard mode
P: Power mode
Button (3) H: High power mode
Power select indicator
2-SPEED TRAVEL SPEED LEVEL SETTING

Blinks upon 2-speed travel Button (1) SCREEN
speed level setting. Button (2) The 2-speed travel speed level is set on this screen.
Press button (3) on the general screen for 2 seconds or more
to display the 2-SPEED TRAVEL SPEED LEVEL SETTING
1 5 8 screen.
S P H
S P H 1. Press button (1) to decrease the 2-speed travel speed
MENU
level.
2. Press button (2) to increase the 2-speed travel speed
2-speed travel speed level Button (3) level.
3. Press button (3) to display the next screen.
OVERSPEED ALARM SETTING SCREEN (OPT)

The traveling speed level for the overspeed alarm is set on
this screen.
Press button (3) on the 2-SPEED TRAVEL SPEED LEVEL
10Km / h SETTING screen to display the OVERSPEED ALARM
S P H
S P H SETTING screen.
MENU
1. Press button (1) to decrease the traveling speed setting.
2. Press button (2) to increase the traveling speed setting.
Button (3) 3. Press button (3) to display the next screen.v
Traveling speed setting
for overspeed alarm
3-13
POWER CONTROL FUNCTION SELECTION

SCREEN
The travel and material handling power control levels can be
set independently using this screen.
P OWE R S E L E C T
Y E S / NO 1. Press button (1) on the POWER CONTROL FUNCTION
S P H
S P H
MENU
SELECTION screen, select “YES” and press button (3)
to display the TRAVEL POWER CONTROL LEVEL
SETTING screen.
Button (3) (1) TRAVELING POWER CONTROL LEVEL SETTING
Select "YES" and screen
press button (3) 1) Press button (1) to select the lower level.
TRAVELING POWER CONTROL 2) Press button (2) to select the higher level.
LEVEL SETTING screen 3) Press button (3) to display MATERIAL HANDLING
POWER CONTROL LEVEL SETTING screen.
(2) MATERIAL HANDLING POWER CONTROL LEVEL
S P H
SETTING screen
S P H
S P H
1) Press button (1) to select the lower level.
2) Press button (1) to select the higher level.
MENU
3) Press button (3) to display the next screen.

Press button (3) 2. To display the next screen, press button (2) on the
POWER CONTROL FUNCTION SELECTION screen,
MATERIAL HANDLING POWER
CONTROL LEVEL SETTING screen select “NO” and press button (3); alternatively, press
button (3) on the MATERIAL HANDLING POWER
CONTROL LEVEL SETTING screen.
S PH
S P H
S P H
MENU
Press button (3)

CLOCK SET FUNCTION
SELECTION screen
3-14
CLOCK SET FUNCTION SELECTION SCREEN

The year, month, day, day of week, time and 12/24-hour display can be set independently.
Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select “NO”, and press
button (3), or press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING
screen to display the CLOCK SET FUNCTION SELECTION screen.
P OWE R S E L EC T
Y E S / NO
Button (3)
Select "NO" and press button (3) Press button (3)
C L OCK S E T C L OCK S E T
Y E S / NO Y E S / NO
Each press of button (3) will shift

the selection item in this order:
month, day, ... and minute. End of clock setting
Press button (3)
1. Press button (1) on the CLOCK SET FUNCTION SELECTION screen, select “YES” and press button
(3) to display the CLOCK SET screen.
(1) CLOCK SET screen
1) Press button (1) to decrease the selected (blinking) value.
2) Press button (2) to increase the selected (blinking) value.
3) Press button (3) to enter the selected (blinking) value and proceed to the next item.
4) Press button (3) when “MINUTES” is selected on the CLOCK SET FUNCTION SELECTION
screen to display the next screen (GENERAL screen).
(2) Press button (3) when “NO” is selected on the CLOCK SET FUNCTION SELECTION screen to
display the next screen (GENERAL screen).
3-15
DIAGNOSIS
Wrench symbol 1. When diagnosis is activated, the diagnosis ON indicator
comes on and blinks on the screen and a beep sounds
to warn the operator that some abnormality has
occurred on the vehicle.
A1 1 A1 2 A1 3
1 2 3 4 5 . Oh 2. Also, up to three diagnosis error codes are displayed on
the screen. When the number of error codes exceeds
S P H
S P H
MENU
three, up to six are displayed on screens.

3. In order to enable battery level checking, battery charge
Diagnosis codes
Abnormality detection time
indicator is displayed during diagnosis error codes
(Key ON hour meter) display.
DIAGNOSIS CODE LIST

Displayed code: Code indicated on the display when an abnormality occurs in the vehicle
Diag memory code: Code indicated on the display when mask function DIAG MEMORY is in use P3-31
C/R: Main controller, DCR_LH: Traveling AC driver 1, DCR_RH: Traveling AC driver 2,
PCR: Material handling AC driver
Diag
Displayed Detection
memory Faulty Phenomenon on vehicle
code controller
code
DCR_LH,
 DCR: Low temperature Display only
DCR_RH
Restricted material
 PCR: Low temperature PCR
handling output
30-1 30-1 DCR_LH: Low voltage DCR_LH
Traveling disabled
30-2 30-2 DCR_RH: Low voltage DCR_RH
Material handling and
30-3 30-3 PCR: Low voltage PCR
power steering stop
31-1 31-1 DCR_LH: Low starting voltage DCR_LH
Traveling disabled
31-2 31-2 DCR_RH: Low starting voltage DCR_RH
31-3 31-3 PCR: Low starting voltage PCR
power steering stop
32-1 32-1 DCR_LH: EEPROM abnormality DCR_LH
32-2 32-2 DCR_RH: EEPROM abnormality Operate under the default DCR_RH
32-3 32-3 PCR: EEPROM abnormality PCR
Communication abnormality from C/R to
33-1 33-1 DCR_LH
DCR_LH
Traveling disabled
33-2 33-2 DCR_RH
DCR_RH
Communication abnormality from C/R to Material handling and
33-3 33-3 PCR
PCR power steering stop
61-1 61-1 Load sensor: Open ·No NL control and forward
tilt restriction C/R
61-2 61-2 Load sensor: Short circuit ·No automatic leveling
3-16
Diag
Displayed Detection
code controller
code
62-1 62-1 Tilt angle sensor: Open ·No forward tilt restriction
C/R
62-2 62-2 Tilt angle sensor: Short circuit ·No automatic leveling
Forward and backward tilt SWs:
63-1 63-1
simultaneously on
·No forward tilt restriction
Forward tilt SW: Short circuit for more than
63-2 63-2 ·No automatic leveling C/R
2 minutes
(Forward tilt disabled)
Backward tilt SW: Short circuit for more
63-3 63-3
than 2 minutes
64-1 64-1 Lift solenoid: Open
Interruption of lift solenoid
64-2 64-2 Lift solenoid: Short circuit C/R
output
64-3 64-3 Lift solenoid: Drive circuit abnormality
65-1 65-1 Tilt solenoid: Open
Interruption of tilt solenoid
65-2 65-2 Tilt solenoid: Short circuit C/R
output
65-3 65-3 Tilt solenoid: Drive circuit abnormality
·No forward tilt restriction
66-1 66-1 Tilt matching abnormality C/R
·No automatic leveling
·No low lift restriction and
67-1 67-1 Lifting height switch abnormality forward tilt restriction C/R
·No automatic leveling
71-1 71-1 Tire angle sensor: Open Traveling stop, no steering
C/R
71-2 71-2 Tire angle sensor: Short circuit knob synchronizer
72-1 72-1 Steering angle sensor: STS1 abnormality
72-2 72-2 Steering angle sensor: STS2 abnormality No steering knob
C/R
72-3 72-3 Steering angle sensor: STSC abnormality synchronizer
72-4 72-4 Steering angle sensor: Open
73-1 73-1 Steering knob synchronizer solenoid: Open
Steering knob synchronizer solenoid: Short Steering knob
73-2 73-2
circuit synchronizer solenoid C/R
Steering knob synchronizer solenoid: output stop
73-3 73-3
Drive circuit abnormality
Traveling restriction,
74-1 74-1 Tire angle sensor matching abnormality C/R
no steering synchronizer
DCR_LH,
A0-1 DCR main drive circuit overheat Restricted traveling output
DCR_RH
Restricted material
A0-2 PCR main drive circuit overheat PCR
handling output
3-17
Diag
Displayed Detection
code controller
code
·Traveling disabled
·Material handling and
A1-1 A1-1 C/R: High voltage C/R
power steering disabled
(solenoid off)
A1-2 A1-2 DCR_LH: High voltage DCR_LH
Traveling disabled
A1-3 A1-3 DCR_RH: High voltage DCR_RH
A1-4 A1-4 PCR: High voltage PCR
A2-1 CPU board overheat Restricted traveling output C/R
DCR_LH,
A2-2 DCR_LH or DCR_RH board overheat Restricted traveling output
DCR_RH
Restricted material han-

A2-3 PCR board overheat PCR
dling output
A3 A3 Incorrect battery connection C/R
·MB not turned on
A4 A4 Accelerator switch abnormality Traveling disabled C/R
A6-1 A6-1 Lift switch abnormality
A6-3 A6-3 Tilt switch abnormality Material handling disabled C/R
A6-5 A6-5 Attachment switch 1 abnormality
AA-1 AA-1 CPU board thermo-sensor abnormality C/R
AA-2 AA-2 DCR_L board thermo-sensor abnormality Restricted traveling output DCR_LH
AA-3 AA-3 DCR_R board thermo-sensor abnormality DCR_RH
Restricted material han-
AA-4 AA-4 PCR board thermo-sensor abnormality PCR
dling output
AC AC Semiconductor switch abnormality C/R
·MB not turned on
Communication abnormality from DCR_L
AD-1 AD-1 Traveling disabled C/R
to C/R (1)
Traveling disabled
Communication abnormality from DCR_L (when AD-4 and AD-6
AD-2 AD-2 C/R
to C/R (2) occur at the same time,
MB not turned on)
Communication abnormality from DCR_R
AD-3 AD-3 Traveling disabled C/R
to C/R (1)
3-18
Diag
Displayed Detection
code controller
code
Traveling disabled
Communication abnormality from DCR_R (when AD-2 and AD-6
AD-4 AD-4 C/R
to C/R (2) occur at the same time,
MB not turned on)
Communication abnormality from PCR to Material handling and
AD-5 AD-5 C/R
C/R (1) power steering disabled
Communication abnormality from PCR to
AD-6 AD-6 (when AD-2 and AD-4 C/R
C/R (2)
occur at the same time,
MB not turned on)
AF-1 AF-1 CPU abnormality (1)
AF-2 AF-2 CPU abnormality (2) ·Traveling disabled
·Material handling disabled C/R
AF-3 AF-3 CPU abnormality (3) ·Power steering disabled
AF-4 AF-4 CPU abnormality (4)
C1-1 C1-1 DCR_LH current sensor offset abnormality
DCR_LH
C1-2 C1-2 DCR_LH: Overcurrent
Traveling disabled
C1-3 C1-3 DCR_RH current sensor offset abnormality
DCR_RH
C1-4 C1-4 DCR_RH: Overcurrent
DCR_LH
C2-1 Drive motor overheat
DCR_RH
Drive motor 1 thermo-sensor Restricted traveling output DCR_LH

C2-2 C2-2
abnormality
Drive motor 2 thermo-sensor
C2-3 C2-3 DCR_RH
abnormality
DCR_LH main drive circuit thermo-sensor
C3-1 C3-1 DCR_LH
abnormality
Restricted traveling output
DCR_RH main drive circuit thermo-sensor
C3-2 C3-2 DCR_RH
abnormality
C4-1 C4-1 Accelerator potentiometer abnormality (1)
C4-2 C4-2 Accelerator potentiometer abnormality (2) Traveling disabled
C/R
C4-3 C4-3 Accelerator potentiometer abnormality (3)
C4-4 C4-4 Accelerator potentiometer abnormality (4) Display only
C7 C7 Direction switch abnormality Traveling disabled C/R
C8-1 C8-1 Drive motor 1 rpm sensor abnormality DCR_LH
Restricted traveling output
C8-2 C8-2 Drive motor 2 rpm sensor abnormality DCR_RH
CB-1 CB-1 MB contactor abnormality C/R
(solenoid off)
3-19
Diag
Displayed Detection
code controller
code
CB-2 CB-2 MB contactor fused Display only C/R
E1-1 E1-1 PCR current sensor offset abnormality Material handling and
PCR
E1-2 E1-2 PCR: Overcurrent power steering disabled
E2-1 Pump motor overheat Restricted material

PCR
handling output
E2-2 E2-2 Pump motor thermo-sensor abnormality
PCR main drive circuit thermo-sensor Restricted material
E3 E3 PCR
abnormality handling output
E8 E8 Pump motor rpm sensor abnormality Material handling disabled PCR
Communication abnormality from display to
EE-1 EE-1
C/R (1)
Display only C/R
EE-2 EE-2
C/R (2)
EE-3 EE-3 Operate under the default C/R
C/R (3)
EF-1 EF-1 EEPROM abnormality (1) Operate under the default
C/R
EF-3 EF-3 CPU abnormality Display only
F1-1 F1-1
display (1)
Display only Display
F1-2 F1-2
display (2)
FF FF D15V overcurrent Display off C/R
H1-1 *1 H1-1 Lift potentiometer abnormality (1)
H1-2 *1 H1-2 Lift potentiometer abnormality (2)
H1-3 *1 H1-3 Lift potentiometer abnormality (3) Lift operation stop C/R
H1-4 *1 H1-4 Lift potentiometer neutral abnormality
H1-5 *1 H1-5 Lift potentiometer matching abnormality
H2-1 *1 H2-1 Tilt potentiometer abnormality (1)
H2-2 *1 H2-2 Tilt potentiometer abnormality (2)
H2-3 *1 H2-3 Tilt potentiometer abnormality (3) Tilt operation stop C/R
H2-4 *1 H2-4 Tilt potentiometer neutral abnormality
H2-5 *1 H2-5 Tilt potentiometer matching abnormality
3-20
Diag
Displayed Detection
code controller
code
Attachment 1 potentiometer abnormality
H3-1 *1 H3-1
(1)
H3-2 *1 H3-2
(2)
Attachment 1 potentiometer abnormality Attachment 1 operation
H3-3 *1 H3-3 C/R
(3) stop
Attachment 1 potentiometer neutral abnor-
H3-4 *1 H3-4
mality
Attachment 1 potentiometer matching
H3-5 *1 H3-5
abnormality
Attachment 2 potentiometer abnormality Attachment 2 operation
H4-1 *1 H4-1 C/R
(1) stop
H4-2 *1 H4-2
(2)
H4-3 *1 H4-3
(3) Attachment 2 operation
C/R
Attachment 2 potentiometer neutral stop
H4-4 *1 H4-4
abnormality
Attachment 2 potentiometer matching
H4-5 *1 H4-5
abnormality
H5-1 *1 H5-1 Lift b1 (UP) solenoid abnormality (1) Lift operation stop
H5-2 *1 H5-2 Lift b1 (UP) solenoid abnormality (2) Material handling disabled
H5-3 *1 H5-3 Lift a1 (DOWN) solenoid abnormality (1) Lift operation stop C/R
H5-4 *1 H5-4 Lift a1 (DOWN) solenoid abnormality (2) Material handling disabled
H5-5 *1 H5-5 Lift solenoid drive circuit abnormality Material handling disabled
H6-1 *1 H6-1 Tilt a2 (FRONT) solenoid abnormality (1) Tilt operation stop
H6-2 *1 H6-2 Tilt a2 (FRONT) solenoid abnormality (2) Material handling disabled
H6-3 *1 H6-3 Tilt b2 (REAR) solenoid abnormality (1) Tilt operation stop C/R
H6-4 *1 H6-4 Tilt b2 (REAR) solenoid abnormality (2) Material handling disabled
H6-5 *1 H6-5 Tilt solenoid drive circuit abnormality Material handling disabled
Attachment 1 operation
H7-1 *1 H7-1 Attachment 1 a3 solenoid abnormality (1)
stop
H7-2 *1 H7-2 Attachment 1 a3 solenoid abnormality (2) Material handling disabled
H7-3 *1 H7-3 Attachment 1 b3 solenoid abnormality (1) C/R
stop
H7-4 *1 H7-4 Attachment 1 b3 solenoid abnormality (2) Material handling disabled
Attachment 1 solenoid drive circuit
H7-5 *1 H7-5 Material handling disabled
abnormality
3-21
Diag
Displayed Detection
code controller
code
H8-1 *1 H8-1 Attachment 2 a4 solenoid abnormality (1)
stop
H8-2 *1 H8-2 Attachment 2 a4 solenoid abnormality (2) Material handling disabled
H8-3 *1 H8-3 Attachment 2 b4 solenoid abnormality (1) C/R
stop
H8-4 *1 H8-4 Attachment 2 b4 solenoid abnormality (2) Material handling disabled
Attachment 2 solenoid drive circuit
H8-5 *1 H8-5 Material handling disabled
abnormality
H9-1 *1 H9-1 Unload valve solenoid open
H9-2 *1 H9-2 Unload valve solenoid short
Material handling disabled C/R
Unload valve solenoid drive circuit
H9-3 *1 H9-3
abnormality
*1: Only on the vehicle with mini lever (OPT).
3-22
MASK FUNCTIONS
GENERAL
In addition to the functions described in the instruction manual for use by general users, the multiple
display provides the following mask functions for use by the service staff for vehicle maintenance and
specification setting.
The mask functions are protected by password to prevent damage of the data by unintentional operation
by users.
Mask Function List
When used
Function Description Board

vehicle
replace- Others
delivery
ment
Displays the vehicle's electrical
Upon vehicle
system operating status and reads
Analyzer   abnormality
the error information detected by
detection
controllers.
Makes fine adjustment of traveling { As requested
Tuning 
and material handling functions. *2 by customer
Specification Sets each vehicle option and other {
 
setting specifications. *1 *2 · *3
Each control
Enables or disables each control {
function enable/  
function. *2 · *3
disable
Option set
{
Hour meter start Starts the hour meter count. { 
*3
Enables or disables the demo Upon new
Demo mode mode. (Material handling prohibition   vehicle
during traveling for vehicle delivery) demonstration
Updates voltage values of sensor
{
Matching signals under the standard vehicle  
*2
condition.
Makes the speedometer reading {
Tire constant set  
appropriate. *2
*1: This matches the controller and screen control according to the installed options and control functions
equipped on the vehicle; note that this function does not enable or disable the option or control function
itself.
*2: Board ··· main controller
*3: Board ··· Multiple display control board
3-23
Preparation for the MASK MENU screen

Caution:
When going to the MASK MENU screen from the general
screen, always jack up the vehicle until the drive wheels
(front tires) leave the ground, and support the vehicle
with wooden blocks under the front frames.
Be sure to fully lower the fork.
1. Check that the battery plug is connected securely and
turn the key switch to ON.
2. Operate mask functions according to Password Input
Procedure. (See page 3-24.)
3-24
PASSWORD
Note on password input
1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button
may be damaged.
2. If a mistake is made part of the way through, turn the key switch to OFF and begin again. If the MASK
MENU screen does not appear after several attempts, the system may be faulty.
Password Input Procedure
3 0 / 9 AM
11 : 00
S P H
S P H
MENU
1. Press buttons (1) and (2) at the same time. MASK MENU screen
Button (1)
3 0 / 9 AM
11 : 00 D* . *
T L * . * TR* . *
C* .
P * .
S P H S P H
S P H S P H
MENU MENU
2. Within 10 seconds, press button (1) 5. The VERSION screen is displayed for
about 3 seconds.
Button (2)
3 0 / 9 AM
11 : 00 3 0 / 9 AM
11 : 00
S P H S P H
S P H S P H
MENU MENU
3. Within 10 seconds, press button (2) 4. Within 10 seconds, press buttons (2) and (3)
at the same time for more than 2 seconds.
Procedure Operation Vehicle operation

1 Press buttons (1) and (2) at the same time. A short beep sounds.
2 Press button (1). (in 10 seconds after pressing button (1) and (2)) A short beep sounds.
3 Press button (2). (in 10 seconds after pressing button (1)) A short beep sounds.
Press buttons (2) and (3) at the same time and hold for 2
4 seconds or more. (in 10 seconds after pressing button (2), End of A short beep sounds.
password input)
5 The version screen is displayed automatically.
After displaying the version screen for 3 seconds, the MASK MENU screen appears
6
automatically.
3-25
OPERATION ON MASK MENU SCREEN

VERSION screen
Button (1) Caution:
Button (2) Unlike the analyzer function selection on of previous
models, display of test screen does not prohibit the
vehicle's ordinary operation.
= ME NU=
1 . ANAL YZ ER 1. Input the password on the general screen (see page 3-24)
S P H
S P H
MENU
to display the MASK MENU screen.
2. Press button (1) or (2) to select the desired menu item,
and press button (3) (enter) to display the menu or
Button (3)
setting screen for each function.
Press button (1) or
(2) to switch screen. (1) ANALYZER screen
This screen displays the vehicle's electrical system
operating status and the error code detected by the
= ME NU= controller.
2 . T U N I NG
S P H
(2) TUNING screen
S P H
MENU Performs fine adjustment of traveling and material
handling control.
Press button (1) or (3) OPTION SET screen
(2) to switch screen. Matches the controller or display control according to
the set option or control.
(4) MATCHING screen
= ME NU=
This screen is for updating the sensor output voltage
3 . OP T I ON SE T
S P H
stored in the controller (output voltage values from the
S P H
MENU SAS function and mini lever function sensors in the
standard vehicle condition).
Press button (1) or (5) WHEEL DIA screen
(2) to switch screen. Updates the tire information in the controller to correct
the speed and trip meter display.
(6) END screen
= ME NU=
GENERAL screen can displayed from this screen.
4 . MA T C H I N G Press button (3) on this screen to display the
S P H
S P H
MENU
GENERAL screen.
As an alternative method, turn the key switch to OFF
Press button (1) or when any screen is displayed to display the general
(2) to switch screen. screen.
= ME NU=
5 . WH E E L D I A
S P H
S P H
MENU
Press button (1) or

(2) to switch screen.
= ME NU=
6 . END
S P H
S P H
MENU
Press button (3)

GENERAL screen
3-26
ANALYZER
GENERAL
1. The analyzer supports inspection and troubleshooting of the control system using the communication
function between the traveling/material handling controller and the display.
2. Setting the display into the ANALYZER screen makes it possible to inspect and detect abnormality in
functions of the operating system and sensors, such as main traveling, material handling, EHPS, SAS
circuits and the accelerator.
3. Utilization of the analyzer functions enables quick, easy servicing.
4. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes detected in the electrical system in the past. The
diagnosis memory function displays these error codes.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors in the traveling, material
handling, EHPS and SAS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(a) I/O MONITOR1
Displays the temperature of each electrical functional part and the analog input voltage
detected by each controller.
(b) I/O MONITOR2
Displays the ON/OFF states of traveling-related switches and the analog input voltages from
related sensors.
(c) I/O MONITOR3
Displays ON/OFF of switches related to traveling and mast control and the analog input
voltage values from related sensors.
(d) I/O MONITOR4
Displays the ON/OFF states of steering knob synchronizer-related and other switches and
the analog input voltage values from related sensors.
(3) Active test function (ACTIVE TEST)
The controller outputs an operation signal (ON or OFF signal) to the selected item in order to permit
operation check of that function.
(4) One error code at the time is displayed in the upper right-hand portion on both the I/O MONITOR
and ACTIVE TEST screens.
3-27
ANALYZER MENU SCREEN

* Values shown in the 2nd column are display examples and not the standard values.
ANALYZER MENU Display

Meaning
screen 1st column 2nd column
DIAG-1 to Error codes and
1. DIAG MEMORY Error display
DIAG-10 detection time
Main drive circuit 1 temperature (heat sink): °C
I/O 1-1 THCD:+25/+25
Main drive circuit 2 temperature (heat sink): °C
I/O 1-2 THCP:+25 Main pump circuit temperature (heat sink): °C
Drive motor 1 temperature: °C
I/O 1-3 TD:+25/+25
Drive motor 2 temperature: °C
I/O 1-4 TP:+25 Pump motor temperature: °C
Traveling AC driver 1 board temperature: °C
I/O 1-5 TBD:+25/+25
Traveling AC driver 2 board temperature: °C
2. I/O MONITOR1 Material handling AC driver board temperature:
I/O 1-6 TBP:+25
(voltage, °C
temperature)
I/O 1-7 TEMP:+25.0 CPU board temperature: °C
I/O 1-8 VB48:50.0 Battery voltage: V
I/O 1-9 VBKS:50.0 Key start voltage: V
I/O 1-10 VBSOL:50 Solenoid voltage: V
I/O 1-11 VBMB:50 Main battery input voltage: V
Traveling AC driver 1 DC_BUS voltage: V
I/O 1-12 VBBD:50/50
Traveling AC driver 2 DC_BUS voltage: V
I/O 1-13 VBBP:50 Material handling AC driver DC_BUS voltage: V
POTA:0.71 Accelerator potentiometer voltage: V
I/O 2-1
SWAC:0 Acceleration switch: 0 (OFF), 1 (ON)
DSF:0 Forward switch: 0 (OFF), 1 (ON)
I/O 2-2
DSR:0 Reverse switch: 0 (OFF), 1 (ON)
LSB:1 Brake switch: 0 (OFF), 1 (ON)
3. I/O MONITOR2 I/O 2-3
LSD:1 Seat switch: 0 (OFF), 1 (ON)
(traveling system)
SSD1:3000 Drove motor 1 rpm: rpm
I/O 2-4
[3000] [Main controller instruction rpm: rpm]
SSD2:3000 Drove motor 2 rpm: rpm
I/O 2-5
I/O 2-6 SPD:10.0 Main traveling speed: km/h
L:−.−− −.−− 1− Lift switch: 0 (OFF), 1 (ON)
4. I/O MONITOR3
(material handling Lift lever angle 1 sensor voltage: V
I/O 3-1 *1 Lift lever angle 2 sensor voltage: V
system and mast
control) L:0.90 3.50 10 Lift raise switch: 0 (OFF), 1 (ON)
Lift lower switch: 0 (OFF), 1 (ON)
3-28

Meaning
L (SOL):−.−− Unused
I/O 3-2 *1
Lift proportional valve current: A
L (SOL):0.35
Forward tilt switch: 0 (OFF), 1 (ON)
T:−.−− −.−− 10
Backward tilt switch: 0 (OFF), 1 (ON)
I/O 3-3 Tilt lever angle 1 sensor voltage: V

*1 Tilt lever angle 2 sensor voltage: V
T:0.90 3.50 10 Forward tilt switch: 0 (OFF), 1 (ON)
Backward tilt switch: 0 (OFF), 1 (ON)
T (SOL):−.−− Unused
I/O 3-4 *1
Tilt proportional valve current: A
T (SOL):0.35
A1: −.−− −.−− 1− Attachment 1 switch: 0 (OFF), 1 (ON)
Attachment 1 lever angle 1 sensor voltage: V
I/O 3-5 *2 Attachment 1 lever angle 2 sensor voltage: V
A1:0.90 3.50 01 Attachment 1 raise switch: 0 (OFF), 1 (ON)
4. I/O MONITOR3 Attachment 1 lower switch: 0 (OFF), 1 (ON)
(material handling
A1 (SOL):−.−− Unused
system and mast
control) I/O 3-6 *2
Attachment 1 proportional valve current: A
A1 (SOL):0.35
A2:−.−− −.−− −− Unused
Attachment 2 lever angle 1 sensor voltage: V
I/O 3-7 *3 Attachment 2 lever angle 2 sensor voltage: V
A2:0.90 3.50 01 Attachment 2 raise switch: 0 (OFF), 1 (ON)
Attachment 2 lower switch: 0 (OFF), 1 (ON)
A2 (SOL):−.−− Unused
I/O 3-8 *3
Attachment 2 proportional valve current: A
A2 (SOL):0.35
I/O 3-9 SWTK:0 Tilt knob switch: 0 (OFF), 1 (ON)
SSP:2000 Pump motor rpm: rpm
I/O 3-10
I/O 3-11 MH:10− Lifting height switch: 0 (OFF), 1 (ON)
I/O 3-12 POTT:2.50 Tilt angle sensor voltage: V
I/O 3-13 SPL:0.84 (1.7) Load sensor voltage: V (MPa display)
3-29

Meaning
I/O 4-1 STS:001 Steering angle sensor pulse: 0 (OFF), 1 (ON)
K-POS:159
I/O 4-2 Steering angle knob position: Actual (target)
(150)
5. I/O MONITOR4
(steering control) Deviation of steering angle knob position
K-DIFF:100
I/O 4-3 Steering knob synchronizer solenoid:
SOL:0
0 (OFF), 1 (ON)
I/O 4-4 TIRE:2.40 Tire angle sensor voltage: V
FAN: ON/OFF Fan output
ACT-1
(48) Fan voltage: V
Steering knob synchronizer solenoid output
KSOL: ON/OFF Steering knob synchronizer solenoid check
ACT-2
6. ACTIVE TEST (0) signal:
(operation test) 0 (normal), 1 (error)
PSOL:−−/−−− (−) Unused
ACT-3 *1
Unload valve output
PSOL:
Unload valve check signal: 0 (normal), 1 (error)
ON/OFF (0)
*1: Mini lever models (OPT)

*2: 3-way and 4-way mini lever models (OPT)
*3: 4-way mini lever models (OPT)
3-30
Operating Procedure
1. Input the password on the general screen (see page 3-24) to display the MASK MENU screen.
2. Check that “1. ANALYZER” is selected on the MASK MENU screen and press button (3) (enter) to
display the ANALYZER MENU screen.
3. Select the menu item using buttons (1) and (2) and then press button (3) (enter) to display the set
screen.
Button (1): To the previous menu item screen
Button (2): To the next menu item screen
Button (3): Enter (to the selected menu item screen)
If you select “7. END” on the MENU screen of the analyzer and press button (3), the MASK MENU screen
is displayed.

MASK MENU screen
= ME N U =
Press button (3)
1 . A NA L Y Z ER
S P H
S P H
MENU
7. END screen
Button (3) = AN L ME NU=

Press button (3) 7 . END
S P H
S P H
1. DIAG MEMORYscreen MENU
Press button (1) or

= AN L ME NU=
1 . D I AG ME MOR Y
S P H
S P H
6. ACTIVE TEST screen
MENU
Press button (1) or
Press button (1) or = AN L ME NU=

6 . A C T I V E T E S T
(2) to switch screen. S P H
S P H
2. I/O MONITORI screen MENU
Press button (1) or

= AN L ME NU=
2 . I / O MON I T OR 1 (2) to switch screen.
S P H
S P H
MENU
5. I/O MONITOR4 screen
Press button (1) or = AN L MENU =

5 . I / O MON I T OR 4
(2) to switch screen. S P H
S P H
3. I/O MONITOR2 screen MENU
Press button (1) or

= AN L ME NU=
3 . I / O MON I T OR 2 (2) to switch screen.
S P H
S P H
MENU
4. I/O MONITOR3 screen
= AN L ME NU=
S P H
Press button (1) or S P H
MENU

3-31
Diagnosis Memory Function (DIAG MEMORY)

The controller stores up to 10 of the most recent errors. The DIAG MEMORY screen displays these
diagnosis error codes together with their detection time (as key ON hour meter reading).
The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to
DIAG-10.
Operating Procedure
Button (1)
ANALYZER MENU screen Button (2) 1. Display the ANALYZER MENU screen.
2. Check that “1. DIAG MEMORY” is displayed and press
button (3) (enter). Past diagnosis codes are displayed
= AN L ME NU= sequentially starting with the newest one.
1 . D I AG ME MOR Y
S P H
3. Functions of buttons on the 1. DIAG MEMORY screen
S P H
MENU are as follows:
Button (1): Unused
Button (3) Button (2): Unused
Press button (3) Button (3): Displays past diagnosis codes
*:
• Press button (3) on the DIAG-10 screen to display the
D I AG 1 ANALYZER MENU screen.
A1 1 1 2 3 4 5 . 6 h
S P H
• When no error codes are displayed on the screen and the
S P H
MENU hour meter time is “0.0h”, it indicates that no error codes
are stored in the memory.
• Other screen cannot be displayed from DIAG MEMORY
Key ON hour meter
Press button (3)
screen. Display ANALYZER MENU screen to display other
screen.
*: For the details of diagnosis error codes, see DIAGNOSIS
D I AG 2
ERROR CODE LIST on page 3-15.
A1 2 1 2 3 4 5 . 6 h
S P H
S P H
MENU
Press button (3)
D I AG 3
0 . 0 h
S P H
S P H
MENU
No error occurrence
is indicated Press button (3)
D I AG 1 0
0 . 0 h
S P H
S P H
MENU
Press button (3)

ANALYZER MENU screen
3-32
Vehicle Abnormalities Not Stored in Diag Memory

Some abnormalities are not stored in diag memory even when the controller detects it and warn the
operator.
Warning indicators Warning method Displayed code
• Indication
Parking brake ON warning: Parking brake ON
Warns if the direction switch is turned to the warning indicator
1
forward or reverse position and the vehicle blinks
travels when the parking brake is on. • Beep
Short beeps
Parking brake OFF warning (OPT):
Warns if the operator vacates the seat without • Beep
2 No display
pulling the parking brake lever. Short beeps
(Warns even when the key switch is OFF)
Overdischarge warning (lift interrupt): • Indication
Warns if the battery discharge exceeds the level Battery charge indica-
3 set by the tuning function. (see page 3-46.) tor blinks
When the warning is activated, material handling • Beep
operation while traveling is disabled. Short beeps
Return to neutral warning:

Warns if the key switch is turned to ON when the • Beep
4 No display
direction switch is in the forward or reverse Short beeps
position.
Material handling lock (OPT):
When the operator leaves the seat while
• Beep
5 operating the mini lever and then sits down No display
Short beeps
again, a buzzer sounds to warn the operator and
the material handling operation will be disabled.
Incomplete matching warning:
(1) Tilt angle sensor at fork in the level position
(2) Tilt angle sensor at the forward tilt restriction
angle
(3) Pressure sensor at no-load state
(4) Tire angle sensor at straight travel position
(5) Lift lever angle sensor at lift lever neutral • Indication
6
position (OPT) Wrench symbol
(6) Tilt lever angle sensor at tilt lever neutral
position (OPT)
(7) Attachment 1 lever angle sensor at
attachment 1 lever neutral position (OPT)
(8) Attachment 2 lever angle sensor at
attachment 2 lever neutral position (OPT)
3-33
I/O MONITOR
This function displays the analog input voltage from each of
Activated Detected error code
at present traveling, material handling and SAS sensors.
function No
Monitoring the displayed values enables the quality of each
circuit/sensor to be judged.
When any abnormality is detected, it is displayed as an error

+ 2 5 / + 2 5
code on the screen.
S P H
S P H
MENU
Description of activated function
I/O MONITOR1
This function displays the temperature of each electrical functional part and the voltage at the respective
terminal.
Operating Procedure
Button (1)
1. Display the ANALYZER MENU screen.
ANALYZER MENU screen Button (2)
2. Press button (2).
3. Check that “2. I/O MONITOR1” is displayed and press
= AN L ME NU=
button (3) (enter). I/O monitor function (1) is activated
2 . I / O MON I T OR 1 and I/O 1-1 to I/O 1-13 are displayed sequential every
S P H
S P H
MENU
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR1 screen are
Button (3)
as follows:
Press button (3) Button (1): Unused
Button (2): Unused
(1) I/O 1-1 screen Button (3): Displays I/O 1-1 to I/O 1-13 screens
sequentially
*: Press button (3) on the I/O 1-13 screen to display the
I / O1
T HCD
1
+ 2 5 / + 2 5
ANALYZER MENU screen.
S P H
S P H Other screen cannot be displayed from I/O MONITOR1
screen.
MENU
Display ANALYZER MENU screen to display other screen.
Press button (3) (1) I/O 1-1 screen

THCD: Main drive circuit (1) (2) temperature (°C)
(2) I/O 1-2 screen Temperatures of the main drive circuit element (1) (2)
are displayed
• Checks if the temperature measurement function is
I / O1
T HCP
2
+ 2 5 functioning properly.
S P H
S P H
MENU
• The temperatures at the time of measurement are
displayed.
(2) I/O 1-2 screen
Press button (3) THCP: Main pump circuit temperature (°C)
Temperature of the main pump circuit element is
I/O 1-3 screen
displayed.
functioning properly.
displayed.
3-34
(3) I/O 1-3 screen

I/O 1-2 screen
TD: Drive motor (1) (2) temperature (°C)
Button (2) Temperatures of the drive motor (1) (2) is displayed.
(3) I/O 1-3 screen
Button (1) • Checks if the temperature measurement function is
I / O1 3
displayed.
T D + 2 5 / + 2 5
S P H
S P H
(4) I/O 1-4 screen
TP: Pump motor temperature (°C)
MENU
Temperature of the pump motor is displayed.

Button (3) • Checks if the temperature measurement function is
Press button (3)
(4) I/O 1-4 screen functioning properly.
displayed.
I / O 1 4
T P : + 2 5 (5) I/O 1-5 screen
S P H
S P H
MENU
TBD:
Traveling AC driver 1/2 board surface temperature (°C)
Surface temperatures of the traveling AC driver 1/2
Press button (3) board are displayed.
(5) I/O 1-5 screen • Checks if the temperature measurement function is
I / O1
T BD :
5
+ 2 5 / + 2 5
displayed.
S P H
S P H
MENU (6) I/O 1-6 screen
TBP:
Material handling AC driver board surface temperature
Press button (3) (°C)
(6) I/O 1-6 screen
Surface temperature of the material handling AC driver
board is displayed.
I / O1 6
T BP + 2 5 functioning properly.
S P H
S P H
MENU
displayed.
Press button (3)

(7) I/O 1-7 screen
(7) I/O 1-7 screen TEMP: CPU board temperature (°C)
The surface temperature of the main controller CPU
board is displayed.
I / O1 7 • Checks if the temperature measurement function is
T E MP + 2 5 . 0
S P H
S P H functioning properly.
MENU
displayed.
Press button (3) (8) I/O 1-8 screen
(8) I/O 1-8 screen VB48: Battery voltage (V)
The battery voltage is displayed.
Standard: 48 V
I / O1 8
VB4 8 5 0 . 0
S P H
S P H
MENU
Press button (3)

I/O 1-9 screen
3-35
(9) I/O 1-9 screen

I/O 1-8 screen VBKS: Key start voltage (V)
Button (2) Power source voltage of traveling and material handling
Button (1) AC drivers are displayed.
(9) I/O 1-9 screen
Standard: 48 V
(10) I/O 1-10 screen
I / O1
VBK S
9
5 0 . 0
VBSOL: Solenoid power source voltage (V)
S P H
S P H Solenoid power source voltage is displayed.
MENU
Standard: 48 V
Button (3) (11) I/O 1-11 screen

Press button (3) VBMB: Main battery voltage input (V)
(10) I/O 1-10 screen Main controller input voltage after the MB contactor is
displayed.
Standard: 48 V
I / O 1 1 0
V BSOL 5 0 (12) I/O 1-12 screen
S P H
S P H
MENU
VBBD: Main drive motor circuit (1) (2) voltage (V)
Voltages of the main drive motor circuit (1) (2) are
displayed.
Press button (3) Standard: 48 V
(11) I/O 1-11 screen (13) I/O 1-13 screen
VBBP: Main pump motor circuit voltage (V)
Voltage of the main pump motor circuit is displayed.
I / O 1 1 1
V BMB 5 0 Standard: 48 V
S P H
S P H
MENU
Press button (3)

I / O 1 1 2
V B BD 5 0 / 5 0
S P H
S P H
MENU
Press button (3)
I / O 1 1 3
V B BP 5 0
S P H
S P H
MENU
Press button (3)

3-36
I/O MONITOR2
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing
control.
Operating Procedure
Button (1)
1. Display the ANALYZER MENU screen.
ANALYZER MENU screen Button (2)
2. Press button (2) twice.
= AN L ME NU=
3 . I / O MON I TOR 2 and I/O 2-1 to I/O 2-6 are displayed sequential every
S P H
S P H
MENU
as follows:
Button (3) Button (1): Unused
(1) I/O 2-1 screen Button (3): Displays I/O 2-1 to I/O 2-6 screens
sequentially

P O T A 0 . 7 1 S WA C 0
S P H
S P H
MENU Other screen cannot be displayed from I/O MONITOR2
screen.
Display ANALYZER MENU screen to display other screen
Press button (3)
(1) I/O 2-1 screen
I/O 2-2 screen
• POTA: Accelerator potentiometer voltage (V)
A: When the accelerator pedal is released
(SWAC: OFF)
Standard: 0.3 to 2.4 V
B: Standard voltage when the accelerator pedal is
depressed to its stroke end
Standard: 1.7 to 4.7 V
B − A = 1.4 V or above
• SWAC: Accelerator switch
When the accelerator pedal is released
SWAC: 0 = OFF
Standard voltage when the accelerator pedal is
depressed to its stroke end
SWAC: 1 = ON
Operate the accelerator pedal to judge switch ON/OFF
quality.
3-37
(2) I/O 2-2 screen

I/O 2-1screen Direction switch inspection
DSF: Forward traveling switch,
Button (2) DSR: Reverse traveling switch
Button (1)
(2) I/O 2-2 screen Indication
DSF DSR
Operation

DSR 1
Forward traveling 1 (=ON) 0 (=OFF)
S P H
S P H
MENU
Neutral 0 (=OFF) 0 (=OFF)
Reverse traveling 0 (=OFF) 1 (=ON)
Button (3)
Operate the direction lever to judge switch ON/OFF
Press button (3)
quality.
(3) I/O 2-3 screen
(3) I/O 2-3 screen
• LSB: Brake switch inspection

When the brake pedal is released
L S B 1 L SD 1
S P H
LSB: 1 = ON
S P H
MENU
When the brake pedal is depressed
LSB: 0 = OFF
Operate the brake pedal to judge switch ON/OFF
quality.
Press button (3)
• LSD: Deadman seat check
(4) I/O 2-4 screen When the seat is occupied
LSD: 1 = ON
When the seat is not occupied

3 0 0 0 [ 3 0 0 0 ]
LSD: 0 = OFF
S P H
S P H Take or leave a seat to judge switch ON/OFF quality.
MENU
(4) I/O 2-4 screen

SSD1: Drive motor 1 rpm [target rpm]
Inspect the rpm sensor while the vehicle is traveling.
Press button (3)
The rpm of the drive motor increases according to the
(5) I/O 2-5 screen speed increase.
(5) I/O 2-5 screen
 SSD2: Drive motor 2 rpm [target rpm]
SS D2 3 0 0 0 [ 3 0 0 0 ]
S P H
Inspect the rpm sensor while the vehicle is traveling.
S P H
MENU The rpm of the drive motor increases according to the
speed increase.
(6) I/O 2-6 screen
Press button (3) SPD: Traveling speed (km/h)
(6) I/O 2-6 screen Check the traveling speed while the vehicle is jacked up.
Gradually depress the accelerator pedal. Check that the
traveling speed increase is almost at the same rate of
 the depression of the accelerator pedal to judge the
S P D 1 0 . 0
S P H
quality.
S P H
MENU
Press button (3)

3-38
I/O MONITOR3
This function displays the ON/OFF status of material handling and mast control switches and analog input
voltages from sensors.
Operating Procedure
Button (1)
2. Press button (2) three times.
= A N L ME NU=
S P H
and I/O 3-1 to I/O 3-13 are displayed sequential every
S P H
MENU time button (3) is pressed.
Button (3) as follows:
(1) I/O 3-1 screen
Button (2): Unused
Standard models Button (3): Displays I/O 3-1 to I/O 3-13 screens
sequentially

. 1 ANALYZER MENU screen.
S P H
S P H
Other screen cannot be displayed from I/O MONITOR3
MENU
screen.
Display ANALYZER MENU screen to display other screen
Mini lever models (OPT)
(1) I/O 3-1 screen
Standard models

1 . 0 0 3 . 0 0 1 0
L: Lift switch inspection
S P H
S P H When the lift lever is in the UP position
L: −.−− −.−− 1− = ON
MENU
When the lift lever is in the neutral or DOWN position

L: −.−− −.−− 0− = OFF
Press button (3) Operate the lift lever to judge ON/OFF quality.
(2) I/O 3-2 screen Mini lever models (OPT)
Standard models L: Lift lever angle 1 sensor voltage (V)
Lift lever angle 2 sensor voltage (V)
Lift raise switch (0=OFF, 1=ON)

. Lift lower switch (0=OFF, 1=ON)
S P H
S P H
Judge the raise and lower input quality by lift lever
MENU
operation.
Lift lever angle 1 Lift lever angle 2
sensor voltage sensor voltage
Raising 1.1 to 2.3 V 2.2 to 3.5 V

L ( SO L ) : 0 . 3 5 Lowering 0.4 to 1.6 V 2.9 to 4.2 V
S P H
S P H
MENU
(2) I/O 3-2 screen

Standard models
Press button (3) L (SOL): Unused
I/O 3-3 screen Mini lever models (OPT)
L (SOL): Lift proportional valve solenoid current (A)
Judge the output quality to lift proportional valve
solenoid by lift lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
3-39
(3) I/O 3-3 screen

I/O 3-2 screen
Standard models
Button (2) T: Forward and backward tilt switch inspection
(3) I/O 3-3 screen Button (1)
Standard models Forward Backward
Operation Display
tilt switch tilt switch
Forward tilt T: −.−− −.−− 10 1 (=ON) 0 (=OFF)

T : . . 1 0
S P H
Neutral T: −.−− −.−− 00 0 (=OFF) 0 (=OFF)
S P H
Backward tilt T: −.−− −.−− 01 0 (=OFF) 1 (=ON)

MENU
Operate the tilt lever to judge ON/OFF quality.

Mini lever models (OPT) Button (3)
T: Tilt lever angle 1 sensor voltage (V)

Tilt lever angle 2 sensor voltage (V)
T : 1 . 0 0 3 . 0 0 1 0
S P H
Forward tilt switch (0=OFF, 1=ON)
S P H
MENU Backward tilt switch (0=OFF, 1=ON)
Judge the forward and backward tilt input quality by lift
lever operation.
Press button (3) Tilt lever angle 1 Tilt lever angle 2
(4) I/O 3-4 screen
sensor voltage sensor voltage
Standard models
Forward tilt 1.1 to 2.3 V 2.2 to 3.5 V

Backward tilt 0.4 to 1.6 V 2.9 to 4.2 V
T ( SO L ) : .
S P H
(4) I/O 3-4 screen
S P H
MENU
Standard models
T (SOL): Unused
T (SOL): Tilt proportional valve solenoid current (A)
Judge the output quality to the tilt proportional valve

T ( SO L ) : 0 . 3 5 solenoid by tilt lever operation.
S P H
S P H
MENU
Standard: 0.3 to 0.85 A (Lever operated)
(5) I/O 3-5 screen
Standard models
Press button (3) A1: Attachment 1 lever inspection
(5) I/O 3-5 screen When the attachment 1 lever is ON
Standard models
A1: −.−− −.−− 1− = ON
When the attachment 1 lever is in the neutral position
A1: −.−− −.−− 0− = OFF

A1 : . . 1 Operate the attachment 1 lever to judge ON/OFF quality.
S P H
S P H
MENU
3-way and 4-way mini lever models (OPT)
A1: Attachment 1 lever angle 1 sensor voltage (V)
Attachment 1 lever angle 2 sensor voltage (V)
3-way and 4-way mini lever models (OPT) Attachment 1 raise switch (0=OFF, 1=ON)
Attachment 1 lower switch (0=OFF, 1=ON)
Judge the input quality by attachment 1 lever operation.

A1 : 1 . 0 0 3 . 0 0 1 0
S P H
Attachment 1 lever Attachment 1 lever
S P H
MENU angle 1 sensor angle 2 sensor
voltage voltage
Press button (3) Raising 1.1 to 2.3 V 2.2 to 3.5 V

I/O 3-6 screen Lowering 0.4 to 1.6 V 2.9 to 4.2 V
3-40
I/O 3-5 screen (6) I/O 3-6 screen

Standard models
Button (2) A1 (SOL): Unused
(6) I/O 3-6 screen Button (1)
Standard models
A1 (SOL): Attachment 1 proportional valve solenoid
current (A)

Judge the output quality to attachment (1) proportional
A 1 ( S OL ) : .
S P H
valve solenoid by attachment 1 lever operation.
S P H
MENU Standard: 0.3 to 0.85 A (Lever operated)
(7) I/O 3-7 screen
Button (3)
Standard models, 2-way and 3-way mini lever
3-way and 4-way mini lever models (OPT) models (OPT)
A2: Unused
4-way mini lever models (OPT)

A 1 ( S OL ) : 0 . 3 5 A2: Attachment 2 lever angle 1 sensor voltage
S P H
S P H
Attachment 2 lever angle 2 sensor voltage
MENU
Attachment 2 raise switch (0=OFF, 1=ON)

Attachment 2 lower switch (0=OFF, 1=ON)
Press button (3) Judge the forward and backward tilt input quality by tilt
(7) I/O 3-7 screen lever operation.
Standard models
Attachment 2 lever Attachment 2 lever
angle 2 sensor angle 2 sensor
voltage voltage
 Raising 1.1 to 2.3 V 2.2 to 3.5 V
A 2 : . .
Lowering 0.4 to 1.6 V 2.9 to 4.2 V

S P H
S P H
MENU
4-way mini lever models (OPT) (8) I/O 3-8 screen

Standard models, 2-way and 3-way mini lever
models (OPT)

A2 (SOL): Unused
A 2 : 1 . 0 0 3 . 0 0 1 0
S P H
S P H
MENU A2 (SOL): Attachment 2 proportional valve solenoid
current (A)
Judge the output quality to attachment 2 proportional
Press button (3)
(8) I/O 3-8 screen valve solenoid by attachment 2 lever operation.
Standard models Standard: 0.3 to 0.85 A (Lever operated)

A 2 ( S OL ) : .
S P H
S P H
MENU

A 2 ( S OL ) : 0 . 3 5
S P H
S P H
MENU
Press button (3)

I/O 3-9 screen
3-41
I/O 3-8 screen

(9) I/O 3-9 screen
SWTK: Automatic fork leveling cancel switch inspection
Button (2) 0 = OFF
(9) I/O 3-9 screen Button (1) 1 = ON
Operate the tilt knob switch to judge ON/OFF quality.

S WT K : 0 SSP: Pump motor rpm [target rpm]
S P H
S P H
MENU
Inspect the rpm sensor during the actual material
handling operation. Check that the pump motor rpm
increases according to the material handling speed
Button (3)
increase.
Press button (3)
MH: Lifting height switch inspection
Combination of lifting height switch ON/OFF
 MH1 MH2-1
SS P : 2 0 0 0 [ 2 0 0 0 ] Lifting height Indication
S P H
S P H switch switch
MENU
Low lifting height 10− 1 (=ON) 0 (=OFF)

High lifting height 01− 0 (=OFF) 1 (=ON)
Press button (3)
Change the lifting height to judge ON/OFF quality.
POTT: Tilt angle sensor voltage (V)

Check the input voltage of tilt angle sensor controller
MH : 1 0
S P H
Standard when the mast is in the vertical position:
S P H
MENU Approx. 1.3 V
When operating the mast forward from the vertical
position: Input voltage decrease
Press button (3) When operating the mast backward from the vertical
position: Input voltage increase
SPL: Load sensor voltage (V), (MPa display)
 Check the input voltage of load sensor controller.
POT T : 2 . 5 0
S P H
Standard without load: Approx. 0.8 V
S P H
MENU Input voltage increases according to the load increase
Press button (3)

S P L :V 0 . 8 4 ( 1 . 7 )
S P H
S P H
MENU
Press button (3)

3-42
I/O MONITOR4
ON/OFF state of steering knob synchronizer and other switches and the analog input value from each
sensor are indicated.
Operating Procedure
Button (1)
2. Press button (2) four times.
= A N L ME N U = button (3) (enter). I/O monitor function (4) is activated
5 . I / O MO N I T OR 4
S P H
S P H and I/O 4-1 to I/O 4-4 are displayed sequential every
MENU
(1) I/O 4-1 screen Button (2): Unused
Button (3): Displays I/O 4-1 to I/O 4-4 screens
sequentially.

ST S : 0 1 0 *: Press button (3) on the I/O 4-4 screen to display the
S P H
S P H
MENU
Other screen cannot be displayed from I/O MONITOR4
screen.
Press button (3) Display ANALYZER MENU screen to display other screen.
I/O 4-2 screen
(1) I/O 4-1 screen

STS: Steering angle sensor inspection
0 = OFF
 1 = ON
ST S : 0 1 0
STS1 STS2 STSC
Turning the steering wheel one round will turn STS1 and
STS2 ON, OFF and then ON. STSC turns on only when
the steering wheel is in the standard position.
159 STSC sensor turns on when the actual value is 80 on
0
1 the I/O 4-2 screen.
80
3-43
(2) I/O 4-2 screen

I/O 4-1 screen
K-POS: Actual value of knob position (target)
Button (2) Actual value:
Button (1) Knob position computed by the controller from the
(2) I/O 4-2 screen
steering angle sensor signal.
Target value:
 Knob position computed by the controller from the tire
K POS 1 5 9 1 5 0
S P H
S P H angle sensor signal.
MENU
Button (3)
Press button (3)
I/O 4-3 screen
Assuming the steering wheel is divided into 160 (0 to

159), the knob position of 80 is as indicated in the
illustration to the left. This value increases when turning
159 the steering wheel clockwise and decreases when
0
1 turning it counterclockwise.
80
(3) I/O 4-3 screen

I/O 4-2 screen • K-DIFF: Deviation of steering angle knob position
Button (2) Difference between target and actual values at I/O 4-2.
Button (1) • SOL: Steering synchronizer solenoid
(3) I/O 4-3 screen 0 = OFF
1 = ON
Operate the steering wheel to check that the steering

K D I FF 1 0 0 SOL 0 synchronizer solenoid turns on when there is deviation
S P H
S P H
MENU
of steering angle knob position.
(4) I/O 4-4 screen
Button (3) TIRE: Tire angle sensor voltage (V)
Press button (3)
Operate the steering wheel to check the variation in
(4) I/O 4-4 screen
voltage.
Standard at tire straight travel position:

Approx. 2.40 V
T I RE : 2 . 40
S P H
S P H
MENU
Press button (3)

3-44
ACTIVE TEST
This function outputs ON/OFF signals to each switch related to the electrical system and compares
controller input signals with those signals.
Operating Procedure
Button (1)
2. Press button (2) five times.
3. Check that “6. ACTIVE TEST” is displayed and press
= AN L ME NU=
button (3) (enter). ACTIVE TEST function is activated
6 . ACT I VE TE ST
S P H
and ACT-1 to ACT-3 are displayed sequential every time
S P H
MENU button (3) is pressed.
4. Functions of buttons on the ACTIVE TEST screen are
Press button (3) Button (1): Forced ON
(1) ACT-1 screen Button (2): Forced OFF
Button (3): Displays ACT-1 and ACT-3 sequentially
< ACT 1 >

*: Press button (3) on ACT-3 screen to display the
F AN : ON / O F F ( 4 8 )
S P H
S P H
MENU Other screen cannot be displayed from ACTIVE TEST
screen.
Display ANALYZER MENU screen to display other screen.
Press button (3)
(2) ACT-2 screen (1) ACT-1 screen
FAN: Fan (fan voltage (V))
Forcibly output the ON/OFF signal to check the fan
< ACT 2 >
K S OL : ON / O F F ( 0 )
operation and display visually.
S P H
S P H • Press button (1) to select ON.
MENU
→Fan rotates and fan voltage is displayed.
• Press button (2) to select OFF.
→Fan stops rotating and fan voltage is displayed.
Press button (3)
Note:
ACT-3 screen Be sure to open the battery hood and remove the side
cover to check the fan operation.
(2) ACT-2 screen
KSOL: Steering knob synchronizer solenoid
1: Signal check line ON (error)
0: Signal check line OFF (normal)
Turn the steering wheel slowly to check the deviation in
the rear tire movement.
ON (bypass open) selected: Tires rarely move
OFF (bypass close) selected: Tires normally move
3-45
(3) ACT-3 screen

ACT-2 screen
Standard models
PSOL: Unused
Button (1) Mini lever models (OPT)
(3) ACT-3 screen
Standard models Button (2) PSOL: Unload valve solenoid
1: Signal check line ON (error)
0: Signal check line OFF (normal)
< ACT 3 >
• Turn the key switch to ON and operate the material
P SOL : ( )
S P H
handling lever.
→If the unload valve turns on normally, material
S P H
MENU
handling operation is possible.If the unload valve

Button (3) stays off, material handling operation is disabled.
Mini lever models (OPT) • Turn the key switch to OFF and operate the material
handling lever.
→If the unload valve turns off normally, material
< ACT 3 >
P S O L : O N / OF F ( 0 )
handling operation is disabled.If the unload valve
S P H
S P H
stays on, material handling operation is possible.
MENU
Press button (3)

3-46
Tuning 1
Parametervärde = BT Standardvärde
Parameter Ämne 1 2 3 4 5 6 7 8
1 Reverseringsbroms Svag Stark
2 Rullbroms Svag Stark
Larmnivå för urladdat Tidigare Senare Ingen

3 batteri varning varning varning
Korrigering av Långsam Snabb

4 batteriindikator ned- ned-
(instrumentets visning) räkning räkning
Ingen
5 Maxfart Långsam Snabb
begr.
Hydraulvarv för Lågt Högt

6 extrafunktion 1 (spak 3) varvtal varvtal
Lågt Högt
7 Hydraulvarv för tilt
varvtal varvtal
Hydraulvarv för Lågt Högt

8 extrafunktion 2 (spak 4) varvtal varvtal
Tid till automatisk

9 avstängning (se option ca 2 min ca 15min
10)
Rullbroms vid hastigheter

10* under 5 Km/h med
påverkat fartreglage
Rullbroms vid hastigheter

11* under 5 Km/h med
opåverkat fartreglage
Pedalrespons, Lång-
12** fartreglage
Snabb
sam
* = Parameter 10 och 11 är endast tillgänglig i programversion 7.9 eller 8.8 (special versioner)
** = Parameter 12 är endast tillgänglig i programversion 2.1 eller 8.8 (fr.o.m 2005)
Programversionen kan avläsas i displayen under ca 3 sek när man har knappat in
lösenordet för programmering. (t.ex C = 2.1)
3-47A
Tuning 2
Sänk Parametervärde = BT Standardvärde

20 Startström Låg Hög
21 Accelerationskurva Flack Brant
22 Slutström Låg Hög
23 Acceleration Långsam Snabb
24 Deceleration Långsam Snabb
Lyft

3-47B
Tuning 3
Tilt framåt Parametervärde = BT Standardvärde

Tilt bakåt

3-47C
Tuning 4
Spak 3 framåt Parametervärde = BT Standardvärde

Spak 3 bakåt

3-47D
Tuning 5
Spak 4 framåt Parametervärde = BT Standardvärde

Spak 4 bakåt

3-48A
Tuning 2 - Parametrar för minispakar

Lyft & Sänk
Ström
1000 mA
3*
(8)
2*
500 mA
2* (1)
1*
Tid
4* 5*
1* Startström - Parameter 20-sänk, 25-lyft
2* Accelerationskurva - Parameter 21-sänk, 26-lyft
3* Slutström - Parameter 22-sänk, 27-lyft
4* Acceleration - Parameter 23-sänk, 28-lyft
5* Deceleration - Parameter 24-sänk, 29-lyft
(4* och 5* - Parametervärde 1=lång fördröjning, 8=kort fördröjning)

3-48B

Tilt
Ström
1000 mA
3*
(8)
2*
500 mA
2* (1)
1*
Tid
4* 5*
1* Startström - Parameter 30-tilt framåt, 35-tilt bakåt
2* Accelerationskurva - Parameter 31-tilt framåt, 36-tilt bakåt
3* Slutström - Parameter 32-tilt framåt, 37-tilt bakåt
4* Acceleration - Parameter 33-tilt framåt, 38-tilt bakåt
5* Deceleration - Parameter 34-tilt framåt, 39-tilt bakåt

3-49A

Sideshift-Spak 3
Ström
1000 mA
3*
(8)
2*
500 mA
2* (1)
1*
Tid
4* 5*
1* Startström - Parameter 40-spak framåt, 45-spak bakåt
2* Accelerationskurva - Parameter 41-spak framåt, 46-spak bakåt
3* Slutström - Parameter 42-spak framåt, 47-spak bakåt
4* Acceleration - Parameter 43-spak framåt, 48-spak bakåt
5* Deceleration - Parameter 44-spak framåt, 49-spak bakåt

3-49B

Gaffelspridning-Spak 4
Ström
1000 mA
3*
(8)
2*
500 mA
2* (1)
1*
Tid
4* 5*
1* Startström - Parameter 50-spak framåt, 55-spak bakåt
2* Accelerationskurva - Parameter 51-spak framåt, 56-spak bakåt
3* Slutström - Parameter 52-spak framåt, 57-spak bakåt
4* Acceleration - Parameter 53-spak framåt, 58-spak bakåt
5* Deceleration - Parameter 54-spak framåt, 59-spak bakåt

3-50
TUNING Screen Operating Procedure

1. Input the password on the GENERAL screen (see page 3-24) to display the MASK MENU screen.
2. Press button (2) to display “2. TUNING” and press button (3) (enter) to display the TUNING MENU
screen.
3. Press button (1) or (2) to display the tuning item desired to be set. Press button (3) (enter) to display
the TUNING screen of the selected item.
Button (1): Display the previous tuning item
Button (2): Display the next tuning item
Button (3): Enter (display the selected tuning item)
*: Press button (3) on the TUNING MENU screen, select “6. END” and press (3) to display MASK MENU
screen.
“2.TUNING2 LIFTV” to “5.TUNING5 ATT2V” (tuning No.20 to 59) are not used on the standard models.
They are only used on the mini lever models (OPT).

MASK MENU screen
=ME NU =
2 . T UN I NG
S P H
S P H
MENU
Button (3)
= T UN MENU= = T UN MENU=
1 . T UN I NG1 6 . END
S P H S P H
S P H S P H
MENU
Press button (1) or MENU
(2) to switch screen
Press button (1) or Press button (1) or

(2) to switch screen (2) to switch screen
2 . T UN I NG2 L I F. T V 5 . T UN I NG5 AT T 2 V
S P H S P H
S P H S P H
MENU MENU
Press button (1) or Press button (1) or

(2) to switch screen (2) to switch screen
3 . T UN I NG3 T I L T V 4 . T UN I NG4 A T T 1V
S P H S P H
S P H S P H
MENU
Press button (1) or MENU
(2) to switch screen

3-51
Button (1) Button (2) TUNING 1

TUNING MENU screen This function sets the tuning level of the standard functions.
OPERATING PROCEDURE
= T U N ME N U =
1 . T UN I NG 1
1. Display the TUNING MENU screen.
S P H
S P H
2. Check that “1. TUNING1” is displayed and press button
(3) (enter) to display TUNING level setting screen.
MENU
Button (3)
3. Press button (3) to display the tuning item desired to be
Press button (3) set.
4. Functions of buttons on the TUNING level setting screen
are as follows:
< T UN > 1 5 8 Button (1): Tuning level down
NO . 1
S P H
S P H
Button (2): Tuning level up
MENU
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.12 setting screen to
Press button (3)
display the TUNING MENU screen.
Other screen cannot be displayed from each level setting
screen of TUNING1. Display TUNING MENU screen to
< T UN > 1 5 8
NO . 2 display other screen.
S P H
S P H
MENU
Press button (3)
< T UN > 1 5 8
NO . 1 2
S P H
S P H
MENU
Press button (3)

TUNING MENU screen
Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels (TUNING No.3)
*: The default is level 7.
Discharge TUNING setting levels
level 1 2 3 4 5 6 7 8
50 to 59%
60 to 69%
70 to 79%
Low remaining battery
charge warning
80%
Battery charge indicator blinks
81 to 89%
90%
Overdischarge warning
91 to 99% Ten segments of battery
charge indicator blink
NO
100%
warning
3-52
Button (1)
TUNING 2 LIFTV
TUNING MENU screen Button (2) This function changes the tuning level of the lift lever.
OPERATING PROCEDURE
= T U N ME N U =
2 . T UN I NG 2 L I F T V
S P H
S P H 2. Press button (1) or (2) to display “2.TUNING2 LIFTV”
MENU
and press button (3) (enter) to display TUNING level
setting screen.
Button (3) 3. Press button (3) to display the tuning item desired to be
Press button (3)
set.
are as follows:
< T UN >
NO . 2 0
1 5 8 Button (1): Tuning level down
S P H
S P H Button (2): Tuning level up
MENU
Press button (3)
screen of TUNING2 LIFTV. Display TUNING MENU screen
< T UN >
NO . 2 1
1 5 8 to display other screen.
S P H
S P H
MENU
Press button (3)
< T UN > 1 5 8
NO . 2 9
S P H
S P H
MENU
Press button (3)

TUNING MENU screen
3-53
Button (1)
TUNING 3 TILTV
TUNING MENU screen Button (2) This function changes the tuning level of the tilt lever.
OPERATING PROCEDURE
= T U N ME N U =
3 . T UN I NG 3 T I L T V
S P H
S P H 2. Press button (1) or (2) to display “3.TUNING3 TILTV”
MENU
setting screen.
Button (3) 3. Press button (3) to display the tuning item desired to be
Press button (3)
set.
are as follows:
< T UN >
NO . 3 0
1 5 8 Button (1): Tuning level down
S P H
S P H Button (2): Tuning level up
MENU
Press button (3)
screen of TUNING3 TILTV. Display TUNING MENU screen
< T UN >
NO . 3 1
1 5 8 to display other screen.
S P H
S P H
MENU
Press button (3)
< T UN > 1 5 8
NO . 3 9
S P H
S P H
MENU
Press button (3)

TUNING MENU screen
3-54
Button (1)
TUNING 4 ATT1V
TUNING MENU screen Button (2)
This function changes the tuning level of the attachment 1
lever.
= T U N ME N U =
OPERATING PROCEDURE
4 . T UN I NG 4 A T T 1 V
S P H
S P H 1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display “4.TUNING4 ATT1V”
MENU

Button (3) setting screen.
Press button (3)
set.
< T UN >
NO . 4 0
1 5 8 are as follows:
S P H
S P H Button (1): Tuning level down
MENU
Press button (3)
< T UN >
NO . 4 1
1 5 8 screen of TUNING4 ATT1V. Display TUNING MENU
S P H
S P H screen to display other screen.
MENU
Press button (3)
< T UN > 1 5 8
NO . 4 9
S P H
S P H
MENU
Press button (3)

TUNING MENU screen
3-55
Button (1)
TUNING 5 ATT2V
TUNING MENU screen Button (2) This function changes the tuning level of the attachment 2
lever.
= T U N ME N U =
OPERATING PROCEDURE
5 . T UN I NG 5 A T T 2 V
S P H
S P H 1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display “5.TUNING5 ATT2V”
MENU

Button (3) setting screen.
Press button (3)
set.
< T UN >
NO . 5 0
1 5 8 are as follows:
S P H
S P H Button (1): Tuning level down
MENU
Press button (3)
< T UN >
NO . 5 1
1 5 8 screen of TUNING5 ATT2V. Display TUNING MENU
S P H
S P H screen to display other screen.
MENU
Press button (3)
< T UN > 1 5 8
NO . 5 9
S P H
S P H
MENU
Press button (3)

TUNING MENU screen
3-56
OPTION SET
OPTION SET Menu List
Selection
No. Indication Description Indi- Indi-
Meaning Meaning
cation cation
Enables simultaneous operation of
OPT-1 DEMO MODE traveling and material handling before Y Enable N Disable
starting the hour meter.
No
OPT-2 H/M START Starts hour meter count. Y Counting N
counting
Disables level setting of traveling/material
OPT-3 P/C LOCK handling power control, 2-speed travel Y Lock N Unlock
speed and overspeed alarm (OPT).
Other
Set the data according to the destination.
OPT-4 DESTI * J Japan I than
Changes the display.
Japan
OPT-5  Not used    
Set to Set to
OPT-6 MPH * Changes the traveling speed unit to mph. Y N
mph km/h
Adjust the charge indicator calculation Feature Feature
OPT-8 BATTERY * A B
constant. A B
Enables/disables operation of the auto
OPT-10 SEAT P-OFF power-off function in relation to the seat Y Enable N Disable
switch.
Enables/disables parking brake OFF
OPT-11 PARKING ERR Y Enable N Disable
warning.
Enables/disables the active mast front tilt
OPT-12 TILT CONT Y Enable N Disable
angle limit.
Enables/disables the mast forward tilt
OPT-14 TILT F-LIM Y Enable N Disable
speed limit control.
OPT-15 B-TYPE * Battery type 1 TYPE1 2 TYPE2
Other
Sets specification of 2-way mini lever
OPT-17 2-WAY VALVE * Y 2-way N than
models.
2-way
Other
Sets specification of 4-way mini lever
OPT-18 4-WAY VALVE * Y 4-way N than
models.
4-way
Sets the wheel indicator of the all-round Non-
OPT-20 WHEEL IND Y Display N
model (OPT) to display/non-display. display
OPT-21 SAS * Enables/disables SAS function Y Enable N Disable
*: The specification of the vehicle is selected at the time of vehicle shipment.
Batterityp Option 8 och 15 A-1 = USA A-2 = Europa B-1 = Japan B-2 = Gelè batterier
3-57
Caution:
• These functions are used to adjust the controller and
display control according to the options installed on
the vehicle; they do not enable or disable the actual
T OF F AM
11 : 00 function of the options.
S P H
S P H
MENU
• When the controller board is replaced, it is necessary
to reset it according to the vehicle specifications.
• When OPT-12 TILT CONT and OPT-21 SAS are
Indication when disable disabled by option setting, the disabled status is
indicated for 5 seconds on the display upon key
switch ON.
30/ 9
Meaning of indication
S AS OF F
AM
11 : 00 T-OFF: TILT CONT (active mast front tilt angle
S P H
S P H
MENU
control) is disabled.
SAS-OFF: SAS (SAS control) is disabled.
Operating Procedure for OPTION SET Screen

2. Press button (2) twice to display “3. OPTION SET” and press button (3) (enter) to display the OPTION
SET MENU screen.
3. Press button (3) to display the desired option item to be set on the screen.
4. Functions of buttons on the OPTION SET screen are as follows:
Button (1): N→Y
Button (2): Y→N
*: Press button (3) on OPT-22 OPTION SET screen to display the MASK MENU screen.
OPT-4 screen
Button (1)
Press button (3)
Button (2)
MASK MENU screen
= ME N U = <OPT 3>
3 . OP T I ON S ET P / C L OCK Y / N
S P H S P H
S P H S P H
MENU MENU
Button (3)
<OP T 1> <OP T 2>

D EMO MOD E Y / N H / M ST ART Y / N
S P H S P H
S P H S P H
MENU Press MENU
button (3)
OPT-2 (H/M START) hour meter starting method:
Press button (2) while keeping button (1) pressed
for 2 seconds or more.
3-58
OPT-3 screen
OPT-16 screen
Button (1) Button (2) Press button (3)
<OP T 4 > <OP T 1 5 >

DES T I J / I B T YPE 1 / 2
S P H S P H
S P H S P H
MENU MENU
Button (3)
Not used
<OPT 5 > <OPT 1 4 >

B L EVEL Y / N T I L T F L I M Y / N
S P H S P H
S P H S P H
MENU MENU

Not used
<OPT 6 > <OPT 1 3 >

MPH Y / N K NOB CONT Y / N
S P H S P H
S P H S P H
MENU MENU

Not used
<OPT 7 > <OPT 1 2 >

C / CN T RE S Y / N T I L T C ON T Y / N
S P H S P H
S P H S P H
MENU MENU
<OPT 8 > <OPT 1 1 >

B ATT ERY A / B P A RK I NG E R R Y / N
S P H S P H
S P H S P H
MENU MENU

Not used
< OP T 9 > < OP T 10 >

S HOU T OK U Y / N S EAT P OF F Y / N
S P H S P H
S P H S P H
MENU MENU
Press button (3)

3-59
OPT-15 screen
Button (2)
Not used Button (1)
<OP T 1 6 >
3 6 V Y / N
S P H
S P H
MENU
Button (3)
Press button (3)
<OPT 1 7 >
2 WA Y V A L V E Y / N
S P H
S P H
MENU
Press button (3)
<OPT 1 8 >
4 WA Y V A L V E Y / N
S P H
S P H
MENU
Press button (3)

Not used
<OPT 1 9 >
U SA Y / N
S P H
S P H
MENU
Press button (3)
< OP T 20 >
WH E E L I ND Y / N
S P H
S P H
MENU
MASK MENU screen

Not used
< OP T 2 1 > <OPT 2 2 >

S AS Y / N F I SH ERMA N Y / N
S P H S P H
S P H S P H
MENU Press MENU
button (3)
3-60
MATCHING
General
Of the sensors used for SAS, the signal voltage values of the tilt angle, load and tire angle sensors in the
mast vertical position, no load state, and tire straight travel position respectively are stored in the controller
at the time of vehicle shipment to be used as the bases for control. Therefore, if maintenance or parts
replacement related to these sensors is performed, matching (updating sensor signal voltage values of the
vehicle in the vehicle standard state) becomes necessary.
Matching of the tilt angle sensor is also necessary when the vehicle posture is remarkably changed.
Matching of the load sensor is also necessary when the load in the no load state is changed including
removal and addition of attachments.
Each lever angle sensor for mini lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment.Therefore, when maintenance or
parts replacement related to these sensors is required, matching needs to be performed.
SAS Matching Items and Conditions
No. Indication Description Condition
*1 · *2 · *3 · *6
1 TILTL Tilt angle sensor output in the fork level position is stored in the controller.
*7 · *8
Tilt angle sensor output of forward tilt control in the mast vertical position *1 · *2 · *3 · *6
2 TILTF
is stored in the controller. *7 · *8
3 LOAD Load sensor output in the no load state is stored in the controller. *1 · *4 · *6 · *7
Tire angle sensor output in the straight travel position is stored in the con-
4 TIRE *1 · *5
troller.
Mini lever Matching Items and Conditions (OPT)
No. Indication Description Condition
Lift lever angle sensor output in the lift lever neutral position is stored in
5 LIFT *1 · *9
the controller.
Tilt lever angle sensor output in the tilt lever neutral position is stored in
6 TILT *1 · *10
the controller.
Attachment 1 lever angle sensor output in the attachment 1 lever neutral
7 ATT1 *1 · *11
position is stored in the controller.
Attachment 2 lever angle sensor output in the attachment 2 lever neutral
8 ATT2 *1 · *12
position is stored in the controller.
Meaning of Conditions
*1: When the main controller is replaced.
*2: When the tilt angle sensor is replaced.
*3: When the tilt angle sensor rod is replaced or its length is changed.
*4: When the load sensor is replaced.
*5: When the tire angle sensor and sensor cover is removed/installed/replaced.
*6: When an attachment is changed.
*7: When the mast is replaced.
*8: When the tilt cylinder is replaced.
*9: When the lift lever angle sensor is replaced
*10: When the tilt lever angle sensor is replaced
*11: When the attachment 1 lever angle sensor is replaced
*12: When the attachment 2 lever angle sensor is replaced
3-61
Before Matching
Vehicle should be in the “Standard state” for matching.
“Standard state” means the vehicle satisfies the following conditions:
1. Tire pressure check
V mast Make sure that the tire pressure is at the specified level.
Low pressure and deviation of tire pressure among the
tires may hinder accurate matching.
2. Surface levelness check
Matching on the unleveled or inclined surface may
cause deviation of the standard. Perform matching on a
level surface (inclination below 0.5°).
500 mm 3. No-load vertical condition check
(19.7 in) Signal voltage of the load sensor in no-load state is
FV∑FSV mast stored. Make sure that the following conditions are met.
• Raise the fork of the V mast to approx. 500 mm (19.7
in). Make sure that the mast is in the vertical position
by checking with an angle gauge.
• The rear cylinder rod extension of the FV and FSV
100 mm mast should be approx. 100 mm (3.9 in).
(3.9 in)
Make sure that the mast is in the vertical position by
checking with an angle gauge.
• Tilt the mast from backward tilt position to forward until
it becomes vertical.
4. Tire straight traveling position check

Signal voltage of the tire angle sensor in tire straight
Within 50 mm (2.0 in)
travel position is stored. Tire straight travel position is

each on the left and
the condition in which driving the vehicle 5 meters (16 ft)

with the steering wheel fixed causes the center of the
vehicle to stay within 50 mm (2.0 in) to the left and right
right sides
of the line.
5 m (16 ft)
Operating Procedure for MATCHING screen

2. Press button (2) three times to display “4. MATCHING” and press button (3) (enter) to display the
MATCHING setting screen.
3. Press button (3) to display the desired matching item.
4. Functions of buttons on the MATCHING setting screen are as follows:
Button (1): Unused
Button (2): Starts matching for the selected item
Button (3): Display the next item
3-62
*: Press button (3) on the ATT2 matching set screen to display the MASK MENU screen.
OK on the display is indicated only after matching (by pressing button (2)).
The value in parentheses is the one stored at present.
The value outside parentheses is the one under the present vehicle condition.
Note:
Matching is necessary when the two values, inside and outside the parentheses are different in the
vehicle standard condition.

MASK MENU screen
= ME N U =
4 . MA T CH I NG
S P H
S P H
MENU
Button (3)
Press button (3)
Press button (3)
< MA T CH I NG > OK < MA T CH I NG >

T I L T L ( 2 . 0 0 ) 2 . 0 0 AT T 2 ( . ) .
S P H S P H
S P H S P H
MENU MENU

T I L T F ( 2 . 0 0 ) 2 . 0 0 AT T 1 ( . ) .
S P H S P H
S P H S P H
MENU MENU

L OAD ( 0 . 7 0 ) 0 . 7 0 T I L T ( . ) .
S P H S P H
S P H S P H
MENU MENU

T I RE ( 2 . 4 0 ) 2 . 4 0 L I F T ( . ) .
S P H S P H
S P H S P H
Press button (3)

MENU MENU
3-63
TIRE CONSTANT SET

General
In order to optimize the speed meter, tire constant that matches the tire outside diameter needs to be input
in the controller.
Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire
size is changed or the tires are worn excessively to a degree affecting the speedometer function.
Operating Procedure for Tire Constant Setting
1. Input the password on the general screen (see page 3-24)
MASK MENU screen
to display the MASK MENU screen.
2. Press button (2) four times to display “5. WHEEL DIA”
and press button (3) (enter) to display the tire constant
= ME N U =
5 . WH E E L D I A setting screen.
S P H
S P H
MENU
3. Press button (1) or (2) to set the desired tire constant
and press button (3) (enter) to display the MASK MENU
screen.
Button (3) 4. Functions of buttons on the tire constant setting screen
Press button (3) are as follows:
Button (1): Decrease the tire constant
Button (2): Increase the tire constant
WH E E L D I A
Button (3): Enter and display MASK MENU screen
2 2
S P H
S P H
MENU
Tire constant
Tire Constant List

Tire type Tire size Applicable model Tire constant
U lug
18 × 7-8 7FBEF15 ·16 ·18 24
J lug
Pneumatic shaped White 18 × 7-8 7FBEF15 ·16 ·18
cushion
U lug 25
J lug 200/50-10 7FBEF20
White
18 × 7-8-14 7FBEF15
Pneumatic J lug 20
18 × 7-8-16 7FBEF16 ·18
3-65
Toyota 7FBEF 15-20 Lösenord för maskerade funktioner
Programmering och felsökning [1] (Turtle) [2] (Clock)
1. Tryck samtidigt på “[1]” och “[2]”.
De maskerade funktionerna i displayen blir 2. Tryck på “[1]” inom 10 sekunder.
tillgängliga efter att man har knappat in ett 3. Tryck på “[2]” inom 10 sekunder.
lösenord. 4. Tryck samtidigt på “[3]” och “[2]” och håll
För en närmare beskrivning av respektive dessa nedtryckta i minst 2 sekunder.
parameter, följ sidhänvisningen till
servicemanualen. Ett kort “pip” hörs efter varje knapptryckning, och
ett längre “pip” hörs när lösenordet är accepterat. [3] (Menu)
Funktion Knappval Meny Knappval Ämne Beskrivning Knappval

1. ANALYZER (Menu): Enter. → 1. Diag Memory (Sid. 3-31) (Menu): Enter. → DIAG-1 Felkod 1 (senaste) (Menu): Gå till nästa parameter. ↓
(Sid. 3-27) (Turtle): Stega uppåt. ↑ (Felkoder Sid. 3-15) (Turtle): Stega uppåt. ↑ I I
(Clock): Stega nedåt. ↓ (Clock): Stega nedåt. ↓ DIAG-10 Felkod 10 (äldsta lagrade)
(Menu): Tillbaka till Meny 1.

2. I/O Monitor 1 (Sid. 3-33) (Menu): Enter. → I/O 1-1 THCD (temperatur på åktransistorerna) (Menu): Gå till nästa parameter. ↓
(spänning och temperaturer) (Turtle): Stega uppåt. ↑ I/O 1-2 THCP (temperatur på hydraultransistorerna)
(Clock): Stega nedåt. ↓ I/O 1-3 TD (temperatur på drivmotorer, vä/hö)
I/O 1-4 TP (temperatur på pumpmotor)
I/O 1-5 TBD (temperatur på åkpanelernas kretskort, vä/hö)
I/O 1-6 TBP (temperatur på hydraulpanelens kretskort)
I/O 1-7 TEMP (temperatur på CPU kortet)
I/O 1-8 VB48 (batterispänning )
I/O 1-9 VBKS (spänning efter nyckel)
I/O 1-10 VBSOL (spänning till solenoider)
I/O 1-11 VBMB (CPU inspänning efter säkring F6)
I/O 1-12 VBBD (åkpanelernas inspänning efter säkring F1)
I/O 1-13 VBBP (hydraulpanelens inspänning efter säkring F1)
3. I/O Monitor 2 (Sid. 3-36) (Menu): Enter. → Se i servicemanualen Se i servicemanualen Lika som I/O Monitor 1 ovan.
(åkfunktioner) (Turtle): Stega uppåt. ↑
(Clock): Stega nedåt. ↓
(hydraulikfunktioner) (Turtle): Stega uppåt. ↑
(funktioner för styrning) (Turtle): Stega uppåt. ↑
6. Active Test (Sid. 3-44) (Menu): Enter. → ACT-1 FAN (fläkt för paneler) (Menu): Gå till nästa parameter. ↓
(test av komponenter) (Turtle): Stega uppåt. ↑ ACT-2 KSOL (shuntventil för styrning) (Turtle)(Clock): ON/OFF
(Clock): Stega nedåt. ↓ ACT-3 PSOL (avlastningsventil)

7. END (Menu): Tillbaka till huvudmenyn.
2. TUNING (Menu): Enter. → (Menu): Enter. → (Menu): Gå till nästa parameter. ↓

(Sid. 3-46) (Turtle): Stega uppåt. ↑ (Turtle): Stega (Turtle)(Clock): Justering av värde ← →
(Clock): Stega nedåt. ↓ uppåt. ↑
(Clock): Stega
nedåt. ↓
TUNING 1: NO. 1-12 Broms, Batteriindikator, Hastighet & Hydraulmotorvarv
TUNING 2: NO. 20-29 Minispakar för lyft och sänk
TUNING 3: NO. 30-39 Minispakar för tilt
TUNING 4: NO. 40-49 Minispakar för extrafunktion 1
TUNING 5: NO. 50-59 Minispakar för extrafunktion 2 (Menu): Tillbaka till “Tuning”menyn.
(Efter sista parametern i varje grupp)
3. OPTION SET (Menu): Enter. → OPT-1 DEMO MODE (Menu): Gå till nästa parameter. ↓
(Sid. 3-56) (Turtle): Stega uppåt. ↑ OPT-2 H/M START (Sid. 3-57) (Turtle)(Clock): Ändra värde ← →
(Clock): Stega nedåt. ↓ OPT-3 P/C LOCK
OPT-4 DESTI
OPT-5 B LEVEL
OPT-6 MPH
OPT-7 C/CNT RES
OPT-8 BATTERY
OPT-9 SHOU-TOKU
OPT-10 SEAT P-OFF
OPT-11 PARKING ERR
OPT-12 TILT CONT
OPT-13 SWG W-LOCK
OPT-14 TILT F-LIM
OPT-15 B-TYPE
OPT-16 NOT USED
OPT-17 2-WAY VALVE
OPT-18 4-WAY VALVE
OPT-19 NOT USED
OPT-20 WHEEL IND
OPT-21 SAS
OPT-22 NOT USED (Menu): Tillbaka till huvudmenyn.
4. MATCHING (Menu): Enter. → TILTL Kalibrering av tiltvinkelsensor. Horisontella gafflar. (Menu): Gå till nästa parameter. ↓
(Kalibrering) (Turtle): Stega uppåt. ↑ TILTF Kalibrering av tiltvinkelsensor. Vertikal mast. (Clock): Kalibrering, lagrar nytt värde →
(Sid. 3-60) (Clock): Stega nedåt. ↓ LOAD Kalibrering av lastsensor. Grundlast.
TIRE Kalibrering av raka styrhjul.
LIFT Kalibrering av lyftspak
TILT Kalibrering av tiltspak
ATT 1 Kalibrering av spak till extrafunktion 1
ATT 2 Kalibrering av spak till extrafunktion 2 (MENU): Tillbaka till huvudmenyn.
5. WHEEL DIA (Menu): Enter. → WHEEL DIA Kompensation för drivhjulsdiameter (Turtle)(Clock): Ändra värde . ← →
(Sid. 3-63) (Turtle): Stega uppåt. ↑ (Menu): Tillbaka till huvudmenyn .
6. END
(Menu): Avsluta. Tillbaka till
normal visning i displayen.
(Turtle): Stega uppåt. ↑
4-1
TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . 4-2
0
TROUBLESHOOTING METHOD . . . . . . . . . . . . . . . 4-4
SST SETTING METHOD . . . . . . . . . . . . . . . . . . . . . . . 4-5 1
DIAGNOSIS CODE LIST . . . . . . . . . . . . . . . . . . . . . . . 4-11 2
WHEN AN ERROR CODE IS DISPLAYED . . . . . . . 4-15 3
CPU BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4
TRAVELING/MATERIAL HANDLING AC DRIVER . . . . 4-98
SAS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130
3
MULTI-DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143 6
WHEN NO ERROR CODE IS DISPLAYED . . . . . . . 4-144 7
8
9
10
11
12
13
14
15
16
17
18
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.
Reference:
Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors.
Inspect especially the sensor connectors with sufficient care.
4-3
Short circuit check

1. Disconnect the connectors at both ends of the
2. Measure the resistance between the corresponding
connector terminal and N1. Always inspect the
connectors at both ends.
Note:
Measure while lightly shaking the wire harness up and
0
down and sideways.
1
3. Measure the resistance between a terminal
corresponding to the connector terminal and N1.Always 2
inspect the connectors at both ends.
Standard: 1 MΩ or more 3
Note:
The wiring may short-circuit due to pinching by the body 4
or defective clamping.
3
6
Visual and contact pressure checks
• Disconnect the connectors at both ends of the 7
• Visually inspect that there is neither rust nor foreign matter 8
trapped at connector terminals.
• Inspect that there is no loosening or damage at the locked 9
portion. Also, lightly pull the wire harness from the
connector to check that it does not come off.
10
11
• Insert a male terminal same as that of the terminal to a
female connector and check the extracting force. 12
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals. 13
Note:
Even if there is rust or foreign matter trapped at the 14
terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition may 15
be changed to normal by disconnecting and
reconnecting the connector.In that case, repeat
connector connection and disconnection several times. 16
If defect is perceived even once, terminal contact may be
defective. 17
18
4-4
TROUBLESHOOTING METHOD
Disconnect the battery plug.

Connect SST1 to CN111 and
connect A and 1.
Defective portion
Repair or replacement
ANL.:I/O ACTIVE TEST ACT-1 0 (OFF)
• CPU board
Turn cooling fan on.
1 (ON) To the next step depending on the result.
CN100-9 (43) OK
b Voltage measurement • Cooling fan replacement
CN111-4 (N1)
NG
Connector and harness NG

inspection between CN100 • Repair or replace the defective portion.
and CN111.
OK
Explanation of Frames
Voltage No. Upper row: Tester positive (+) probe
A single frame indicates measurement with a
CN100-9 (43) tester or an ordinary step.
b Voltage measurement
CN111-4 (N1)
Lower row: Tester negative (-) probe
Connector and pin No.

Test item
A double frame indicates inspection by an
ANL.:I/O ACTIVE TEST ACT-1 analyzer function.
Turn cooling fan on.
Test method
A dash-line frame indicates SST connection.
An oval frame indicates connector or wire

harness inspection.
4-5
SST SETTING METHOD

Use SSTs for quick, accurate electrical troubleshooting on the 7FBEF 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. Part No. SST name Remarks

Shorting harness
SST2 09232-13130-71
(for CN19, 32, 52, 55, 58, 86 and 90) SST 09230-13130-71 0
(Controller check har-
Accelerator potentiometer check harness
SST8 09238-13130-71
(for CN26, 41 and 42)
ness for 7FB) 1
SST13 09234-13900-71 Shorting harness (for CN101 and 102) 2
Drive and pump motor rpm sensor check
SST19 09231-21320-71 harness 3
(for CN109, 110 and 111)
Lift, Tilt, ATT1, ATT2 solenoid check harness
4
SST20 09232-21320-71
(for CN74 and 75)
3
Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug 6
is kept connected, various boards may be damaged.
7
8
9
10
11
12
13
14
15
16
17
18
4-6
SST19 Setting Method

Set SST19 when the error codes C8-1 and E8 are displayed.
(2) Connect SST19 and CN110 (CN109, CN111) and connect CN1 and CN3 of SST19.
(4) Turn key switch ON and check LED while traveling.
SST19 CN1
CN2
CN3
Two LEDs
CN110
CN109
CN1
CN2
CN3
Two LEDs
SST19
CN111
4-7
CPU BOARD CONNECTOR
CN104 CN103 CN102 CN101
CN105
CN100
CN101 CN102 CN103 CN104
10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 8 7 6 5 4 3 2 1
1615 1413 12 11 11 10 9 8 7 7 6 5 1312 11 10 9
26252423222120191817 171615141312 11 10 9 8 2120191817161514
34333231 30 292827 222120 1918 1615141312 28272625 242322
CN101 CN102 CN103 CN104

No. P J No. P J No. P J No. P J
1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B48V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B48V
3 65 LSB 3 317 POTH 3 147 CANGND 3 SOLL+
3
4 66 LSPB 4 56 POTTA 4 43 VBKY (3) (SOL1+)
5 67 LSD 5 59 SPL 5 SSO+ 4 SOLL-
4
6 60 LSL 6 SSO- (4) (SOLb1)
6
7 OPTO (20) (POTL1) 7 41 VBBT 5 5 SOLa1
8 LEDTK 7 21 POTL2 8 CHK15V 6 SOLT+
6
9 39 FAN- 61 LSTF 9 CHK5V (6) (SOL2+)
8
10 39 FAN- (22) (POTT1) 10 16 D15V 7 SOLT-
7
11 63 LSAT1+ 62 LSTR 11 CHK3.3V (7) (SOLa2)
9
12 SSTMA (23) (POTT2) 12 14 GNDD 8 8 SOLb2
13 SSTMK 63 LSAT1∑LSAT2 13 144 SMTDK 9 55 CPR
10
14 SMTSA (24) (POTAT11) 14 143 SDTMK 10 55 CPR
15 SMTSK 11 25 POTAT12 15 142 SDTMA 11 9 SOL3+
16 51 LS- 12 26 POTAT21 16 141 SMTDA 12 10 SOLa3
17 62 LSTR+ 13 27 POTAT22 13 11 SOLb3
18 70 SWTK 14 53 POTA+ 11 10 9 8 7 6 5 4 3 2 1 14 44 VBMB
19 90 MH1 15 316 POTH+ 15 44 VBMB
20 91 MH2-1 16 57 POTTA+ CN105 16 34 SOL4+
21 314 STSC 17 58 SPL+ No. P J 17 35 SOLa4
22 LSAT2+ 18 28 POTL+ 1 39 FAN- 18 36 SOLb4
23 61 LSTF+ 19 29 POTT+ 2 39 FAN- 19 1 MB+
24 312 STS1 20 30 POTAT1+ 3 39 FAN- 20 2 MB-
25 21 31 POTAT2+ 4 130 FAN1 21 329 SOLST+
26 51 LS- 22 51 POT- 5 131 FAN2 22 N2 N2
27 SWLE 6 132 FAN3 23 N2 N2
28 8 7 6 5 4 3 2 1 7 133 FAN4 24 39 FAN-
29 8 134 FAN5 25 42 KEYSTART
30 313 STS2 CN100 9 135 FAN6 26 12 SOLP+
31 No. P J 10 FAN7 27 13 SOLP-
32 60 LSL+ 1 C5V 11 CHKG 28 330 SOLST-
33 2 GNDC
34 51 POT- 3 FTXD
4 FWE
5 MD1
6 FRES
7 FRXD
8 SELR
4-8
MAIN CONTROLLER CONNECTOR • COMPONENTS
CPR
CN126 2 1
CN126
No. P J
1 55 CPR
2 P2 P2
CN101 CN102 CN103 CN104

4-9
TRAVELING AC DRIVER 1 CONNECTOR • COMPONENTS
CN110
U V W
P3 P7 P8 P9 N1
TRAVELING AC DRIVER 2 CONNECTOR • COMPONENTS
CN109
U V W
P3 P71 P81 P91 N1

4-10
MATERIAL HANDLING AC DRIVER CONNECTOR • COMPONENTS
N2 P16 P15 P14 P3
W V U
CN111
4-11
DIAGNOSIS CODE LIST

When an Error Code is Displayed
Diag memory
Displayed code Error mode Page
code
30-1 30-1 Traveling AC driver 1 low voltage 4-98
30-2 30-2 Traveling AC driver 2 low voltage 4-99
30-3 30-3 Material handling AC driver low voltage 4-100
31-1 31-1 Traveling AC driver 1 low starting voltage 4-101
31-2 31-2 Traveling AC driver 2 low starting voltage 4-102
31-3 31-3 Material handling AC driver low starting voltage 4-103
32-1 32-1 Traveling AC driver 1 EEPROM abnormality 4-104
32-2 32-2 Traveling AC driver 2 EEPROM abnormality 4-104
32-3 32-3 Material handling AC driver EEPROM abnormality 4-105
Main controller → Traveling AC driver 1 communication
33-1 33-1 4-106
abnormality
Main controller → Traveling AC driver 2 communication
33-2 33-2 4-107
abnormality
Main controller → Material handling AC driver
33-3 33-3 4-108
communication abnormality
61-1,2 61-1,2 Load sensor abnormality 4-130
62-1,2 62-1,2 Tilt angle sensor abnormality 4-132
63-1,2,3 63-1,2,3 Tilt switch abnormality 4-15
64-1,2,3 64-1,2,3 Lift solenoid abnormality 4-16
65-1,2,3 65-1,2,3 Tilt solenoid abnormality 4-18
66-1 66-1 Tilt matching abnormality 4-133
67-1 67-1 Lifting height switch abnormality 4-134
71-1,2 71-1,2 Tire angle sensor abnormality 4-20
72-1,2,3,4 72-1,2,3,4 Steering angle sensor abnormality 4-136
73-1,2,3 73-1,2,3 Steering knob synchronizer solenoid abnormality 4-141
74-1 74-1 Tire angle matching abnormality 4-22
A0-1 Main drive circuit overheat 4-109
A0-2 Main pump circuit overheat 4-110
A1-1 A1-1 Main controller high voltage 4-23

A1-2 A1-2 Traveling AC driver 1 high voltage 4-111
A1-3 A1-3 Traveling AC driver 2 high voltage 4-112
A1-4 A1-4 Material handling AC driver high voltage 4-113
4-12

Diag memory
code
A2-1 CPU board overheat 4-24
A2-2 Traveling AC driver board overheat 4-114
A2-3 Material handling AC driver board overheat 4-115
A3 A3 Battery connection incorrect (CHG) 4-25

A4 A4 Acceleration switch abnormality 4-26
A6-1,3,5 A6-1,3,5 Material handling switch abnormality 4-27
AA-1 AA-1 CPU board thermo-sensor abnormality 4-29
AA-2 AA-2 Traveling AC driver 1 board thermo-sensor abnormality 4-115
AA-3 AA-3 Traveling AC driver 2 board thermo-sensor abnormality 4-116
Material handling AC driver board thermo-sensor
AA-4 AA-4 4-116
abnormality
AC AC Semiconductor switch abnormality 4-30
Traveling AC driver 1 → main controller communication
AD-1 AD-1 4-32
abnormality
AD-2 AD-2 4-33
abnormality
AD-3 AD-3 4-34
abnormality
AD-4 AD-4 4-35
abnormality
Material handling AC driver → main controller
AD-5 AD-5 4-36
Material handling AC driver → main controller
AD-6 AD-6 4-37
AF-1,2,3,4 AF-1,2,3,4 CPU abnormality 4-38
C1-1 C1-1 Traveling AC driver 1 current sensor offset abnormality 4-117
C1-2 C1-2 Traveling AC driver 1 overcurrent 4-117
C1-3 C1-3 Traveling AC driver 2 current sensor offset abnormality 4-118
C1-4 C1-4 Traveling AC driver 2 overcurrent 4-118
C2-1 Drive motor overheat 4-119
C2-2 C2-2 Drive motor 1 thermo-sensor abnormality 4-120

C2-3 C2-3 Drive motor 2 thermo-sensor abnormality 4-121
4-13

Diag memory
code
Traveling AC driver 1 main drive circuit thermo-sensor
C3-1 C3-1 4-122
abnormality
Traveling AC driver 2 main drive circuit thermo-sensor
C3-2 C3-2 4-122
abnormality
C4-1,2,3,4 C4-1,2,3,4 Accelerator potentiometer abnormality 4-39
C7 C7 Direction switch abnormality 4-41
C8-1 C8-1 Drive motor 1 rpm sensor abnormality 4-123
C8-2 C8-2 Drive motor 2 rpm sensor abnormality 4-124
CB-1 CB-1 MB contactor abnormality 4-42
CB-2 CB-2 MB contactor fusion 4-44
Material handling AC driver current sensor offset
E1-1 E1-1 4-125
abnormality
E1-2 E1-2 Material handling AC driver overcurrent 4-125
E2-1 Pump motor overheat 4-126
E2-2 E2-2 Pump motor thermo-sensor abnormality 4-127

Material handling AC driver main drive circuit
E3 E3 4-128
thermo-sensor abnormality
E8 E8 Pump motor rpm sensor abnormality 4-129
EE-1,2,3 EE-1,2,3 Abnormal communication from multi-display 4-45
EF-1,2,4 EF-1,2,4 Main controller EEP-ROM abnormality 4-46
EF-3 EF-3 Main controller CPU abnormality 4-46
Main controller → multi-display communication
F1-1,2 F1-1,2 4-143
abnormality
FF FF D15 overcurrent 4-47
H1-1,2 H1-1,2 Lift lever potentiometer abnormality 4-48
H1-3 H1-3 Lift lever potentiometer abnormality 4-53
H2-1,2 H2-1,2 Tilt lever potentiometer abnormality 4-57
H2-3 H2-3 Tilt lever potentiometer abnormality 4-62
H3-1,2 H3-1,2 Attachment 1 lever potentiometer abnormality 4-66
H3-3 H3-3 Attachment 1 lever potentiometer abnormality 4-71
H4-1,2 H4-1,2 Attachment 2 lever potentiometer abnormality 4-75
4-14

Diag memory
code
H5-1,2,3,4,5 H5-1,2,3,4,5 Lift solenoid abnormality 4-84
H6-1,2,3,4,5 H6-1,2,3,4,5 Tilt solenoid abnormality 4-87
H7-1,2,3,4,5 H7-1,2,3,4,5 Attachment 1 solenoid abnormality 4-90
H8-1,2,3,4,5 H8-1,2,3,4,5 Attachment 2 solenoid abnormality 4-93
H9-1,2,3 H9-1,2,3 Unload valve solenoid abnormality 4-96
When no Error Code is Displayed

Displayed code Vehicle condition Page
− No display on multi-display 4-144
− The vehicle does not move at all (display off) 4-145
− Only traveling disabled (no motor revolution) 4-146
− Wobbling 4-148
− Only material handling is disabled (standard models) 4-149
− Only material handling is disabled (Mini lever models) 4-150
− Steering knob not in the right position 4-151
− Constant automatic fork leveling 4-152
Traveling AC driver 1, 2 low temperature warning 4-153
Material handling AC driver low temperature warning 4-153

4-15
WHEN AN ERROR CODE IS DISPLAYED

CPU BOARD
63-1,2,3 Tilt switch abnormality
Related portion
CN101-23 (61, LSTF+) Tilt switch

J35 CN130 CN87
CN102-8 (61, LSTF)
15 1
CPU CN101-17 (62, LSTR+)
J36 16 3
board
CN102-9 (62, LSTR)
8 J2 4
CN101-16 (51, LS-)
J21 2
Condition for error detection

Output when open or short circuit of the tilt switch line from the CPU board to the tilt switch is detected.
63-1 Forward and backward tilt switch abnormality
63-2 Forward tilt switch abnormality
63-3 Backward tilt switch abnormality
A6-3 error is
Disconnect battery plug.
indicated
Connect battery plug again and turn Perform troubleshooting for A6-3.
key switch ON.
No error
63-1 error is
Check if an error is detected when indicated • Tilt switch installation defect
the tilt lever is operated in either • Tilt switch abnormality
direction.
No error
ANL : I/O MONITOR 3 I/O3-3 1 is displayed on either switch.

Operate the tilt lever in either
direction and check the switch
input valve when the tilt lever is
neutral position.
0 is displayed on either switch after

operating the tilt lever several times.
Memory 63-2, 63-3 The tilt lever has been turned ON for two
Check the diagnosis memory
minutes or more in the past.
Memory 63-1
The forward and backward tilt switches were

turned ON at the same time in the past.
(Check adjustment of each switch installation)
4-16
64-1,2,3 Lift solenoid abnormality
Related portion
CN88
CN104-3 (3, SOLL+)
1
CPU Lift
board CN104-4 (4, SOLL-) solenoid
2

Output when open or short circuit of the lift solenoid line from the CPU board to the lift solenoid is
detected.
64-1 Lift solenoid open
64-2 Lift solenoid load short
63-3 Lift solenoid drive circuit MOS short circuit
• 64-1
Disconnect battery plug
and disconnect CN88.
Connect battery plug, and turn the

key switch to ON.
Check the voltage of solenoid drive 5 V or more
Lift solenoid defect
CN88-1 (3)
CN88-2 (4)
Less than 5 V

and disconnect CN104.
CN104-3 (3)
b Continuity check Continuity
CPU board defect
CN88-1 (3)
CN104-4 (4)
b Continuity check
CN88-2 (4)
No continuity
Harness defect
4-17
• 64-2
Disconnect battery plug and
disconnect CN88.
64-2 error is
Connect battery plug, and turn key not indicated
Lift solenoid defect
switch ON.
64-2 error is
indicated

disconnect CN104.
Continuity
CN104-3 (3) Harness defect
b Continuity check
CN104-4 (4)
No continuity
CPU board defect
• 64-3
disconnect CN104, and turn key
switch ON.
Continuity
Check continuity of harness Harness defect
CN104-3 (3)~P1
CN104-3 (3)~P2
CN104-4 (4)~P1
CN104-4 (4)~P2
No continuity
CPU board defect

4-18
65-1,2,3 Tilt solenoid abnormality
Related portion
CN89
CN104-6 (6, SOLT+)
1
CPU Tilt
board CN104-7 (7, SOLT-) solenoid
2

Output when open or short circuit of the tilt solenoid line from the CPU board to the tilt solenoid is
detected.
65-1 Tilt solenoid open
65-2 Tilt solenoid load short
65-3 Tilt solenoid drive circuit MOS short circuit
• 65-1
Connect battery plug, and turn key
No error
switch ON. Operate the tilt lever to Connector connection check
the forward position.
65-1 error is indicated

disconnect CN89.
Connect battery plug, and turn key

switch ON. Operate the tilt lever to
5 V or more
Check the voltage of solenoid drive Tilt solenoid defect
CN89-1 (6)
CN89-2 (7)
Less than 5 V

disconnect CN104.
CN104-6(6)
b Continuity check Continuity
CN89-1 (6) CPU board defect
CN104-7 (7)
b Continuity check
CN89-2 (7)
No continuity
Harness defect
4-19
• 65-2
65-2 error is
Connect battery plug and turn key
not indicated
switch ON. Operate the tilt lever to Connector connection check
65-2 error
is indicated

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

switch ON. Operate the tilt lever to not indicated
Tilt solenoid defect

Disconnect CN104. Continuity
b Continuity measurement
CN104-7 (7)
No continuity
CPU board defect
• 65-3
65-3 error is
not indicated
switch ON. Operate the tilt lever to Connector connection defect

Disconnect CN104, and turn key
switch ON.
Continuity check Continuity
Harness defect
CN104-6 (6)~P1
CN104-6 (6)~P2
CN104-7 (7)~P1
CN104-7 (7)~P2
No continuity
CPU board defect

4-20
71-1,2 Tire angle sensor abnormality
Related portion
CN32
CN102-15 (316, POTH+)
1
CPU CN102-3 (317, POTH) Tire angle
board 2 sensor
CN102-22 (51, POT-)
3

Output when the voltage of the tire angle sensor is outside the specified range (open or short).
71-1 Tire angle sensor open
71-2 Tire angle sensor short
• 71-1
disconnect CN32. Connect SST2 71-2 error is
between CN32-1 and CN32-2 indicated.
Tire angle sensor defect
(Main harness side). Connect
battery plug and turn key switch
ON.
71-2 error is not
indicated.

Disconnect CN102.
(SST2 is the connection state.) No continuity
Main harness defect
CN102-15 (316)
b Continuity check
CN102-3 (317)
Continuity
(SST2 is the connection state.)

CN102-3 (317) No continuity
CPU board defect
b Continuity check
CN102-22 (51)
Continuity
Main harness defect

4-21
• 71-2
Disconnect battery plug, disconnect
Change to 71-1 error.
CN32, connect battery plug, and
turn key switch ON.
71-2 error is indicated.

Disconnect CN102.
No continuity
b Continuity check
CN102-3 (317)
Continuity
Disconnect CN142.
Connect SST2 between CN32-2
Main harness defect and CN32-3. (Main harness side)
CN102-3 (317)
b Continuity check
CN102-22 (51)
Continuity No continuity
Tire angle sensor defect Harness defect

4-22
74-1 Tire angle matching abnormality
Related portion
CPU board

Output when the tire angle matching value is outside the specified range.
• CPU board defect

4-23
A1-1 Main controller high voltage
Related portion
F6 P2
CN104-14,15 (44, VBMB)
CPU
board

Output when overcurrent is detected on VBMB line.
Turn key switch to OFF and then

ON again.
YES ANL : I/O MONITOR 1 I/O1-11 Less than 110 V

Is A1-1 error displayed?
VBMB: Voltage value check.
NO
110 V or more CPU board defect
110 V or more
Battery voltage check.
Approx. 48 V
Replace battery
CPU board defect
NG (∞ Ω)
F6 fuse inspection. Replace F6 fuse
OK (0 Ω)
Was the battery plug disconnected YES Do not disconnect battery plug during
during traveling? traveling except in an emergency.
NO
Check battery plug.

4-24
A2-1 CPU board overheat
Related portion
CPU board
Thermo-sensor
TH101

Output when the thermo-sensor on the CPU board detects a voltage over the set level.
ANL : I/O MONITOR 1 I/O1-7

80 °C or more
TEMP: CPU board temperature Allow vehicle to stand for a while
check. (approx. 30 min.)
Less than 80 °C
Has the vehicle been subjected to YES Stop vehicle and perform check test with
continuous overloaded operation? standard load after 30 minutes.
NO
CPU board defect

4-25
A3 Battery connection incorrect (CHG)
Related portion
F5 P
CN104-2 (18, B48V)
CPU
board

Output when the voltage of B48V line after F5 fuse exceeds the set level.
NO Do not connect charger plug to the controller

Is A3 error being displayed?
side plug.
YES
OPTION SET : OPT-16 36V

The settings are wrong.
Check the settings of battery Correct the settings
voltage (36 V / 48 V)
The settings are correct.
ANL : I/O MONITOR 1 I/O1-8 Less than 65 V

Voltage check CPU board defect
65 V or more
P1+ Less than 65 V

b Voltage measurement CPU board defect
N1-
65 V or more
Check the battery and replace it

with the a correct battery.
4-26
A4 Acceleration switch abnormality
Related portion
CN132 CN26
CN102-1 (64, SWAC) CN26-2 Accele-
12
CPU rator
board CN102-22 (51, POT-) CN26-1 potentio-
J22 9 J3 meter
CN130

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

Normal
upon battery plug connection?
NO
Disconnect CN26.
Reconnect battery plug.
NO
Is A4 error displayed? Adjust acceleration switch
YES

Continuity
disconnect CN102.
(Less than 20 Ω)
b Continuity check
CN102-22 (51)
No continuity
CPU board defect

4-27
A6-1,3,5 Material handling switch abnormality
Related portion
CN11
CN101-32 (60, LSL+)
J34 1
CN102-6 (60, LSL) Lift switch
CN130 2
14 CN21
CN101-11 (63, LSAT1+)
J37 17 1
Attachment
CN102-10 (63, LSAT1)
CPU 2 No.1 switch
board CN87
CN101-23 (61, LSTF+)
J35 1
Forward
CN102-8 (61, LSTF) tilt switch
15 2
CN101-17 (62, LSTR+)
J36 16 3 Backward
CN102-9 (62, LSTR) tilt switch
8 J2 4
CN101-16 (51, LS-)
J21

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

YES
operated upon battery plug Normal
connection?
NO
Disconnect CN11 (A6-1), CN87

(A6-3) or CN21 (A6-5), and connect
battery plug.
NO
Is A6 error displayed? Adjust limit switch or switch abnormality.
YES
A
4-28

Disconnect CN101, CN102.
Continuity check
• A6-1
CN101-32 (60)~CN102-6 (60) NG (open circuit)
• A6-3 Harness defect
CN101-23 (61)~CN102-8 (61)
CN101-17 (62)~CN102-9 (62)
• A6-5
CN101-11 (63)~CN102-10 (63)
OK (short circuit)
Continuity check
• A6-1
CN102-6 (60)~CN101-16 (51)
• A6-3 NG (short circuit)
CN102-8 (61)~CN101-16 (51) Harness defect
CN102-9 (62)~CN101-16 (51)
• A6-5
CN102-10 (63)~CN101-16 (51)
OK (open circuit)
CPU board defect

4-29
AA-1 CPU board thermo-sensor abnormality
Related portion
CPU board
Thermo-sensor
TH101

Output upon CPU board thermo-sensor abnormality detection
• To correct, replace the CPU board

4-30
AC Semiconductor switch abnormality
Related portion
CN126
CN104-9 (55, CPR)
CPR
P1
P3
P2 F1 CN104-2 (18, B48V)
F5 Traveling AC CN109-7 CPU

driver 2 board
CN104-25
Traveling AC CN110-7 (42, KEY START)
J29
driver 1
Material
CN111-7
handling AC
driver

Output when overcurrent in the semiconductor switch of the CPU board is detected.
If CB-1 occurs at the same time, perform troubleshooting for CB-1 first.
Disconnect CN126, connect battery AC error is not indicated.
A
plug and turn key switch ON.
AC error is indicated.
Disconnect CN110, and measure
AC error is not
resistance between 7 pins by the Approx. 20 Ω
Disconnect CN110, connect battery indicated.
side of harness, and N1. or more
7 pin [Tester probe -]
AC error is indicated. b Resistance measurement
N1 [Tester probe +]
Approx. 20 Ω or less Traveling AC driver
1 defect
Harness check
AC error is not Disconnect CN109, and measure

indicated. resistance between 7 pins by the Approx. 20 Ω
Disconnect CN109, connect battery
side of harness, and N1. or more
N1 [Tester probe +]
Approx. 20 Ω or less Traveling AC driver
2 defect
Harness check
Disconnect CN111, and resistance
AC error is not
measurement between 7 pins by Approx. 20 Ω
Disconnect CN111, connect battery indicated.
the side of harness, and N1. or more
N1 [Tester probe +]
• CPU board defect Approx. 20 Ω or less Material handling

• Harness defect AC driver defect
Harness check
4-31
NG (Other than OK)

CPR resistance check CPR defect
OK (Approx. 20 Ω)
It short-circuits for a
moment and resistance
P2 [Tester probe -]
rises gradually
b Resistance measurement CPU board defect
N1 [Tester probe +]
Short circuit
Disconnect P3 and N1 cable or

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

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

copper bar from the material
handling controller defect.
Short circuit
Resistance measurement between Material handling defect
P3 of controller side and N1.
P3 [Tester probe -]
N1 [Tester probe +]
Open circuit
Check P3 or N1 cable
4-32
AD-1 Traveling AC driver 1 → main controller communication abnormality
Related portion
CN103-1 (145, CANH) CN110-3 (145, CANH)

CN103-2 (146, CANL) CN110-4 (146, CANL)
CPU CN103-3 (147, CANGND) CN110-6 (147, CANGND) Traveling
board AC driver 1
CN104-25 (42, KEY START) CN110-7 (42, KEY START)
J25
CN112
1
R
2
3

Output when the CPU board cannot receive data from the traveling AC driver 1 within specified time.
YES
Is AD-2 error displayed? See AD-2 error.
NO
• Check CN103, CN104, CN110 and CN112
Was traveling AC driver 1 just YES connection condition.
replaced? • Turn the key switch OFF and ON, and it checks
NO that an error is not displayed.
• Traveling AC driver 1 resets on the way.
(There is possibility that traveling AC driver 1 is
ANL. : I/O MONITOR 1 I/O1-1, 3, 5, 12
Indicate data defect.)
The data check from the traveling
• Harness check (Especially No. 42 line)
AC driver 1.
• Check CN103, CN104, CN110 and
Blank display CN112 connection condition
Disconnect CN110. 15 V or
CN110-7 (42)
Less than 15 V CN110-7 (42) more
N1
N1
15 V or more
Less than
15 V
Disconnect battery plug, disconnect defect
CN112 Other than
120 ± 10 Ω CN104-25 (42)
CN112-1 Less than 15 V
N1
CN112-2
15 V or more
120 ± 10 Ω Resister defect CPU board defect
Harness defect
Check the continuity of
communication line harness No continuity (∞ Ω)
Harness defect
CN103-1 (145) ~ CN110-3 (145)
CN103-1 (145) ~ CN112-1 (145)
CN103-2 (146) ~ CN110-4 (146) Continuity (0 Ω) Traveling AC driver 1 defect
CN103-2 (146) ~ CN112-2 (146) (There is possibility that CPU board is defect.)
CN103-3 (147) ~ CN110-6 (147)
4-33
Related portion
CN103-1 (145, CANH) CN110-3 (145, CANH)

CN103-2 (146, CANL) CN110-4 (146, CANL)
board AC driver 1
J25
CN112
1
R
2
3

Output when the CPU board cannot receive ID code from the traveling AC driver 1 upon key switch on.
YES • Check CN103, CN104, CN110 and

Was traveling AC driver 1 just
CN112 connection condition
replaced?
• Harness check (Especially No. 42 line.)
NO
Is AD-2 error displayed even if it

repeats the key switch with OFF NO
and ON?
YES
Disconnect CN110. 15 V or
CN110-7 (42)
Less than 15 V CN110-7 (42) more
N1
N1
15 V or more
Less than 15 V Traveling AC driver 1
Disconnect battery plug, disconnect defect
Other than
CN112. CN104-25 (42)
120 ± 10 Ω Less than 15 V
CN112-1 b Voltage measurement
b Resistance measurement N1
CN112-2
15 V or more
120 ± 10 Ω Resister defect CPU board defect
Check the continuity of Harness defect

communication line harness.
CN103-1 (145) ~ CN110-3 (145) No continuity (∞ Ω)
CN103-1 (145) ~ CN112-1 (145) Harness defect
CN103-2 (146) ~ CN110-4 (146)
CN103-2 (146) ~ CN112-2 (146)
CN103-3 (147) ~ CN110-6 (147)
Continuity (0 Ω)
Traveling AC driver 1 defect

(There is possibility that CPU board is defect.)
4-34
Related portion
CN103-1 (145, CANH) CN109-3 (145, CANH)

CN103-2 (146, CANL) CN109-4 (146, CANL)
board AC driver 2
J25
CN112
1
R
2
3

Output when the CPU board cannot receive data from the traveling AC driver 2 within specified time.
YES
NO
YES • Check CN103, CN104, CN109 and CN112

Was traveling AC driver 2 just
connection condition.
replaced?
• Turn the key switch OFF and ON, and it checks
• Traveling AC driver 2 resets on the way.
ANL : I/O MONITOR 1 I/O1-1, 3, 5, 12 (There is possibility that traveling AC driver 2 is
Indicate data
The data check from the traveling AC defect.)
driver 2. • Harness check (Especially No. 42 line)
Blank display connection condition.
CN109-7 (42) Disconnect CN109. 15 V or

b Voltage measurement Less than 15 V CN109-7 (42) more
N1 b Voltage measurement
N1
15 V or more
Less than Traveling AC driver
Disconnect battery plug, disconnect Other than 15 V 2 defect
CN112 120 ± 10 Ω Less than
CN112-1 CN104-25 (42)
b Voltage measurement 15 V
CN112-2 N1
120 ± 10 Ω Resister defect 15 V or more

CPU board defect
Harness defect
Check the continuity of No continuity (∞ Ω)
communication line harness Harness defect
CN103-1 (145) ~ CN109-3 (145)
CN103-1 (145) ~ CN112-1 (145)
CN103-2 (146) ~ CN109-4 (146) Continuity (0 Ω) Traveling AC driver 2 defect
CN103-3 (147) ~ CN109-6 (147)
4-35
Related portion
CN103-1 (145, CANH) CN109-3 (145, CANH)

CN103-2 (146, CANL) CN109-4 (146, CANL)
CN103-3 (147, CANGND) CN109-6 (147, CANGND) Traveling AC
CPU
board CN104-25 (42, KEY START) CN109-7 (42, KEY START) driver 2
J25
CN109-1 (82, CUDID0)
CN112 CN109-10 (82, SSD-, TD2-)
1
R
2
3

Output when the CPU board cannot receive ID code from the traveling AC driver 2 upon key switch on.
Was traveling AC driver 2 just YES • Check CN103, CN104, CN109 and CN112
replaced? connection condition
NO • There is possibility that AD-4 error will be
displayed upon key switch turning to ON at first
Is AD-4 error displayed even if it repeats NO
time after replacing the traveling AC driver 2.
the key switch with OFF and ON?
YES
CN109-7 (42)
Less than 15 V Disconnect CN109. 15 V or
b Voltage check
CN109-7 (42) more
N1
b Voltage check
15 V or more N1
Disconnect battery plug, disconnect Less than Traveling AC driver 2
Other than
CN112. 15 V defect
120 ± 10 Ω
CN112-1
b Resistance measurement Less than
CN104-25 (42)
CN112-2 15 V
b Voltage check
120 ± 10 Ω N1
Check the continuity of Resister defect 15 V or more
communication line harness. CPU board defect
Harness defect
CN103-2 (146) ~ CN109-4 (146)
CN103-2 (146) ~ CN112-2 (146)
CN103-3 (147) ~ CN109-6 (147)
Continuity (0 Ω)
CN109-1 (82) No continuity (∞ Ω)
b Continuity check Harness defect
CN109-10 (82)
Continuity (0 Ω)
4-36
AD-5 Material handling AC driver → main controller communication abnormality
Related portion
CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
Material
CPU CN103-3 (147, CANGND) CN111-6 (147, CANGND)
handling
board
AC driver
J25
CN112
1
R
2
3

Output when the CPU board cannot receive data from the material handling AC driver within specified time.
YES
NO
Was material handling controller YES connection condition.
just replaced? • Turn the key switch OFF and ON, and it checks
• Material handling AC driver resets on the way.

ANL.: I/O MONITOR 1 I/O1-2, 4, 6, 13 (There is possibility that material handling AC
Indicate data
The data check from the material driver is defect.)
handling controller. • Harness check (Especially No. 42 line)
• Check CN103, CN104, CN111 and
Blank display CN112 connection condition
CN111-7 (42) Disconnect CN111. 15 V or

b Voltage measurement Less than 15 V CN111-7 (42) more
N1
15 V or more
Less than Material handling
Disconnect battery plug, disconnect Other than 15 V AC driver defect
CN112 120 ± 10 Ω
Less than
CN112-1 CN104-25 (42) 15 V
b Resistance measurement b Voltage measurement
CN112-2 N1
120 ± 10 Ω Resister defect 15 V or more
CPU board defect
Check the continuity of Harness defect
communication line harness No continuity (∞ Ω)
Harness defect
CN103-1 (145) ~ CN111-3 (145)
CN103-1 (145) ~ CN112-1 (145)
CN103-2 (146) ~ CN111-4 (146) Continuity (0 Ω) Material handling AC driver defect
CN103-3 (147) ~ CN111-6 (147)
4-37
AD-6 Material handling AC driver → main controller communication abnormality
Related portion
CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
CPU CN103-3 (147, CANGND) CN111-6 (147, CANGND) Material
board handling
J25 AC driver
CN111-2 (87, CUPID1)
CN112 CN111-10 (87, SSP-, TP-)
1
R
2
3

Output when the CPU board cannot receive ID code from the material handling AC driver upon key
switch on.
Was material handling AC driver YES • Check CN103, CN104, CN111 and CN112
just replaced? connection condition
NO • There is possibility that AD-6 error will be
displayed upon key switch turning to ON at first
Is AD-6 error displayed even if it repeats NO
time after replacing the material handling AC
the key switch with OFF and ON?
driver.
YES
CN111-7 (42)
Less than 15 V Disconnect CN111. 15 V or
b Voltage check
CN111-7 (42) more
N1
b Voltage check
15 V or more N1
Disconnect battery plug, disconnect Less than Material handling
Other than
CN112. 15 V AC driver defect
120 ± 10 Ω
CN112-1
b Resistance measurement Less than
CN104-25 (42)
CN112-2 15 V
b Voltage check
120 ± 10 Ω N1
Check the continuity of Resister defect 15 V or more
communication line harness. CPU board defect
Harness defect
CN103-2 (146) ~ CN111-4 (146)
CN103-2 (146) ~ CN112-2 (146)
CN103-3 (147) ~ CN111-6 (147)
Continuity (0 Ω)
CN111-2(87) No continuity (∞ Ω)
b Continuity check Harness defect
CN111-10(87)
Continuity (0 Ω)
Material handling AC driver defect
4-38
AF-1,2,3,4 CPU abnormality
Related portion
CPU board
CPU

Output when abnormality of CPU element is detected.

4-39
C4-1,2,3,4 Accelerator potentiometer abnormality
Related portion
CN132 CN26
CN102-1 (64, SWAC) CN26-2
12
CN102-2 (52, POTA) CN26-3

13
Accelerator
CN102-14 (53, POTA+) CN26-4
14 potentiometer
CPU
board CN130
CN102-22 (51, POT-) CN26-1
J22 9 J3

C4-1 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is on.
C4-2 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is on.
C4-3 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is off.
C4-4 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is being
operated.
• C4-1
ANL : I/O MONITOR 2 I/O 2-1

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

ANL : I/O MONITOR 2 I/O 2-1
changes.
Check the POTA value as the Potentiometer adjustment defect
accelerator is depressed further.
The POTA value does

not change.
Disconnect CN26, and short
Error is not indicated
between
POTA and POTA+ with SST8.
Error is indicated CN102-2 (52)
Potentiometer defect N1
4.8 V or more Less than 4.8 V
CPU board defect Main harness defect

4-40
• C4-2
Does C4-2 go out after YES
Accelerator potentiometer check
disconnecting CN26?
NO
CN102-2 (52) 4.5 V or more

b Voltage measurement Main harness defect
N1
Less than 4.5 V
CPU board defect
• C4-3

Check if the SWAC value changes 0 remains
Accelerator switch defect
from 0 to 1 as the accelerator
pedal is depressed.
Changes to 1.
ANL : I/O MONITOR 2 I/O2-1 Less than 2.5 V YES

Check maximum POTA value Is C4-3 error displayed?
when SWAC is 0.
NO
2.5 V or more
CPU board defect
Does C4-3 go out after YES

Accelerator potentiometer check
disconnecting CN26?
NO
CN102-2 (52)
2.5 V or more
b Voltage measurement Main harness defect
N1
Less than 2.5 V
CPU board defect
• C4-4
If C4-2, 3 occurs at the same time, perform troubleshooting for C4-2, 3 first.

Check the POTA value when the 1.4 V or more
Potentiometer adjustment defect
SWAC display is turned from 0 to
1 or from 1 to 0.
Less than 1.4 V
CPU board defect

4-41
C-7 Direction switch abnormality
Related portion
CN130 CN9
CN101-1 (45, DSF)
2 5
CPU CN101-2 (46, DSR) Direction

3 4
board switch
CN101-16 (51, LS-)
J21 1 J1 6

Output when both forward and reverse direction switches are ON.

disconnect CN9.
ANL : I/O MONITOR 2 I/O2-2 Becomes 0.

Direction switch inspection
Check the value of DSF, DSR.
DSF or DSR display will be 1.
CN101-1 (45)
CN101-2 (46) NG (Other than OK)
b Voltage measurement Harness short circuit
N1
OK (approx. 5 V)
CPU board defect

4-42
CB-1 MB contactor abnormality
Related portion
P1 CN104-14,15 (44, VBMB)
P2 F6
CN104-1,2 (18, B48V)
F5 CPU
MB contactor coil CN134 CN136 board
CN104-19 (1, MB+)
2
CN104-20 (2, MB-)
1

Output when the voltage difference between B48V and VBMB lines exceeds the set level.
If 31-1, 2, 3, A1-1, 2, 3, 4, AD-2, 4, 6, C1-2, 4 and E1-2 occurs at the same time, perform troubleshooting
for 31-1, 2, 3, A1-1, 2, 3, 4, AD-2, 4, 6, C1-2, 4 and E1-2 first.
Is the contactor ON sound heard NO
upon key switch ON? A
YES
Less than
ANL : I/O MONITOR1 I/O1-8,11 30V ANL : I/O MONITOR1 I/O1-8 Less than 43 V
Check the deference of voltage
VB48 : Battery voltage check
value between VB48 and VBMB.
43 V or more Battery charge
30 V or more
NG (∞ Ω)
F6 fuse check
OK (0 Ω) B
Replace F6 fuse
Check the deference of voltage
value between P1 and P2
P1, P2 30 V or more
MB contactor defect
N1
Less than 30 V
The voltage difference check of 1 and 2.

1.CN104-14 (44)
N1
30 V or more
2.CN104-1 (18) Harness check
N1
Check the deference of voltage value
between CN104-1 and CN104-147.
Less than 30 V
CPU board defect

4-43
Measure contactor signal voltage. Signal voltage check of CPU board

NG
Disconnect connector of contactor, connector. Less than 9 V
(Less than 9 V)
and measure voltage between CN104-19 (1)
connector terminals on CPU board b Voltage measurement
side. CN104-20 (2)
CPU board defect
OK (9 V or more) 9 V or more
MB contactor defect
Check the harness between CN104
and MB contactor.
ANL : I/O MONITOR1 I/O1-11

20 V or more
Check the VBMB voltage at the CPU board defect
time of traveling/material handling
operation.
Less than 20 V
Check the P2 voltage at the time of

traveling/material handling 20 V or more
operation. • F6 fuse check
P2 • Harness check
N1
Less than 20 V
MB contactor defect
4-44
CB-2 MB contactor fusion
Related portion
P1 CN104-14,15 (44, VBMB)

P2 F6
CPU
board
MB contactor coil CN134 CN136
2 CN104-19 (1, MB+)
CN104-20 (2, MB-)

1

Output when the battery (VBMB line) voltage does not drop after key switch OFF
If 30-3, 31-3, 33-3, A0-2, A1-4, A2-3, AC, AD-5, 6, E1-1, 2 and E2-1 occurs at the same time, perform
troubleshooting for 30-3, 31-3, 33-3, A0-2, A1-4, A2-3, AC, AD-5, 6, E1-1, 2 and E2-1 first.
Is contactor OFF sound heard upon YES Check voltage change upon key
key switch ON to OFF? switch OFF.
P2
NO A b Voltage measurement
N1
Disconnect battery plug, and Fusion Drop to 15 V or less in No voltage change
inspect contactor contact. 5 seconds after key upon key switch
switch OFF. OFF.
Normal
Replace
MB contactor. CPU board defect • Material handling AC driver
abnormality
Connect battery plug, turn key Although there was voltage
Error • Under Material handling
switch ON, and check the error change for a moment after
prohibition error generation
display. key switch OFF, it went up
again by more than 15 V.
No error
CPU board defect
Perform troubleshooting of the corresponding error.
Except CB-2
Is MB contactor turned OFF with YES Turn key switch ON, and check the
the key switch OFF? error display.
NO No error CB-2 display
Turn key switch OFF.

Check CN104,CN134,CN136
CN104-19 (1) NG (8 ~ 10 V) A
CN104-20 (2)
OK (0 V)
MB contactor defect • Harness leak
4-45
EE-1,2,3 Abnormal communication from multi-display
Related portion
CN131 CN1
CN103-13 (144, SMTDK) CN70-23
4 7
CN103-14 (143, SDTMK) CN70-24
5 4
CN103-15 (142, SDTMA) CN70-21
6 8
CPU CN103-16 (141, SMTDA) CN70-22 Display
7 3
board
CN103-10 (16, D15V) CN70-14

3 2
CN103-12 (14, GNDD) CN70-30
2 1

Output upon detection of communication data abnormality from display
• EE-1
YES
Is F1 error displayed? See F1 error
NO
Was the battery plug connected YES

when the display is removed? Connect the display
NO
Disconnect CN1
Does the display turn on upon key NO CN103-10 (16)
switch ON? b Voltage measurement
YES CN103-12 (14)
14 V or more Less than 14 V
• EE-2
• Sub harness defect • CPU board defect
• Display defect • Harness defect
Disconnect battery plug and NG

disconnect CN103 and CN70. (other than 0 Ω)
Check the continuity. • Connector connection defect
CN103-15 (142) ~ CN70-21 (142) • Harness defect
CN103-14 (143) ~ CN70-24 (143)
OK (Approx. 0 Ω)
• Display defect
• EE-3
• Reset the tuning value.
• If EE-3 is displayed frequently, either the CPU board or the display may be defective.
4-46
EF-1,2,4 Main controller EEP-ROM abnormality
Related portion
CPU board

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

Output when abnormality of CPU element is detected.

4-47
FF D15 overcurrent
Related portion
CN131 CN1
CN103-10 (16, D15V) CN70-14 (16, D15V)
CPU 3 J4 2 Multi-display
board CN103-12 (14, GNDD) CN70-30 (14, GNDD) board
2 1

Output when overcurrent of D15V power source is detected.
Disconnect CN70, connect battery No error

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

CN103, and measure the Approx.
resistance between 10 pin and 12 1 kΩ or less
Harness defect
pin of harness side.
CN103-10 pin (Tester probe -)
CN103-12 pin (Tester probe +)
Approx. 1 kΩ or more
CPU board defect

4-48
H1-1,2 Lift lever potentiometer abnormality
Related portion
CN41 CN77
CN102-18 (28,POTL+)
3 1
CN102-6 (20,POTL1)
1 2
CPU
board CN102-7 (21,POTL2) Lift lever
2 3
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the lift lever potentiometer is outside the specified range (open or short).
• Error indication (reference)
H1-1 Lift lever potentiometer open abnormality
H1-2 Lift lever potentiometer short abnormality
• H1-1
Do not operate the material handling lever during all checking.
H1-1 error is
Connect battery plug.
not indicated.
Turn key switch ON. Check connector connection
Lift lever at neutral position.
H1-1 error is
indicated.

Check the lift lever potentiometer
voltage.
Only voltage Only voltage Both voltage 1

1 is less than 2 is less than and 2 are less
0.3 V. 0.3 V. than 0.3 V.
A B C
4-49

Disconnect CN41.
H1-2 error is Connect CN41.
Short between CN41-3 (28) and H1-1 remains.
indicated. Replace the connectors of lift lever
CN41-1 (20) (at main harness side)
(CN77) with tilt lever (CN78).
with SST8.
Turn key switch ON.
Turn key switch ON.
H1-2 error is H1-1 changes
not indicated. to H2-1. Sub-harness defect
Lift potentiometer defect

Disconnect CN101 and CN102.
(SST8 is the connection state.) 1. No continuity
1. CN102-18 (28) 2. Continuity
b Continuity check Main harness defect
CN102-6 (20)
2. CN102-6 (20)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-50

Disconnect CN41.
with SST8.
Turn key switch ON.
Turn key switch ON.

CN102-7 (21)
2. CN102-7 (21)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-51

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

H1-2 error is
not indicated.
with SST8. CN102-7 (21)
H1-2 error is CN101-34 (51)
Disconnect battery plug. CPU board defect

Connect CN41.
Replace the connectors of lift lever H1-1 remains
Turn key switch ON.
H1-1 changes
to H2-1 Sub-harness defect

4-52
• H1-2
H1-2 error is
not indicated.
Lift lever at neutral position.
H1-2 error is
indicated.

Disconnect battery plug. H1-2 changes
Disconnect CN101 No continuity
Disconnect CN41. to H1-1.
CN101-34 (51)
Connect battery plug and turn the
b Continuity check
key switch to ON.
CN41-10 (51)
H1-2 remains.
Continuity
Main harness
defect
Disconnect CN102. Disconnect battery plug.
1. CN102-18 (28) 1. Continuity Connect CN41 and CN101.
b Continuity check 2. Continuity Replace the connectors of lift lever H1-2 remains
CN102-6 (20) (CN77) with tilt lever (CN78).
2. CN102-18 (28) Connect battery plug.
b Continuity check Turn key switch ON.
CN102-7 (21) H1-2 changes
Main harness to H2-2
1. No continuity defect Sub-harness defect
2. No continuity

CPU board defect
4-53
H1-3 Lift lever potentiometer abnormality
Related portion
CN41 CN77
CN102-18 (28,POTL+)
3 1
CN102-6 (20,POTL1)
1 2
CPU
2 3
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the lift lever potentiometers 1, 2 with the lift lever at neutral position is outside
the specified range.
H1-3 error is
not indicated.
Lift lever operation.
H1-3 error is
indicated.

Chek the lift lever potentiometer
voltage (*1)

Replace the connectors of the lift
lever (CN77) with the tilt lever
(CN78).
key switch to ON.

Within (*1) ± 0.2 V Lift lever potentiometer
Chek the tilt lever potentiometer
voltage defect
Below or above (*1) ± 0.2 V
A
4-54

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

0.3 V or more
Chek the lift lever potentiometer CPU board defect
voltage
0.3 V or less

Short at the connectors below (CPU
board side) with the alligator clip of
SST13 in connection.
switch ON.
CN101-11 (63) ~ CN102-6 (20)
CN101-11 (63) ~ CN102-7 (21)

4.5 V or more
Chek the lift lever potentiometer Harness defect
voltage
4.5 V or less
CPU board defect

4-55
Related portion
CN41 CN77
CN102-18 (28,POTL+)
3 1
CN102-6 (20,POTL1)
1 2
CPU
2 3
CN101-34 (51,POT-)
10 J49 4

Output when the lift lever voltage value is outside the specified neutral range (lever operated) upon key
switch ON.
H1-4 Lift lever neutral abnormality
Check that the lift lever returned to

neutral position. H1-4 goes out.
Normal
Turn key switch ON again. Do not operate the lever upon key switch ON.
H1-4 remains.
Check the installation state of the lift NG

lever potentiometer. Readjustment
OK
MATCHING: LIFT
Perform matching of the lift lever OK
Vehicle operation can be started.
potentiometer neutral voltage
again.
NG

4-56
Related portion
CPU board

Output when lift lever neutral matching value is outside the specified range.
H1-5 Lift lever neutral matching value abnormality

4-57
H2-1,2 Tilt lever potentiometer abnormality
Related portion
CN41 CN78
CN102-19 (29,POTT+)
6 1
CN102-8 (22,POTT1)
4 2
CPU
board CN102-9 (23,POTT2) Tilt lever
5 3
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the tilt lever potentiometer is outside the specified range (open or short).
H2-1 Tilt lever potentiometer open
H2-2 Tilt lever potentiometer short
• H2-1
H2-1 error is
not indicated.
Tilt lever at neutral position.
H2-1 error is
indicated.

voltage.

0.3 V. 0.3 V. than 0.3 V.
A B C
4-58

Disconnect CN41.
with SST8.
Turn key switch ON.
Turn key switch ON.
Tilt potentiometer defect

CN102-8 (22)
2. CN102-8 (22)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-59

Disconnect CN41.
with SST8.
Turn key switch ON.
Turn key switch ON.

CN102-9 (23)
2. CN102-9 (23)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-60

H2-2 error is
not indicated.
with SST8. CN102-8 (22)
H2-2 error is CN101-34 (51)
CPU board defect

H2-2 error is
not indicated.
with SST8. CN102-9 (23)
H2-2 error is CN101-34 (51)

Connect CN41.
Replace the connectors of lift lever H2-1 remains.
Turn key switch ON.
H2-1 changes
to H1-1. Sub-harness defect

4-61
• H2-2
H2-2 error is
not indicated.
Tilt lever at neutral position.
H2-2 error is
indicated.

CN101-34 (51)
b Continuity check
key switch to ON.
CN41-10 (51)
H2-2 remains.
Continuity
Main harness
defect
1. CN102-19 (29) 1. Continuity Connect CN41 and CN101.
b Continuity check 2. Continuity Replace the connectors of lift lever H2-2 remains.
CN102-8 (22) (CN77) with tilt lever (CN78).
2. CN102-19 (29) Connect battery plug.
b Continuity check Turn key switch ON.
CN102-9 (23) H2-2 changes
Main harness to H1-2.
2. No continuity

CPU board defect
4-62
H2-3 Tilt lever potentiometer abnormality
Related portion
CN41 CN78
CN102-19 (29,POTT+)
6 1
CN102-8 (22,POTT1)
4 2
CPU
5 3
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the tilt lever potentiometers 1, 2 with the tilt lever at neutral position is outside
the specified range.
H2-3 error is
not indicated.
Tilt lever operation.
H2-3 error is
indicated

voltage. (*1)

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

Within (*1) ± 0.2 V Tilt lever potentiometer
voltage. defect
A
4-63

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

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

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

4.5 V or more
Chek the tilt lever potentiometer Harness defect
voltage
4.5 V or less
CPU board defect

4-64
Related portion
CN41 CN78
CN102-19 (29,POTT+)
6 1
CN102-8 (22,POTT1)
4 2
CPU
5 3
CN101-34 (51,POT-)
10 J49 4

Output when the tilt lever voltage value is outside the specified neutral range (lever operated) upon key
switch ON.
H2-4 Tilt lever neutral abnormality
Check that the tilt lever returned to

neutral position. H2-4 goes out.
Normal
H2-4 remains.
Check the installation state of the tilt NG

lever potentiometer. Readjustment
OK
MATCHING: LIFT
Perform matching of the tilt lever OK
potentiometer neutral voltage
again.
NG

4-65
Related portion
CPU board

Output when tilt lever neutral matching value is outside the specified range.
H2-5 Tilt lever neutral matching abnormality
4-66
H3-1,2 Attachment 1 lever potentiometer abnormality
Related portion
CN41 CN79
CN102-20 (30,POTAT1+)
9 1
CN102-10 (24,POTAT11)
7 2
CPU Attachment 1
board CN102-11 (25,POTAT12) lever
8 3
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the attachment 1 lever potentiometer is outside the specified range (open or
short).
H3-1 Attachment 1 lever potentiometer open
H3-2 Attachment 1 lever potentiometer short
• H3-1
Connect battery plug. H3-1 error is
Turn key switch ON. not indicated.
Attachment 1 lever at neutral Check connector connection
position.
H3-1 error is
indicated.

Chek the attachment 1 lever
potentiometer voltage.

0.3 V. 0.3 V. than 0.3 V.
A B C
4-67
Disconnect battery plug. Disconnect battery plug.

Disconnect CN41. Connect CN41.
H3-2 error is
Short between CN41-9 (30) and Replace the connectors of the lift H3-1 remains.
indicated.
CN41-7 (24) (at main harness side) lever (CN77) with the attachment 1
with SST8. lever (CN79).
Connect battery plug. Connect battery plug.
Turn key switch ON. Turn key switch ON.
Disconnect battery plug. Attachment 1 potentiometer

Disconnect CN101 and CN102. defect
CN102-10 (24)
2. CN102-10 (24)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-68

Disconnect CN41. Connect CN41.
H3-2 error is
indicated.

CN102-11 (25)
2. CN102-11 (25)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-69

H3-2 error is
not indicated.
with SST8. CN102-10 (24)
H3-2 error is CN101-34 (51)
CPU board defect

H3-2 error is
not indicated.
with SST8. CN102-11 (25)
H3-2 error is CN101-34 (51)

Connect CN41.
Replace the connectors of the lift H3-1 remains.
lever (CN77) with the attachment 1
lever (CN79).
Turn key switch ON.
H3-1 changes

4-70
• H3-2
H3-2 error is
not indicated.
Attachment 1 lever at neutral
position.
H3-2 error is
indicated.

CN101-34 (51)
b Continuity check
key switch to ON.
CN41-10 (51)
H3-2 remains.
Continuity
Main harness
defect
1. CN102-20 (30) 1. Continuity Connect CN41.
b Continuity check 2. Continuity Replace the connectors of the lift H3-2 remains.
CN102-10 (24) lever (CN77) with the attachment 1
2. CN102-20 (30) lever (CN79).
b Continuity check Connect battery plug.
CN102-11 (25) Turn key switch ON.
Main harness H3-2 changes
2. No continuity to H1-2.
CPU board defect Attachment 1 potentiometer defect

4-71
H3-3 Attachment 1 lever potentiometer abnormality
Related portion
CN41 CN79
CN102-20 (30,POTAT1+)
9 1
CN102-10 (24,POTAT11)
7 2
CPU Attachment 1
8 3
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the attachment 1 lever potentiometer 1, 2 with the attachment 1 lever at
neutral position is outside the specified range.
H3-3 error is
not indicated.
Attachment 1 lever operation.
H3-3 error is
indicated

potentiometer voltage. (*1)

lever (CN79).
key switch to ON.

Within (*1) ± 0.2 V Attachment 1 potentiometer
voltage. defect
A
4-72

Disconnect CN102.
(CN77) and the attachment 1 lever
connector (CN79) to the original
connection.
switch ON.

0.3 V or more
Chek the attachment 1 lever CPU board defect
0.3 V or less

switch ON.
CN101-11 (63) ~ CN102-10 (24)
CN101-11 (63) ~ CN102-11 (25)

4.5 V or more
Chek the attachment 1 lever Harness defect
4.5 V or less
CPU board defect

4-73
Related portion
CN41 CN79
CN102-20 (30,POTAT1+)
9 1
CN102-10 (24,POTAT11)
7 2
CPU Attachment 1
8 3
CN101-34 (51,POT-)
10 J49 4

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

returned to neutral position. H3-4 goes out.
Normal
H3-4 remains.
Check the installation state of the NG

attachment 1 lever potentiometer. Readjustment
OK
MATCHING: ATT1
Perform matching of the OK
attachment 1 lever potentiometer
neutral voltage again.
NG
Attachment 1 potentiometer
defect
4-74
Related portion
CPU board

Output when attachment 1 lever neutral matching value is outside the specified range.
H3-5 Attachment 1 lever neutral matching value abnormality
4-75
H4-1,2 Attachment 2 lever potentiometer abnormality
Related portion
CN42 CN80
CN102-21 (31,POTAT2+)
3 1
CN102-12 (26,POTAT21)
1 2
CPU Attachment 2
2 3
CN41
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the attachment 2 lever potentiometer is outside the specified range (open or
short).
H4-1 Attachment 2 lever potentiometer open
H4-2 Attachment 2 lever potentiometer short
• H4-1
Attachment 2 lever at neutral Check connector connection
position.
H4-1 error is
indicated.

Check the attachment 2 lever

0.3 V. 0.3 V. than 0.3 V.
A B C
4-76

Disconnect CN41, CN42. Connect CN41, CN42.
H4-2 error is
indicated.

CN102-12 (26)
2. CN102-12 (26)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-77

Disconnect CN41, CN42. Connect CN41, CN42.
H4-2 error is
indicated.

CN102-13 (27)
2. CN102-13 (27)
b Continuity check
CN101-34 (51)
1. Continuity
2. No continuity
CPU board defect

4-78

Disconnect CN41, CN42. (SST8 is the connection state.) 1. No continuity
H4-2 error is
not indicated.
with SST8. CN102-12 (26)
H4-2 error is CN101-34 (51)
CPU board defect

Disconnect SST8 from CN41. (SST8 is the connection state.) 1. No continuity
H4-2 error is
not indicated.
with SST8. CN102-13 (27)
H4-2 error is CN101-34 (51)

Connect CN41, CN42.
Replace the connectors of the lift H4-1 remains.
lever (CN80).
Turn key switch ON.
H4-1 changes
defect
4-79
• H4-2
H4-2 error is
not indicated.
Attachment 2 lever at neutral
position.
H4-2 error is
indicated.

Disconnect CN41, CN42. to H4-1.
CN101-34 (51)
b Continuity check
key switch to ON.
CN41-10 (51)
H4-2 remains.
Continuity
Main harness
defect
1. CN102-21 (31) 1. Continuity Connect CN41, CN42.
b Continuity check 2. Continuity Replace the connectors of the lift H4-2 remains.
CN102-12 (26) lever (CN77) with the attachment 2
2. CN102-21 (31) lever (CN80).
b Continuity check Connect battery plug.
CN102-13 (27) Turn key switch ON.
Main harness H4-2 changes
2. No continuity to H1-2.
CPU board defect Attachment 2 potentiometer

defect
4-80
Related portion
CN42 CN80
CN102-21 (31,POTAT2+)
3 1
CN102-12 (26,POTAT21)
1 2
CPU Attachment 2
2 3
CN41
CN101-34 (51,POT-)
10 J49 4

Output when the voltage of the attachment 2 lever potentiometer 1, 2 with the attachment 2 lever at
neutral position is outside the specified range.
H4-3 error is
not indicated.
Attachment 2 lever operation.
H4-3 error is
indicated

potentiometer voltage. (*1)

lever (CN80).
key switch to ON.

Within (*1) ± 0.2 V Attachment 2 potentiometer
voltage. defect
A
4-81

Disconnect CN102.
(CN77) and the attachment 2 lever
connector (CN80) to the original
connection.
switch ON.

0.3 V or more
Chek the attachment 2 lever CPU board defect
0.3 V or less

switch ON.
CN101-11 (63) ~ CN102-12 (26)
CN101-11 (63) ~ CN102-13 (27)

4.5 V or more
Chek the attachment 2 lever Harness defect
4.5 V or less
CPU board defect

4-82
Related portion
CN42 CN80
CN102-21 (31,POTAT2+)
3 1
CN102-12 (26,POTAT21)
1 2
CPU Attachment 2
2 3
CN41
CN101-34 (51,POT-)
10 J49 4

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

returned to neutral position. H4-4 goes out.
Normal
H4-4 remains.
Check the installation state of the NG

Readjustment
attachment 2 lever potentiometer.
OK
MATCHING: ATT2
Perform matching of the OK
attachment 2 lever potentiometer
neutral voltage again.
NG
defect
4-83
Related portion
CPU board

Output when attachment 2 lever neutral matching value is outside the specified range.
H4-5 Attachment 2 lever neutral abnormality
4-84
H5-1,2,3,4,5 Lift solenoid abnormality
Related portion
CN130 CN75
CN104-3 (3,SOL1+) J45
14 4
Lift a1 (DOWN)
CN104-5 (5,SOLa1) solenoid
15 8
CPU
board CN74
4
CN132 Lift b1 (UP)
CN104-4 (4,SOLb1) solenoid
15 8

Output when open or short circuit is detected in the lift solenoid line from CPU board to the lift solenoid
(raise and/or lower).
H5-1 Lift b1 (UP) solenoid open-circuit abnormality
H5-2 Lift b1 (UP) solenoid load short-circuit abnormality
H5-1 Lift a1 (DOWN) solenoid open-circuit abnormality
H5-2 Lift a1 (DOWN) solenoid load short-circuit abnormality
H5-5 Lift solenoid drive circuit MOS short-circuit
• H5-1
H5-1 error is
not indicated.
Lift raising operation.
H5-1 error is indicated.

0.1 A or more
Check lift solenoid current (during CPU board defect
lift raising operation).
0.1 A or less

Replace CN74 with CN75.
(Use SST 20)
Connect battery plug and turn key H5-1 error is

switch ON. not indicated.
Lift b1 (UP) solenoid defect
Lift raising operation. (note that lift
on the vehicle is lowered.)
Harness defect
4-85
• H5-2
H5-2 error is
not indicated.

Disconnect CN74.

Turn key switch ON. indicated.
Lift b1 (UP) solenoid defect

b Continuity check
CN104-4 (4)
No continuity
CPU board defect
• H5-3
H5-3 error is
not indicated.
Lift lowering operation.

0.1 A or more
Check lift solenoid current (during CPU board defect
lift lowering operation).
0.1 A or less

(Use SST 20)

Lift a1 (DOWN) solenoid defect
Lift lowering operation. (note that lift
on the vehicle is raised.)
Harness defect
4-86
• H5-4
H5-4 error is
not indicated.

Disconnect CN75.

Lift a1 (DOWN) solenoid defect

b Continuity check
CN104-5 (5)
No continuity
CPU board defect
• H5-5
Check connector connection
Lift raising/lowering operation.
H5-5 error is
indicated.

Disconnect CN104.
switch ON. 10 V or more
Lift lever at neutral position. Harness defect
Check the voltage between
CN104-3 (3) and CN104-23 (N2),
CN104-5 (5) and CN104-23 (N2),
CN104-4 (4) and CN104-23 (N2).
10 V or less
CPU board defect

4-87
H6-1,2,3,4,5 Tilt solenoid abnormality
Related portion
CN130 CN75
CN104-6 (6,SOL2+) J46
16 3
Tilt a2 (FRONT)
17 3
CPU
board CN74
CN132 7
Tilt b2 (REAR)
16 7

Output when open or short circuit is detected in the tilt solenoid line from CPU board to the tilt solenoid
(forward and/or backward).
H6-1 Tilt a2 (FRONT) solenoid open-circuit abnormality
H6-2 Tilt a2 (FRONT) solenoid load short-circuit abnormality
H6-3 Tilt b2 (REAR) solenoid open-circuit abnormality
H6-4 Tilt b2 (REAR) solenoid load short-circuit abnormality
H6-5 Tilt solenoid drive circuit MOS short-circuit
• H6-1
H6-1 error is
not indicated.
Forward tilt operation.

0.1 A or more
Check tilt solenoid current (during CPU board defect
forward tilt operation).
0.1 A or less

(Use SST 20)

H6-1 error is
switch ON.
not indicated.
Forward tilt operation. (note that Tilt a2 (FRONT) solenoid defect
mast is tilted backward on the
vehicle.)
Harness defect
4-88
• H6-2
H6-2 error is
not indicated.

Disconnect CN75.

Tilt a2 (FRONT) solenoid defect

b Continuity check
CN104-7 (7)
No continuity
CPU board defect
• H6-3
H6-3 error is
not indicated.
Backward tilt operation.

0.1 A or more
Check tilt solenoid current (during CPU board defect
backward tilt operation).
0.1 A or less

(Use SST 20)

H6-3 error is
switch ON.
not indicated.
Backward tilt operation. (note that Tilt b2 (REAR) solenoid defect
mast is tilted forward on the
vehicle.)
Harness defect
4-89
• H6-4
H6-4 error is
not indicated.
Backward tilt operation.

Disconnect CN74.

Tilt b2 (REAR) solenoid defect

b Continuity check
CN104-8 (8)
No continuity
CPU board defect
• H6-5
Forward/backward tilt operation.
H6-5 error is
indicated.

Disconnect CN104.
Tilt lever at neutral position. Harness defect
CN104-6 (6) and CN104-23 (N2),
CN104-7 (7) and CN104-23 (N2),
CN104-8 (8) and CN104-23 (N2).
10 V or less
CPU board defect

4-90
H7-1,2,3,4,5 Attachment 1 solenoid abnormality
Related portion
CN131 CN75
CN104-11 (9,SOL3+) J47
8 2
Attachment 1
CN104-13 (11,SOLb3) b3 solenoid
17 6
CPU
board CN132 CN74
CN131 2
Attachment 1
CN104-12 (10,SOLa3) a3 solenoid
9 6

Output when open or short circuit is detected in the attachment 1 solenoid line from the CPU board to the
attachment 1 solenoid (raise and/or lower).
H7-1 Attachment 1 a3 solenoid open-circuit abnormality
H7-2 Attachment 1 a3 solenoid load short-circuit abnormality
H7-3 Attachment 1 b3 solenoid open-circuit abnormality
H7-4 Attachment 1 b3 solenoid load short-circuit abnormality
H7-5 Attachment 1 solenoid drive circuit MOS short-circuit
• H7-1
H7-1 error is
not indicated.
Attachment 1 raising operation.

Check attachment 1 solenoid 0.1 A or more
current (during attachment 1 CPU board defect
raising operation).
0.1 A or less

(Use SST 20)

Attachment 1 raising operation. Attachment 1 a3 solenoid defect
(note that the attachment 1 is
lowered on the vehicle.)
Harness defect
4-91
• H7-2
H7-2 error is
not indicated.

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

Disconnect CN104.
Continuity
b Continuity check
CN104-12 (10)
No continuity
CPU board defect
• H7-3
H7-3 error is
not indicated.
Attachment 1 lowering operation.

lowering operation).
0.1 A or less

(Use SST 20)

Attachment 1 lowering operation. Attachment 1 b3 solenoid defect
(note that the attachment 1 is raised
on the vehicle.)
Harness defect
4-92
• H7-4
H7-4 error is
not indicated.

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

Disconnect CN104.
Continuity
b Continuity check
CN104-13 (11)
No continuity
CPU board defect
• H7-5
Attachment 1 raising/lowering
operation.
H7-5 error is
indicated.

Disconnect CN104.
switch ON.
Attachment 1 lever at neutral 10 V or more
Harness defect
position.
CN104-11 (9) and CN104-23 (N2),
CN104-12 (10) and CN104-23 (N2),
CN104-13 (11) and CN104-23 (N2).
10 V or less
CPU board defect

4-93
H8-1,2,3,4,5 Attachment 2 solenoid abnormality
Related portion
CN131 CN75
CN104-16 (34,SOL4+) J48
11 1
Attachment 2 a4
12 5
CPU
board CN74
CN132 1
Attachment 2 b4
18 5

Output when open or short circuit is detected in the attachment 2 solenoid line from the CPU board to the
attachment 2 solenoid (forward and/or backward).
H8-1 Attachment 2 a4 solenoid open-circuit abnormality
H8-2 Attachment 2 a4 solenoid load short-circuit abnormality
H8-3 Attachment 2 b4 solenoid open-circuit abnormality
H8-4 Attachment 2 b4 solenoid load short-circuit abnormality
H8-5 Attachment 2 solenoid drive circuit MOS short-circuit
• H8-1
H8-1 error is
not indicated.
Attachment 2 forward tilt operation.

forward tilt operation).
0.1 A or less

(Use SST 20)

Attachment 2 forward tilt operation. Attachment 2 a4 solenoid defect
(note that the attachment 2 is tilted
backward on the vehicle.)
Harness defect
4-94
• H8-2
H8-2 error is
not indicated.

Disconnect CN75.
H8-1 error is
indicated.
Turn key switch ON. Attachment 2 a4 solenoid defect

Disconnect CN104.
Continuity
b Continuity check
CN104-17 (35)
No continuity
CPU board defect
• H8-3
Attachment 2 backward tilt Check connector connection
operation.

backward tilt operation).
0.1 A or less

(Use SST 20)

Attachment 2 backward tilt Attachment 2 b4 solenoid defect
operation. (note that the attachment
2 is tilted forward on the vehicle.)
Harness defect
4-95
• H8-4
Attachment 2 backward tilt Check connector connection
operation.

Disconnect CN74.

Attachment 2 b4 solenoid defect
Attachment 2 backward tilt
operation.

Disconnect CN104.
Continuity
b Continuity check
CN104-18 (36)
No continuity
CPU board defect
• H8-5
Attachment 2 forward/backward
operation.
H8-5 error is
indicated.

Disconnect CN104.
switch ON.
Attachment 2 lever at neutral 10 V or more
Harness defect
position.
CN104-16 (34) and CN104-23 (N2),
CN104-17 (35) and CN104-23 (N2),
CN104-18 (36) and CN104-23 (N2).
10 V or less
CPU board defect

4-96
VV
H9-1,2,3 Unload valve solenoid abnormality
Related portion
CN132 CN76
CN104-26 (12,SOLP+)
1 1
CPU Unload valve
board CN104-27 (13,SOLP-) solenoid
2 2
CN130

Output when open or short circuit is detected in the unload valve solenoid line from the CPU board to the
unload valve solenoid.
H9-1 Unload valve solenoid open-circuit abnormality
H9-2 Unload valve solenoid load short-circuit abnormality
H9-3 Unload valve solenoid drive circuit MOS short-circuit
• H9-1
ACTIVE TEST : ACT-3 PSOL H9-1 error is

Set the unload valve solenoid to not indicated.
ON in the ACTIVE TEST. Check connector connection
(Connect battery plug and turn key
switch ON.)
H9-1 error is
indicated.

Disconnect CN104
CN104-26 (12) 9.9±1 Ω (at 25 °C)
CPU board defect
b Harness continuity check
CN104-27 (13)
Other than 9.9±1Ω

(at 25°C)
Disconnect CN76
CN76-1 (12)
b Solenoid resistance check 9.9±1 Ω (at 25 °C)
Other than 9.9±1 Ω

(at 25 °C)
Unload valve solenoid defect

4-97
• H9-2
ACTIVE TEST : ACT-3 PSOL H9-2 error is

Set the unload valve solenoid to not indicated.
switch ON.)

Disconnect CN76.
ACTIVE TEST : ACT-3 PSOL

H9-2 error is
Set the unload valve solenoid to
not indicated.
ON in the ACTIVE TEST. Unload valve solenoid defect
switch ON.)

Disconnect CN104. Continuity exists
b Harness continuity check
CN104-27 (13)
No continuity
CPU board defect
• H9-3
ACTIVE TEST : ACT-3 PSOL

H9-3 error is
Set the unload valve solenoid to
not indicated.
switch ON.)

Disconnect CN104.
Voltage check (short circuit in the Harness defect
harness) between
CN104-26 (12) and CN104-23 (N2),
CN104-27 (13) and CN104-23 (N2).
10 V or less
CPU board defect

4-98
TRAVELING/MATERIAL HANDLING AC DRIVER
30-1 Traveling AC driver 1 low voltage
Related portion
P1 P2 F1 P3
Traveling
AC driver 1

Output when low voltage of the battery (P3) line of the traveling AC driver 1 is detected.
If 31-1 and CB-1 occurs at the same time, perform troubleshooting for 31-1 and CB-1 first.
31-1 error is
indicated.
Turn key switch ON. Perform troubleshooting for 31-1
No error
30-1 error is ANL : I/O MONITOR 1 I/O1-12
indicated. Turn key switch OFF and then ON 15 V or more
During traveling operation, does an again. With traveling operation,
error come on? check the VBBD voltage when an
error occurs.
CB-1 error is No error
indicated. Traveling AC
Less than 15 V
driver 1 defect
• P3 cable and terminal check
• F1 fuse check ANL : I/O MONITOR 1 I/O1-8
Turn key switch OFF and then ON Less than 15 V
Perform troubleshooting again. With traveling operation,
for CB-1 check the VB48 voltage when an
error occurs.
• Battery plug check
15 V or more
• Battery charge
Turn key switch OFF and then ON Turn key switch OFF and then ON
again. With traveling operation, Less than again. With traveling operation,
check the battery voltage between 15 V check the traveling AC driver 1
P2 and N1 when an error occurs. input voltage between P3 and N1
P2 when an error occurs.
b Voltage measurement P3
N1
Less than 15 V 15 V or more
15 V or more
MB contactor defect • P3 cable and terminal check
• F1 fuse check
4-99
30-2 Traveling AC driver 2 low voltage
Related portion
P1 P2 F1 P3
Traveling
AC driver 2

Output when low voltage of the battery (P3) line of the traveling AC driver 2 is detected.
31-2 error is
indicated.
No error

During traveling operation, does an again. With traveling operation,
error come on? check the VBBD voltage when an
error occurs.
CB-1 error No error
is indicated. Less than 15 V Traveling AC
driver 2 defect
• F1 fuse check
Perform troubleshooting Turn key switch OFF and then ON Less than 15 V
for CB-1 again. With traveling operation,
check the VB48 voltage when an
error occurs.
15 V or more • Battery plug check

• Battery charge
check the battery voltage between 15 V check the traveling AC driver 2 input
P2 and N1 when an error occurs. voltage between P3 and N1 when an
P2 error occurs.
Less than 15 V 15 V or more N1
15 V or more

• F1 fuse check Traveling AC driver 2 defect
4-100
30-3 Material handling AC driver low voltage
Related portion
P1 P2 F1 P3
Material
handling
AC driver

Output when low voltage of the battery (P3) line of the material handling AC driver is detected.
31-3 error is
indicated.
No error

During lifting operation is carried again. With traveling operation,
out, does an error come on? check the VBBP voltage when an
error occurs.
CB-1 error is No error
indicated. Less than 15 V Material handling
AC driver defect
• F1 fuse check ANL : I/O MONITOR 1 I/O1-8
Turn key switch OFF and then ON Less than 15 V
Perform troubleshooting again. With traveling operation,
for CB-1 check the VB48 voltage at the time
of an error.
15 V or more • Battery plug check

• Battery charge
check the battery voltage between 15 V check the material handling AC
P2 and N1 when an error occurs. driver input voltage between P3 and
P2 N1 when an error occurs.
Less than 15 V 15 V or more N1
15 V or more

• F1 fuse check Material handling AC driver defect
4-101
31-1 Traveling AC driver 1 low starting voltage
Related portion
P1 P2 F1
P3
Traveling
AC driver 1
CPR
CN104-9 (55, CPR)
CPU
F5
CN104-2 (18, B48V) board

Output when voltage of P3 of the traveling AC driver 1 is detected not to exceed the set level.
31-1 error is
indicated ANL : I/O MONITOR 1 I/O1-12 23 V or more
Turn key switch ON.
VBBD : Voltage check
No error
Less than 23 V
Check the traveling AC driver 1 defect
• Battery plug check
input voltage between P3 and N1. 23 V or more
• Traveling AC driver cable and terminal check
P3
• CPR check
• Harness check
N1

defect
23 V or more ANL : I/O MONITOR 1 I/O1-9
Check the CPR resistance
VBKS : Key start voltage check
Approx. 20 Ω Other than
approx. 20 Ω Less than 23 V
F1 fuse check CPR defect ANL : I/O MONITOR 1 I/O1-8 23 V or more

B48V : Voltage check
Less than 23 V
CPU board defect

Check the battery voltage
P1 23 V or more
N1
Less than 23 V
• F5 fuse check
Battery charge • Harness check
4-102
31-2 Traveling AC driver 2 low starting voltage
Related portion
P1 P2 F1
P3 Traveling
AC driver 2
CPR
CN104-9 (55, CPR)
CPU
F5
CN104-2 (18, B48V) board

Output when voltage of P3 of the traveling AC driver 2 is detected not to exceed the set level.
31-2 error is
Turn key switch ON. VBBD : Voltage check
No error
Less than 23 V
defect
• Battery plug check Check the traveling AC driver 2
• Traveling AC driver cable and terminal check input voltage between P3 and N1. 23 V or more
• CPR check P3
• Harness check b Voltage measurement
N1

defect
VBKS : Voltage check
ANL : I/O MONITOR 1 I/O1-8 23 V or more

F1 fuse check CPR defect
Less than 23 V
CPU board defect

P1 23 V or more
N1
Less than 23 V • F5 fuse check
• Harness check
Battery charge
4-103
31-3 Material handling AC driver low starting voltage
Related portion
F1
P1 P2 P3 Material
handling
AC driver
CPR
CN104-9 (55, CPR)
CPU
F5
CN104-2 (18, B48V) board

Output when voltage of P3 of the material handling AC driver is detected not to exceed the set level.
31-3 error is
Turn key switch ON.
VBBP voltage check
No error
Less than 23 V
Material handling
AC driver defect
• Battery plug check Check the material handling AC

• Material handling AC driver cable and terminal driver input voltage. 23 V or more
check P3
• CPR check b Voltage measurement
• Harness check N1
Less than 23 V Material handling

AC driver defect

VBKS : Voltage check
F1 fuse check CPR defect ANL : I/O MONITOR 1 I/O1-8 23 V or more

Less than 23 V
CPU board defect

P1 23 V or more
N1
Less than 23 V • F5 fuse check
• Harness check
Battery charge
4-104
32-1 Traveling AC driver 1 EEPROM abnormality
Related portion

Data abnormality when traveling AC driver 1 is activated
EEPROM element of traveling AC driver 1 CPU board damaged
Turn key switch OFF and ON No error Was traveling AC driver 1 just
several times. replaced?
32-1 error is indicated. NO YES
Traveling AC driver 1 defect Traveling AC driver 1 connector Normal

check (ID signal)
32-2 Traveling AC driver 2 EEPROM abnormality
Related portion

Data abnormality when traveling AC driver 2 is activated
EEPROM element of traveling AC driver 2 CPU board damaged
Turn key switch OFF and ON No error Was traveling AC driver 2 just
several times replaced?
32-2 error is indicated NO YES
Traveling AC driver 2 defect Traveling AC driver 2 connector Normal

check (ID signal)
4-105
32-3 Material handling AC driver EEPROM abnormality
Related portion

Data abnormality when pump motor circuit is activated
EEPROM element of pump motor driver CPU board damaged
32-3 error is
Turn key switch OFF and ON indicated
several times. Material handling AC driver defect
No error
Was material handling AC driver YES

just replaced? Normal
NO

connector check (ID signal)
4-106
33-1 Main controller → Traveling AC driver 1 communication abnormality
Related portion
CN103-1 (145, CANH) CN110-3 (145, CANH)

CN103-2 (146, CANL) CN110-4 (146, CANL)
CN103-3 (147, CANGND) CN110-6 (147, CANGND)
Traveling
CPU
AC driver 1
board CN104-25 (42, KEYSTART) CN110-7 (42, KEYSTART)
J25
CN112
1
R
2
3

Output when the traveling AC driver 1 cannot receive data from the CPU board within specified time.
Does AD-1 error display or YES

Perform troubleshooting for AD-1.
diagnosis memory memorize?
NO
Check CN103, CN104, CN110 and CN112

Was traveling AC driver 1 just YES connection condition. Turn key switch OFF and
replaced? ON, and it checks that an error is not displayed.
NO
No error • CN103, CN104, CN110, CN112 connector check

Turn key switch ON.
• Harness check
33-1 error is indicated. AD-1 or AD-2
(AD-1 and AD-2 are is indicated.
not indicated.)
Perform troubleshooting for AD-1 or AD-2.
• Harness check
• Traveling AC driver 1 defect
4-107
33-2 Main controller → Traveling AC driver 2 communication abnormality
Related portion
CN103-1 (145, CANH) CN109-3 (145, CANH)

CN103-2 (146, CANL) CN109-4 (146, CANL)
CPU Traveling
board CN104-25 (42, KEYSTART) CN109-7 (42, KEYSTART) AC driver2
J25
CN112
1
R
2
3

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

NO

Was traveling AC driver 2 just YES connection condition. Turn key switch OFF and
replaced? ON, and it checks that an error is not displayed.
NO
No error
Turn key switch ON. • CN103, CN104, CN109, CN112 connector check
33-2 error is indicated. AD-3 or AD-4 • Harness check
(AD-3 and AD-4 are is indicated.
not indicated.)
Perform troubleshooting for AD-3 or AD-4.
• Harness check
• Traveling AC driver 2 defect
4-108
33-3 Main controller → Material handling AC driver communication abnormality
Related portion
CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
Material
CPU
handling
board CN104-25 (42, KEYSTART) CN111-7 (42, KEYSTART)
J25 AC driver
CN112
1
R
2
3

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

NO

Is material handling AC driver just YES connection condition. Turn key switch OFF and ON,
replaced? and it checks that an error is not displayed.
NO
No error • CN103, CN104, CN111, CN112 connector check

Turn key switch ON.
• Harness check
33-3 error is indicated. AD-5 or AD-6 is
(AD-5 and AD-6 are indicated.
not indicated.)
Perform troubleshooting for AD-5

or AD-6.
• Harness check
• Material handling AC driver defect
4-109
A0-1 Main drive circuit overheat
Related portion
CN104-14,15 (44, VBMB) 1 CN113

J30
CN101-9 (39, FAN-) 2 FAN
J23
Short harness
CN105-2 (FAN-) Traveling
CPU CN105-3 (FAN-) AC driver 1 1 CN114
board CN105-4 (FAN1) FAN
Traveling 2
CN105-5 (FAN2)
AC driver 2
CN105-6 (FAN3)
CN105-7 (FAN4)
CN105-8 (FAN5)
CN105-9 (FAN6)

Output when the temperature detected by the main drive circuit thermo-sensor exceeds the set level.
Allow the vehicle to stand for a

No abnormality
while (about 15 min.) and operate. Normal
Immediate indication of
overheat warning
The temperature
ANL : ACTIVE TEST ACT-1 ANL : I/O MONITOR 1 I/O1-1
Run does not change.
Turn all cooling fans ON and THCD : Check the value of
check that they run normally. traveling AC driver thermo-sensor
while traveling.
Not run
The temperature
changes.
Traveling AC driver 1/2 defect
• Is the exhaust port covered with paper?
• Is it overloaded?
Less than Short harness continuity check
ANL : ACTIVE TEST ACT-1
20 V CN105-2,3 Some 0 Ω
Turn the cooling fan ON and check
the voltage. b Resistance measurement
CN105-4,5,6,7,8,9
20 V or more
All ∞
CPU board defect
CN113-1 Short harness defect
b Voltage measurement 20 V or
CN113-2 more • Fan check
CN114-1 • Connector connection check
CN114-2
Less than 20 V
CN104~CN113, CN104~CN114 Harness defect

4-110
A0-2 Main pump circuit overheat
Related portion
CN104-14,15 (44, VBMB) 1 CN113

J30
CN101-9 (39, FAN-) 2 FAN
J23
Short harness
CN105-2 (FAN-)
Material 1 CN114
CPU CN105-3 (FAN-) handling
board CN105-4 (FAN1) AC driver 2 FAN
CN105-5 (FAN2)
CN105-6 (FAN3)
CN105-7 (FAN4)
CN105-8 (FAN5)
CN105-9 (FAN6)

Output when the temperature detected by the main pump circuit thermo-sensor exceeds the set level.
Allow the vehicle to stand for a

No abnormality
while (about 15 min.) and operate. Normal
Immediate indication of
overheat warning
The temperature
ANL : ACTIVE TEST ACT-1 ANL : I/O MONITOR 1 I/O1-2
Run does not change.
Turn all cooling fans ON and THCP : Check the value of material
check they run normally. handling AC driver thermo-sensor
while material handling operation.
Not run
The temperature
Material handling
changes.
AC driver defect
• Is the exhaust port covered with paper?
• Is it overloaded?
Less than Short harness continuity check

ANL : ACTIVE TEST ACT-1 CN105-2,3 Some 0 Ω
20 V
Turn the cooling fan ON and check b Resistance measurement
the voltage. CN105-4,5,6,7,8,9
20 V or more All ∞
CN113-1 Short harness defect CPU board defect

b Voltage measurement 20 V or
CN113-2 more • Fan check
CN114-1 • Connector connection check
CN114-2
Less than 20 V
CN104~CN113, CN104~CN114 Harness defect

4-111
A1-2 Traveling AC driver 1 high voltage
Related portion
F1
P3
Traveling AC
driver 1

Output when overvoltage of the battery line of the traveling AC driver 1 is detected.
If A1-1 occurs at the same time, perform troubleshooting for A1-1 first.
A1-2 error
is indicated ANL : I/O MONITOR 1 I/O1-12 Less than 66 V
Turn key switch ON.
No error
66 V or more
Traveling AC driver
1 defect.
66 V or more
Approx. 48 V
Replace battery.
Traveling AC driver 1 defect.
NG (∞ Ω)
F1 fuse inspection Replace F1 fuse.
OK (0 Ω)
Was the battery plug disconnected YES Do not disconnect battery plug during traveling except
during traveling? in an emergency.
NO
Check battery plug.

4-112
A1-3 Traveling AC driver 2 high voltage
Related portion
F1
P3
Traveling AC
driver 2

Output when overvoltage of the battery line of the traveling AC driver 2 is detected.
A1-3 error is
indicated ANL: I/O MONITOR 1 I/O1-12 Less than 66 V
Turn key switch ON.
No error
66 V or more
Traveling AC driver
2 defect.
66 V or more
Approx. 48 V
Replace battery.
Traveling AC driver 2 defect.
NG (∞ Ω)
OK (0 Ω)
YES
Was the battery plug disconnected Do not disconnect battery plug during traveling
during traveling? except in an emergency.
NO
Check battery plug.

4-113
A1-4 Material handling AC driver high voltage
Related portion
F1
P3
Material
handling
AC driver

Output when overvoltage of the battery line of the material handling AC driver is detected.
A1-4 error is
indicated ANL: I/O MONITOR 1 I/O1-13 Less than 66 V
Turn key switch ON.
VBBP voltage check
No error
66 V or more
Material handling AC
driver defect
66 V or more
Battery voltage check
Approx. 48 V
Replace battery.
NG (∞ Ω)
OK (0 Ω)
YES
Was the battery plug disconnected Do not disconnect battery plug during traveling
during traveling? except in an emergency.
NO
Check battery plug.

4-114
A2-2 Traveling AC driver board overheat
Related portion
Traveling AC driver 1 Traveling AC driver 2
PCB Thermo-sensor PCB Thermo-sensor

Output when the temperature detected by the traveling AC driver 1/2 thermo-sensor exceeds the
specified level.
Display only for safe monitor.
ANL : I/O MONITOR 1 I/O1-5 113 °C or more

TBD: Traveling AC driver 1/2 Allow the vehicle to stand for a while.
board temperature check. (about. 30 min.)
Less than 113 °C
YES
Has the vehicle been subjected to Stop vehicle and perform check test with
NO
Traveling AC driver 1/2 defect

4-115
A2-3 Material handling AC driver board overheat
Related portion
PCB Thermo-sensor

Output when the temperature detected by the material handling AC driver thermo-sensor exceeds the
specified level.
Display only for safe monitor.

104 °C or more
TBP: Material handling AC driver Allow the vehicle to stand for a while.
board temperature check. (about. 30 min.)
Less than 104 °C
YES
Has the vehicle been subjected to Stop vehicle and perform check test with
NO
AA-2 Traveling AC driver 1 board thermo-sensor abnormality:
Related portion
PCB Thermo-sensor

Output when abnormality of the traveling AC driver 1 thermo-sensor is detected.
If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
• To correct, replace the traveling AC driver 1.
4-116
AA-3 Traveling AC driver 2 board thermo-sensor abnormality
Related portion
PCB Thermo-sensor

Output when abnormality of the traveling AC driver 2 thermo-sensor is detected.
AA-4 Material handling AC driver board thermo-sensor abnormality
Related portion
PCB Thermo-sensor

Output when abnormality of the material handling AC driver thermo-sensor is detected.
• To correct, replace the material handling AC driver.
4-117
C1-1 Traveling AC driver 1 current sensor offset abnormality
Related portion
Current sensor

Output when abnormality is detected for current sensor offset adjustment when starting the traveling AC
driver 1.
C1-2 Traveling AC driver 1 overcurrent
Related portion
P7
Traveling AC P8 Drive
driver 1 motor 1
P9

Output when overcurrent of the traveling AC driver 1 is detected.
No error • Drive motor 1 cable check

Turn key switch ON and OFF
• Drive motor 1 continuity check
several times.
C1-2 error is
indicated

4-118
C1-3 Traveling AC driver 2 current sensor offset abnormality
Related portion
Current sensor

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

driver 2 motor 2
P91

Output when overcurrent of the traveling AC driver 2 is detected.
No error • Drive motor 2 cable check

several times. • Drive motor 2 continuity check
C1-4 error is
indicated

4-119
C2-1 Drive motor overheat
Related portion
Drive motor
Traveling AC
driver
Thermo-sensor

Output when the thermo-sensor value of the drive motor is above the specified level.
If AD-1 and AD-3 occurs at the same time, perform troubleshooting for AD-1 and AD-3 first.
• Stand the vehicle for a while (about 30 minutes).
4-120
C2-2 Drive motor 1 thermo-sensor abnormality
Related portion
CN58
CN110-13 (87, TD1+) 2
Traveling AC Drive motor 1
driver 1 CN110-10 (78, TD1-) Thermo-sensor
1
J27

Output when the drive motor 1 thermo-sensor output value is outside the specified range (disconnection
or short circuit)
CN110-13 (87)
Disconnect battery plug. Except b Continuity check No continuity
Disconnect CN110. 300~2k Ω CN58-2 (87) (∞ Ω)
CN110-13 (at harness side) CN110-10 (78)
b Resistance measurement b Continuity check
CN110-10 (at harness side) CN58-1 (78) Harness defect
300~2k Ω Continuity (0 Ω)
Connect CN110 and Disconnect Disconnect CN58.

CN58. Connect battery plug and Continuity
CN58-2 (at harness side) (0 Ω)
turn the key switch ON. Less than 1 V
b Continuity check
CN58-2 CN58-1 (at harness side)
CN58-1 No continuity (∞ Ω) Harness defect
1 V or more Traveling AC driver NG
1 defect CN58 connector check
Disconnect battery plug. OK
Connect SST2 between CN58-1 Repair or replace
and CN58-2. harness
CN58-2 (at sensor side)
key switch ON. 300~2k Ω Except 300~2k Ω
CN110-13
Thermo-sensor defect
CN110-10
0~0.1 V Except 0~0.1 V There is possibility that connector connection defect.
Connect CN110, CN58 and check CN110, CN58
Thermo-sensor defect connection condition.
• Traveling AC driver 1 defect Connect battery plug, turn the key switch ON, and it
• Harness defect checks that an error is not displayed.
4-121
C2-3 Drive motor 2 thermo-sensor abnormality
Related portion
CN52
CN109-13 (88, TD2+) 2
Traveling AC Drive motor 2
driver 2 Thermo-sensor
CN109-10 (82, TD2-) 1
J28

Output when the drive motor 2 thermo-sensor output value is outside the specified range (disconnection
or short circuit)
CN109-13 (88)
Disconnect battery plug. Except b Continuity check
Disconnect CN109. No continuity
300~2k Ω CN52-2 (88)
CN109-13 (at harness side) (∞ Ω)
CN109-10 (82)
Connect CN109 and Disconnect

CN52. Connect battery plug and Disconnect CN52. Continuity
turn the key switch ON. Less than 1 V CN52-2 (at harness side) (0 Ω)
CN52-2 b Continuity check
b Voltage measurement CN52-1 (at harness side)
CN52-1
No continuity (∞ Ω) Harness defect
1 V or more
Traveling AC
driver 2 defect
NG
Disconnect battery plug. CN52 connector check
Connect SST2 between CN52-1 OK
and CN52-2. Repair or replace
harness
key switch ON.
CN109-13 300~2k Ω Except 300~2k Ω
CN109-10
Thermo sensor defect
0~0.1 V Except 0~0.1 V
There is possibility that connector connection defect.
Connect CN109, CN52 and check CN109, CN52
Thermo-sensor defect connection condition.
• Traveling AC driver 2 defect Connect battery plug, turn the key switch ON, and it
• Harness defect checks that an error is not displayed.
4-122
C3-1 Traveling AC driver 1 main drive circuit thermo-sensor abnormality
Related portion
Traveling AC driver1
Thermo-sensor

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

Output when abnormality of the traveling AC driver 2 heat sink thermo-sensor exceeds the specified
level.
4-123
C8-1 Drive motor 1 rpm sensor abnormality
Related portion
CN59
CN110-9 (75, SSD1+) CN59-1 (75, SSD1+)
CN110-11 (76, SSD11) CN59-2 (76, SSD11)

Traveling AC
driver 1 CN110-12 (77, SSD12) CN59-4 (77, SSD12)
CN110-10 (86, SSD1-) CN59-3 (78, SSD1-)

J27
Drive motor 1
rpm sensor

Output when the traveling AC driver 1 detects the abnormality of the drive motor 1 rpm sensor.
Disconnect battery plug, connect

SST19 to CN110, and connect
CN1 and CN3 of SST19.
Connect battery plug, turn the key

2 LEDs ON Disconnect battery plug, connect
switch ON, and check the state of
SST19 to CN110, and connect
LEDs of SST during traveling
CN2 and CN3 of SST19.
operation.
One of LEDs turns OFF. 2 LEDs OFF
Check the CN1 and Traveling AC driver

CN3 connection of 1 defect
SST. Connect battery plug, turn the key
NG (Both LEDs blink.) switch ON, and check the state of
operation.
Other than NG
Disconnect CN59.
NG (all 8 V ~ 13 V) CN59-1 [+], 2 [+], 4 [+]
CN59-3 [-]
Drive motor 1 rpm Other than NG

sensor defect
Harness defect
4-124
C8-2 Drive motor 2 rpm sensor abnormality
Related portion
CN53
CN109-9 (79, SSD2+) CN53-1 (79, SSD2+)
CN109-11 (80, SSD21) CN53-2 (80, SSD21)

Traveling AC
driver 2 CN109-12 (81, SSD22) CN53-4 (81, SSD22)
CN109-10 (82, SSD2-) CN53-3 (82, SSD2-)

J28
Drive motor 2
rpm sensor

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

SST19 to CN109, and connect CN1
and CN3 of SST19.

and CN3 of SST19.
operation.
One of LEDs turns OFF. 2 LEDs OFF
Check the CN1 and Traveling AC

CN3 connection of driver 2 defect
SST. Connect battery plug, turn the key
NG (Both LEDs blink). switch ON, and check the state of
operation.
Traveling AC driver 2 defect Other than NG
Disconnect CN53.
NG (all 8 V ~ 13 V) CN53-1 [+], 2 [+], 4 [+]
CN53-3 [-]
Drive motor 2 rpm Other than NG
sensor defect
Harness defect
4-125
E1-1 Material handling AC driver current sensor offset abnormality
Related portion
Current sensor

Output when abnormality is detected for current sensor offset adjustment when starting the material han-
dling AC driver.
E1-2 Material handling AC driver overcurrent
Related portion
P14
Material handling P15

Pump motor
AC driver
P16

Output when overcurrent of the material handling AC driver is detected.
No error • Pump motor cable check

several time. • Pump motor continuity check
E1-2 error is
indicated

4-126
E2-1 Pump motor overheat
Related portion
Pump motor
Material handling
AC driver
Thermo-sensor

Output when the pump motor thermo-sensor value is above the specified level.
• Stand the vehicle for a while (about 30 minutes).
4-127
E2-2 Pump motor thermo-sensor abnormality
Related portion
CN55
CN111-13 (89, TP+) 2
Material Pump motor
handling AC CN111-10 (86, TP-) 1 thermo-sensor
driver J26

Output when the pump motor thermo-sensor output value is outside the specified range. (disconnection
or short circuit)
CN111-13 (89)
Disconnect battery plug, disconnect except b Continuity check
CN111 300~2k Ω CN55-2 (89) No continuity (∞ Ω)
CN111-13 (at harness side) CN111-10 (86)
Connect CN111, disconnect CN55. Disconnect CN55

Connect battery plug and turn the CN55-2 (at harness side)
key switch ON. Continuity (0 Ω)
Less than 1 V b Continuity check
CN55-2 CN55-1 (at harness side)
CN55-1 No continuity (∞ Ω) Harness defect
1 V or more Material handling
NG
AC driver defect CN55 connector check
Disconnect battery plug, short OK
between CN55-1 and CN55-2 with Repair or replace
SST2 harness
Connect battery plug and turn the 300~2k Ω Except 300~2k Ω
key switch ON.
CN111-13
b Voltage measurement Thermo-sensor defect
CN111-10 There is possibility that connector connection defect.
0~0.1 V Except 0~0.1 V Connect the CN111, CN55 and check CN111, CN55
Connect battery plug, turn the key switch ON, and it
Thermo-sensor • Material handling AC driver defect
checks that an error is not displayed.
defect • Harness defect
4-128
E3 Material handling AC driver main drive circuit thermo-sensor abnormality
Related portion
Thermo-sensor

Output when abnormality of the material handling AC driver heat sink thermo-sensor exceeds the
specified level.
4-129
E8 Pump motor rpm sensor abnormality
Related portion
CN56
CN111-9 (83, SSP+) CN56-1 (83, SSP+)
CN111-11 (84, SSP1) CN56-2 (84, SSP1)

Material
handling AC CN111-12 (85, SSP2) CN56-4 (85, SSP2)
driver
CN111-10 (86, SSP-) CN56-3 (86, SSP-)
J26
Pump motor
rpm sensor

Output when the material handling AC driver detects the abnormality of the pump motor rpm sensor.

and CN3 of SST19.

LEDs of SST during material
and CN3 of SST19.
handling operation.
One of LEDs turns 2 LEDs OFF
OFF.
Check the CN1 and CN3 Material handling AC

connection of SST driver defect
NG (Both LEDs
blink.)
LEDs of SST during material
handling operation.
Material handling AC driver defect Other than NG
Disconnect CN56
NG (all 8 V ~ 13 V) CN56-1 [+], 2 [+], 4 [+]
CN56-3 [-]
Pump motor rpm Other than NG

sensor defect
Harness defect
4-130
SAS SYSTEM
61-1,2 Load sensor abnormality
Related portion
CN130 CN90 CN91

CN102-17 (58, SPL+)
11 4 1
CPU CN102-5 (59, SPL) Load
board 10 3 2 sensor
CN102-22 (51, POT-)
J22 9 J3 8 3

Output when the voltage of the load sensor is outside the specified range (open or short).
61-1 Load sensor open
61-2 Load sensor short
• 61-1
Disconnect CN90. 61-2 error is
Short between CN90-3 and CN90-4 indicated. • Load sensor defect
of main harness side with SST2. • Sub harness defect
key switch ON.
61-2 error is not indicated.

Disconnect CN102.
(SST2 is connection state.) No continuity
Main harness defect
CN102-17 (58)
b Continuity check
CN102-5 (59)
Continuity
CN102-5 (59)
b Continuity check No continuity
CPU board defect
CN102-22 (51)
Continuity
Main harness defect

4-131
• 61-2
CN90, connect battery plug, and Change to 61-1 error.
turn the key switch ON.
61-2 error remains.

b Continuity check
CN102-5 (59)
Continuity

• Main harness defect Disconnect CN102
Short between CN90-3 and CN90-8
of main harness side with SST2.
CN102-5 (59)
b Continuity check
CN102-22 (51)
• Load sensor defect Main harness defect

• Sub harness defect
4-132
62-1,2 Tilt angle sensor abnormality
Related portion
CN130 CN8
CN102-16 (57, POTTA+)
13 1
CPU CN102-4 (56, POTTA) Tilt angle
board 12 2
sensor
CN102-22 (51, POT-)
J22 9 J3 3

Output when the voltage of the tilt angle sensor is outside the specified range (open or short).
62-1 Tilt angle sensor open
62-2 Tilt angle sensor short
• 62-1
Disconnect CN86. 62-2 error is
Short between CN86-1 and CN86-2 indicated.
Tilt angle sensor defect
switch ON.
62-2 error is not
indicated.

Disconnect CN102
CN102-16 (57) Main harness defect
b Continuity check
CN102-4 (56)
Continuity
(SST2 is connection state.)

CPU board defect
b Continuity check
CN102-22 (51)
Continuity
Main harness defect

4-133
• 62-2
CN86, connect battery plug, and Change to 62-1 error.
turn the key switch ON.
62-2 error remains.

Disconnect CN102.
No continuity
b Continuity check
CN102-4 (56)
Continuity Disconnect battery plug.
Disconnect CN102.
Main harness defect CN102-4 (56)
b Continuity check
CN102-22 (51)
Tilt angle sensor defect
Main harness defect
66-1 Tilt matching abnormality
Related portion
CPU board

Output when any of tilt neutral position matching, forward tilt angle matching and load sensor matching is
outside the specified range.

4-134
67-1 Lifting height switch abnormality
Related portion
Lifting height
CN130 CN90 CN92 switch
CN101-20 (91, MH2-
6 1 3
CPU CN101-19 (90, MH1)
board 7 6 2
CN101-16 (51, LS-)
J21 1 J1 2 1

Output when open or short circuit of the lifting height switch line from the CPU board to the lifting height
switch is detected.
ANL : I/O MONITOR 3-11 MH : 00−

A
Check the lifting height switch
input value.
Other than MH : 00−

disconnect CN90.
ANL : I/O MONITOR 3-11

MH : 00− • Sub harness defect
Check the lifting height switch
input value. (with battery plug • Lifting height switch defect
connected)
Other than MH : 00−

disconnect CN101, and check the
continuity. No continuity
CN101-20 (91)~CN101-16 (51) CPU board defect
CN101-19 (90)~CN101-16 (51)
CN101-20 (91)~CN101-19 (90)
Continuity
Main harness defect

4-135
Disconnect battery plug and CN90,

and check continuity.
Check the lifting height upon error H2000 or more CN90-6 (90) ~ CN90-2 (51)
indicating. [OK] No continuity, [NG] Continuity
CN90-1 (91) ~ CN90-2 (51)
Less than H2000
[OK] Continuity, [NG] No continuity
NG OK
Disconnect battery plug and CN90,

and check continuity.
CN90-6 (90) ~ CN90-2 (51)
NG • Sub harness defect
[OK] Continuity, [NG] No continuity
CN90-1 (91) ~ CN90-2 (51) • Lifting height switch defect
[OK] No continuity, [NG] Continuity
OK

CN101 and CN103, and check the
continuity.
• Short between CN90-6 and
CN90-2 of main harness side with
SST2.
the harness continuity.
Main harness defect
b Continuity check
CN101-16 (51)
• Short between CN90-1
and CN90-2 of main harness side
with SST2.
CN101-20 (91)
b Continuity check
CN101-16 (51)
Continuity
CPU board defect

4-136
72-1,2,3,4 Steering angle sensor abnormality
Related portion
CN131 CN19
CN103-10 (16, D15V)
3 J4 1
CN101-24 (312, STS1)

15 3
CN101-30 (313, STS2) Steering

CPU 16 4
angle
board
CN101-21 (314, STSC) sensor
17 5
2
CN130
CN101-16 (51, LS-) J1
J21 1

Output when open or short circuit of the sensor line from the CPU board to the steering angle sensor is
detected.
72-1 Steering angle sensor STS1 abnormality
72-2 Steering angle sensor STS2 abnormality
72-3 Steering angle sensor STSC abnormality
72-4 Steering angle sensor open
• 72-1
72-1 error is
not indicated
key switch ON. Connector connection check
Turn the steering wheel.
72-1 error is
indicated

Remain 1
Check the STS1 input value B
turning the steering wheel.
Remain 0
A
4-137
A B

Disconnect CN32.
key switch ON.
ANL : I/O MONITOR 4 I/O4-1 Change to 1

Steering angle sensor defect
Check the STS1 input value
Remain 0

Disconnect CN101.
b Continuity check
CN101-16 (51) Disconnect battery plug.
Disconnect CN19.
Continuity Connect battery plug and turn the
key switch ON.
CPU board defect
Change to 0 ANL : I/O MONITOR 4 I/O4-1

Remain 1

Continuity
b Continuity check
CN101-16 (51)
No continuity
CPU board defect

4-138
• 72-2
72-2 error is
Connect battery plug and turn the not indicated
Connector connection check
key switch ON.
72-2 error is
indicated

Remain 1
Remain 0

Disconnect CN32.
key switch ON.

Remain 0

Disconnect CN101.
b Continuity check
CN101-16 (51) Disconnect battery plug.
Continuity Disconnect CN19.
key switch ON.
CPU board defect

Remain 1

Continuity Disconnect CN19, CN101.
b Continuity check
CN101-16 (51)
No continuity
CPU board defect

4-139
• 72-3
Connect battery plug and turn the 72-3 error is
key switch ON. not indicated Connector connection check
Turn the steering wheel to left or
right for one round or more.

Remain 1
Check the STSC input value
Remain 0

Disconnect CN32.
key switch ON.

Check the STSC input value Steering angle sensor defect
Remain 0

Disconnect CN101.
Main harness defect
CN101-21 (314)
CN101-16 (51)
Disconnect CN19.
Continuity Connect battery plug and turn the
key switch ON.
CPU board defect

Steering angle sensor defect Check the STSC input value
Remain 1

Continuity Disconnect CN19, CN101.
CN101-16 (51)
No continuity
CPU board defect

4-140
• 72-4
72-4 error is
Connect battery plug and turn the not indicated
key switch ON. Connector connection check

Disconnect CN19.

Check voltage of power supply for Connect battery plug.
steering angle sensor. Approx. 0 V Check voltage of power supply for Approx. 0 V
CN19-1 (16) steering angle sensor (at controller
b Voltage measurement side connector).
CN19-2 (51) CN103-10 (16)
Approx. 15 V b Continuity check
CN101-16 (51)
Approx. 15 V
CPU board defect
Connect CN19.
Connect battery plug and turn the Main harness defect
key switch ON.
Perform troubleshooting for 72-1 (STS1), 72-2 (STS2)

4-141
73-1,2,3 Steering knob synchronizer solenoid abnormality
Related portion
CN131 CN98
CN104-21 (329, SOLST+)
19 1 Steering knob
CPU
board synchronizer
CN104-28 (330, SOLST-) solenoid
20 2

Output when open or short circuit of the solenoid line from the CPU board to the steering knob synchro-
nizer solenoid is detected.
73-1 Steering knob synchronizer solenoid open
73-2 Steering knob synchronizer solenoid short
73-3 Drive circuit MOS of steering knob synchronizer solenoid short
• 73-1
73-1 error is not
ACTIVE TEST : ACT-2 KSOL indicated.
Turn the steering knob Connector connection check
synchronizer solenoid ON.
73-1 error is
indicated.

Disconnect CN98.

Disconnect CN104. 9.9 ± 1 Ω (at 25 °C)
CN104-28 (330)
Other than 9.9 ± 1 Ω
(at 25 °C)
Disconnect CN98.
CN98-1 (329) 9.9 ± 1 Ω (at 25 °C)
Main harness defect
CN98-2 (330)
Other than 9.9 ± 1 Ω
(at 25 °C)
Steering knob synchronizer solenoid defect

4-142
• 73-2
73-2 error is not
73-2 error is
indicated.

Disconnect CN98.
73-1 error is
Turn the steering knob Steering knob synchronizer solenoid defect
73-2 error is
indicated.

b Continuity check
CN104-28 (330)
No continuity
CPU board defect
• 73-3
73-3 error is not
73-3 error is
indicated.

Disconnect CN152 and turn the key
switch ON.
Check continuity Continuity
Harness defect
CN104-21 (329)~P1
CN104-21 (329)~P2
CN104-28 (330)~P1
CN104-28 (330)~P2
No continuity
CPU board defect

4-143
MULTI-DISPLAY
F1-1,2 Main controller → multi-display communication abnormality
Related portion
CN131 CN1
CN103-16 (141, SMTDA) 7 3 CN70-22 (141, SMTDA)
CPU
CN103-13 (144, SMTDK) 4 7 CN70-23 (144, SMTDK) Multi-display
board

Output upon detection of communication data abnormality from CPU board
CN103, CN131, CN70 and CN1 NG

Correct the defect
connection condition check
OK

CN103 and CN70.
CN103-16 (141) Continuity • CPU board defect
b Continuity check • Multi-display defect
CN70-22 (141)
CN103-13 (144)
b Continuity check
CN70-23 (144)
No continuity
Harness defect
(Between CN103 and CN70)
NOTE:
Other error codes, if any, are not indicated because of no communication from the CPU board
when F1-1 occurs. F1-1 is kept indicated on the multi-display screen regardless of key switch On
or OFF.
4-144
WHEN NO ERROR CODE IS DISPLAYED
No display on multi-display
Related portion
CN131 CN1
CN103-10 (16, D15V) 3 2 CN70-14 (16, D15V)
CPU
CN103-12 (14, GNDD) 2 1 CN70-30 (14, GNDD)
board Multi-display

• No power supply to multi-display
• Multi-display defect
It is possible to perform traveling NG

See page 4-145. (Vehicle does not move.)
and material handing operation.
OK

OK CN1, disconnect CN70, and
CN1, and connect battery plug.
(Approx. 15 V) connect battery plug.
CN1-2 (16) NG (0 V)
CN70-14 (16)
CN1-1 (14)
CN70-30 (14)
NG (0 V)
OK
(Approx. 15 V)
Disconnect battery plug, Harness defect
disconnect CN1 and CN103. (Between CN1 and
1. Multi-display defect
CN70)
CN1-2 (16)
b Continuity check
NG (1. ∞ Ω
CN103-10 (16)
2. Approx. 0 Ω) Harness defect
CN1-1 (14)
b Continuity check (Between CN1 and CN103)
CN103-12 (14)
2.
CN1-2 (16)
b Short-circuit check
CN1-1 (14)
OK (1. Approx. 0 Ω
2. ∞ Ω)
CPU board defect

4-145
The vehicle does not move at all (display off)
Related portion
P1 P2 F6
CN104-14,15 (44, VBMB)
CN104-1,2 (18, B48V)

F5
CN103-4 (43, VBKY) CPU
board
CN103-7 (41, VBBT)
N2
CN104-22 (N2, N2)
P1 [+]
Less than 20 V
b Voltage measurement Battery charge
N1 [-]
20 V or more
NG (∞ Ω)
Check the F5 fuse Replace F5 fuse
OK (0 Ω)
CN104-1 (18)
Less than 20 V
b Voltage measurement Harness check
CN104-22 (N2)
20 V or more
Check the voltage with the key

switch ON.
1. NG
CN103-4 (43) (Other than OK) NG
Check the key switch
CN104-22 (N2) OK
2.
CN103-7 (41) Replace the key
b Voltage measurement switch
CN104-22 (N2)
OK (Voltage of 2 is 15 V or more, Battery plug check or battery

and voltage difference of 1 and 2 is check or harness check
13 V or less.
CPU board defect

4-146
Only traveling disabled (no motor revolution)
Related portion
CN130 CN9
CN101-1 (45, DSF) 5
CN101-2 (46, DSR) 4 Direction
switch
CN101-16 (51, LS-) 1
J1
CN132 CN26
CN102-1 (64, SWAC) CN26-2
CPU
board CN102-2 (52, POTA) CN26-3
Accelerator
CN102-14 (53, POTA+) CN26-4 potentiometer
CN102-22 (51, POT-) CN26-1
J2
CN130 CN22
CN101-5 (67, LSD) 7
8 Seat switch
J1
YES Accelerator OFF, direction switch

Has beep sound been output?
OFF, and parking OFF (It returns.)
NO
ANL : I/O MONITOR 2 I/O2-1 Both have no

SWAC and POTA value check with change.
Accelerator check
accelerator pedal depressing.
Both change.
ANL : I/O MONITOR 2 I/O2-2 No change

DSF and DSR value check with Direction switch check
direction switch operation.
Changes
ANL : I/O MONITOR 2 I/O2-3 Display 0

LSD value check by sitting on the Seat switch check
seat.
Display 1
Voltage measures with direction

switch ON and accelerator ON. *1
P7 [+], P8 [+], P9 [+]
b Voltage measurement Other than OK
N1 [-] Traveling AC driver defect
P71 [+], P81 [+], P91 [+]
N1 [-]
OK (All approx. 24 V) *1: When it cannot be measured, even the seat is not
occupied, it can be measured by disconnecting
CN22 and connecting SST8.
A
4-147
NO
Is there sound from the motor? Motor cable and motor check
YES

Does front wheels rotate when jack Does not rotate
up the vehicle to cause the front Brake check
wheels to float?
Rotates
Perform troubleshooting for C8

4-148
Wobbling
Jack up the vehicle to cause the Both of front wheels rotate at

front wheels to float, and keep the the same speed Type of tires, a diameter of tires and air
steering wheel in straight position. pressure valve check.
Both of front wheels does

not rotate at the same speed
Changes Normal
Does change upon turning the Perform matching No.4
steering wheel?
Wobbling
Does not change
Use it as it is.
Abnormal
Installation check of the tire angle
sensor.
Normal
* Install to correct
position.
Disconnect drive motor cables
Turn direction switch ON
Accelerator ON CPU board defect
P7 [+]
Other than OK
b Voltage measurement Traveling AC driver defect
N1 [-]
P71 [+]
N1 [-]
OK (All approx. 24 V)
NO
Is there sound from the motor? Motor cables and motor check
YES
Disconnect battery plug. Does not rotate

Does front wheels rotate when jack Brake check
up the vehicle to cause the front
wheels to float?
Rotates
* When it cannot measure, even if it does not

sit on the seat, it can measure by
Perform troubleshooting for C8. disconnecting CN22 and connecting SST8.
4-149
Only material handling is disabled.

• Standard models (STD lever)
ANL : I/O MONITOR 3 I/O3-1,3 The switch is not operated

Lift, tilt switch check
Lift, tilt switch check
The switch is operated
Does pump motor rotate upon Rotates

Control valve check
turning steering wheel?
Does not rotate
Disconnect the material handling

AC driver cable. Operate the lift
lever to up position.
P14 [+]
N1 [-] Other than OK
P15 [+]
N1 [-]
P16 [+]
N1 [-]
NG
Pump motor cable check Cable repair
OK
Perform troubleshooting for E8.

4-150
• Mini lever models
OPTION SET : OPT-17,18

Material handling is disabled only Yes Do the set values of OPTION SET No
when a certain operation is match with the actual number of
performed. levers and control valves of the
No vehicle?
Yes Reset the values
of OPTION SET
Does pump motor rotate upon Rotates
turning steering wheel? Value does not
ANL : I/O MONITOR 3 change
Does not rotate Check the value when operating
the lever that does not work for
A material handling operation.
Value Lever angle sensor
Disconnect motor cable and changes inspection
measure the voltage at the pump
motor driver terminal with the lift
Approx. 0.5 A
switch ON. ANL : I/O MONITOR 3
or more
P14 [+] Check the current of proportional
b Voltage measurement Other than OK valve that does not work for
N1 [-] material handling.
P15 [+] Less than Control valve
b Voltage measurement approx. 0.5 A
Material handling inspection
N1 [-]
P16 [+] AC driver defect
b Voltage measurement Measure the solenoid resistance of Approx. 7 Ω
N1 [-] the proportional valve that does not
work for material handling
Other than Harness
approx. 7 Ω inspection
NG
Pump motor cable check Solenoid inspection
OK
Cable repair
Perform troubleshooting for E8.
Approx.
Measure the solenoid resistance of 10 Ω
A NG
the proportional valve that does not Inspect harness connected to CN76
work for material handling
OK
Other than
approx. 10 Ω Harness defect
Solenoid inspection Control valve inspection

4-151
Steering knob not in the right position
OPTION SET : OPT-13

Setting is N.
Check the steering knob Change the setting to Y.
synchronizer setting.
Setting is Y.
ANL : ACTIV TEST ACT-2

Set the steering knob synchronizer
6 rotates or more Steering knob synchronizer solenoid
solenoid to OFF. Check the
number of rotation when rotate the valve check.
steering wheel from end to end.
(The speed of rotation is 1 rotation
/2~3 minutes.)
Less than 6 rotates
ANL : ACTIVE TEST ACT-2

Set the steering knob synchronizer
Does not idle Steering knob synchronizer solenoid
solenoid to OFF. Check if that the
steering wheel idles at tire end valve check.
position. (The speed of rotation is
1 rotation /2~3 minutes.)
Idles
Normal
Perform matching No.4 Use it as it is.
Abnormal
Installation check of the tire angle Abnormal

Install to correct position.
sensor and the steering angle
Normal
CPU board defect

4-152
Constant automatic fork leveling
Related portion
CN132 CN84
CN101-18 (70, SWTK)
CPU
Knob switch
board CN101-16,26 (51, LS-)
CN130
ANL : I/O MONITOR 3 I/O3-9 Operate

ON (display 1) normally
Check the valve of automatic fork Tilt knob switch OFF
leveling switch
Automatic fork
OFF (display 0) leveling is remained
ON Use it as it is.

OFF (display 0)
Check the valve of automatic fork
leveling switch
ON (display 1)
CN101-18 [+] Approx. 0 V

CN101-16,26 [-]
Approx. 5 V
CPU board defect
• Harness defect
Leaned forward • Switch defect
from leveling
Lift down the fork and operate the position
tilt lever to the forward position. Perform matching No.1, No.2
Not leaned forward

from leveling position
Does pump motor stop without a

turning steering wheel when Stops
direction switch is neutral position CPU board defect
and the fork is at leveling position?
Does not stop
Tilt cylinder check

4-153
Safety monitor Traveling AC driver 1/2 low temperature warning

Output when the temperature detected by the traveling AC driver 1/2 main drive circuit thermo-sensor is
below the specified level.
Output when the temperature detected by the traveling AC driver 1/2 board thermo-sensor is below the
specified level.
Output when the temperature detected by the drive motor 1/2 thermo-sensor is below the specified level.
• If the temperature rises after some traveling, the warning will go out.
Safety monitor Material handling AC driver low temperature warning

Output when the temperature detected by the material handling AC driver main drive circuit
thermo-sensor is below the specified level.
Output when the temperature detected by the material handling AC driver board thermo-sensor is below
the specified level.
Output when the pump motor thermo-sensor value is below the specified level.
• If the temperature rises after some material handling, the warning will go out.
5-1
MOTOR
Page
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
0
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 1
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 2
3
4
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 6
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
7
8
9
10
11
12
13
14
15
16
17
18
5-2
DRIVE MOTOR
GENERAL
SPECIFICATIONS
Vehicle model
All Models
Item
Three-phase alternating
Type
current
Nominal voltage V 48
Rated output (rated in 60 min) kW 4.9
Size (Outer shape × length) mm (in) φ180 × 227 (φ7.1 × 8.9)
Weight (Including drive unit case) kg (N) 37 (362.8)
Insulation class F
5-3
COMPONENTS
1401
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
5-4
1401
5-5
T=N·m (kgf·cm) [ft·lbf]
T=117.6~196.0
(1199.2~1998.6) 0
[86.8~144.6]
T=157.0~216.0
1
(1601.0~2202.6)
[115.8~159.4]
12
2
3
3
4
14
T=21.6~50.4 5
(220.3~513.9)
13 [15.9~37.1]
6
7
T=63.0~147.0 7
(642.4~1499.0)
8
[46.5~108.5] 8
10 9
9
3 2 10
11
Removal Procedure
1 Disconnect the battery plug. 12
2 Remove the mast ASSY. (P12-4)
3 Jack up the vehicle and remove front wheels. [Point 1] 13
4 Drain gear oil. [Point 2]
5
6
Disconnect the piping and wiring.
Disconnect the brake ASSY link.
14
7 Remove the tie rod.
8 Remove the reamer bolt of the drive unit bracket (RH). [Point 3] 15
9 Remove the drive unit W/ drive motor (RH). [Point 4]
10 Remove the drive unit ASSY (RH). [Point 5] 16
11 Remove the brake ASSY and disc brake of the drive motor (RH).
12 Remove the reamer bolt of the drive unit bracket (LH). [Point 3] 17
13 Remove the drive unit W/ drive motor (LH). [Point 4]
14 Remove the drive unit ASSY (LH). [Point 5]
15 Remove the brake ASSY and disc brake of the drive motor (LH).
18
5-6
Point Operations
[POINT 1]
Removal:
Always jack up the vehicle at the jack-up point. Jacking
up the vehicle at the other location is very dangerous.
Always support the load of jacked-up vehicle with
wooden blocks at specified points.
[POINT 2]
Installation:
After installation, fill hypoid gear oil to the specified level.
A=10mm (0.39 in) or less
[POINT 3]
Removal:
SST 09310-23320-71
[POINT 4]
Removal:
For removal of the drive motor, place a garage jack at
the drive motor bracket and hoist the drive motor.
[POINT 5]
Installation:
Apply gasket sealant to the mating face with the drive
unit.
Liquid gasket: 08826-76002-71
(08826-00090)
5-7

T= 3.0 7.0
(30.6 71.4)
[2.2 5.2]
3
T= 3.0 7.0
(30.6 71.4)
[2.2 5.2]
T= 31.2 46.8
(318.2 477.2)
[23.0 34.5]
1 Remove the terminal.
2 Remove the end frame. [Point 1]
3 Remove the rpm sensor bearing.
4 Remove the rotor ASSY. [Point 2]
5 Remove the stator ASSY. [Point 3]
6 Remove the bracket. [Point 4]
Caution:
Be sure not to apply impact to the rpm sensor bearing.
5-8
Point Operations
[POINT 1]
SST Disassembly:
SST 09950-76013-71
(09950-40010)
Reassembly:
After installing the end bracket, use the SST and hand
press and install the rpm sensor bearing.
SST 09608-76003-71
SST (09608-04031)
Reference:
After installing the brake disk wheel, it may as well be
used the brake disk wheel set nut to install the rpm
sensor bearing.
[POINT 2]
Disassembly:
Use a copper bar to remove the rotor ASSY.
Reassembly:
Use the SST and hand press to install the rotor ASSY.
SST 09150-10920-71
Hand press
Caution:
• After inserting the bearing in the front axle bracket
SST and fitting the oil seal, set the stator and press fit the
rotor in the bearing.
• Before inserting the bearing, make sure that the shield
of the bearing is positioned lower.
[POINT 3]
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
5-9
Inspection:
Check continuity between motor cables.
Measurement terminals: U-V,V-W,W-U
Standard: 0 Ω
Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of
temperature sensor connector
Standard: 540 to 620 Ω (at 20 °C)
[POINT 4]
SST(2) Disassembly:
SST(1) Use the SST to remove the bearing.
SST 09950-76018-71......(1)
(09950-60010)
SST 09950-76020-71......(2)
(09950-70010)
Reassembly:
Use the SST and hand press to install the bearing and
oil seal.
SST 09950-76018-71......(1)
SST(2) SST(1) (09950-60010)
SST 09950-76020-71......(2)
(09950-70010)
5-10
PUMP MOTOR
GENERAL
SPECIFICATIONS
Vehicle model
All Model
Item
Three-phase alternating
Type
current
Nominal voltage V 48
Rated output (rated in 60 min) kW 9.2
Size (Outer shape × length) mm (in) φ 180 × 290 (φ7.1 × 11.4)
Weight kg (N) 31 (304.0)
Insulation class F
5-11
COMPONENTS
1402
1402
5-12
24.0 (244.7) [17.7]
11
4
6
11
8 9 10
Removal Procedure
1 Remove the battery ASSY.
2 Remove the toe board (FR, RR) and tilt cover.
3 Disconnect the piping of the priority valve.
4 Remove the front battery cover.
5 Disconnect the pump motor wiring.
6 Remove the return filter set bolt and keep the filter free.
7 Drain hydraulic oil. [Point 1]
8 Disconnect the oil pump piping (outlet hose).
9 Temporarily hoist the pump motor. [Point 2]
10 Hoist the pump motor W/ oil pump and disconnect the inlet hose. [Point 3]
11 Remove the oil pump and insulator.
Note:
Apply grease to the spline section of the pump before installation.
5-13
Point Operations
[POINT 1]
Removal:
Remove the gauge and filter and drain the hydraulic oil.
[POINT 2]
Removal:
Loosen the set bolt of the terminal bracket and hoist the
pump motor.
[POINT 3]
ƒŒ
Removal:
When hoisting the pump motor, make sure not to apply
excess force on the hose.
Note:
• Be sure to loosen the hose clamp sufficiently.
• If the hose and tank pipe stick hard, do not forcefully
hoist the pump motor as it may damage the hydraulic
oil tank.
• Remove the adhesion of the hose and tank pipe.
5-14

T= 3 7
(30.6 71.4)
2
[2.2 5.2]
1
3
T= 3 7
(30.6 71.4)
[2.2 5.2]
5
T= 31.2 46.8
(318.2 477.2)
[23.0 34.5]
1 Remove the terminal.
2 Remove the end frame. [Point 1]
3 Remove the rpm sensor bearing.
4 Remove the rotor ASSY. [Point 2]
5 Remove the stator ASSY. [Point 3]
6 Remove the bracket.
Caution:
Be sure not to apply impact to the rpm sensor bearing.
5-15
Point Operations
[POINT 1]
Disassembly:
SST (2) SST (1)
SST 09950-76013-71......(1)
(09950-40010)
SST 09140-10920-71......(2)
Reassembly:
After installing the end bracket, use the SST and hand
press and install the rpm sensor bearing.
SST 09608-76003-71
SST (09608-04031)
Reassembly:
Install the end frame and rpm sensor to the position with
A
the dimension A.
Dimension A: 11.0 to 13.3 mm (0.43 to 0.52 in)
[POINT 2]
Inspection:
Inspect the bearing of the rotor ASSY and replace it if
abnormal noise or damage is observed.
Disassembly:
SST (1) SST 09950-76014-71......(1)
(09950-40011)
SST (2) SST 09950-76018-71......(2)
(09950-60010)
Reassembly:
SST 09410-40120-71
SST
5-16
[POINT 3]
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Inspection:
Check continuity between motor cables.
Measurement terminals: U-V,V-W,W-U
Standard: 0 Ω
Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of
temperature sensor connector
Standard: 540 to 620 Ω (at 20 °C)
6-1
DRIVE UNIT & FRONT AXLE

Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
0
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 1
FRONT AXLE HUB & DRIVE UNIT . . . . . . . . . . . . . 6-5 2
REMOVAL • INSTALLATION . . . . . . . . . . . . . . . . . . . . . 6-5 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
6-2
GENERAL
6-3
SPECIFICATIONS
Vehicle model
7FBEF15 7FBEF16 7FBEF18 7FBEF20
Item 0
Total reduction ratio 27.040 ← ← ←
1
Front tire size 18 × 7-8/4.33 ← ← 200/50-10/6.50
Rim size 4.33R-8 ← ← 6.50F-10 2
Rim type Side ring ← ← ← 3
4
Vehicle model
7FBE10 7FBE18 7FBE20
Item
7FBE13-15
5
Total reduction ratio 27.040 ← ← ←
Front tire size 18 × 7-8-10PR 18 × 7-8-14PR 18 × 7-8-16PR 18 × 7-8/4.33
kPa (kgf/cm2) 750 (7.5) 900 (9) 1000 (10)
Tire pressure ←
[psi] [107] [128] [142]
Rim size 8 × 4.25 DT ← 8 × 4.33R TB ←
6
7
8
9
10
11
12
13
14
15
16
17
18
6-4
4201
6-5
FRONT AXLE HUB & DRIVE UNIT

0
1
2
3
4
T=21.6~50.4
(220.3~513.9) 5
[15.9~37.1]
T=117.6~196.0
T=15~44
(153.0~448.7)
(1199.2~1998.6) 6
[86.8~144.6]
[11.1~32.5]
1 7
8
4
9
3 10
11
Removal Procedure 12
1 Jack up the vehicle and remove front wheels. [Point 1]
2 Drain gear oil. [Point 2] 13
3 Remove the front axle hub. [Point 3]
4 Remove the drive unit ASSY. [Point 4]
14
The installation procedure is the reverse of the removal procedure. 15
Note:
• Type and quantity of gear oil 16
STD
Type
Cold storage type
Hypoid gear oil W 17
Quantity 0.4 l (0.1 US gal) 18
• Type of grease
STD
MP grease
Cold storage type
6-6
Point Operations
[POINT 1]
Removal:
Always jack up the vehicle at the jack-up point.Jacking
up the vehicle at the other location is very dangerous.
Always support the load of jacked-up vehicle with
wooden blocks at specified points.
[POINT 2]
Installation:
After installation, fill hypoid gear oil to the specified level.
A=10 mm (0.39 in) or less
[POINT 3]
Removal:
SST 09950-76014-71
(09950-40011)
SST
Inspection:
Measure the front axle hub starting force.
N (kgf) [lbf]
Standard
7FBEF15·16·18 23.9 ~ 47.3 (2.4 ~ 4.8) [5.3 ~ 10.6]
7FBEF20 27.2 ~ 53.9 (2.8 ~ 5.5) [6.2 ~ 12.1]
[POINT 4]
Installation:
For installation, apply gasket sealant to the mating face
with the drive unit.Be sure to remove the grease on the
face.
Liquid gasket: 08826-76002-71
(08826-00090)
6-7
3 2
3 6
1 Remove the idle gear bearing. [Point 1]
2 Remove the planetary gear. [Point 2]
3 Remove the axle shaft bearing and inner bearing.
4 Remove the oil seal and outer bearing. [Point 3]
5 Remove the bearing outer race. [Point 4]
6 Remove the inner bearing outer race. [Point 5]
Note:
Apply gear oil to the planetary gear and bearing and install them.
6-8
Point Operations
[POINT 1]
Disassembly:
Use the SST to remove the idle gear bearing.
SST 09950-76014-71
(09950-40011)
SST
Disassembly:
Use the SST to install the idle gear bearing.
SST 09950-76018-71......(1)
(09950-60010)
SST 09950-76020-71......(2)
(09950-70010)
SST (2)
SST (1)
[POINT 2]
Reassembly:
Measure the backlash of the planetary gear, idle gear
and ring gear.
Standard: 0.2 mm (0.008 in) or less
[POINT 3]
Reassembly:
Use the SST to install the oil seal.
SST 09700-30200-71
SST
[POINT 4]
Disassembly:
SST Use the SST to remove the outer bearing outer race.
SST 09700-30200-71
6-9
Reassembly:
Use the SST to install the outer bearing outer race.
SST SST 09700-30200-71
[POINT 5]
Disassembly:
SST Use the SST to remove the inner bearing outer race.
SST 09700-30200-71
Reassembly:
Use the SST to install the inner bearing outer race.
SST SST 09700-30200-71
7-1
REAR AXLE
Page
REAR AXLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
0
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 3
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 2
3
DISASSEMBLY · INSPECTION · REASSEMBLY . . . . . 7-7
4
REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
REMOVAL · INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7-12 5
REAR AXLE CYLINDER ASSY . . . . . . . . . . . . . . . . . 7-15 6
7
8
9
10
11
12
13
14
15
16
16
18
7-2
REAR AXLE ASSY

GENERAL
7-3
SPECIFICATIONS
Model
Item
7FBE13
Type Full-floating
Rear tire size 15 × 41/2-8/3.00 ← ← 16 × 6-8/4.33
Rim size 3.00D-8 ← ← 4.33R-8 0
Rim type side ring ← ← ←
3
COMPONENTS
2
Rear axle ASSY
4301 3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
18
7-4
4302
7-5
10 ~ 16
(102.0 ~ 163.2) 0
[7.4 ~ 11.8] 1
3
250 ~ 350
(2549.3 ~ 3569.0) 2
[184.4 ~ 258.2] 4
5 3
7
117.6 ~ 196.0 4
(1199 ~ 1999)
[86.8 ~ 144.6]
5
6
9 7
8
3 9
10
11
Removal Procedure 12
1 Remove the rear cover.
2 Remove the counterweight. 13
3 Jack up the vehicle and remove the rear wheels. [Point 1]
4 Disconnect the piping of the power steering cylinder. 14
5 Remove the tire angle sensor.
6 Measure the rear axle ASSY starting force. [Point 2]
7 Loosen the rear axle set bolts.
15
8 Hoist the rear axle temporarily and remove the set bolts. [Point 3]
9 Remove the rear axle. 16
Installation Procedure 16
Note: 18
When the tire angle sensor is removed and installed or replaced, perform matching.
(See page 16-16.)
7-6
Point Operations
[POINT 1]
Removal:
Jack up the vehicle at the specified jack-up point.
Jacking up at any other point is very dangerous.
Always support the vehicle with wooden blocks at
specified points.
[POINT 2]
Inspection:
Measure the rear axle ASSY starting force.
Standards: 100 ~ 200 N (10 ~ 20 kgf) [22.1 ~ 44.1 lbf]
Installation:
When correct value is obtained, securely caulk the lock
nut.
[POINT 3]
Removal:
Temporarily hoist the rear axle as shown in the
illustration.
7-7

10 ~ 20
1 (102.0 ~ 203.9)
[7.4 ~ 14.8]
2 6
3
12 ~ 32
(122.4 ~ 326.0)
5 7 [8.9 ~ 23.6]
4
10
11
8
9
9
8
11
10
1 Remove the lock nut.
2 Remove the upper bearing.
3 Disconnect the rear axle cylinder W/ holder ASSY and rear axle ASSY.
4 Remove the lower oil seal. [Point 1]
5 Remove the lower bearing outer race. [Point 2]
6 Remove the upper bearing outer race. [Point 3]
7 Remove the lower bearing. [Point 4]
8 Remove the hub cap, rear axle hub and outer bearing. [Point 5]
9 Remove the oil seal and inner bearing. [Point 6]
10 Remove the outer bearing outer race. [Point 7]
11 Remove the inner bearing outer race. [Point 8]
7-8
Note:
• Apply grease before installation.
Outer bearing Inner bearing Inside rear axle hub
STD MP grease
Type Cold storage
Esso beacon 325
spec.
14 ~ 19 11 ~ 15 22 ~ 27
Amount g (lb)
(0.03 ~ 0.04) (0.02 ~ 0.03) (0.05 ~ 0.06)
• After tightening the castle nut, fill MP grease (Esso beacon 325) in the hub cap.
Point Operations
[POINT 1]
SST
Reassembly:
SST 09700-30200-71
[POINT 2]
SST Disassembly:
Use the SST to remove the lower bearing outer race.
SST 09950-76014-71
(099950-40011)
Reassembly:
SST (2) Use the SST to install the lower bearing outer race.
SST 09320-10410-71......(1)
SST 09950-76020-71......(2)
(09950-70010)
SST (1)
7-9
[POINT 3]
Disassembly:
Use the SST to remove the upper bearing outer race.
SST
SST 09700-30200-71
Reassembly:
Use the SST to install the upper bearing outer race.
SST 09950-76019-71......(1)
SST (2)
(09950-60020)
SST (1) SST 09950-76020-71......(2)
(09950-70010)
[POINT 4]
SST (1) Disassembly:
Use the SST to remove the lower bearing.
SST 09950-76014-71......(1)
SST (2) (09950-40011)
SST 09950-76018-71......(2)
(09950-60010)
Reassembly:
Use the SST to install the lower bearing.
SST 09370-10410-71
SST
[POINT 5]
Reassembly:
Use the SST to remove the rear axle hub.
SST 09950-76014-71
(09950-40011)
SST
7-10
Inspection:
Measure the rear axle hub starting force.
Standard: 15 ~ 39 N (1.5 ~ 4 kgf) [3.3 ~ 8.8 lbf]
Reassembly:
Face without When installing a claw washer, position it with its edge
edge facing the rear axle.
Face with edge
[POINT 6]
SST Disassembly:
Use the SST to remove the inner bearing.
SST 09950-76014-71
(09950-40011)
Reassembly:
Use the SST to install the inner bearing.
SST 09316-76008-71
(09316-60011)
SST
Reassembly:
SST 09700-30200-71
SST
7-11
[POINT 7]
Disassembly:
Use a copper bar to remove the outer bearing outer
race.
Reassembly:
Use the SST to install the outer bearing outer race.
SST (2)
SST 09950-76019-71......(1)
(09950-60020)
SST 09950-76020-71......(2)
SST (1) (09950-70010)
[POINT 8]
Disassembly:
Use a copper bar to remove the inner bearing outer
race.
Reassembly:
Use the SST to install the inner bearing outer race.
SST 09950-76019-71......(1)
(09950-60020)
SST (2)
SST 09950-76020-71......(2)
(09950-70010)
SST (1)
7-12
REAR AXLE HUB

12 ~ 32
1 (122.4 ~ 326.0)
[8.9 ~ 23.6]
2
3
117.6 ~ 196.0 4
(1199 ~ 1999)
[86.8 ~ 144.6]
3
2
Removal Procedure
1 Jack up the vehicle and remove the rear wheels. [Point 1]
2 Remove the hub caps.
3 Remove the rear axle hub. [Point 2]
4 Remove the oil seal and inner bearing. [Point 3]
Note:
• Apply grease before installation.
Outer bearing Inner bearing Inside rear axle hub
STD MP grease
Type Cold storage
Esso beacon 325
spec.
14 ~ 19 11 ~ 15 22 ~ 27
Amount g (lb)
(0.03 ~ 0.04) (0.02 ~ 0.03) (0.05 ~ 0.06)
• After tightening the castle nut, fill MP grease (Esso beacon 325) in the hub cap.
7-13
Point Operations
[POINT 1]
Removal:
Jack up the vehicle at the specified jack-up
point.Jacking up at any other point is very dangerous.
Always support the vehicle with wooden blocks at
specified points.
[POINT 2]
Reassembly:
Use the SST to remove the rear axle hub.
SST 09950-76014-71
(09950-40011)
SST
Inspection:
Measure the rear axle hub starting force.
Standard: 15 ~ 39 N (1.5 ~ 4 kgf) [3.3 ~ 8.8 lbf]
Reassembly:
When installing a claw washer, position it with its edge
facing the rear axle.
Face without
edge
Face with edge
[POINT 3]
Disassembly:
Use the SST to remove the inner bearing.
SST 09950-76014-71
(09950-40011)
SST
7-14
Reassembly:
Use the SST to install the inner bearing.
SST 09316-76008-71
(09316-60011)
SST
Reassembly:
SST 09700-30200-71
SST
7-15
REAR AXLE CYLINDER ASSY

T=N·cm (kgf·cm) [ft·lbf]
T=10 ~ 20
(100 ~ 200)
[7.4 ~ 11.8]
T=250 ~ 350
(2549 ~ 3569)
[184.4 ~ 258.2]
2
T=12 ~ 32
(122.4 ~ 326.0)
[8.9 ~ 23.6]
Removal Procedure
1. Remove the rear axle ASSY. (See page 7-5.)
2. Remove the rear axle cylinder ASSY. [Point 1]
7-16
Point Operations
[POINT 1]
Installation:
Adjust the installation of the steering cylinder
(1) Apply MP grease thoroughly to the moving face (inside and outside) until the excess grease can be
seen from the clearance of the moving face.
(2) Position the white tooth of the rack between the two white teeth of the pinion.Apply Moly cote
grease 321R evenly and thoroughly in the area of more than 180 ° of the engagement of the pinion
and rack.
(3) Tighten the lock nut and caulk the lock nut in two places to ensure the starting force of the rear axle.
(4) Tightening torque of frame installation: 250 to 350 N·m (2500 to 3500 kgf·cm)
250 350N m 10 20N m

(2500 3500kgf cm) (100 200kgf cm)
[184.4 258.2ft lbf] [7.4 14.8ft lbf]
(reference value)
7-17
2
1
3 5
2 1
1. Remove the steering cylinder end.
2. Remove the piston.
3. Remove the bushing.
4. Remove the rack.
5. Remove the steering torque cylinder. [Point 1]
Note:
• Apply hydraulic oil to each part before installation.
• Replace O-ring, U-packing and dust seal.
7-18
Point Operations
[POINT 1]
Inspection:
Measure the steering cylinder bore.
Inside diameter standard: 70.0 mm (2.76 in)
Wear limit: 70.35 mm (2.77 in)
8-1
STEERING
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
0
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 1
STEERING WHEEL • MAST JACKET . . . . . . . . . . . 8-8 2
DISASSEMBLY • REASSEMBLY . . . . . . . . . . . . . . . . . . 8-10
4
HYDROSTATIC STEERING VALVE ASSY . . . . . . . 8-11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
5
DISASSEMBLY • INSPECTION • REASSEMBLY . . . . . 8-14 7
INSPECT AND ADJUST
THE RELIEF PRESSURE. . . . . . . . . . . . . . . . . . . . . 8-17
8
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 9
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 10
11
12
13
14
15
16
17
18
8-2
GENERAL
8-3
SPECIFICATIONS
Model
All Models
Item
Steering wheel diameter mm (in) 360 (14.2)
Steering wheel play mm (in) 20 ~ 50 (0.79 ~ 1.97)
Power steering type Hydrostatic steering 0
Discharge: cc (cm3) [cu·in (in3)] 50.0 [3.1]
1
Rated flow rate: l·min
Hydrostatic steering 8 (2.1)
valve
(US gal·min) 2
Relief set pressure
MPa (kgf·cm2) [psi]
10.6 ~ 11.1 (108 ~ 113) [1535.8 ~ 1606.9] 3
COMPONENTS 4
4501 5
6
7
8
9
10
11
12
13
14
15
16
17
18
8-4
4502
4502
8-5
4502
0
1
2
3
4
5
6
7
8
4503
9
10
11
12
13
14
15
16
17
18
8-6
4503
4507
8-7
4507
4507
8-8
STEERING WHEEL • MAST JACKET

2
T= 25.0 45.0
(254.9 458.9)
[18.4 33.2]
3 8
7
10
8
3
13
4
11
12
Removal Procedure
2 Remove the steering wheel. [Point 1]
3 Remove the direction cover (front and rear).
4 Remove the column cover (rear).
5 Disconnect the connectors of the display, direction switch and turn signal switch.
6 Disconnect the connectors of the lamp switch and key switch.
7 Remove the column covers (upper and lower).
8 Remove the display and direction switch.
9 Remove the return spring.
10 Remove the tilt lock mechanism. [Point 2]
11 Remove the tilt steering lock release lever.
12 Remove the steering valve set bolts and set the steering valve free.
13 Remove the mast jacket ASSY.
8-9
Caution:
Cover the brake with cloth to prevent hydraulic oil adhesion.
Note:
• Apply MP grease to each sliding portion of the tilt lock mechanism and tilt steering lock release
lever.
• Add MP grease at the coupling between the steering shaft and steering valve.
Point Operations
[POINT 1]
SST Removal:
SST 09950-76003-71
(09950-50012)
Installation:
Steering wheel installation procedure
(1) Before removing the steering wheel, make a
positioning mark at the top of the steering shaft.
(2) Apply rubber grease to the sliding portion of the turn
signal switch.
(3) Install the steering wheel by referring to the
positioning mark made in (1).
(4) Turn the steering wheel after installation.Turning the
steering wheel will automatically position the three
pins of the turn signal switch at the pin holes of the
steering wheel.
[POINT 2]
Installation:
Install so that the lines of the tilt lever and column cover
are parallel as illustrated, and check that tilt lock
operation is normal.
Parallel
8-10
DISASSEMBLY • REASSEMBLY
1
3
1 Remove the snap ring.
2 Remove the steering shaft.
3 Remove the bearing.
4 Remove the direction switch bracket.
8-11
HYDROSTATIC STEERING VALVE ASSY

TROUBLESHOOTING
Only hydraulic related items are listed. (For electrical troubles, see section 4)
Symptom Probable cause Action
• The piping is damaged. Replace
The steering wheel cannot
be rotated • The steering valve drive shaft is installed Inspect and correct or
incorrectly or damaged. replace.
• Tire pressure is low. (For Pneumatic tire) Adjusting the tire pressure
Inspect and adjust the relief
• The oil pressure does not rise.
The steering wheel is heavy. pressure.
• The high and low pressure pipes are
Inspect and correct.
connected in reverse.
• The high and low pressure pipes are
connected in reverse.
• The relief valve is faulty or not closed. Inspect and correct.
The oil pressure does not
Inspect and correct or
rise. • Oil pump function is deteriorated.
replace.
• Priority valve spool fused. Overhaul
• Hydraulic oil level is low. Add
• Tire pressure is low. (For Pneumatic tire) Adjusting the tire pressure
The steering wheel does not • The steering valve spool does not move Correct or replace the steer-
return properly. smoothly. ing valve ASSY
• The rear axle sliding motion is improper. Add lubricant or correct.
• The steering valve spool does not move Correct or replace the steer-
smoothly. ing valve ASSY
The steering wheel pulls to • The steering valve drive shaft is dam- Replace the steering valve
one side when released aged. ASSY.
• The piping is blocked (crushed or Inspect and correct or
clogged). replace.
Replace the steering valve
• Oil moves in the steering valve.
ASSY.
• The steering valve spool does not move Correct or replace the steer-
Play is excessive and the smoothly. ing valve ASSY
vehicle wobbles
Inspect and correct or
• Air is sucked from the piping.
replace.
• The steering shaft is defective. Inspect and correct.
The steering wheel shim- • The steering valve drive shaft is installed
mies. incorrectly.
8-12
Symptom Probable cause Action

The tires are steered oppo-
• The cylinder piping is connected in
site to the steering wheel Inspect and correct.
reverse
operated direction.
Inspect the pressure and
• The relief valve is defective.
correct or adjust.
Abnormal noise is gener- Inspect and correct or
• Air is sucked from the piping.
ated. replace.
• The piping is blocked (crushed or Inspect and correct or
clogged). replace.
8-13
2
3
5
6
Removal Procedure
2 Remove the direction lever (front and rear).
3 Remove the column covers (upper, lower and rear).
4 Remove the instrument panel.
5 Remove the steering valve ASSY.
6 Remove the knob synchronizer valve.
7 Remove the fitting. [Point 1]
Caution:
Note:
Add MP grease at the coupling between the steering shaft and steering valve.
Point Operations
[POINT 1]
Reassembly:
Install the fitting with the angle shown in the illustration
to the left.
8-14

Note:
Clean dirt from ports and joints before disassembly and perform operation in a clean place.
1 Remove the end cap. [Point 1]
2 Remove the star, rotor and drive shaft. [Point 2]
3 Remove the spacer plate and check valve.
4 Remove the spool and sleeve ASSY. [Point 3]
5 Remove the pin from the spool and sleeve ASSY. [Point 4]
6 Remove the centering spring.
7 Remove the dust seal and bearing.
8 Remove the relief valve. [Point 5]
Note:
Wash each part with clean hydraulic oil before assembly.
8-15
Point Operations
[POINT 1]
Disassembly:
Make match marks.
Reassembly:
Align match marks when reassembling.
Disassembly:
When removing each retainer screw, operate carefully
so as not to lose the steel ball.
Reassembly:
Position the retainer screw and steel ball as shown in
the illustration.
[POINT 2]
Reassembly:
Reassemble the drive shaft and star as follows:
(1) Rotate the spool and sleeve ASSY to bring the pin
parallel with the housing port surface.
(2) Install the O-ring in the housing and place the spacer
plate by aligning the match marks made before
removal.
(3) Insert the drive and fit the pin.

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

8-16
[POINT 3]
Reassembly:
Install the spring as shown in the illustration.
Reassembly:
Install the bearing by positioning the race bearing as
shown in the illustration.
[POINT 4]
Reassembly:
Assemble the spool ASSY by aligning the positioning
mark.
Disassembly:
If the positioning mark for the spool and sleeve is not
provided, provide it with a marker.
Reassembly:
Install the spool and sleeve by holding the cross pin with
the flange facing downward.
[POINT 5]
Disassembly:
Measure the relief valve length before removal.
Caution:
Remove the relief valve only when abnormality of relief
valve is found.
8-17
Reassembly:
Make sure that the relief valve length is the same length
as before the removal.Adjust the relief valve length
when not meeting the standard.
INSPECT AND ADJUST

THE RELIEF PRESSURE.
SST
1. Install a pressure gauge on the P port of the priority
valve.
(1) Disconnect the hose from the P port and connect the
adapter.
SST 09450-23320-71
(2) Install the pressure gauge.
Fitting size: PT1/8
2. When the steering wheel is rotated to the end, relief

state is achieved, so read the pressure on the pressure
gauge at that time.
0
Standard:
All Models 10.6 to 11.1 (108 to 113)
MPa (kgf·cm2) [psi] [1535.8 to 1606.9]
4. If the relief pressure is out of the standard range,
remove the steering valve and adjust at the adjusting
section.
8-18
PRIORITY VALVE
COMPONENTS
4507
8-19
4507
8-20
T=10.5 24.5
(107.1 249.8)
[7.7 18.1]
Removal Procedure
1 Remove the toe board (front and rear) and tilt cover.
2 Disconnect the piping.
3 Remove the priority valve.
Caution:
Point Operations
[POINT 1]
8 Reassembly:
Install the priority valve fitting with the angle shown in
the illustration to the left.
85
8-21

T= 40 60
(407.9 611.8)
[29.5 66.0]
2
3
T= 40 60
(407.9 611.8)
[29.5 66.0]
1 Remove the plug.
2 Remove the plug.
3 Remove the shaft.
9-1
BRAKE
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
0
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 2
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 3
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
4
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
5
DISK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 9-11 7
BRAKE DISC WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
8
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9
BRAKE PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . 9-15 11
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
12
PARKING BRAKE ADJUSTMENT. . . . . . . . . . . . . . . . . 9-17
13
14
15
16
16
18
9-2
GENERAL
9-3
SPECIFICATIONS
Model
All models
Item
Foot brake type Mechanical disc brake
Parking brake type Mechanical disc brake
mm Diameter 203 (8.0) 0

Brake wheel
(in) Thickness 9.0 (0.4) 1
35.28 × 2 × 2
Area cm2 (in2)
Brake pad (5.468 × 0.079 × 0.079) 2
Thickness mm (in) 6 (0.2)
3
COMPONENTS
4
PARKING BRAKE
4601 5
6
7
8
9
10
11
12
13
14
15
16
16
18
9-4
BRAKE PEDAL
4701
9-5
DISC BRAKE
4716
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
18
9-6
4716
9-7
4716
9-8
DISC BRAKE
T=24.0 ~ 36.0
(244.7 ~ 367.1)
[17.7 ~ 26.6]
T=60.0 ~ 90.0
T=70.0 ~ 140.0
(611.8 ~ 917.7)
(713.8 ~ 1427.6)
[44.3 ~ 66.4]
[51.6 ~ 103.3]
T=70.0 ~ 140.0
(713.8 ~ 1427.6)
6 [51.6 ~ 103.3]
Removal Procedure
1 Raise the inner mast and securely fix it to prevent lowering. [Point 1]
2 Remove the brake cover.
3 Remove the toe board (front and rear) and tilt cylinder cover.
5 Disconnect the links from the brake pedal and parking brake.
6 Disconnect the brake rods between frame and brake ASSY (LH and RH).
7 Remove the brake ASSY (LH).
8 Remove the brake ASSY (RH).
9-9
Point Operations
[POINT 1]
Removal:
Raise the inner mast and support it by putting wooden
block inside the outer mast rail to prevent the inner mast
lowering.
9-10

8.0 18.0
(81.6 183.5)
[5.9 13.3]
1 Remove the pin, castle nut and lever.
2 Separate the lever ASSY No.1 and 2. [Point 1]
9-11
Point Operations
[POINT 1]
Inspection:
Measure the pad thickness.
Standard: 6.0 mm (0.24 in)
Limit: 3.5 mm (0.14 in)
DISK BRAKE ADJUSTMENT

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

B=9.8 to 10.2 mm (0.39 to 0.40 in)
C=9 mm (0.35 in)
9-12
BRAKE DISC WHEEL

2 T=100.0 ~ 145.0
(1019.7 ~ 1478.6)
[73.8 ~ 107.0]
Removal Procedure
1 Remove the disc brake ASSY. (See page 9-8)
2 Remove the brake disc wheels (LH and RH). [Point 1]
9-13
Point Operations
[POINT 1]
Removal:
Raise the inner mast and support it by putting wooden
block inside the outer mast rail to prevent the inner mast
lowering.
[POINT 2]
Inspection:
Inspect the brake disc wheel thickness.
Limit: 8.0 mm (0.31 in)
9-14
BRAKE PEDAL
T=3.0 ~ 7.0
T=14.4 ~ 33.6
(31 ~ 71)
(146.8 ~ 342.6)
[2.2 ~ 5.1]
[10.6 ~ 24.8]
Removal Procedure
1 Remove the toe board (front and rear) and tilt cylinder cover.
3 Remove the brake pedal set bolt.
4 Disconnect the link and remove the brake pedal.
5 Disconnect the parking brake wire.
6 Remove the brake pedal adjusting nut.
7 Remove the brake pedal link.
8 Remove the parking brake adjusting nut.
9 Remove the parking brake link.
10 Remove the brake ASSY link.
11 Remove the brake link ASSY.
12 Remove the brake link ASSY pin.
Note:
Inspect the bushing for wear and damage and replace it if necessary.
9-15
BRAKE PEDAL ADJUSTMENT

1. Inspect brake pedal height A (from pedal to the upper
side of the pedal).
Standard: A = 110 to 115 mm [4.3 to 4.5 in]
Adjust if the pedal height is outside the specified range
B
with a stopper bolt.
A
C
Stopper bolt
2. Tighten the adjusting nut until the equalizer is securely

fixed. Adjust the pedal stroke B when the clearance
between the brake pad and disc is within the standard
(0.4 to 0.6 mm[0.016 to 0.024 in]).
(Reference value): B = 30 to 35 mm [1.18 to 1.38 in]
3. After the adjustment, inspect the ground clearance C
(from the toe board to the top of the pedal) with fully
Adjusting nut depressing the brake pedal. If the ground clearance C is
standard or below, adjust the clearance between the
brake pad and disc.
Standard: C = 55mm [2.17 in]
9-16
PARKING BRAKE
3.0 7.0 (30.6 71.4) [2.2 5.2]
Removal Procedure
2 Disconnect the parking brake wire.
3 Remove the parking brake ASSY.
9-17
PARKING BRAKE ADJUSTMENT
Backside pole
Frontside pole
50 mm
(2.0 in)
150 N
(15.3 kg)
[33.7 lb]
1Notch
2Notch
3Notch
4Notch
5Notch
Adjustment nut
1. Adjust the parking brake so that the front pole fits at the third or fourth notch of the sector when the
parking brake lever operating force is at 150 N (15.3 kg) [33.7 lb] (measure at the point in the
illustration).
2. When the disc brake drags, adjust it so that the front pole fits at the fifth notch.
10-1
BODY & FRAME

Page
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
0
BATTERY HOOD ASSY . . . . . . . . . . . . . . . . . . . . . . . 10-6
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 2
3
OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
4
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 5
FUSE INSTALLATION LOCATIONS . . . . . . . . . . . . . . . 10-9 6
NAMES (APPLICABLE FUNCTIONS) 7
AND CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
8
9
10
12
12
13
14
15
16
16
18
10-2
COMPONENTS
Frame & Weight
5101
5101
10-3
5101
0
1
2
3
4
5
6
7
8
5201
9
10
12
12
13
14
15
16
16
18
10-4
5301
5301
10-5
5308
0
1
2
3
4
5
6
7
8
5401
9
10
30
CO
DZ
CG 31 12
12
KJ
13
KJ
14
KJ
15
16
16
18
5401-286
10-6
BATTERY HOOD ASSY

Removal Procedure
2 Open the battery hood
3 Use string to tie the battery hood ASSY W/seat ASSY to the head guard rear pillar.
4 Disconnect the wiring of the seat switch.
5 Disconnect the battery hood damper (on the frame side).
6 Close the battery hood
7 Remove the battery hood hinge set bolt.
8 Remove the battery hood ASSY W/ seat ASSY.
10-7
COUNTERWEIGHT
Note:
See page 0-11 for counterweight and select an appropriate wire rope for the counterweight.
T=N·m (kgf-cm) [ft-lbf]
2
5
T=110~250
4
(1122~2549)
[81.2~184.4]
Removal Procedure
3 Remove the draw bar and temporarily hoist the counterweight by slinging with a wire rope.
4 Remove the counter weight set bolt.
5 Remove the counterweight. [Point 1]
Point Operations
[POINT 1]
Installation:
Be sure to keep the balance when installing the
counterweight.
10-8
OPERATOR’S SEAT
Removal Procedure
1 Open the battery hood
2 Disconnect the wiring of the seat switch.
3 Remove the operator’s seat set nuts. (Be careful not to drop the operator’s seat.)
4 Remove the operator’s seat.
10-9
FUSES
FUSE INSTALLATION LOCATIONS
Fuses F1 and F4 to F6 are located in the lower portion of the rear right controller box.F1 is a module type
and F4 to F6 are blade type fuses. Previously F1 was for traveling and F2 was for material handling, but
they are integrated to F1 as traveling/material handling fuse.
F1
A view F4 F5 F6
A view
NAMES (APPLICABLE FUNCTIONS) AND CAPACITIES
7FBE13 7FBEF15, 16, 18, 20
F1 For drive and material handling 450 A 500 A

F4 For lights 10 A
F5 For controller circuit 10 A
F6 SAS, for solenoid 10 A
Caution for fuse replacement

Before fuse replacement, be sure to disconnect the battery plug and completely discharge CO
(overall condenser) with Approx. 100Ω resistor between P3-N2.
11-1

Page
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
0
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
RETURN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 1
NATURAL DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . 11-9 3
NATURAL FORWARD TILT TEST . . . . . . . . . . . . . . 11-9
4
OIL LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 6
7
8
9
10
11
12
13
14
15
16
17
18
11-2
HYDRAULIC CIRCUIT
Lift Cylinder
Oil controi valve
Oil tank
Return filter
Tilt cylinder
Steering valve
Solenoid Oil pump

valve Priority
valve
Pump motor
11-3
COMPONENTS
6801
0
1
2
3
4
5
6
7
8
6801 9
10
11
12
13
14
15
16
17
18
11-4
V Mast
6801
FV Mast
6801
11-5
FSV Mast
6801
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
11-6
FV Mast
6802
FSV Mast (7FBEF15, 16, 18)
6802
FSV Mast (7FBEF20)
AA
AK
AD
41
EQ
NI
NE
20
BL
NJ
BP NK
BW
CR
30
CZ 31
BW
BP
17
FZ
EY CG
BH
48 DO
DO
AR
17 EW CG
FIG.6801-EN
6802-573
6802
11-7
11-8
RETURN FILTER
Removal procedure
2 Remove the toe boards (front and rear) and tilt cylinder cover.
3 Disconnect hoses from the front and rear of the return filter.
4 Remove the return filter.
Installation procedure
Caution:
11-9
NATURAL DROP TEST

1. Set the mast in the vertical position with the standard
load on the fork, lift the fork by 1 to 1.5 m (39.3 to 59.1
in), and turn the key switch to OFF.
2. Draw datum lines on the inner and outer masts, and

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

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

Model Natural forward tilt mm (in)
7FBEF15, 16, 18 15 (0.6) or less
7FBEF20 20 (0.8) or less
11-10
OIL LEAK TEST

LIFT CYLINDER
load on the fork, lift the fork by 1.0 to 1.5 m (39.3 to 59.1
in).
Tilt the mast forward slowly. After waiting 5 minutes with
the key switch OFF, disconnect the oil control valve to oil
tank hose and measure the amount of oil that leaks in
one minute.
Standard (lift port section): 8 cm3 (0.49 in3) or less
Note:
If the natural drop is great even though the oil leak
amount is within the standard range, either the lift lock
valve or the lift cylinder packing is defective.
TILT CYLINDER
load on the fork, lift the fork by 50 m (19.7 in), and turn
the key switch to OFF.
2. After waiting 5 minutes with the key switch OFF,
disconnect the oil control valve to oil tank hose and
measure the amount of oil that leaks in one minute.
Standard (total amount for lift and tilt):
16 cm3 (0.98 in3) or less
3. The leak amount at the tilt port is the total leak amount
less the leak amount from the lift port.
Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard range, either the tilt lock
valve or the tilt cylinder packing is defective.
12-1
MAST
Page
V MAST ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
0
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
REMOVAL • INSTALLATION (W/LIFT BRACKET) . . . . 12-6 2
MAST ASSY DISASSEMBLY • INSPECTION
• REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
3
LIFT BRACKET DISASSEMBLY • INSPECTION • 4
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
5
MAST ADJUSTMENT (V MAST) . . . . . . . . . . . . . . . . . . 12-11
MAST ROLLER REMOVAL • INSTALLATION. . . . . . . . 12-16 6
CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17 7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
8
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
9
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 10
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
14
FV · FSV MAST ASSY . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19 14
MAST ADJUSTMENT (FV • FSV) . . . . . . . . . . . . . . . . . 12-23 15
LIFT CYLINDER ROD SHIM ADJUSTMENT 16
(PREVENTION OF UNEVEN LIFTING) . . . . . . . . 12-27
16
18
12-2
V MAST ASSY
COMPONENTS
MAST ASSY (V)
6101
12-3
LIFT BRACKET ASSY

6301
0
1
2
3
4
5
6
7
8
CHAIN AND CHAIN WHEEL ASSY
9
6302
10
11
12
14
14
15
16
16
18
12-4
10
T=60.0~140.0
(610~1430)
[44.1~103.5]
T=86.2~129.4
(880~1320)
8 [63.7~95.5]
Removal Procedure
1 Set the mast in the vertical position and fully lower the fork.
2 Disconnect the chain. [Point 1]
3 Remove the chain wheel. [Point 2]
4 Remove the lift bracket ASSY. (Raise the inner mast until it comes off the lift bracket, and slowly run
the vehicle in reverse to detach from the lift bracket.)
5 Disconnect the lifting height switch, remove the load sensor clamp and disconnect the wiring.
6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift
cylinder.)
7 Slightly hoist the mast.
8 Remove the tilt cylinder front pin. [Point 3]
9 Remove the mast support cap.
10 Remove the mast ASSY.
Note:
• Apply chassis grease special to the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced. (See page 12-27.)
• Adjust the chain tension after installation. (See page 12-18.)
• When the mast is replaced, perform SAS matching after installation. (See section 16.)
12-5
Point Operations
[POINT 1]
Removal · Installation:
SST 09630-23600-71
[POINT 2]
1
Removal:
If the fitting is stiff, use the SST for removal. 2
SST 09950-76014-71
(09950-40011) 3
4
5
[POINT 3] 6
Removal:
Make match marks to clarify the relative positions of the
front pin, stopper plate and lock bolt. Match marks,
7
however, are unnecessary when the mast or mast ASSY
is replaced as mast tilt angle adjustment is to be done 8
after replacement.
9
10
Removal:
If the fitting is stiff, use the driver for removal. 11
12
14
14
15
Inspection:
Measure the mast support bushing thickness. 16
Limit: 1.0 mm (0.039 in)
16
18
12-6
REMOVAL • INSTALLATION (W/LIFT BRACKET)

T=60.0~140.0
(610~1430)
[44.1~103.5]
2 T=86.2~129.4
(880~1320)
7 [63.7~95.5]
5
8
Removal Procedure
1 Set the mast in the vertical position.
2 Remove the fork. (See page 12-18.)
3 Disconnect the lifting height switch, remove the load sensor clamp and disconnect the wiring.
4 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.)
5 Tie the lift bracket and outer mast tie beam with a wire rope.
8 Remove the mast support cap.
9 Remove the mast ASSY W/lift bracket.
12-7
Note:
• Apply chassis grease special to the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced. (See page 12-27.)
• Adjust the chain tension after installation. (See page 12-18.)
• When the mast is replaced, perform SAS matching after installation. (See section 16.)
Point Operations
[POINT 1]
Removal:
front pin, stopper plate and lock bolt.Match marks,
is replaced as mast tilt angle adjustment is to be done
after replacement.
Removal:
If the fitting is stiff, use the driver for removal.
Inspection:
Measure the mast support bushing thickness.
Limit: 1.0 mm (0.039 in)
12-8
MAST ASSY DISASSEMBLY • INSPECTION • REASSEMBLY
2
9
7 8
1 Remove the lifting height switch.
2 Remove the hose cover.
3 Disconnect the overflow hose and high pressure hose.
4 Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]
5 Remove each cylinder support. [Point 2]
6 Remove each cylinder bottom set bolt, and remove each lift cylinder.
7 Slide the inner mast downward, and remove the lift rollers.
8 Remove the mast strip. [Point 3]
9 Remove the outer mast.
12-9
Point Operations
[POINT 1]
Disassembly:
Shim adjustment is made at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Keep a record of where the adjustment is made and the
number of shims used.
[POINT 2]
Disassembly:
Keep a record of the number of cylinder support shims
used.
Reassembly:
Perform cylinder support shim adjustment if the mast or
either cylinder is replaced.
With the cylinder rod end inserted to the inner mast,
eliminate any clearance between the cylinder support
and outer mast by inserting shim.Shims should be
slightly thicker than the clearance.
[POINT 3]
Inspection:
Measure the mast strip thickness.
Limit: 1.5 mm (0.059 in)
12-10
LIFT BRACKET DISASSEMBLY • INSPECTION • REASSEMBLY

3
1
T=98~182
(999~1856)
[72.3~134.3]
1 Remove the lift rollers. [Point 1]
2 Remove side rollers. [Point 2]
3 Remove the back rest.
Point Operations
[POINT 1]
Disassembly:
SST 09950-76014-71
(09950-40011)
SST
[POINT 2]
Reassembly:
Install side rollers in the correct direction.
The greater chamfering on the outside of the roller
should be on the vehicle front side.
12-11
MAST ADJUSTMENT (V MAST)

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

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

(4) After adjustment, check that the inner mast moves
smoothly in the outer mast.
12-12
2. Outer mast roller clearance adjustment

(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, and measure on the
opposite side the clearance between the roller side
face and mast at the point where they are the closest.
Standard: B=0 ~ 0.5 mm (0 ~ 0.020 in)
If the standard is not met, adjust by changing the
outer mast roller shim thickness. (See removal and
installation of mast roller (See page 12-16))
(4) After adjustment, check that the inner mast moves
smoothly in the outer mast.
12-13
Roller Adjustment at Lift Bracket

1. Middle/lower lift roller and side roller clearance adjustment
(1) Bring the center of the upper lift roller in the lift bracket
to 100 mm (3.94 in) from the top of the inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and measure the
clearance of the middle and lower lift rollers when the
clearance between the opposite rollers and the mast
is minimum. (No adjustment is necessary for the
upper lift rollers as they are fastened by snap rings)
Standard:
C=0 ~ 0.8 mm (0 ~ 0.031 in)
If the standard is not met, adjust by changing the lift
roller shim thickness.
12-14

(5) Install side rollers.
(6) After adjusting the middle and lower lift rollers, bring
the side roller on one side into contact with the side of
the mast and measure on the opposite side the
clearance between the side roller and the innermost
side face.
Standard:
D=0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not met, adjust by changing the side
roller shim thickness.
(7) Distribute shims equally to the left and right side

rollers.
(See “Lift Bracket Disassembly · Inspection ·
Reassembly” section for the side roller installation
method.Shim replacement is possible on the vehicle)
(8) After adjustment, check that the lift bracket moves
smoothly along the entire length of the mast.
Shims
12-15
Mast Strip Adjustment

1. Mast strip clearance adjustment
(1) Fully lower the inner mast.

(2) With the inner mast in contact with the outer mast
roller, measure the clearance between the mast strip
and inner mast.
Standard: E=0 ~ 0.8 mm (0 ~ 0.031 in)
If the standard is not met, adjust by changing the mast
strip shim thickness. (See removal and installation of
mast roller. (See page 12-16))
(3) After adjustment, check the mast for smooth

movement.
12-16
MAST ROLLER REMOVAL • INSTALLATION

1. Remove the lift bracket. (See steps 1 to 4 of the mast
ASSY removal procedure on page 12-4)
2. Jack up the vehicle and support with wooden blocks
under the tires.Chock the wheels.
3. Remove the lift cylinders. (See page 13-6)
4. Remove mast rollers.

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

5. The installation procedure is the reverse of the removal
procedure.
12-17
CHAIN
INSPECTION
1. Inspect the chain elongation using the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement scale differs according
to the chain type, set the corresponding scale on the
chain as illustrated.
(2) Check the chain no. of the chain to be inspected, and
check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, it has reached the limit; replace the chain.
Chain link pitch standard
Pitch CHAIN
Vehicle Type
mm (in) No.
15.88
7FBEF15 to18 BL534 50
(0.625)
19.05
7FBEF20 BL634 60
(0.778)
Note:
• Perform measurement without removing the chain
from the vehicle.
• Inspect elongation over the entire chain length as it
may be localized.
REASSEMBLY
1. Installing direction
Applicable
FV: Lift bracket
mast and V: Lift bracket FSV: Inner mast
FSV: Lift bracket
section
Center of Center of Front of

vehicle vehicle vehicle
Split pin Split pin Split pin

Rough sketch
Install with the split pin direct- Install with the split pin direct- Install with the split pin direct-
ing toward the center of the ing toward the center of the ing front of the vehicle.
vehicle. vehicle.
12-18
2. Chain adjusting nut tightening procedure

(1) Tighten nut (a), (b).T=49.0 ~ 78.0 N·m (500 ~ 800 kgf·cm) [36.1 ~ 57.5 ft·lbf]
(2) Tighten nuts (c).
Applicable
FV: Front cylinder
mast and V: Outer mast FSV: Outer mast
FSV: Front cylinder
section
Rough
sketch
ADJUSTMENT
1. Park the vehicle on a flat surface and set the mast in the vertical position.
2. Lower the fork to the ground, and adjust to eliminate any chain sag by turning the adjusting nut.
3. Check to see that the chain tension is equal on the left and right sides.
4. Check that the chain is not twisted.
5. Check that the lifting height meets the standard.
6. In the uppermost position, check that the lift bracket fall-out prevention stopper at the inner mast upper
beam is not in contact with the lift bracket.
FORK
REMOVAL
1. Raise the fork to approx. 20 cm (7.9 in) from the ground.
2. Place a wooden block under the notched section of the
fork rail.
3. Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1. Inspect misalignment of the fork tip ends.
Limit: 10 mm (0.39 in)
If the limit is exceeded, inspect individual fork bend,
looseness of fork installation and lift bracket finger bar
distortion.
12-19
FV · FSV MAST ASSY

COMPONENTS
MAST ASSY (FV)
6101
12-20
MAST ASSY (FSV)

6101
12-21
LIFT BRACKET ASSY (FV)

6301
LIFT BRACKET ASSY (FSV)

6301
12-22
CHAIN & CHAIN WHEEL (FV)

6302
CHAIN & CHAIN WHEEL (FSV)

6302
12-23
MAST ADJUSTMENT (FV • FSV)

Lift Roller Adjustment at Mast
1. Inner mast roller (FV · FSV) and middle mast lower roller (FSV) clearance adjustment

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

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

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

1. Mast strip clearance adjustment
(1) Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.
Standard: E=0 ~ 0.8 mm (0 ~ 0.031 in)
If the standard is not met, adjust by changing the shim thickness.
(3) After adjustment, check the mast for smooth movement.
12-27
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN

LIFTING)
Note:
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• Perform inspection and adjustment when any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY and inner mast SUB-ASSY.
• After adjustment, perform SAS matching. (See section 16.)
1. Inspection method
Slowly raise the inner mast, and observe the stopping
condition of the left and right cylinder rods at the
moment when the inner mast reaches the maximum
height.
(1) Normal case
Both the left and right rods stop almost
simultaneously with almost no shaking of the inner
mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
SST (1) Raise the inner mast, attach the SST to the outer
mast tie beam, and lower the inner mast until it comes
into contact with the SST.
SST 09610-22000-71
(2) Remove the cylinder rod end set bolt on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end, and slowly raise
the cylinder rod end into the inner mast.
(5) Install the cylinder rod end set bolt.
(6) Raise the inner mast again for reinspect ion.
(7) Repeat the inspection and adjustment until the
number of shims is determined.
13-1
CYLINDER
Page
LIFT CYLINDER (V) •
REAR LIFT CYLINDER (FV • FSV) . . . . . . . . . . . . 13-2 0
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
2
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
3
FLOW REGULATOR VALVE (V • FV • FSV) . . . . . 13-14 5
6
SAFETY DOWN VALVE (V • FV • FSV) . . . . . . . . . . 13-16
7
REMOVAL • INSTALLATION (V) . . . . . . . . . . . . . . . . . . 13-17
REMOVAL • INSTALLATION (FV • FSV) . . . . . . . . . . . . 13-18 8
FRONT LIFT CYLINDER (FV • FSV) . . . . . . . . . . . . 13-19 9
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19
10
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-19
11
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
12
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
15
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24 16
18
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT
(PREVENTION OF UNEVEN TILTING). . . . . . . . . . . . 13-30
13-2
LIFT CYLINDER (V) • REAR LIFT CYLINDER (FV • FSV)

GENERAL
Lift Cylinder (V)
7FBEF15, 16, 18
7FBEF20
Rear Lift Cylinder (FV)
RH
LH
Rear Lift Cylinder (FSV)

13-3
SPECIFICATIONS
Lift Cylinder (V)
Model
Item
Cylinder type Single-acting type
Cylinder bore mm (in) 45 (1.77) ← ← 50 (1.97)
Piston rod outside diameter mm (in) 35 (1.38) ← ← 40 (1.57) 0
Piston seal type U packing ← ← ←
Rod seal type U packing ← ← ←
1
Others
Built-in flow regulator valve (RH) 2
Built-in safety down valve (LH)
3
Model 4
Item
Cylinder type Single-acting type −
5
Cylinder bore mm (in) 45 (1.77) ← ← − 6
Piston rod outside diameter mm (in) 32 (1.26) ← ← −
Rod seal type U packing ← ← − 7
Built-in flow regulator valve (RH)
Others
Built-in safety down valve (LH)
− 8
Rear Lift Cylinder (FSV) 9
Model
7FBEF15 7FBEF16 7FBEF18 7FBEF20 10
Item
Cylinder type Single-acting type 11
Piston rod outside diameter mm (in) 35 (1.38) ← ← 40 (1.57) 12
13
Others Built-in safety down valve (LH)
12
15
16
16
18
13-4
COMPONENTS
Lift Cylinder (V)
6501

6503
13-5

7FBEF15, 16, 18
6503
0
1
2
3
4
5
6
7
8
7FBEF20
6503
9
10
11
12
13
12
15
16
16
18
13-6
3
2
10
5
11
8
6
7
9
Removal Procedure
1 Set the mast in the vertical position and fully lower the fork.
2 Remove the lift cylinder rod end set bolt.
3 Hoist the inner mast by slinging with wire and disconnect the lift cylinder rod end.
[Point 1]
4 Hoist the mast until the lift cylinder ASSY can be removed toward the front side of the vehicle.
5 Support the bottom of the inner mast with wooden blocks and fix the outer mast with string.
6 Remove the hose cover.
7 Disconnect the hose.
8 Remove the load sensor cover and disconnect the wiring. (FV · FSV)
9 Remove the lift cylinder bottom end set bolt.
10 Remove the lift cylinder support. [Point 2]
11 Remove the lift cylinder ASSY.
13-7
NOTE:
After installing the lift cylinder, follow the steps below.
1. Without a load, repeat full-stroke raising and lowering of the cylinder to bleed air and check normal
functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect lift cylinders for uneven lifting, and make any necessary adjustment. (See page 12-27.)
Point Operations
[POINT 1]
Removal:
Perform shim adjustment at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Record at which cylinder the adjustment is made and
also the number of shims used.
[POINT 2]
Removal:
Temporarily fasten the cylinder support, and eliminate
any clearance between the cylinder support and outer
mast by shim insertion after connecting the rod end.
(The shim thickness should be slightly greater than the
clearance)
13-8

Lift Cylinder (V)
T = 343 ~ 441 (3500 ~ 4500)

[253 ~ 326]
4
2
4
4
3
7
1
5
6
6
6
Flow regulator valve
T = 58.8 ~ 68.6 (600 ~ 700) [43.4 ~ 50.6]
Safety down valve
T = 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9]
1 Remove the flow regulator valve or safety down valve.
2 Remove the cylinder cover.
3 Remove the rod guide.
4 Remove the seals from the cylinder cover.
5 Remove the piston rod. [Point 1]
6 Remove the seals on the piston rod.
7 Remove the lift cylinders. [Point 2]
NOTE:
• Apply MP grease or hydraulic oil to packings, O-rings and dust seal lips.
• Apply sealant (08833-76002-71 (08833-00080)) to the threaded portion of the cylinder cover
before tightening.
13-9
Point Operations
[POINT 1]
Inspection: Measure the piston rod outside diameter.
Unit: mm (in)
Standard: Limit
7FBEF15 to 18 35.0 (1.378) 34.92 (1.3748)
V
7FBEF20 40.0 (1.575) 39.92 (1.5717)
Inspection: Measure the bend of the piston rod.

Limit: 2.0 mm (0.079 in)
[POINT 2]
Inspection: Measure the lift cylinder bore.
Unit: mm (in)
Standard: Limit
7FBEF15 to 18 45.0 (1.772) 45.20 (1.7795)
7FBEF20 50.0 (1.969) 50.20 (1.9764)
13-10

T = 343 ~ 441 (3500 ~ 4500)

[253 ~ 326]
4 4
2 2
4 4
4 4
3 3
7 7
4 4
4 4
1
5
5
6 6
Safety down valve Flow regulator valve
T = 29.4 ~ 39.2 T = 58.8 ~ 68.6
(300 ~ 400) [21.7 ~ 28.9] (600 ~ 700) [43.4 ~ 50.6]
1 Remove the flow regulator valve or safety down valve.
4 Remove the seals from the cylinder cover and rod guide.
NOTE:
before tightening.
13-11
Point Operations
[POINT 1]
Unit: mm (in)
Standard: Limit
FV 7FBEF15 to 18 32.0 (1.260) 31.92 (1.2567)

Limit: 2.0 mm (0.079 in)
[POINT 2]
Unit: mm (in)
Standard: Limit
7FBEF15 to 18 45.0 (1.772) 45.20 (1.7795)
13-12

T = 343 ~ 441
(3500 ~ 4500) [253 ~ 326] 4
4
2
3
4
8
1
6
6
6
5
T = 29.4 ~ 39.2 7
(300 ~ 400) [21.7 ~ 28.9]
1 Remove the safety down valve. (RH cylinder)
4 Remove the seals from the cylinder cover.
7 Remove the check valve from the piston rod.
NOTE:
before tightening.
13-13
Point Operations
[POINT 1]
Unit: mm (in)
Standard: Limit
7FBEF15 to 18 35.0 (1.378) 34.92 (1.3748)
FSV
7FBEF20 40.0 (1.575) 39.92 (1.5717)

Limit: 2.0 mm (0.079 in)
[POINT 2]
Unit: mm (in)
Standard: Limit
7FBEF15 to 18 45.0 (1.772) 45.20 (1.7795)
7FBEF20 50.0 (1.969) 50.20 (1.9764)
13-14
FLOW REGULATOR VALVE (V • FV • FSV)
Lowering Speed Specifications

Unit: mm/sec (fpm)
Mast
V FV FSV
Model
No-load 550 (108) 420 (83) 450 (89)
7FBEF15
Load 500 (98) 480 (94) ←
No-load 550 (108) 420 (83) 450 (89)
7FBEF16
Load 500 (98) 480 (94) ←
No-load 550 (108) 420 (83) 450 (89)
7FBEF18
Load 500 (98) 480 (94) ←
No-load 500 (98)  450 (89)
7FBEF20
Load 500 (98)  480 (94)
13-15
NOTE:
• The explanation here is for the flow regulator valve for the V or FV mast.
• In the case of the FSV mast, the flow regulator valve is installed on the outer mast.
T=59~69 2
(600~700)
[43.4~50.6]
Removal Procedure
1 Hoist the inner mast. [Point 1]
2 Remove the flow regulator valve.
Point Operations
SST
[POINT 1]
Hoist the inner mast by slinging with wire, set the SST
on the inner mast tie beam, and lower the inner mast
until it comes into contact with the SST.
SST 09610-22000-71
13-16
SAFETY DOWN VALVE (V • FV • FSV)

Safety Down Valve Section (for V) (for FV · FSV Rear Lift Cylinder)
Safety Down Valve Section (for FV · FSV Front Lift Cylinder)

13-17
REMOVAL • INSTALLATION (V)

8
T=22~26
(220~270)
[15.9~19.5]
T=29~39
9 (300~400)
[21.7~29.0]
3
10
T=44~54
(450~550)
6 [32.6~39.8]
Removal Procedure
3 Remove the front hose cover and load sensor bracket.
4 Remove the lift cylinder (LH) bottom end set bolt.
5 Loosen the lift cylinder (LH) support set bolt.
7 Remove the load sensor cover.
8 Disconnect the load sensor connector and remove the load sensor.
9 With the lift cylinder (LH) hoisted slightly upward, remove the three-way.
10 Remove the safety down valve.
Point Operations
SST
[POINT 1]
Hoist the inner mast by slinging with wire, set the SST
on the inner mast tie beam, and lower the inner mast
until it comes into contact with the SST.
SST 09610-22000-71
13-18
REMOVAL • INSTALLATION (FV • FSV)

8 T=22~26
(220~270)
[15.9~19.5]
6 7
T=29~39
(300~400)
4
[21.7~29.0]
T=44~54
(450~550)
[32.6~39.8]
3
Removal Procedure
3 Remove the front hose cover.
4 Remove the lift cylinder (LH) bottom end set bolt.
5 Loosen the lift cylinder (LH) support set bolt.
7 Remove the load sensor bracket.
8 Disconnect the load sensor connector and remove the load sensor.
9 With the lift cylinder (LH) hoisted slightly upward, remove the three-way.
Point Operations
SST
[POINT 1]
Hoist the inner (middle) mast by slinging with wire, set
the SST on the inner (middle) mast tie beam, and lower
the inner mast until it comes into contact with the SST.
SST 09610-22000-71
13-19
FRONT LIFT CYLINDER (FV • FSV)

GENERAL
FRONT LIFT CYLINDER (FV · FSV)
SPECIFICATIONS
Model
Item 7FBEF15 7FBEF16 7FBEF18 7FBEF20
Cylinder type Single-acting type
Piston rod outside diameter mm (in) 70 (2.76) ← ← 75 (2.95)
Others Built-in safety down valve
13-20
COMPONENTS
6502
Removal Procedure
1 Remove the lift bracket W/fork.
2 Disconnect the piping.
3 Remove the front lift cylinder.
NOTE:
After installing the lift cylinder, follow the steps below.
1. Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Adjust the lift chain tension equally on the left and right sides.
13-21

T = 343 ~ 441 (3500 ~ 4500) [253 ~ 326]

3
3
3
2
3
3
3 6
4
1
5
T = 29.4 ~ 39.2 (300 ~ 400)

[21.7 ~ 28.9]
2 Remove the cylinder rod guide. [Point 1]
3 Remove the rod guide seals.
5 Remove the wear ring.
NOTE:
• Apply sealant (08833-00080) to the threaded portion of the rod guide before tightening.
13-22
Point Operations
[POINT 1]
Disassembly · Reassembly:
SST 09620-10100-71
[POINT 2]
Inspection:
Measure the piston rod outside diameter.
Unit: mm (in)
Vehicle model Standard: Limit
7FBEF15 to 18 70.0 (2.756) 69.91 (2.7524)
7FBEF20 75.0 (2.953) 74.91 (2.9429)
Inspection:
Measure the bend of the piston rod.
Limit: 2.0 mm (0.079 in)
[POINT 3]
Inspection:
Measure the lift cylinder bore.
Unit: mm (in)
Vehicle model Standard: Limit
7FBEF15 to 18 85.0 (3.346) 85.40 (3.3622)
7FBEF20 90.0 (3.543) 90.40 (3.5591)
13-23
TILT CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double acting type
Cylinder bore mm (in) 70 (2.76)
Piston rod outside diameter mm (in) 30 (1.18)
Piston seal type U packing
Rod seal type U packing

13-24
COMPONENTS
6511
13-25
6511
13-26
8 9
T=86.2~129.4
(845~1269)
[61.1~91.8]
7
Removal Procedure
3 Remove the fender cover and step.
5 Disconnect the hose. (After releasing the residual pressure in the tilt cylinder by operating the tilt lever
several strokes).
6 Disconnect the tilt angle sensor link. (RH)
8 Remove the tilt cylinder rear pin.
9 Remove the tilt cylinder ASSY.
NOTE:
• Apply MP grease to the insertion portions of the tilt cylinder front and rear pins before
installation.
• After installation, slowly tilt the mast forward and backward a few times to check normal
functioning.
• Check the hydraulic oil level and add if insufficient.
• After installation, perform SAS matching. (See section 16.)
13-27
Point Operations
[POINT 1]
Removal:
front pin, stopper plate and lock bolt. Match marks,
is replaced as mast tilt angle adjustment is to be done
after replacement.
Removal:
If the fitting is stiff, use the driver for removal.
13-28

2 6
1 Remove the Fitting.
2 Loosen the rod guide. [Point 1]
3 Extract the piston rod W/piston.
4 Remove the tilt cylinder. [Point 2]
5 Remove the piston.
NOTE:
• Apply sealant (08833-76002-71 (08833-00080)) to the threaded portion of the rod guide before
reassembly.
13-29
Point Operations
[POINT 1]
Disassembly · Reassembly:
SST 09620-10100-71
[POINT 2]
Inspection:
Measure the cylinder bore.
Limit: 70.35 mm (2.770 in)
[POINT 3]
Inspection:
Measure the piston rod outside diameter.
Limit: 29.92 mm (1.178 in)
Inspection:
Measure the bend of the piston rod.
Limit: 1.0 mm (0.039 in)
13-30
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (PREVENTION OF

UNEVEN TILTING)
NOTE:
• Adjust the mast forward and backward tilt angles (to prevent uneven tilting) when the tilt
cylinder and mast ASSY are replaced or overhauled.
• After adjustment, perform SAS matching. (See section 16.)
1 With the mast in the neutral position, set the tilt cylinder pin eccentric direction on the lower side and
install the stopper.
Eccentric direction
2 Inspect the forward and backward tilt angles and unevenness in tilting at the pin position above.
Standard:
Mast forward tilt angle: Standard set angle -36’ to +96’
Mast forward tilt angle: Standard set angle -48’ to +36’
Uneven tilting: 1 mm (0.04 in) or less
3 When the standard is not met, adjust with the eccentric pin at the two holes on the pin fixing plate at
the front and rear sides by trying four ways of adjustment. (Turning the eccentric pin to move the joint
center axis ±4 mm (±0.16 in).)
4 After adjustment, tighten the stopper set bolt to lock the front pin.
14-1
OIL PUMP
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
0
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
REMOVAL • INSTALLATION . . . . . . . . . . . . . . . . . . . 14-4 1
DISASSEMBLY • INSPECTION • REASSEMBLY . 14-5 2
TEST METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 3
4
5
6
7
8
9
10
11
12
13
14
16
16
16
18
14-2
GENERAL
Vehicle model 7FBEF15 to 20

Oil pump name Single gear pump
Oil pump type TMG1A21A3H5-L (Shimadzu)
Drive system Direct motor drive
Delivery (pump at 1500 rpm) l (US gal) /min 30.8 (8.14)
Theoretical discharge cm3 (in3) /rev 21.9 (1.336)
14-3
COMPONENTS
6701
0
1
2
3
4
5
6
7
8
6701 9
10
11
12
13
14
16
16
16
18
14-4
T=24
(245)
[17.7]
6
5 7
Removal Procedure
3 Remove the return filter set bolt and set the filter free.
4 Disconnect the pump outlet hose at the oil pump side.
5 Remove the oil pump set bolts.
6 Disconnect the pump inlet hose at the oil pump side.
7 Remove the oil pump ASSY W/ fitting.
Note:
• Apply chassis grease at the spline section of the oil pump before installation.
• Clean the flange that meets the motor before installation.
14-5

0
1
2
T=88~98
(897~999)
[64.9~72.3]
2 3
6
4
5
3 6
7
4
8
1 Make match marks between the front cover and body and between the rear cover and body. [Point 1]
9
2 Place the front cover face downward, and remove the bolts (4 pcs.).
3 Remove the rear cover ASSY (rear cover, bushing, gasket and figure 3 gasket). [Point 2] 10
4 Remove the body and side plate. [Point 3]
5 Remove the drive gear, driven gear and side plate. [Point 4] 11
6 Remove the oil seal. [Point 5]
Reassembly Procedure 12
Note:
13
• Wash each part, blow compressed air and apply hydraulic oil before installation.
• Always use new seals for reassembly.
14
Match mark Match mark

Point Operations 16
between front between rear [POINT 1]
cover and body cover and body Disassembly: 16
Make match marks between the front cover and body
and between the rear cover and body. 16
Reassembly:
Align match marks when reassembling.
18
Front cover Rear cover
Body
14-6
[POINT 2]
bushing
Lubricating Inspection:
groove Rear cover The bushing inner surface should not be roughened and
should not be worn to the extent that the metal on the
rear side is visible.
Wear limit:0.15 mm
[POINT 3]
(0.0059 in) or less Inspection:
The side plate surface (LBC surface) in contact with
LBC surface
(yellow) gears should not be worn beyond the limit shown at left.
Discharge Suction port
port
Erosion by cavitation Strong contact

around this portion around here
Wipe depth Inspection:

Discharge 0.01~0.06 mm Inspect the body inner surface for the wipe mark.
port (0.0004~0.0024 in) Normal wipe depth: 0.01 to 0.06 mm
Suction
(0.0004 to 0.0024 in)
port
Wipe mark
[POINT 4]
Inspection:
Make match marks on the tooth flanks of the drive and
Drive gear driven gears.
Reassembly:
Driven gear Align match marks when reassembling.
Front cover
Inspection:
Check the gear side surface for wear and the tooth
flanks for roughening.
Shaft diameter limit: 21.997 mm (0.86602 in)
Tooth width limit: 25.5 mm (1.004 in)
Shaft diameter
oth
To th
wid
14-7
Oil seal [POINT 5]

Inspection:
(1) Check that there is no wear (that makes edge
rounded portion invisible) or damage at oil seal lip.
(2) Check that the figure 3 gasket is not damaged.
(3) Check that the outward leak-preventing gasket is not
damaged.
(4) Check that seals are not swollen.
Gasket Figure 3 gasket

14-8
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 15-11)
• Measure the time of full stroke of the lift cylinder with the hydraulic oil temperature at 50 to 55 °C (122 ~
131°F) and calculate the lifting speed.
However, due to soft start by material handling chopper circuit, lifting speed is 10 ~ 20 mm/sec (2.0 ~
3.9fpm) lower than the value obtained from the table.The lifting speed can be calculated more
accurately by measuring the full stroke operation time excluding the soft start period.
The lifting speed may differ depending on the conditions of the battery, hydraulic oil temperature and mast
adjustment.
The values below are based on a certain condition.
Lifting speed <reference value>
mm/s (fpm)
V-mast FSV-mast FV-mast
Vehicle model
No load Load No load Load No load Load
H 610 (120) 430 (85) 560 (110) 400 (79) 560 (110) 400 (79)
7FBEF15 Lift P 540 (106) 350 (69) 490 (96) 330 (65) 490 (96) 330 (65)
S 480 (94) 280 (55) 430 (85) 270 (53) 430 (85) 270 (53)
H 610 (120) 420 (83) 560 (110) 390 (77) 560 (110) 390 (77)
7FBEF16 Lift P 540 (106) 340 (67) 490 (96) 320 (63) 490 (96) 320 (63)
S 480 (94) 260 (51) 430 (85) 250 (49) 430 (85) 260 (51)
H 610 (120) 390 (77) 560 (110) 380 (75) 560 (110) 380 (75)
7FBEF18 Lift P 540 (106) 320 (63) 490 (96) 310 (61) 490 (96) 310 (61)
S 480 (94) 250 (49) 430 (85) 240 (47) 430 (85) 240 (47)
H 500 (98) 340 (67) 470 (93) 320 (63) − −
7FBEF20 Lift P 450 (89) 280 (55) 420 (83) 270 (53) − −
S 400 (79) 220 (43) 360 (71) 210 (41) − −
15-1
OIL CONTROL VALVE

Page
OIL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
0
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . 15-5 1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 2
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
3
OIL CONTROL VALVE ASSY . . . . . . . . . . . . . . . . . . . . 15-8
RELIEF PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . 15-11
4
LIFT LOCK UNLOCKING BOLT . . . . . . . . . . . . . . . . . . 15-12 5
CONTROL VALVE LEVER ASSY . . . . . . . . . . . . . . . . . 15-13 6
OIL CONTROL VALVE (FOR MINI LEVER) . . . . . . 15-14
7
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . 15-17
8
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17 9
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18 10
OIL CONTROL VALVE ASSY (FOR MINI LEVER) . . . . 15-20
11
MATERIAL HANDLING OPERATION START TIMING
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25 12
RELIEF PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . 15-26
13
LIFT LOCK UNLOCKING BOLT . . . . . . . . . . . . . . . . . . 15-27
14
MINI LEVER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-28
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-28 15
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29 16
15
18
15-2
OIL CONTROL VALVE

GENERAL
Oil Control Valve
15-3
Control Valve Sectional View
0
1
2
3
4
5
6
7
8
9
Lift Block Sectional View
10
11
Solenoid valve
12
13
14
15
16
15
Relief valve
18
15-4
Tilt Block Sectional View
Solenoid valve
Relief valve
Tilt Limit Switch Section
Front tilt switch Backward tilt switch

15-5
HYDRAULIC CIRCUIT DIAGRAM
C5 (ATT)
C3 (TILT)
C1 (LIFT)
Lift lock unlocking bolt
C4
C2
0
1
2
3
4
P
5
6
7
8
T2
T1 9
10
SPECIFICATIONS 11
Model
Item
All Models 12
Type Add-on type (1·2 spool mono block) 13
RELIEF PRESSURE Lift 17.2 (175) [2490]
MPa (kgf/cm2) [psi] Tilt 13.7 (140) [1990] 14
Spool outside diameter mm (in) 16.0 (0.63)
Stroke mm (in) 7.0 (0.28) 15
Others Built-in lift and tilt lock valves
16
15
18
15-6
COMPONENTS
6705
AA
PB
BV AZ
EC LE
KZ
50D 50A
BU
50C
09
BT 50A
50A
CA
50B
BW
50A
50A
CA
BT
6705-A30
6709
6705
15-7
15-8
OIL CONTROL VALVE ASSY

Note:
Operate the control lever to bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the material handling system before starting
removal.
T=21.6 ~ 50.4
(220.3 ~ 513.9)
[15.9 ~ 37.2]
3
Removal Procedure
3 Disconnect the piping and wiring.
4 Remove the set pin for the oil control valve and lever.
5 Remove the oil control valve.
Note:
• Adjust the limit switch after installing the oil control valve.
(See page 2-39.)
• Apply MP grease to oil control valve lever linkage.
• Check the hydraulic oil level, and add if insufficient.
15-9

Note:
• As parts are finished with high precision, carefully disassemble and reassemble to prevent any
damage.
• Choose a clean location for the job.
T=1.49 ~ 1.83
T=34.3 ~ 44.1 2 (15.0 ~ 19.0)
(350 ~ 450) [1.09 ~ 1.37]
[25.3 ~ 32.6]
9
3 3
4 4
16 5
7
13
12
2 14
2
13
5 15
2
11
1
T=0.29 ~ 0.49
(3.0 ~ 5.0)
[0.22 ~ 0.36]
1 Remove the limit switch. [Point 1]
2 Remove the limit switch holder and spring cover.
3 Remove the solenoid ASSY. [Point 2]
4 Remove the solenoid valve.
5 Remove the lift spool ASSY.
6 Disassemble the lift spool ASSY. [Point 3]
7 Remove the tilt spool ASSY.
8 Disassemble the tilt spool ASSY. [Point 3]
9 Remove the additional spool ASSY.
10 Disassemble the additional spool ASSY. [Point 3]
11 Remove the lift pilot relief valve set.
12 Remove the tilt pilot relief valve set.
13 Remove the check plunger.
14 Remove the valve seat.
15 Remove the lift lock cheap valve.
16 Remove the outlet housing.
15-10
Note:
• Fully loosen the relief valve adjusting screw before reassembly.
Point Operations
[POINT 1]
Disassemble · Reassembly:
SST 09610-10160-71
15-11
RELIEF PRESSURE ADJUSTMENT

Note:
• Always follow the procedure below for adjustment.Careless adjustment may cause high-
pressure generation, resulting in damage to hydraulic units such as the oil pump.
• No adjustment is needed when the relief valve is not disassembled or is replaced with a new
one.
Lift relief valve Tilt relief vzlve
Pressure detection port plug
1. Remove the plug (9/16-18UNF-2B) from the top of the oil control valve and install a pressure gauge
there.
Pressure resistance of pressure gauge: 19600 kPa (200 kgf/cm2) or more
2. Loosen the lift relief valve adjusting screw.
Loosen the lock nut (for better workability, remove the limit switch before) and loosen the adjusting
screw but to the extent it stays on the body.
3. Adjust the oil pressure as follows:
(2) Slowly operate the lift lever in the lifting direction, and gradually tighten the adjusting screw until the
fork starts to rise.
(3) Lift the fork fully and read the oil pressure at that position.Tighten the adjusting screw for the normal
pressure reading.
(4) Tighten the lock nut and re-check the oil pressure.
4. Adjust the tilt relief valve oil pressure.
The adjustment process is the same as for the lift relief valve, but tilt the mast fully backward when
measuring the oil pressure.
Relief Pressure Standards
Unit: MPa (kgf/cm2) [psi]
All Models
Lift relief pressure 17.2 (175) [249]
Tilt relief pressure 13.7 (140) [199]
5. Remove the oil pressure gauge, and install the plug.

15-12
LIFT LOCK UNLOCKING BOLT

Action when the fork cannot be lowered due to solenoid valve failure
T=N·m (kgf-cm) [ft-lbf]
Forward tilt switch
Backward tilt switch
Lift lock unlocking bolt

T=1.49 1.83 (15 19)
[1.09 1.37] Solenoid valve (tilt)
Solenoid valve (lift)
1 Loosen the lock nut.

2 Loosen the lift lock unlocking bolt and operate the lift lever to manually lower the fork.
Note:
Always retighten the unlocking bolt after repair.If the lift lock unlocking bolt is left loose, much
hydraulic oil is released from the oil pump and the lifting speed is significantly decreased,
resulting in difficulty in smooth operation.
15-13
CONTROL VALVE LEVER ASSY

5
4
3 2 4
1
4
Removal Procedure
2 Tilt lever: Disconnect wiring of the knob switch.
3 Remove the set bolt.
4 Disconnect the lever rod.
5 Remove the control valve lever. [Point 1]
Note:
Apply grease (MP grease) to control valve lever link portions.
Point Operations
[POINT 1]
Inspection:
Inspect the knob switch for continuity.
Standard: Switch ON: 0 Ω
Switch OFF: ∞ Ω
15-14
OIL CONTROL VALVE (FOR MINI LEVER)

GENERAL
Oil Control Valve
T2
C2
G1
C4
C5
C1
C3
15-15
Control Valve Sectional View
Unload valve
Relief valve
Pressure
compensated
valve
pressure reducing valve
Lift Block Sectional View
Lift lock check valve
Lift select valve
Proportional solenoid
15-16
Tilt Block Sectional View
Tilt lock check valve
Tilt select valve
Attachment Block Section View

15-17
HYDRAULIC CIRCUIT DIAGRAM
Lift lock check valve Tilt lock check valve

Pressure Pressure
compensated reducing
valve valve
T1 P C1 C2 C3 C4 C5
G2
G1
T2
Unload valve Relief valve Lift select valve Tilt select valve
Inlet Lift Tilt ATT
SPECIFICATIONS
Model
All Model
Item
Type Add-on type
RELIEF PRESSURE
17.2 (175) [249]
MPa (kgf/cm2) [psi]
Others With proportional solenoid valve
COMPONENTS
15-18
01K=(INCL. )
36
KB QA
LY QB
NY
CL AP
EZ JZ
NP EW AI DZ
MI AV
DZ MB AQ EZ
NA AX AT
46 AW
BN MA MG AC DG
GW AF DZ
AO LT AD DZ
LX EZ
AX AE EZ
AD DI
MG KV CH
BH MD LW
AN
MC ER
AW
AE AP
AJ DM BS
AO LY AH DO BS
MC DQ
KB AE AK PH AV AI
AQ
LH KV MC PG AD NZ
MD DM
BN AK AE DM CH
BC KC EU
AJ BA AJ DM AN LW
EZ AH DO ER 40
40 DK DZ AK DO
NH BR AE AD
AN AY
LW DM AK
DM PG
CH DO BQ DM
AK AE
CK DM
BC KC
AJ BA AJ CH
EU GF EZ AH LW
40 DK DZ
AE AN
AN NH BR
AY DM PG
LW DM
CH AK AE DM
DO BQ DM
CK BC KC
CF[SEAL] AJ BA
EZ
EU GF 40 DK DZ
FU[CAP]
MV[PLATE] AN NH BR
AY DM
LW DM
CH DO BQ
CK
KY[TUBE] EU GF
LD[CLAMP]
6705-A48
6705
15-19
6705
15-20
OIL CONTROL VALVE ASSY (FOR MINI LEVER)

Note:
Operate the control lever to bring the mast and fork to the vertical and lowermost positions,
respectively, to release the residual pressure in the material handling system before starting
removal.
T=21.6 ~ 50.4
(220.3 ~ 513.9)
[15.9 ~ 37.2]
Removal Procedure
4 Remove the oil control valve.
Note:
Check the hydraulic oil level, and add if insufficient.
Caution:
15-21

Note:
• As parts are finished with high precision, carefully disassemble and reassemble to prevent any
damage.
• Choose a clean location for the job.
T=58.8 (599.6) [43.4]
26 T=6.9(70.4)
25 [5.1]
17 18
29 20
27
19
28
2]
) [7.
21 (9 9.9
= 9.8 9
T
23
10
30
11
T=58.8 22
(599.6) 10
[43.4]
24 [7 .2]
.9)
16 12 (99
9 .8
T=9.8 (99.9) T= 2]
[7.2] ) [7.
14 .9
8 (99
.
T =9 4
13 3
15
8 6
T=9.8 (99.9)
[7.2]
T=39.2 (399.7) [28.9]
5
7
2
T=9.8 (99.9)
[7.2]
1
15-22
1 Remove the outlet housing. [Point 1]
2 Remove the ATT bock ASSY.
3 Remove the spring cover W/ adjusting screw. [Point 2]
4 Remove the spring ASSY.
6 Remove the spring ASSY and ATT spool. [Point 3]
7 Remove the solenoid valve ASSY. [Point 4]
8 Remove the tilt block ASSY.
9 Remove the tilt sleeve ASSY. [Point 5]
10 Remove the spring block W/ adjusting screw. [Point 2]
11 Remove the tilt lock check valve. [Point 6]
14 Remove the spring ASSY and tilt spool. [Point 3]
16 Remove the lift block ASSY.
17 Remove the release bolt from the lift block.
18 Remove the lift sleeve ASSY. [Point 5]
19 Remove the spring block W/ adjusting screw. [Point 2]
20 Remove the lift lock check valve. [Point 6]
23 Remove the spring ASSY and lift spool. [Point 3]
25 Remove the inlet block ASSY.
26 Remove the relief valve. [Point 7]
27 Remove the unload valve. [Point 3]
28 Disconnect the plug.
29 Remove the solenoid valve.
30 Pilot relief valve
Note:
• Fully loosen the relief valve adjusting screw before reassembly.
Point Operations
3
Match [POINT 1]
2 mark
1 3 Disassembly:
2 Put match marks and then remove the solenoid valve.
1
Reassembly: Align the match marks and then reassemble
3 the solenoid valve.
2
1 3
2
1
15-23
Adjusting screw [POINT 2]

Reassembly:
Adjust the adjusting screw set dimension A to the
following value.
Standard: A = 1.8 mm (0.071 in)
After installing the oil control valve ASSY in the vehicle,

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

15-25
Raise lift MATERIAL HANDLING OPERATION START

Tilt backward
TIMING ADJUSTMENT
NOTE:
When the oil control valve is disassembled or a
component is replaced, check and adjust the material
handling operation start timing.
1. Slowly operate the lever, check each operation start
timing, and adjust the timing when it is off.
Lower lift Tilt forward
2. Loosen the lock nuts on the end of each spool and turn
the adjusting screw to adjust the material handling
operation start timing.
Turn to the right (tightening side):
Delays the start timing.
Turn to the left (loosening side):
Advances the start timing.
NOTE:
• For the screw turning angle, use ±45º as a reference.
• If the adjusting screw is tightened too much, material
handling speed will be slow with the lever full-stroke.
• If the adjusting screw is loosened too much, jolt will
happen at the start of material handling operation.
3. Use the lock nut to lock the adjusting screw, and then
check the timing again.
15-26
RELIEF PRESSURE ADJUSTMENT

Note:
• Always follow the procedure below for adjustment.Careless adjustment may cause high-
pressure generation, resulting in damage to hydraulic units such as the oil pump.
• No adjustment is needed when the relief valve is not disassembled or is replaced with a new
one.
• The tilt side relief pressure does not need to be adjusted.
1. Remove the plug (9/16-18UNF-2B) from the top of the oil control valve and install a pressure gauge
there.
Pressure resistance of pressure gauge: 19600kPa (200 kgf/cm2) or more
2. Remove globe nut A, loosen lock nut B to just before the point where it comes off from the body, and
then loosen adjusting screw C.
3. Adjust the relief pressure.
(2) Move the lift lever upward while gradually tightening adjusting screw C, and then move the fork to
the top most position.
(3) Settle adjusting screw C so that the hydraulic pressure when the forks are in the top most position
(relief state) is within the standard.
(4) Tighten the lock nut and globe nut, and then recheck the relief pressure.
(5) Remove the oil pressure gauge and reinstall the plug.
Relief Pressure Standards
Unit: MPa (kgf/cm2) [psi]
All Models
Lift relief pressure 17.2 (175) [249]

15-27
LIFT LOCK UNLOCKING BOLT

T = N⋅m (kgf⋅cm) [ft⋅lbf]
Lift lock
unlocking bolt
T=3.5 ~ 4.3
(36 ~ 44)
[2.6 ~ 3.2]
1 Loosen the lock nut.

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

GENERAL
ATT2
ATT1
Tilt
Lilt
Fork automatic leveling switch
E2 VTA2 VTA1 VC
E2 VTA2 VTA1 VC
15-29
COMPONENTS
6712
6712
15-30
Removal Procedure
2 Open the battery hood.
3 Remove the harness clamp and disconnect the wiring.
4 Close the battery hood and remove the knob, spacer, and slide adjusting bolt.
5 Remove the mini lever box. [Point 1]
Point Operations
[Point 1]
Removal Installation:
•
Slide the mini lever box to the rear, lift up the rear side,
and remove the mini lever box.
15-31

T = N⋅m (kgf⋅cm) [ft⋅lbf]
1 Remove the lower box.
2 Remove the arm pad ASSY.
3 Disconnect the connector and remove the fork automatic leveling switch. [Point 1]
4 Disconnect the connector and remove the potentiometer. [Point 2]
5 Disassemble the potentiometer. [Point 3]
Note:
• Conduct matching when removing, reinstalling, or replacing the lift lever potentiometer, tilt lever
potentiometer, attachment lever 1 potentiometer, or attachment lever 2 potentiometer (OPT).
(See page 3-60.)
15-32
Point Operations
[POINT 1]
Reassembly:
Orient the washer in the direction shown in the figure
and then install the washer.
Washer
Inspection:
Check the continuity of the fork automatic leveling
switch.
Standard ON : 0 Ω
OFF : ∞ Ω
ON
OFF
[POINT 2]
Disassembly:
Attach a number to the connector that matches the
number of the upper box.
4-1
Reassembly:
Be certain to make the correct wiring connections and
connect the connectors to match the numbers.
Inspection:
A standalone inspection of the potentiometer cannot be
performed. Check the voltage on the display's analyzer
screen. (See page 3-26.)
15-33
[POINT 3]
Reassembly:
1. Loosely connect the potentiometer to the position
shown in the figure.
2. Rotate the potentiometer all the way to the left and
tighten the screw.
3. Check to see if the lever operates normally.
Reassembly:
Align the plate A hole with the lever body pin point and
install the plate.
A
Plate
Reassembly:
Apply MP grease to the locations shown by arrows in the
figure and install the component.
16-1
SAS FUNCTIONS
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
0
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
FOR REPAIR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-7 1
STEERING KNOB SYNCHRONIZER VALVE . . . . 16-8 2
TIRE ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 16-10
4
5
TILT ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 16-12
LOAD SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13 7
8
MAST LIFTING HEIGHT SWITCH . . . . . . . . . . . . . . 16-15
9
MATCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-16 10
VEHICLE STANDARD STATE . . . . . . . . . . . . . . . . . . . . 16-17 11
CAUTIONS ON MODIFYING VEHICLES . . . . . . . . 16-18 12
13
14
15
16
17
18
16-2
GENERAL
SAS (System of Active Stability) System
Sensors and switches installed at each portion of the vehicle detect the vehicle movement and send
signals to the controllers. These signals are controlled with the controllers to drive each actuator for mast
control and steering knob synchronizer.
Control
Functional part Mast Steering
tilting knob syn-
control chronizer
Lifting height switch Control

Functional part Mast Steering
Tilt angle sensor tilting knob syn-
control chronizer
Main controller
Forw.tilt switch/pot Oil control valve
Backw. tilt switch/pot Steering knob

Input Output synchronizer valve
Tilt knob switch
LCD display
Load sensor
Diagnosis
Rpm sensor
Steering wheel
angle sensor
Tire angle sensor
Lifting height switch

Tilt knob switch
Combination meter
Diagnosis
Combination switch Tilt angle sensor

Steering wheel angle sensor
Steering knob
synchronizer valve
Main controller
Load sensor
Tire angle sensor
Oil control valve

Forward tilt switch
Backward tilt switch
16-3
COMPONENTS
Rpm sensor
1401
0
1
2
3
4
5
6
7
8
Steering knob synchronizer valve
9
4507
10
11
12
13
14
15
16
17
18
16-4
Steering wheel angle sensor

5702
Lifting height switch (V mast)

5803
16-5
Lifting height switch (FV, FSV mast)

5803
0
1
2
3
4
5
6
7
8
Tilt angle sensor
5803 9
10
11
12
13
14
15
16
17
18
16-6
Load sensor (V, FV mast)

5803
Load sensor (FSV mast)

5803
16-7
FOR REPAIR WORK

Caution:
Before starting SAS repair, make sure you fully understand the SAS functions.
1. Preparation for repair work
(1) Avoid washing the vehicle as much as possible; for cleaning, blow compressed air. If washing with
water is required, avoid water jet washing. Always blow compressed air to remove water after
washing.
(2) Transport the controller in a packed state, and keep it packed until installation. Never transport it in
an exposed state. Be sure not to drop or apply impact to the controller.
(3) If matching is required after repair, park the vehicle on a flat surface in advance.
(4) Prepare necessary tools, testers (analog tester) and SST 09580-10920-71.
2. During repair work
(1) Don't turn the key switch to ON or OFF carelessly while the sensor wiring is disconnected. Key
switch ON in this state may cause an error and the error code will be stored in the controller. Error
codes cannot be cleared. When the stored error codes exceeds ten, the error codes are cleared
from the oldest one. Therefore necessary repair information becomes unavailable.
(2) Don't drive the vehicle during matching, as SAS function is disabled.
(3) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(4) When the oil control valve lift lock unlocking bolt is loosened, always tighten it to the specified
torque and return the bolt to the original state after the end of repair.
(5) Tighten the set bolts of respective functional parts to the specified torque.
(6) No adjustment is necessary for each sensor at the time of installation, but be sure to perform
matching after the installation.
(7) When disconnecting a connector, don't pull it at the harness.
(8) When inspecting the harness, be sure to avoid taken not to damaging the connector terminals.
(9) Positioning of the low- and high-lifting heights described in the troubleshooting section are as
follows:
Classification How to distinguish
Fully lowered to height with lifting height switch MH1

Low lifting height
(Less than approx. 2 m)
High lifting height Height with lifting height switch MH2-1 (Approx. 2 m or more)
3. Emergency Action
If the mast cannot be lowered because of trouble when
the lift lever is operated to the down position, it can be
lowered as an emergency action as follows.
Loosen the lift unlock bolt and operate the lift lever to the
down position.
Lift unlock bolt
Note:
After repair, do not forget to retighten the lift lock
unlocking bolt. If the lift lock unlocking bolt is loosened,
the lifting speed is remarkably decreased.
16-8
STEERING KNOB SYNCHRONIZER VALVE

T=33.0~45.0 (337~459) [9.22~12.55]
Removal Procedure
2 Remove the column cover (lower).
3 Remove the left instrument panel.
5 Remove steering synchronizer valve ASSY W/ fitting.
6 Remove the fitting and O-ring. [Point 1]
Note:
When disconnecting the piping, cover the brake with cloth to prevent hydraulic oil adhesion.
16-9
Point Operations
[POINT 1]
Installation:
The fitting angle should be as illustrated for reassembly.
16-10
TIRE ANGLE SENSOR

T=1.6~2.0(16~20)[1.16~1.45]
T=10~16(102~163)
[7.38~11.79] 5
Removal Procedure
3 Disconnect the wiring connector.
4 Remove the tire angle sensor and joint. [Point 1]
5 Remove the tire angle sensor plate. [Point 2]
6 Remove the bracket.
7 Remove the joint cover.
Caution:
Align the tapping screw axis and the sensor plate hole straight for installation. If screwed out of
position, replace the sensor plate with a new one.
When the tapping screw is removed, the sensor plate should be replaced with a new one.
Note:
• Be sure to set the tires to the straight traveling position before tire angle sensor installation.
• Apply Approx. 2 cc of MP grease to the inside of the joint cover for installation.
• Perform matching when the tire angle sensor is removed, installed or replaced. (See page 16-
16.)
16-11
Point Operations
[POINT 1]
Installation:
After positioning the sensor as the illustration to the left,
rotate it by Approx. 110° to align the holes.
[POINT 2]
Installation:
Use the SST to adjust the concentricity of the rear axle
SST
and sensor plate holes.
The tip of SST 09580-10920-71
the SST (1) Temporarily secure the bracket and sensor plate.
(2) Securely set the tip of the SST at the hole at the top of
the rear axle shaft and position the bracket and
sensor plate.
(3) Securely tighten the bracket and sensor plate bolt and
remove the SST.
Installation:
Apply MP grease from the sensor plate hole of the rear
axle shaft groove.
Groove part
16-12
TILT ANGLE SENSOR

T=10~16 (102~163)
[7.38~11.79]
7
T=1.4~2.0 (14~20) [1.01~1.45]
T=6.9~16.1
(70~164)
[5.06~11.87]
Removal Procedure
2 Remove the toe boards (front and rear).
3 Remove the right instrument panel.
4 Remove the tilt cylinder cover.
5 Disconnect the tilt angle sensor link.
7 Remove the tilt angle sensor.
Note:
• Perform matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is
adjusted in length or replaced. (See page 16-16.)
• For installation, apply MP grease on sliding section of the end.
16-13
LOAD SENSOR
T=22~26
(224~265)
[16.21~19.17]
T=25~28
(255~286)
[18.45~20.69]
Removal Procedure
1 Hoist the inner mast. (See page 13-15.)
2 Remove the hose cover. (V mast)
3 Remove the insulator.
5 Remove the load sensor W/hose.
6 Remove the load sensor.
Note:
Perform matching when the load sensor is removed, installed or replaced. (See page 16-16.)
16-14
Rear face of the Rear face of the

Point Operations
insulator lift cylinder [POINT 1]
Within 5 mm
Installation:
(0.2 in)
V, FV mast
When installing, make sure that rear face of the insulator
comes within around 5 mm (0.2 in) from the rear face of
the lift cylinder.
Rear portion of the insulator

FSV mast
Make sure that the rear face of the lift cylinder and the
Rear face of the lift cylinder
rear portion of the insulator is within the dimension A
A
below.
Vehicle model A
7FBEF15 to 18 12.0 to 16.0 mm (0.47 to 0.63 in)
7FBEF20 10.4 to 14.6 mm (0.41 to 0.57 in)
27° to 33°
Note:
For installation of the insulator, adjust the position so
that there is no interference between the tie wrap
connection and the front protector, inner mast (V, FV
mast), middle mast (FSV mast) and their piping.
16-15
MAST LIFTING HEIGHT SWITCH

V mast
2 T=15~25 (153~255)
3 [11.07~18.45]
FV∑FSV mast
2
T=14.4~33.6
(147 343)
[10.64~24.82]
3
1
T=6.9~16.1 (70 164) [5.06~11.87]
Removal Procedure
1 Remove the lower cover. (FV, FSV mast)
3 Remove the mast lifting height switch.
16-16
MATCHING
Of the sensors used for the SAS function, the tilt angle and load sensors are controlled based on the
signal voltage values for the mast vertical position, no-load state and tire straight travel position stored in
the controller at the time of shipment from the factory. When servicing these sensors or replacing related
parts, matching (updating the sensor signal voltage under the standard vehicle condition) is necessary.
Also, matching must be performed for the tilt angle sensor when the vehicle posture has changed greatly,
and for the load sensor when the load under no load condition is changed because of the addition or
removal of any attachment.
Matching is performed with the mask function of the display. Perform matching selecting “MATCHING” on
the mask function.
Matching items and examples of necessary operation
Forward tilt Tires in straight
Automatic No-load
Content of matching restriction traveling
fork leveling standard load
position position
Mast in vertical Mast in vertical Tires at straight
Matching condition No-load
position position * travel angle
Displayed code TILTL TILTF LOAD TIRE
Tilt angle Tilt angle Tire angle
Object sensor Load sensor
sensor sensor sensor
Maintenance operation examples:
1. When replacing main controller { { { {
2. When replacing tilt angle
{ { { {
sensor
3. When changing the tilt angle
sensor rod length or replacing { {
the sensor
4. When replacing load sensor {
5. When removing or replacing
{
tire angle sensor
6. When changing attachment { { {
7. When replacing mast { { {
8. When replacing tilt cylinder { {
9. When adjusting tilt cylinder for
{ {
uneven lifting
*: In order to store the reference position for the controller to calculate the forward tilt restriction position,
perform matching by setting the mast to the vertical position.
Note:
The matching value for the tilt angle sensor determines the mast stop position in automatic fork
leveling. If the fork does not stop horizontally because of the site condition (such as an inclined
surface), perform matching with the mast in the vertical position. In this case, the mast stop angle
may differ from that on the level surface.
16-17
VEHICLE STANDARD STATE

Select a level surface without any irregularity for matching, as if the surface on which matching is to be
performed is slanted, error occurs in the standard state.
Note:
The finishing accuracy of floors for factories, warehouses and buildings in general calls for the
floor inclination to be 0.5° or under; therefore, matching on these floors is not affected--however,
don't perform matching on a floor that is inclined over 0.5° for draining purposes.
Fork stop position with automatic leveling and forward

V mast tilting limit position
Set the vehicle to the following state in order to store the
signal voltage values of the tilt angle sensor when the mast is
perpendicular to the floor.
No-load standard load
Set the vehicle as follows so as to have the load sensor
signal voltage value stored under no-load conditions.
500 mm
(19.7 in) Standard: For V mast, raise the fork to 500 mm
(19.7 in) or for FV and FSV mast, raise the rear
FV∑FSV mast shaft cylinder to 100 mm (3.9 in) and position a
level (angle gauge) at the height of 1200 to
1500 mm (47.2 to 59.1 in) on the front or rear
surface of the outer mast with the mast in the
100 mm vertical position.
(3.9 in) Note:
• Set the mast in the vertical position from the backward
tilted position. (Do not set the mast in the vertical
position from the forward tilted position)
• If there is a detachable attachment, keep the
attachment installed on the vehicle.
Tires in straight traveling position

In order to store the tire angle sensor signal voltage value at
Within 50 mm (2.0 in)
the tire in straight travel position, set the vehicle to the

each on the left and
following state.
Standard: Align the center line of the vehicle to the line
right sides
on the level road surface, fix the steering wheel

and drive 5 m (16 ft). The center line of the
5 m (16 ft) vehicle is within 50 mm (2.0 in) to right and left
of the line of the road.
16-18
CAUTIONS ON MODIFYING VEHICLES

When replacing mast
• When the mast is replaced, the mast harness has to be replaced with the one suitable for the
new lifting height.
• When placing an order for a mast ASSY, check the need for sensors (lifting height switch, load
sensor, mast harness, and other SAS-related parts) and place an order accordingly.
• Be sure to perform matching after replacement (See page 3-60).
Other functional parts
• See Section 5 for the rpm sensor.
• See Section 8 for the steering angle sensor.
• See Section 15 for the oil control valve solenoid 1, 2, backward and forward tilt switch and tilt
lever knob button.
• For the inspection of functional parts, see Section 4 TROUBLESHOOTING.
17-1
APPENDIX
Page
SST LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
0
SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . 17-6
CPU BOARD CONNECTOR . . . . . . . . . . . . . . . . . . . . 17-13 1
CONNECTOR DRAWING . . . . . . . . . . . . . . . . . . . . . . 17-14 2
CONNECTING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 17-25 3
ELECTRIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . 17-28 4
Elschema, Fram&Back omkopplare på armstöd..........17-29 5
6
7
8
9
10
11
12
13
14
15
16
17
18
17-2
SST LIST
Section
Illust Part number Part name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Puller B set
09140-10920-71 extension {
tool
09150-10920-71 Spacer {
GENEO B
09230-13130-71 controller {
diagnosis kit
For CN20,
52, 55, 58,
(09232-13130-71) {
86, 90 and
94
CN25
(09238-13130-71) {
sub-harness
09230-13700-71 IC check pin { {
For CN109,
09231-21320-71 110, 111 {
Sub-harness
09232-21320-71 Sub-harness {
Short har-
09234-13900-71 {
ness
17-3
Section
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
09240-23400-71 IC clip { {
0
Reamer bolt 1
09310-23320-71 {
remover
2
Transmis- 3
09316-76008-71 sion & trans-
{
(09316-60011) fer bearing 4
replacer
5
Front axle
09320-10410-71
hub inner
bearing
{ 6
replacer
7
Front axle 8
09370-10410-71 bearing {
replacer 9
Steering 10
warm
09410-40120-71
bearing
{
11
replacer
12
09450-23320-71 Adapter { 13
14
Tire angle 15
09580-10920-71 sensor set {
tool 16
Front hub 17
inner
09608-76003-71
(09608-04031)
bearing { 18
cone
replacer
17-4
Section
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Oil control
valve spring
09610-10161-71 {
remover &
replacer
Inner mast
09610-22000-71 { {
stopper
Cylinder cap
09620-10100-71 remover & {
replacer
09630-23600-71 Deep socket {
Wear scale
09631-22000-71 {
chain
Spring pin
09700-30200-71 { {
tool remover
09950-76003-71
Puller C set { {
(09950-50012)
09950-76014-71
Puller B set { { { {
(09950-40011)
09950-76018-71
Replacer set { { { {
(09950-60010)
17-5
Section
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
09950-76019-71 Replacer
{
(09950-60020) set No.2
0
09950-76020-71 1
Handle set { { { {
(09950-70010)
2
3
Battery
25009-13200-71 {
hanger 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
17-6
SERVICE STANDARDS
BATTERY
Item All models
Specific gravity upon
(at 20 °C) 1.280
perfect charging
Specific gravity upon end
(at 20 °C) 1.150
of discharge
Voltage upon end of
V 42.5
discharge
Insulation resistance MΩ 1 or more
CONTROLLER
Item All models
F1 (fuse for drive and pump circuits) A 500
F4 (fuse for lamp circuit) A 10
F5 (fuse for control circuit) A 10
F6 (fuse for SAS and solenoid circuit) A 10
The higher the resistance the better, but it varies
Control panel insulation MΩ greatly with the vehicle operating condition, place,
environment and weather. (Approx. 1 MΩ or more)
MB (power supply contactor) coil resistance Ω Approx. 20 (at 20 °C)
Driver motor input voltage V 2 or less
Pump motor input voltage V 2 or less
Tightening torque: N·m (kgf·cm) [ft·lbf]
Pump and drive motor driver terminal Standard: 13 to 17 (133 to 173) [10 to 13]
Pump and drive motor terminal Standard: 11 to 15 (112 to 153) [8 to 11]
Item All models
Acceleration switch Pedal not operated ∞

Ω
(SWAC) Pedal operated Continuity
Accelerator potentiome- Not operating 0

Ω
ter resistance Operating ∞
17-7
DIRECTION SWITCH
Lever position
Forward Neutral Rear
DSF 0Ω ∞Ω ∞Ω
DSR ∞Ω ∞Ω 0Ω
DSBU ∞Ω ∞Ω 0Ω
BRAKE LIMIT SWITCH

Item All models
Limit switch ON dimension See page 2-38.
DRIVE MOTOR
Item All models
Stator ASSY insulation resis-
MΩ Standard: 1 or more
tance
Motor cable continuity Ω Standard: 0
Thermo-sensor resistance Ω Standard: 464 to 817
PUMP MOTOR
Item All models
Clearance between the end mm 11.0 to 13.3
Standard:
frame and rpm sensor. (in) (0.4 to 0.5)
Stator ASSY insulation resis-
MΩ Standard: 1 or more
tance
Motor cable continuity Ω Standard: 0
Thermo-sensor resistance Ω Standard: 464 to 817
DRIVE UNIT & FRONT AXLE

Item All models
23.9 to 47.3 (2.4 to 4.8)
1.5 , 1.6 ton
[5.3 to 10.6]
Hub starting force N (kgf) [lbf] Standard:
27.2 to 53.9 (2.8 to 5.5)
1.8 , 2.0 ton
[6.2 to 12.1]
Tightening torque N·m (kgf·cm) [ft·lbf]
Gear case set bolt Standard: 17.5 to 32.5 (179 to 332) [12.9 to 24.0]
Hub nut Standard: See page 6-5.
17-8
REAR AXLE
Item All models
Rear axle ASSY
Rear axle ASSY starting force N (kgf) [lbf] Standard: 100 to 171 (10.2 to 17.4) [22 to 37]
Rear axle hub
Rear axle hub starting force (at hub
N (kgf) [lbf] Standard: 15 to 39 (1.5 to 4.0) [4 to 9]
bolt) N (Kgf)
Rear axle cylinder
Standard: 70.00 (2.76)
Rear axle cylinder bore mm (in)
Limit 70.35 (2.77)
Rear axle ASSY lock nut Standard: 10 to 20 (102 to 204) [7 to 15]
Hub nut Standard: See page 7-5.
10.6 to 11.1 (108 to 113)
Rear axle cylinder set bolt Standard:
[1535.8 to 1606.9]
STEERING
Item All models
Steering wheel play mm (in) Standard: 20 to 50 (0.79 to 1.97)
Hydrostatic steering valve assy
kPa (kgf·cm2)
Relief set pressure Standard: 10.6-11.1 (108 ~ 113) [1535.8-1606.9]
[PSi]
Steering wheel set nut Standard: 25 to 45 (254.9 to 458.9)[18.4 to 33.2]
BRAKE
Item All models
Foot brake
Standard: 6 (0.24)
Brake pad thickness mm (in)
Limit 3.5 (0.14)
Standard: 9 (0.35)
Brake disc wheel thickness mm (in)
Limit 8.0 (0.31)
Brake pedal
Brake pedal height (no pad) mm (in) Standard: 110 to 115 (4.3 to 4.5)
Brake pedal play mm (in) Standard: 35 (1.4)
Parking Brake
Number of operation notches of brake lever 3 to 4
Standard:
Operating force 150 N (15 kgf) [331 lbf]
17-9
FRAME
Item All models
Counterweight
Counterweight set bolt Standard: 10.8 to 24.5 (110 to 250) [8.0 to 18.1]

Item
Natural drop test
Natural drop mm (in) Limit 45
Natural forward tilt test
1 ton series Standard: 15 (0.59) or less
Natural forward tilt mm (in)
2 ton series Limit 20 (0.79) or less
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard: 8 (0.49) or less
Tilt cylinder oil leak amount
cm3 (in3) Standard: 16 (0.98) or less
(total for lift and tilt)
MAST
Item
Mast adjustment (V MAST)
Inner mast roller clearance mm (in) Standard: 0 to 0.8 (0 to 0.031)
Mast rollers
Outer mast roller clearance mm (in) Standard: 0 to 0.5 (0 to 0.020)
Middle and lower lift roller
mm (in) Standard: 0 to 0.8 (0 to 0.031)
Lift bracket rollers clearance
Side roller clearance mm (in) Standard: 0 to 0.6 (0 to 0.024)
Mast strip to inner mast clearance mm (in) Standard: 0 to 0.8 (0 to 0.031)
Mast strip thickness mm (in) Limit 1.5 (0.059)
Fork
Fork front end misalignment mm (in) Limit 10 (0.39)
60.0 to 140.0 (611.8 to 1427.6)
Mast support cap set bolt Standard:
[44.3 to 103.3]
98.0 to 182.0 (999.0 to 1856.0)
Back rest set bolt Standard:
[72.3 to 134.3]
49.0 to 78.0 (500 to 800)
Chain adjusting nut Standard:
[36.2 to 57.9]
17-10
CYLINDER
Item
Lift cylinder (V · FSV)
Standard: 35.0 (1.3780)
1 ton series
Piston rod outside mm Limit 34.92 (1.3748)
diameter (in) Standard: 40.0 (1.5748)
2 ton series
Limit 39.92 (1.5433)
Standard: 45.0 (1.7717)
1 ton series
mm Limit 45.2 (1.7795)
Cylinder bore
(in) Standard: 50.0 (1.9685)
2 ton series
Limit 50.2 (1.9764)
Piston rod bend mm (in) Standard: 2.0 (0.08)
Lift cylinder (FV)
Piston rod outside Standard: 32.0 (1.2598)
mm (in)
diameter Limit 31.92 (1.2567)
Standard: 45.0 (1.7717)
Cylinder bore mm (in)
Limit 45.2 (1.7795)
Front cylinder (FV · FSV)
Standard: 70.0 (2.756)
1 ton series
Piston rod outside mm Limit 69.91 (2.7524)
diameter (in) Standard: 75.0 (2.953)
2 ton series
Limit 74.91 (2.9429)
Standard: 85.0 (3.346)
1 ton series
mm Limit 85.4 (3.3622)
Cylinder bore
(in) Standard: 90.0 (3.543)
2 ton series
Limit 90.4 (3.5591)
Tilt cylinder
Standard: 30 (1.1811)
Piston rod outside diameter mm (in)
Limit 29.92 (1.1780)
Standard: 70 (2.7559)
Cylinder bore mm (in)
Limit 70.35 (2.7697)
17-11
Item
284.4 to 421.7 (2900 to 4300)
Lift cylinder cover Standard:
[209.8 to 311.1]
59.0 to 69.0 (601.6 to 703.6)
Flow regulator valve Standard:
[43.5 to 50.9]
29.0 to 39.0 (295.7 to 397.7)
Safety down valve Standard:
[21.4 to 28.8]
343.2 to 441.3 (3500 to 4500)
Front lift cylinder rod guide Standard:
[253.2 to 325.6]
410.0 to 462.0
Tilt cylinder piston castle nut Standard: (4180.8 to 4711.1)
[302.5 to 340.8]
284.0 to 421.0
Tilt cylinder cover Standard: (2896.0 to 4293.0)
[209.5 to 310.6]
OIL PUMP
Item
Oil pump assy
0.15 (0.006) or less at LBC
Side plate thickness mm (in) Limit
surface
Gear shaft outside diameter mm (in) Limit 21.997 (0.87)
Body inside surface flaw depth mm (in) Limit 0.15 (0.006)
OIL CONTROL VALVE

Item
Oil control valve
Relief set pressure Lift Standard: 17200 (175) [2488.5]
kPa (kgf·cm2) [PSi] Tilt Standard: 13700 (140) [1990.8]
Oil control valve (For Mini Lever)
Relief set pressure
Lift Standard: 17200 (175) [2488.5]
kPa (kgf·cm2) [PSi]
17-12
SAS
Item
1.6 to 2.0 (16.3 to 20.4)
Tire angle sensor set bolt Standard:
[1.2 to 1.5]
10 to 16 (102.0 to 163.3)
Tire angle sensor cover set bolt Standard:
[7.4 to 11.8]
10 to 16 (102.0 to 163.3)
Tilt angle sensor set bolt Standard:
[7.4 to 11.8]
22 to 26 (224.5 to 265.3)
Load sensor Standard:
[16.2 to 19.2]
15.0 to 25.0 (153.0 to 255.1)
V· Standard:
[11.1 to 18.5]
Lifting height switch ASSY set bolt
14.4 to 33.6 (146.9 to 342.9)
FV · FSV Standard:
[10.6 to 24.8]
17-13
CPU BOARD CONNECTOR
CN104 CN103 CN102 CN101
CN105
CN100
CN101 CN102 CN103 CN104
10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 8 7 6 5 4 3 2 1
1615 1413 12 11 11 10 9 8 7 7 6 5 1312 11 10 9
26252423222120191817 171615141312 11 10 9 8 2120191817161514
34333231 30 292827 222120 1918 1615141312 28272625 242322
CN101 CN102 CN103 CN104

No. P J No. P J No. P J No. P J
1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B48V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B48V
3 65 LSB 3 317 POTH 3 147 CANGND 3 SOLL+
3
4 66 LSPB 4 56 POTTA 4 43 VBKY (3) (SOL1+)
5 67 LSD 5 59 SPL 5 SSO+ 4 SOLL-
4
6 60 LSL 6 SSO- (4) (SOLb1)
6
7 OPTO (20) (POTL1) 7 41 VBBT 5 5 SOLa1
8 LEDTK 7 21 POTL2 8 CHK15V 6 SOLT+
6
9 39 FAN- 61 LSTF 9 CHK5V (6) (SOL2+)
8
10 39 FAN- (22) (POTT1) 10 16 D15V 7 SOLT-
7
11 63 LSAT1+ 62 LSTR 11 CHK3.3V (7) (SOLa2)
9
12 SSTMA (23) (POTT2) 12 14 GNDD 8 8 SOLb2
13 SSTMK 63 LSAT1∑LSAT2 13 144 SMTDK 9 55 CPR
10
14 SMTSA (24) (POTAT11) 14 143 SDTMK 10 55 CPR
15 SMTSK 11 25 POTAT12 15 142 SDTMA 11 9 SOL3+
16 51 LS- 12 26 POTAT21 16 141 SMTDA 12 10 SOLa3
17 62 LSTR+ 13 27 POTAT22 13 11 SOLb3
18 70 SWTK 14 53 POTA+ 11 10 9 8 7 6 5 4 3 2 1 14 44 VBMB
19 90 MH1 15 316 POTH+ 15 44 VBMB
20 91 MH2-1 16 57 POTTA+ CN105 16 34 SOL4+
21 314 STSC 17 58 SPL+ No. P J 17 35 SOLa4
22 LSAT2+ 18 28 POTL+ 1 39 FAN- 18 36 SOLb4
23 61 LSTF+ 19 29 POTT+ 2 39 FAN- 19 1 MB+
24 312 STS1 20 30 POTAT1+ 3 39 FAN- 20 2 MB-
25 21 31 POTAT2+ 4 130 FAN1 21 329 SOLST+
26 51 LS- 22 51 POT- 5 131 FAN2 22 N2 N2
27 SWLE 6 132 FAN3 23 N2 N2
28 8 7 6 5 4 3 2 1 7 133 FAN4 24 39 FAN-
29 8 134 FAN5 25 42 KEYSTART
30 313 STS2 CN100 9 135 FAN6 26 12 SOLP+
31 No. P J 10 FAN7 27 13 SOLP-
32 60 LSL+ 1 C5V 11 CHKG 28 330 SOLST-
33 2 GNDC
34 51 POT- 3 FTXD
4 FWE
5 MD1
6 FRES
7 FRXD
8 SELR
17-14
CONNECTOR DRAWING
CN1 DISPLAY CN8 TURN & LIGHT SW.
6 5 4 3 2 1 1 2 3 4 5 6
4 3 2 1 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14
1 2 3 4
8 7 6 5
5 6 7 8 TAB REC
NO P C J NO P C J
TAB REC 1 1
NO P C J NO P C J 2 2
1 14 B-W CN70-30 1 14 B-W CN131-2 3 3
2 16 R CN70-14 2 16 R J4 4 4
3 141 W-R CN70-22 3 141 W-R CN131-7 5 5
4 143 R-Y CN70-24 4 143 R-G CN131-5 6 6
5 5 7 7
6 6 8 115 - LH 8 115 P CN45-3
7 144 G-R CN70-23 7 144 G-R CN131-4 9 116 - LT 9 116 LG CN46-3
8 R-B R-B CN70-21 8 142 R-B CN131-6 10 N2 - EL 10 N2 W-B J8
11 11
CN3 HORN SW.
12 108 - TR 12 108 R-Y J14
13 109 - TL 13 109 G-Y J13
1 1
14 110 - TB 14 110 GR CN12-1
2 2
CN9 DIRECTIONAL SW.
TAB REC
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
NO P C J NO P C J
1 48 - HO+ 1 48 P HORN 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18
2 41 - HO- 2 41 BR J6
TAB REC
CN4 KEY SW.
NO P C J NO P C J
2 1 1 2 1 1
4 3 3 4 2 103 - DSBU 2 103 R-W CN132-7
3 120 - DSFO 3 120 Y-R CN132-8
TAB REC 4 46 - DSR 4 46 G-Y CN130-3
NO P C J NO P C J 5 45 - DSF 5 45 W CN130-2
1 41 - AM 1 41 BR CN29-1 6 51 - LS- 6 51 R-L J1
2 2 7 43 - VBKY 7 43 B-Y J5
3 3 8 43 - VBKY 8 43 B-Y J5
4 43 - IG 4 43 B-Y CN29-2 9 9
10 10
CN5 STOP LAMP SW.
11 11
12 12
2 1 1 2 13 13
14 14
TAB REC 15 15
16 16
NO P C J NO P C J
17 17
1 101 Y LS ST 1 101 Y J9
18 18
2 111 B-Y LS ST 2 111 R-L CN132-4
CN6 BRAKE SW.
2 1 1 2
TAB REC
NO P C J NO P C J
1 51 R-L LS B 1 51 R-L J1
2 65 Y-G LS B 2 65 Y-G CN130-4
17-15
CN9 <OPT> DIRECTIONAL PEDAL

CN15 PARKING SW.
3 2 1 1 2 3 2 1 1 2
6 5 4 4 5 6
TAB REC
TAB REC
NO P C J NO P C J
NO P C J NO P C J 1 51 - LSPB 1 51 R-L J1
1 51 - LS- 1 51 R-L J1 2 66 - LSPB 2 66 R CN130-5
2 120 - DSFO 2 120 Y-R CN132-8
3 103 - DSBU 3 103 R-W CN132-7 CN16 HEAD LAMP RH
4 46 - DSR 4 46 G-Y CN130-3

5 45 - DSF 5 45 W CN130-2 2 1 1 2
6 43 - VBKY 6 43 B-Y J5
TAB REC
CN11 LIFT SW.
NO P C J NO P C J
1 102 - LH-R 1 102 R-G CN13-3
2 1 1 2 2 N2 - LH-R 2 N2 W-B J51
TAB REC CN17 FR COMBI LH
NO P C J NO P C J
1 60 R-L LS L 1 60 W-G CN130-14 3 2 1 1 2 3
2 51 Y-G LS L 2 51 R-Y J2 6 5 4 4 5 6
TAB REC
CN12 FLASHER RILAY
NO P C J NO P C J
1 1 1 N2 W-B J51 1 N2 W-B J8
2 104 G-R CN18-4 2 104 G-R J10
2 2 3 102 R-G CN20-1 3 102 R-G J11
4 109 G-Y CN18-1 4 109 G-Y J13
TAB REC 5 N2 G CN18-2 5 N2 W-B J8
1 110 - FRY 1 110 GR CN8-14
2 43 - FRY 2 43 B-Y J5
CN18 FR COMBI LH
CN13 FR COMBI RH 2 1 1 2
4 3 3 4
3 2 1 1 2 3
6 5 4 4 5 6
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 109 - LF-L 1 109 G-Y CN17-4
1 N2 W-B J51 1 N2 W-B J8 2 N2 - LF-L 2 N2 G CN17-5
2 104 G-R CN14-4 2 104 G-R J10 3 N2 - LC-L 3 N2 W-B J51
3 102 R-G CN16-1 3 102 R-G J11 4 104 - LC-L 4 104 G-R CN17-2
4 108 R-Y CN14-1 4 108 R-Y J14
CN19 STEERING SENSOR
5 N2 G CN14-2 5 N2 W-B J8
6 6
2 1 1 2
CN14 FR COMBI RH
6 5 4 3 3 4 5 6
2 1 1 2
4 3 3 4 TAB REC
NO P C J NO P C J
TAB REC 1 16 R J4
1 16 - IG
NO P C J NO P C J 2 51 - ESS 2 51 R-L J1
1 108 - LF-R 1 108 G-Y CN13-4 3 312 - SS1 3 312 G-W CN131-15
2 N2 - LF-R 2 N2 G CN13-5 4 313 - SS2 4 313 R-Y CN131-16
3 N2 - LC-R 3 N2 W-B J51 5 314 - SSC 5 314 L CN131-17
4 104 - LC-R 4 104 G-R CN13-2 6 6
17-16
CN20 HEAD LAMP LH CN27 F4,F5 FUSE
2 1 1 2 2 1 1 2
4 3 3 4
TAB REC
TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 102 - LH-L 1 102 R-G CN17-3
1 P1 - F4 1 P1 B CN136-3
2 N2 - LH-L 2 N2 W-B J51
2 101 - F4 2 101 Y CN132-1
CN21 ATT SW. 3 P1 - F5 3 P1 W CN136-4
4 41 - F5 4 41 BR J29
2 1 1 2
CN28 F6 FUSE
TAB REC
2 1 1 2
NO P C J NO P C J
4 3 3 4
1 63 R-L LS ATT 1 63 P-W CN130-17
2 51 Y-G LS ATT 2 51 R-Y J2 TAB REC
CN22 SEAT SW. NO P C J NO P C J
1 P2 - F6 1 P2 P CN136-6
2 1 1 2 2 44 - F6 2 44 Y-G J30
3 3
TAB REC 4 4
NO P C J NO P C J
1 67 - LS D 1 67 L CN101-5 CN29 KEY SW.
2 51 - LS D 2 51 R-L J21
2 1 1 2
CN23 BUZZER
1 1 TAB REC
2 2 NO P C J NO P C J
1 41 BR CN4-1 1 41 BR J6
TAB REC
2 43 B-Y CN4-2 2 43 B-Y J5
NO P C J NO P C J
1 103 - BZ 1 103 R-W J32 CN31 RR COMBI LH
2 N2 - BZ 2 N2 W-B J31
2 1 1 2
CN24 CHIME
4 3 3 4
1 1
2 2 TAB REC
NO P C J NO P C J
TAB REC 1 104 L TL 1 104 G-R J55
NO P C J NO P C J 2 111 L STP 2 111 R-L J53
1 1 120 Y-R J33 3 109 L TRN 3 109 G-Y CN38-6
2 2 N2 W-B J31 4 N2 L E 4 N2 W-B J54
CN26 ACCEL CN32 TIRE ANGLE SENSOR
4 3 2 1 1 2 3 4 3 2 1 1 2 3
TAB REC TAB REC

NO P C J NO P C J NO P C J NO P C J
1 51 - E2 1 51 R-W J3 1 51 - GND 1 51 R-W J22
2 64 - IDL 2 64 R CN132-12 2 317 - OUT 2 317 G-Y CN102-3
3 52 - VTA 3 52 GR CN132-13 3 316 - VCC 3 316 R-Y CN102-15
4 53 - VC 4 53 R-G CN132-14
17-17
CN34 RR COMBI RH CN42 <OPT> MINI LEVER
2 1 1 2 4 3 2 1 1 2 3 4
4 3 3 4 8 7 6 5 5 6 7 8
6 5 5 6 TAB REC
NO P C J NO P C J
1 26 B-Y CN80-2 1 26 B-Y CN102-12
TAB REC
2 27 Y-G CN80-3 2 27 Y-G CN102-13
NO P C J NO P C J
3 31 P CN80-1 3 31 P CN102-21
1 104 R TL 1 104 G-R J55
4 4
2 111 R STP 2 111 R-L J53
5 70 BR CN85-2 5 70 BR CN101-18
3 103 R B/U 3 103 R-W CN38-3
6 6
4 4
7 67 L CN43-1 7 67 L CN101-5
5 108 R TRN 5 108 R-Y CN38-5
8 51 R-L CN43-2 8 51 R-L J21
6 N2 R E 6 N2 W-B J54
CN43 <OPT> SEAT SW
CN38 RR UPR
3 2 1 1 2 3 2 1 1 2
8 7 6 5 4 4 5 6 7 8
TAB REC
NO P C J NO P C J
TAB REC
1 67 - SOL P 1 67 L CN42-7
NO P C J NO P C J
2 51 - SOL P 2 51 R-L CN42-8
1 120 Y-R J33 1 120 Y-R LF-R
2 111 R-L CN132-4 2 111 R-L J53 CN45 HEAD LAMP RELAY
3 103 R-W J32 3 103 R-W CN34-3
4 104 G-R CN132-2 4 104 G-R J55 2 1 1 2
5 108 R-Y CN132-6 5 108 R-Y CN34-5 4 3 3 4
6 109 G-Y CN132-5 6 109 G-Y CN31-3
7 107 R-B CN132-3 7 107 R-B LW TAB REC
8 N2 W-B J31 8 N2 W-B J54 NO P C J NO P C J
1 101 - COIL+ 1 101 Y J9
CN41 <OPT> MINI LEVER 2 101 - SW+ 2 101 Y J9
3 115 - COIL- 3 115 P CN8-8
5 4 3 2 1 1 2 3 4 5 4 102 - SW- 4 102 R-G J11
10 9 8 7 6 6 7 8 9 10
CN46 TAIL LAMP RELAY
TAB REC
NO P C J NO P C J 2 1 1 2
1 20 W-G CN77-2 1 20 W-G CN102-6 4 3 3 4
2 21 P-G CN77-3 2 21 P-G CN102-7
TAB REC
3 28 B-W CN77-1 3 28 B-W CN102-18
NO P C J NO P C J
4 22 G-R CN78-2 4 22 G-R CN102-8
1 101 - COIL+ 1 101 Y J9
5 23 B-R CN78-3 5 23 B-R CN102-9
2 101 - SW+ 2 101 Y J9
6 29 W-R CN78-1 6 29 W-R CN102-19
3 116 - COIL- 3 116 LG CN8-9
7 24 P-W CN79-2 7 24 P-W CN102-10
4 104 - SW- 4 104 G-R J10
8 25 G-W CN79-3 8 25 G-W CN102-11
9 30 O CN79-1 9 30 O CN102-20 CN52 DM TEMP RH
10 51 R-W J49 10 51 R-L CN101-34
2 1 1 2
TAB REC
NO P C J NO P C J
1 82 B TD2- 1 82 P J28
2 88 R TD2+ 2 88 W-G CN109-13
17-18
CN53 DM SPEED RH CN70 DISPLAY
REC
1 2 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3 4 3 4
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TAB
TAB REC
NO P C J NO P C J 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 79 R SSD2+ 1 79 G-R CN109-9 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
2 80 W SSD21 2 80 BR CN109-11
3 82 B SSD2- 3 82 P J28 TAB REC
4 81 L SSD22 4 81 B-W CN109-12 NO P C J NO P C J
CN55 PM TEMP
1 43 - 48V 1
2 2
2 1 1 2 3 3
4 137 - SL/L+ 4
TAB REC 5 138 - SL/L- 5
1 86 B TP- 1 86 P-G J26 7 180 - AVD(+) 7
2 89 R TP+ 2 89 Y-G CN111-13 8 124 - CHG LED1 8
9 125 - CHG LED2 9
CN56 PM SPEED 10 126 - CHG LED3 10
11 127 - CHG LED4 11
1 2 1 2 12 182 - AVD2 12
3 4 3 4 13 181 - AVD1 13
14 16 - D15V 14 16 R CN1-2
TAB REC 15 N2 - N1 15
1 83 R SSP+ 1 83 B-R CN111-9 17 17
2 84 W SSP1 2 84 W-R CN111-11 18 18
3 86 B SSP- 3 86 P-G J26 19 139 - STT 19
4 85 L SSP2 4 85 R-L CN111-12 20 140 - SLL 20
21 142 - SDTMA 21 142 R-B CN1-8
CN58 DM TEMP LH
22 141 - SMTDA 22 141 W-R CN1-3
23 144 - SMTDK 23 144 G-R CN1-7
2 1 1 2
24 143 - SDTMK 24 143 R-Y CN1-4
25 123 - CHG SW3 25
TAB REC
26 122 - CHG SW2 26
NO P C J NO P C J
27 121 - CHG SW1 27
1 78 B TD1- 1 78 P J27
28 183 - AVD3 28
2 87 R TD1+ 2 87 W-G CN110-13
29 184 - AVD4 29
CN59 DM SPEED LH 30 14 - GNDD 30 14 B-W CN1-1
1 2 1 2
CN74 <OPT> C/V SOL.(UPR)
3 4 3 4
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
TAB REC
NO P C J NO P C J TAB REC
1 75 R SSD1+ 1 75 G-R CN110-9 NO P C J NO P C J
2 76 W SSD11 2 76 BR CN110-11 1 34 - SOL ATa4 (+) 1 34 G-Y J48
3 78 B SSD1- 3 78 P J27 2 9 - SOL ATa3 (+) 2 9 Y-B J47
4 77 L SSD12 4 77 B-W CN110-12 3 6 - SOL Ta2 (+) 3 6 R-G J46
4 3 - SOL Lb1 (+) 4 3 W-R J45
5 36 - SOL ATb4 (-) 5 36 G-W CN132-18
6 11 - SOL ATb3 (-) 6 11 G-B CN132-17
7 8 - SOL Tb2 (-) 7 8 P-G CN132-16
8 4 - SOL Lb1 (-) 8 4 B-R CN132-15
17-19
CN75 <OPT> C/V SOL.(LWR)

CN80 <OPT> ATT2 LEVER
4 3 2 1 1 2 3 4
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
TAB REC TAB REC
1 34 - SOLATa4 (+) 1 34 G-Y J48 1 31 - VC 1 31 P CN42-3
2 9 - SOLATa3 (+) 2 9 Y-B J47 2 26 - VTA1 2 26 B-Y CN42-1
3 6 - SOLTa2 (+) 3 6 R-G J46 3 27 - VTA2 3 27 Y-G CN42-2
4 3 - SOLLb1 (+) 4 3 W-R J45 4 51 - E2 4 51 R-W J49
5 35 - SOLATa4 (-) 5 35 B-L CN131-12
6 10 - SOLATa3 (-) 6 10 R-L CN131-9 CN84 TILT KNOB SW.
7 7 - SOLTa2 (-) 7 7 B-G CN130-17

8 5 - SOLLa1 (-) 8 5 Y CN130-15 2 1 1 2
CN76 <OPT> C/V PRESSURE SOL.
TAB REC
1 2 NO P C J NO P C J
2 1
1 70 - SOLD(+) 1 70 BR CN132-11
TAB REC 2 51 - SOLD(-) 2 51 R-L J1
NO P C J NO P C J CN85 <OPT> TILT KNOB SW.
1 12 - SOL P 1 12 P CN132-11
2 13 - SOL P 2 13 R-Y CN130-8 2 1 1 2
CN77 <OPT> LIFT LEVER
TAB REC
NO P C J NO P C J
4 3 2 1 1 2 3 4 1 51 - SWTK(-) 1 51 R-W J49
2 70 - SWTK(+) 2 70 BR CN42-5
TAB REC
NO P C J NO P C J CN86 TILT SENSOR
1 28 - VC 1 28 B-W CN41-3
2 20 - VTA1 2 20 W-G CN41-1 3 2 1 1 2 3
3 21 - VTA2 3 21 P-G CN41-2 TAB REC
4 51 - E2 4 51 R-W J49 NO P C J NO P C J
CN78 <OPT> TILT LEVER 1 57 - VRAT 1 57 L CN130-13
2 56 - VRAT 2 56 G CN130-12
3 51 - VRAT 3 51 R-W J3
4 3 2 1 1 2 3 4
CN87 TILT SW.
TAB REC
NO P C J NO P C J
1 29 - VC 1 29 W-R CN41-6 2 1
1 2
2 22 - VTA1 2 22 G-R CN41-4 4 3
3 23 - VTA2 3 23 B-R CN41-5 3 4
4 51 - E2 4 51 R-W J49
TAB REC
CN79 <OPT> ATT1 LEVER
NO P C J NO P C J
1 61 - LSTF 1 61 G-R CN130-15
4 3 2 1 1 2 3 4 2 51 - LS- 2 51 R-Y J2
3 62 - LSTR 3 62 B-R CN130-16
TAB REC 4 51 - LS- 4 51 R-Y J2
NO P C J NO P C J
1 30 - VC 1 30 O CN41-9 CN88 LIFT SOL.
2 24 - VTA1 2 24 P-W CN41-7

3 25 - VTA2 3 25 G-W CN41-8 2 1 1 2
4 51 - E2 4 51 R-W J49
TAB REC
NO P C J NO P C J
1 3 - SOLL + 1 3 W-R CN104-3
2 4 - SOLL - 2 4 B-R CN104-4
17-20
CN89 TILT SOL. CN101 MAIN CONT.
2 1 1 2 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
16 15 14 13 12 11 11 12 13 14 15 16
TAB REC
26 25 24 23 22 21 20 19 18 17 17 18 19 20 21 22 23 24 25 26
NO P C J NO P C J
1 6 - SOLT + 1 6 R-G CN104-6 34 33 32 31 30 29 28 27 27 28 29 30 31 32 33 34
2 7 - SOLT - 2 7 B-G CN104-7 ( ):OPT
TAB REC
CN90 MAST HARNESS NO P C J NO P C J
1 45 - DSF 1 45 W CN130-2
4 3 2 1 1 2 3 4 2 46 - DSR 2 46 G-Y CN130-3
8 7 6 5 5 6 7 8 3 65 - LSB 3 65 Y-G CN130-4
4 66 - LSPB 4 66 R CN130-5
TAB REC 5 67 - LSD 5 67 L CN22-1(CN42-7)
1 91 GR CN92-3 1 91 GR CN130-6 7 7
2 51 R-L CN92-1 2 51 R-L J1 8 8
3 59 Y-R CN91-2 3 59 Y-R CN130-10 9 39 - FAN- 9 39 B J23
4 58 R CN91-1 4 58 BR CN130-11 10 10
5 5 11 63 - LSAT1+ 11 63 P-W J37
6 90 O CN92-2 6 90 O CN130-7 12 12
7 7 13 13
8 51 R-W CN91-3 8 51 R-W J3 14 14
15 15
CN91 PRESSURE SENSOR
16 51 - LS- 16 51 R-L J21
17 62 - LSTR+ 17 62 B-R J36
1 1 18 70 - SWTK 18 70 BR CN132-11(CN42-5)
2 2
3 19 90 - MH1 19 90 O CN130-7
3
20 91 - MH2-1 20 91 GR CN130-6
TAB REC 21 314 - STSC 21 92 R-B CN131-17
1 58 - SP L 1 58 BR CN90-4 23 61 - LSTF+ 23 61 G-R J35
2 59 - SP L 2 59 Y-R CN90-3 24 312 - STS1 24 312 G-W CN131-15
3 51 - SP L 3 51 R-W CN90-8 25 25
26 26
CN92 HEIGHT SW.
27 27
28 28
3 2 1 1 2 3
29 29
30 313 - STS2 30 313 R-Y CN131-16
TAB REC 31 31
NO P C J NO P C J 32 60 - LSL+ 32 60 W-G J34
1 51 R-L CN90-2 1 51 - SWMH1 33 33
2 90 O CN90-6 2 90 - SWMH1 34 51 - POT- 34 (51) (R-L) (CN41-10)
3 91 GR CN90-1 3 91 - SWMH1
CN98 STEERING SOL.
2 1 1 2
TAB REC
NO P C J NO P C J
1 329 B-O CN131-19 1 329 - SOL ST
2 330 GR CN131-20 2 330 - SOL ST
17-21
CN102 MAIN CONT. CN104 MAIN CONT.
6 5 4 3 2 1 1 2 3 4 5 6 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
11 10 9 8 7 7 8 9 10 11 13 12 11 10 9 9 10 11 12 13
17 16 15 14 13 12 12 13 14 15 16 17 21 20 19 18 17 16 15 14 14 15 16 17 18 19 20 21
22 21 20 19 18 18 19 20 21 22 28 27 26 25 24 23 22 22 23 24 25 26 27 28
TAB REC ( ):OPT ( ):OPT TAB REC ( ):OPT

1 64 -SWAC 1 64 R CN132-12 1 1
2 52 -POTA 2 52 GR CN132-13 2 18 - B48V 2 18 O J29
3 317 -POTH 3 317 G-Y CN32-2 3 3 - SOLL+(SOL1+) 3 3 W-R CN88-1(CN130-14)
4 56 -POTTA 4 56 G CN130-12 4 4 - SOLL-(SOLb1) 4 4 B-R CN88-2(CN132-15)
5 59 - SPL 5 59 Y-R CN130-10 5 5 - SOLa1 5 (5) (Y) (CN130-15)
6 20,60 POTL1,LSL
- 6 60(20) W-G J34(CN41-1) 6 6 - SOLT+(SOL2+) 6 6 R-G CN89-1(CN130-16)
7 21 -POTL2 7 (21) (P-G) (CN41-2) 7 7 - SOLT-(SOLa2) 7 7 B-G CN89-2(CN130-17)
8 22,61 -
POTT1,LSTF 8 61(22) G-R J35(CN41-4) 8 8 - SOLb2 8 (8) (P-G) (CN132-16)
9 23,62 -
POTT2,LSTR 9 62(23) B-R J36(CN41-5) 9 55 - CPR 9 55 W-G CN126-2
10 24,63 -
POTAT11,LSAT1 10 63(24) P-W J37(CN41-7) 10 10
11 25 -
POTAT12 11 (25) (G-W) (CN41-8) 11 9 - SOL3+ 11 (9) (Y-B) (CN131-8)
12 26 -
POTAT21 12 (26) (B-Y) (CN42-1) 12 10 - SOLa3 12 (10) (R-L) (CN131-9)
13 27 -
POTAT22 13 (27) (Y-G) (CN42-2) 13 11 - SOLb3 13 (11) (G-B) (CN132-17)
14 53 -POTA+ 14 53 R-G CN132-14 14 44 - VBMB 14 44 Y-G J30
15 316 -POTH+ 15 316 R-Y CN32-3 15 44 - VBMB 15 44 Y-G J30
16 57 -
POTTA+ 16 57 L CN130-13 16 34 - SOL4+ 16 (34) (G-Y) (CN131-11)
17 58 -SPL+ 17 58 BR CN130-11 17 35 - SOLa4 17 (35) (B-L) (CN131-12)
18 28 -POTL+ 18 (28) (B-W) (CN41-3) 18 36 - SOLb4 18 (36) (G-W) (CN132-18)
19 29 -POTT+ 19 (29) (W-R) (CN41-6) 19 1 - MB+ 19 1 V CN136-2
20 30 -
POTAT1 20 (30) (O) (CN41-9) 20 2 - MB- 20 2 R CN136-1
21 31 -
POTAT2 21 (31) (P) (CN42-3) 21 329 - SOLST+ 21 329 B-O CN131-19
22 51 -POT- 22 51 R-W J22 22 N2 - N2 22 N2 W-B N2 TERM
23 N2 - N2 23 N2 W-B N2 TERM
CN103 MAIN CONT.
24 24
25 42 - KEYSTART 25 42 GR J25
4 3 2 1 1 2 3 4 26 12 - SOLP+ 26 (12) (P) (CN132-11)
7 6 5 5 6 7 27 13 - SOLP- 27 (13) (R-Y) (CN130-8)
11 10 9 8 8 9 10 11 28 330 - SOLST- 28 330 GR CN131-20
16 15 14 13 12 12 13 14 15 16 CN109 DRIVE CONT.RH
6 5 4 3 2 1 1 2 3 4 5 6
TAB REC 13 12 11 10 9 8 7 7 8 9 10 11 12 13
NO P C J NO P C J
1 145 - CANH 1 145 B CN110-3 TAB REC
2 146 - CANL 2 146 W CN110-4 NO P C J NO P C J
3 147 - CANGND 3 147 Y CN110-6 1 82 - CUDID0 1 82 P CN109-10
4 43 - VBKY 4 43 B-Y CN131-13 2 - CUDID1 2
5 5 3 145 - CANH 3 145 B CN110-3,CN111-3
6 6 4 146 - CANL 4 146 W CN110-4,CN111-4
7 41 - VBBT 7 41 BR J29 5 - CANTRD 5
8 8 6 147 - CANGND 6 147 Y CN110-6,CN111-6
9 9 7 42 - KEYSTART 7 42 GR J25
10 16 - D15V 10 16 R CN131-3 8 - CUDON 8
11 11 9 79 - SSD2+ 9 79 G-R CN53-1
12 14 - GNDD 12 14 B-W CN131-2 10 82 - SSD2-,TD2- 10 82 P J28,CN109-1
13 144 - SMTDK 13 144 G-R CN131-4 11 80 - SSD21 11 80 BR CN53-2
14 143 - SDTMK 14 143 R-G CN131-5 12 81 - SSD22 12 81 B-W CN53-4
15 142 - SDTMA 15 142 R-B CN131-6 13 88 - TD2+ 13 88 W-G CN52-2
16 141 - SMTDA 16 141 W-R CN131-7
17-22
CN110 DRIVE CONT.LH CN114 FAN(EX)
6 5 4 3 2 1 1 2 3 4 5 6
13 12 11 10 9 8 7 7 8 9 10 11 12 13 2 1 1 2
TAB REC TAB REC

1 - CUDID0 1 1 44 R FAN EX (+) 1 44 Y-G J30
2 - CUDID1 2 2 39 B FAN EX (-) 2 39 B J23
3 145 - CANH 3 145 B CN103-1,CN109-3
4 146 - CANL 4 146 W CN103-2,CN109-4 CN126 RESISTOR
5 - CANTRD 5 1 1
6 147 - CANGND 6 147 Y CN103-3,CN109-6 3 2 2 3
7 42 - KEYSTART 7 42 GR J25
8 - CUDON 8 TAB REC
9 75 - SSD1+ 9 75 G-R CN59-1 NO P C J NO P C J
10 78 - SSD1-,TD1- 10 78 P J27 1 1
11 76 - SSD11 11 76 BR CN59-2 2 55 W CPR 2 55 W-G CN104-9
12 77 - SSD12 12 77 B-W CN59-4 3 P2 W P2 3 P2 G CN136-5
13 87 - TD1+ 13 87 W-G CN58-2
CN111 PUMP CONT.
6 5 4 3 2 1 1 2 3 4 5 6
13 12 11 10 9 8 7 7 8 9 10 11 12 13
TAB REC
NO P C J NO P C J
1 - CUPID0 1
2 86 - CUPID1 2 86 P-G CN111-10
3 145 - CANH 3 145 B CN109-3,CN112-1
4 146 - CANL 4 146 W CN109-4,CN112-2
5 - CANTRD 5
6 147 - CANGND 6 147 Y CN109-6,CN112-3
7 42 - KEYSTART 7 42 GR J25
8 - CUPON 8
CN130 JOINT
9 83 - SSP+ 9 83 B-R CN56-1

10 86 - SSP-,TP- 10 86 P-G J26,CN111-2 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
11 84 - SSP1 11 84 W-R CN56-2
12 85 - SSP2 12 85 R-L CN56-4 181716 1514 13 12 11 10 9 9 10 11 12 13 1415 161718
13 89 - TP+ 13 89 Y-G CN55-2
( ):OPT TAB REC ( ):OPT
CN112 RESISTOR
NO P C J NO P C J
1 51 R-L J1 1 51 R-L J21
3 2 1 1 2 3
2 45 W CN9-5 2 45 W CN101-1
3 46 G-Y CN9-4 3 46 G-Y CN101-2
TAB REC 4 65 Y-G CN6-2 4 65 Y-G CN101-3
NO P C J NO P C J 5 66 R CN15-2 5 66 R CN101-4
1 145 B CN111-3 1 145 - R 6 91 GR CN90-1 6 91 GR CN101-20
2 146 W CN111-4 2 146 - R 7 90 O CN90-6 7 90 O CN101-19
3 147 Y CN111-6 3 8 51(13) R-Y J2(CN76-2) 8 51(13) R-Y J21(CN104-27)
CN113 FAN(EX) 9 51 R-W J3 9 51 R-W J22
10 59 Y-R CN90-3 10 59 Y-R CN102-5
2 1 1 2 11 58 BR CN90-4 11 58 BR CN102-17
12 56 G CN86-2 12 56 G CN102-4
13 57 L CN86-1 13 57 L CN102-16
TAB REC
14 60(3) W-G(W-R) CN11-1(J45) 14 60(3) W-G(W-R) J34(CN104-3)
NO P C J NO P C J
15 61(5) G-R(Y) CN87-1(CN75-8) 15 61(5) G-R(Y) J35(CN104-5)
1 44 R FAN EX (+) 1 44 Y-G J30
16 62(6) B-R(R-G) CN87-3(J46) 16 62(6) B-R(R-G) J36(CN104-6)
2 39 B FAN EX (-) 2 39 B J23
17 63(7) P-W(B-G) CN21-1(CN75-7) 17 63(7) P-W(B-G) J37(CN104-7)
18 N2 W-B J8 18 N2 W-B J31
17-23
CN131 JOINT CN136 CONTACTOR
9 8 7 6 5 4 3 2 1 3 2 1 1 2 3
TAB 6 5 4 4 5 6
20 19 18 17 16 15 14 13 12 11 10
TAB REC
1 2 3 4 5 6 7 8 9 NO P C J NO P C J
REC 1 2 R CN104-20 1 2 - MB-
10 11 12 13 14 15 16 17 18 19 20 2 1 V CN104-19 2 1 - MB+
( ):OPT TAB REC ( ):OPT 3 P1 B CN27-1 3 P1 - P1 TERM
NO P C J NO P C J 4 P1 W CN27-3 4 P1 - P1 TERM
1 1 5 P2 G CN126-3 5 P2 - P2 TERM
2 14 B-W CN1-1 2 14 B-W CN103-12 6 P2 P CN28-1 6 P2 - P2 TERM
3 16 R J4 3 16 R CN103-10
4 144 G-R CN1-7 4 144 G-R CN103-13
5 143 R-G CN1-4 5 143 R-G CN103-14
6 142 R-B CN1-8 6 142 R-B CN103-15
7 141 W-R CN1-3 7 141 W-R CN103-16
8 (9) (Y-B) (J47) 8 (9) (Y-B) (CN104-11)
9 (10) (R-L) (CN75-6) 9 (10) (R-L) (CN104-12)
10 10
11 (34) (G-Y) (J48) 11 (34) (G-Y) (CN104-16)
12 (35) (B-L) (CN75-5) 12 (35) (B-L) (CN104-17)
13 43 B-Y J5 13 43 B-Y CN103-4
14 41 BR J6 14 41 BR J29
15 312 G-W CN19-3 15 312 G-W CN101-24
16 313 R-Y CN19-4 16 313 R-Y CN101-30
17 314 L CN19-5 17 314 L CN101-21
18 18
19 329 B-O CN98-1 19 329 B-O CN104-21
20 330 GR CN98-2 20 330 GR CN104-28
CN132 JOINT
8 7 6 5 4 3 2 1
TAB
18 17 16 15 14 13 12 11 10 9
1 2 3 4 5 6 7 8
REC
9 10 11 12 13 14 15 16 17 18
( ):OPT TAB REC ( ):OPT
NO P C J NO P C J
1 101 Y J9 1 101 Y CN27-2
2 104 G-R J10 2 104 G-R CN38-4
3 107 R-B SWR 3 107 R-B CN38-7
4 111 R-L CN5-2 4 111 R-L CN38-2
5 109 G-Y J13 5 109 G-Y CN38-6
6 108 R-Y J14 6 108 R-Y CN38-5
7 103 R-W CN9-2(CN9-3) 7 103 R-W J32
8 120 Y-R CN9-3(CN9-2) 8 120 Y-R J33
9 9
10 10
11 70(12) BR(P) CN84-1(CN76-1) 11 70(12) BR(P) CN101-18(CN104-26)
12 64 R CN26-2 12 64 R CN102-1
13 52 GR CN26-3 13 52 GR CN102-2
14 53 R-G CN26-4 14 53 R-G CN102-14
15 (4) (B-R) (CN74-8) 15 (4) (B-R) (CN104-4)
16 (8) (P-G) (CN74-7) 16 (8) (P-G) (CN104-8)
17 (11) (G-B) (CN74-6) 17 (11) (G-B) (CN104-13)
18 (36) (G-W) (CN74-5) 18 (36) (G-W) (CN104-18)
17-24
JOINT ( ):OPT
CN9-7(CN9-6)
CN6-1 CN87-4 CN130-9 CN1-2
CN12-2
CN84-2 CN130-1 CN11-2 CN90-8
CN90-2 CN19-1 J5
J1 J2 J3 J4
CN29-2 CN131-13
CN19-2 CN15-1 CN87-2 CN130-8 CN86-3
CN9-8
CN9-6(CN9-1) CN21-2 CN26-1 CN131-3
(43,B-Y)
(51,R-L) (51,R-Y) (51,R-W) (16,R)
CN3-2 CN8-10 CN13-3

CN5-1 CN132-2
CN13-1 CN45-1 CN132-1 CN17-2
J6 CN29-1 CN17-5 J8 CN17-1 CN45-2 J10 J11 CN45-4
J9
CN13-5 CN130-18 CN46-2 CN46-1 CN13-2
H
CN131-14 SWR CN46-4 CN17-3
(41,BR) (N2,W-B) (101,Y) (104,G-R) (102,R-G)
CN8-13 CN8-12 CN22-2(CN42-8) CN32-1 CN101-9
CN130-8 CN130-9 CN114-2

J13 CN17-4 J14 CN13-4 J21 CN101-16 J22 J23
CN132-5 CN132-6 CN130-1 CN102-22 CN113-2

(109,G-Y) (108,R-Y) (51,R-L) (51,R-W) (39,B)
CN111-7 CN55-1 CN58-1 CN52-1 CN27-4
CN104-25 CN104-2
J25 J26 CN56-3 J27 CN59-3 J28 CN53-3 J29
CN109-7 CN103-7
CN110-7 CN111-10 CN110-10 CN109-10 CN131-14
(42,GR) (86,P-G) (78,P) (82,P) (41,BR)
CN28-2 CN130-18 CN23-1 CN24-1 CN101-32
CN114-1 CN104-14 CN23-2 CN102-6

J30 J31 J32 CN132-7 J33 CN38-1 J34
CN113-1 CN24-2 CN38-8
CN104-15 N2 TERMINAL CN38-3 CN132-8 CN130-14

(44,Y-G) (N2,W-B) (103,R-W) (120,Y-R) (60,W-G)
CN101-23 CN101-17 CN101-11 CN75-4 CN75-3

CN102-8 CN102-9 CN102-10
J35 J36 J37 J45 CN74-4 J46 CN74-3
CN130-15 CN130-16 CN130-17 CN130-14 CN130-16

(61,G-R) (62,B-R) (63,P-W) (3,W-R) (6,R-G)
CN75-2 CN75-1 CN77-4 CN16-2,CN20-2 CN31-2
CN85-1 CN78-4 CN38-2

J47 CN74-2 J48 CN74-1 J49 CN79-4 J51 J53
CN80-4 CN13-1,CN17-1
CN14-3,CN18-3 CN34-2
CN131-8 CN131-11 CN41-10
(9,Y-B) (34,G-Y) (51,R-W) (N2,W-B) (111,R-L)
CN31-4 CN38-4
LR
J54 CN38-8 J55 CN31-1
LW
CN34-6 CN34-1
(N2,W-B) (104,G-R)
SWITCH SWITCH
LAMP WORKING TILT KNOB
<LEVER CONT. UNIT>
SWITCH
KEY CN9
LIMIT SWITCH
REC
TAB
Kopplingsschema
PARKING SWD
SWH
BRAKE CN3 SWD
SWL
REC
TAB
SWH
SST DISPLAY
CN19 (101,Y) (107,R-B) TAB
RELAY RELAY RELAY TAB REC
REC
TAB
J9 CN132-3
FLASHER TAIL LAMP HEAD LAMP REC
CN70
CN4 CN8
CN84
REC
TAB
SWL
TAB
TAB REC LAMP LAMP
REC HEAD RH
FLASHER
CN46 CN45 TAB
CN12 REC LH
TAB TAB TAB R-L
REC REC CN15 REC COM
Y-G
CN29 NO
NC
LAMP
FLASHER
LIMIT SWITCH RH
ATTCHMENT CN16
TAB CN14 TAB
LAMP HEAD LAMP REC
REC
TAB
(LH) FLASHER REC
LH
CN21
REC
CN6 TAB
LAMP REC TAB

TAB CN5 REC
CLEARANCE REC
TAB TILT ANGLE CN13
LH
CN1 SWITCH
TAB
TAB
REC <MINI-LEVER OPT>
REC R-L
CN20 CN18
COM
Y-G ACCELERATOR
NO
POTENTIONMETER TAB CN86 TILT KNOB
NC REC SWITCH
TAB LIMIT SWITCH LIFT TILT ATT1 ATT2
REC BRAKE (48,P)CN3-1 LEVER LEVER LEVER LEVER
CN17 TAB
COM
Y
(N2,W-B)J8
HORN REC
NO CN26
B-Y
NC
TAB TAB TAB TAB TAB
LIMIT SWITCH REC REC REC REC REC
STOP LAMP CN77 CN78 CN79 CN80 CN85
(1) (2) (3) (4)
CN90
TAB
REC
REC
CN11 TAB
REC
CN98 <DIRECTIONAL
REC TAB CN87
LIMIT SWITCH TAB CONTROL PEDAL OPT>
KNOB POSITION
LIFT
R-L LIMIT SWITCH CORRECTING
COM
Y-G TILT (FR) SOLENOID
NO
LIMIT SWITCH CN43
CN91 NC LIMIT SWITCH
TILT (RR) DEADMAN TAB
REC
TAB REC
CN9
TAB
REC
<MINI-LEVER OPT>
LOAD SENSOR ATT1 TILT
SOLENOID SOLENOID
B2(REAR)
CN74
A3
TAB
REC
COM
ATT2
REC
TAB
NO SOLENOID LIFT
NC CN92 A4 SOLENOID
A1(UP)
MAST LIFTING U
HEIGHT SWITCH
TILT V
BATT
LIFT SOLENOID
SOLENOID
W PM TAB
CN55
STM P REC
CN52
TAB
REC
STM D
W CN76
DM CN56
TAB
REC
TAB
REC
RH SSP
V CN53 - +
TAB
REC
SSD CN41 CN42

U CN75
TAB
REC
TAB TAB
ATT2 TILT REC REC
SOLENOID SOLENOID
B4 ATT1 B2(REAR)
LIFT
SOLENOID SOLENOID
B3 A1(DOWN)
CN130 CN131 CN132
CN58 TAB TAB TAB
REC REC REC
TAB
REC
STM D
W
DM
LH V CN59
CN89
TAB
REC
SSD MATERIAL HANDLING

TAB TAB
REC REC
U +
AC DRIVE
U
CONTACTOR
CN88
PANEL
V
P3 P1
W
- F4 F6
R F5
TAB TAB
REC TAB REC REC CN136
TAB REC
CN27 CN28 REC
CN112 CN111 TAB
TRAVELING AC TRAVELING AC
+ +
DRIVER 2(RH) DRIVER 1(LH)
U U
V V MAIN CONTROLLER <STD>

PANEL (EXCEPT MINI
W W CN104 -LEVER OPT)
REC REC REC REC
TAB TAB TAB TAB
N2 TERMINAL - - CN103
TAB TAB CN102

REC REC
LIMIT SWITCH
CN110 CN109 CN101 DEADMAN
CN22
REC
TAB
TAB
CN126 REC
LAMP FAN EXHAUST

WORKING CONTROL UNIT
LW
TAB
REC
CHIME
W
TAB
REC
CN113
CN114
CN32
REC FAN EXHAUST
W-B
R-B
TAB
CONTROL UNIT
TAB
CN24 REC REC CN23
(F) (R)
L T -L L T -R
LF-LL L BU -R L F -RR
L ST -L L ST -R
17-25
TIRE ANGEL SENSOR
TAB TAB
REC REC
CN31 CN34
CN38
REC
TAB
17-27 7FBEF 15-20 Symbolbeteckningar på elschemat
AM D1 Drivmotor, vänster PB CPU CPU kort, åkning och hydraulik
AM D2 Drivmotor, höger RT CAN bus resistor
AM P Pumpmotor SA Skyddskrets
BZ Backlarm SOL ATa3 Solenoid, Aux1 (nedre)
BATT Batteri SOL ATb3 Solenoid, Aux1 (övre)
CPR Resistor SOL ATa4 Solenoid, Aux2 (nedre)
CU D1 Åkpanel, vänster SOL ATb4 Solenoid, Aux2 (övre)
CU D2 Åkpanel, höger SOL La1 Solenoid, sänk
CU P Hydraulpanel SOL Lb1 Solenoid, lyft
DS BU Brytare, backljus SOL P Solenoid, avlastningsventil
DS F Brytare, fram SOL ST Shuntventil, styrning
DS FO Brytare, fram (option) SOL Ta2 Solenoid, tilt framåt
DS R Brytare, back SOL Tb2 Solenoid, tilt bakåt
F1 Huvudsäkring SPL Lastsensor
F4 Säkring, belysning SSD1 Hastighetssensor, drivmotor vä.
F5 Manöversäkring före nyckel SSD2 Hastighetssensor, drivmotor hö.
F6 Säkring, fläktar & solenoider SSP Hastighetssensor, pumpmotor
FAN Ex Kylfläkt, Paneler SST Rattsensor
FR Y Blinkrelä STMD1 Tempsensor, drivmotor vä.
H Signal STMD2 Tempsensor, drivmotor hö.
HR Y Relä, strålkastare STMP Tempsensor, pumpmotor
L BU-R Backljus, höger SW AC Brytare, fartreglage (1 MS)
L C-L Positionsljus, vänster SW F Blinkersomkopplare
L C-R Positionsljus, höger SW H Signalknapp
L F-L Blinkerslampa, Vä fram SW K Nyckelbrytare
L F-LR Blinkerslampa, Vä bak SW L Omkopplare, belysning
L F-R Blinkerslampa, Hö fram SW MH1 Brytare, lyfthöjd 1
L F-RR Blinkerslampa, Hö bak SW TK Knapp på tiltspak
L H-L Strålkastare, Vä fram TR Y Relä, bakljus & parkeringsljus
L H-R Strålkastare, Hö fram VRAD Fartreglage
L ST-L Bromsljus Vä VRAH Potentiometer, styrhjulsvinkel
L ST-R Bromsljus Hö VRAT Potentiometer, tiltvinkel
L T-L Bakljus Vä VRAL 1 Potentiometer, lyft 1
L T-R Bakljus Hö VRAL 2 Potentiometer, lyft 2
LW Arbetsbelysning bakåt VRAT 1 Potentiometer, tilt 1
LCD DISP Display VRAT 2 Potentiometer, tilt 2
LS B Bromsbrytare VRAAT 11 Potentiometer, Aux1 1
LS D Stolsbrytare VRAAT 12 Potentiometer, Aux1 2
LS PB Brytare, parkeringsbroms VRAAT 21 Potentiometer, Aux2 1
LS ST Brytare, bromsljus VRAAT 22 Potentiometer, Aux2 2
MB Huvudkontaktor
Kabelfärger på elschemat
B = Svart BR = Brun DG = Mörkgrå G = Grön GR = Grå
L = Blå LG = Ljusgrön O = Orange P = Rosa PU = Lila
R = Röd W = Vit Y = Gul

P1
48V
BATT
N1
(P1,B)
(48,P)
(116,LG)
MB
SWL
H
(104,G-R)
SWH
F4
F5
TR Y
L C-L
L C-R
T
SA
L T-L
L T-R
(115,P)
SWL
(101,Y)
P2
(P2,G)
(41,BR)
(102,R-G)
HR Y
L H-L
L H-R
HS
(109,G-Y)
LF
L F-L
(107,R-B)
-LR
(110,GR)
LW
F1
FR Y
HM
LF
(111,R-L)
SWF
L F-R
-RR
-L
(108,R-Y)
-R
L ST
L ST
LS ST
(103,R-W)
BZ
-R
F6
L BU
SW K
CPR
DS BU
(120,Y-R)
DS FO
P3
(N2,W-B)
FAN
EX
N2
N2
FAN
(43,B-Y)
EX
VBKY
(39,Y) (41,BR)
VBBT
FAN- (18,O)
CUPON B48V
(130,Y) (44,Y-G)
CUPID0 FAN1 VBMB
(131,Y) (44,Y-G)
CUPID1 VBMB
FAN2
CANTRP (132,Y) (55,W-G)
CPR
KEYSTART FAN3
(133,Y) (1,V) + -
CANH
FAN4 MB+ MB
CANL (134,Y) (2,R)
FAN5 MB-
CANGND
(86,P-G) (135,Y)
SSP-,TP- FAN6 (51,R-W)
(89,Y-G) POT-
CUP
TP+
Principschema Toyota 7FBEF 15-20
(83,B-R) (64,R) SW AC
SSP+ SWAC
-
(84,W-R) (39,B)
SSP1 FAN- (52,GR)
(85,R-L) POTA
SSP2
VRAD
(42,GR) (53,R-G)
ACCEL
KEYSTART POTA+
(145,B)
CANH
(146,W)
N2
CANL (59,Y-R)
(147,Y) SPL
SPL
CANGND
(58,BR)
SPL+
(V)
(U)
(W)
P16
P15
P14
-
(56,G)
SSP
POTTA
AMP
TILT
VRAT
(57,L)
+
POTTA+
(316,R-Y)
POTH+
STMP
(51,R-L)
+
POT-
(317,G-Y)
POTH
-
VRAH
-
(20,W-G)
(51,R-W) POTL1
POT-
TIRE ANGLE
VRAL1
+ -
CUDON (21,P-G)
LIFT
CUDID0 POTL2
VRAL2
(28,B-W)
+
LEVER
CUDID1 POTL+
(312,G-W)
CANTRD STS1
(313,R-Y)
KEYSTART STS2
-
SST
(314,L)
CANH STSC (22,G-R)
(51,R-L) POTT1
CANL LS-
VRAT1
CANGND
(78,P)
+ -
SSD1-,TD1-
(87,W-G) (23,B-R)
TILT
TD1+ POTT2
(75,G-R) (329,B-O)
CUD1 (LH)
SOLST+
VRAT2
SSD1+ (29,W-R)
+
LEVER
(76,BR) POTT+
SSD11
(77,B-W) (330,GR)
SOL ST
SSD12 SOLST-
-
(24,P-W)
PB CPU
POTAT11
VRAAT11
N1
(3,W-R)
SOL1+
+ -
(25,G-W)
POTAT12
ATT1
(V)
(4,B-R)
(U)
P9
P8
P7
(W)
SOL Lb1
SOLb1
VRAAT12
(30,O)
+
LEVER
POTAT1+
SSD1
(5,Y)
-
AMD1
SOL La1
SOLa1
(6,R-G) (26,B-Y)
SOL2+ POTAT21
DS BU
103(R-W)
VRAAT21
(7,B-G)
STMD1
SOLa2
+ -
43(B-Y)
(27,Y-G)
POTAT22
ATT2
VRAAT22
(8,P-G)
120(Y-R)
(31,P)
+
LEVER
SOLb2 POTAT2+
DS FO
(9,Y-B)
SOL3+
CONTROL PEDAL
FOR DIRECTIONAL
CUDON
(10,R-L)
DS F
SOLa3 LEDTK
CUDID0
45(W)
CUDID1 (51,R-L)
LS-
CANTRD
51(R-Y)
(11,G-B) (70,BR)
KEYSTART SOLb3
(34,G-Y) SWTK
CANH SOL4+
DS R
46(G-Y)
CANL
(35,B-L)
CANGND SOLa4 (45,W)
(82,P) DSF
SSD2-,TD2-
(88,W-G)
SW TK DS F DS R
TD2+ (46,G-Y)
(79,G-R) (36,G-W) DSR
SOLb4
CUD2 (RH)
SOL Ta2 SOL Tb2 SOL ATa3 SOL ATb3 SOL ATa4 SOL ATb4
SSD2+
(80,BR)
RT
SSD21 (65,Y-G)
(81,B-W) LSB
SSD22
(12,P)
LS B
SOLP+
R
(66,R)
LSPB
AC-S
AC-R
(13,R-Y)
SOL P
N1
SOLP- (67,L)
LSD
MSCH STT
CHGSW1
LS PB LS D
LCD
CHGSW2 SWLE
DISP
(V)
(U)
(W)
P91
P81
P71
SLL
CHGSW3
CHGLED1
CHGLED2 LSL+
SSD2
AMD2
CHGLED3 FANR+ LSTF+

CHGLED4 LSTR+
FANR-
LSAT1+
STMD2
LSAT2+
+15V
48V
SMTDA
SDTMA
SDTMK
SMTDK
N1
GNDD
(14,B-W) (91,GR)
GNDD MH2-1
(16,R) (90,O)
D15V MH1
(144,G-R)
SMTDK
(143,R-G)
SW MH1
SDTMK
17-28
(142,R-B)
SDTMA OPTO
(141,W-R)
SMTDA
17-29
Plint vid original F&B kablage
G/G 5
Svart-Gul (7) 43, Matning backljus
4 4
Röd-Vit (2) 103, Backljus
2 2
Vit (5) 45, Fram
1 1
Röd-Blå (6) 51, Matning F&B
Numrering sett 3
3
från hylssidan i Grön-Gul (4) 46, Back
kontaktstycket
3 2 1
1 2 3
1 2 3 6 5 4
4 5 6
4 5 6
5 4 2 1 3
Kopplingsplint
mellan armstöd
3 2 1
G/G
och maskin.
3
4
2
6 5 4
Fram&Back
brytare på
Numrering sett armstöd.
från stiftsidan i Backljus Fram&Back
kontaktstycket.
Fram&Back brytare
2 1 3
Framåt
G/G 4
Spår för
låsbricka
17-30
Original kopplingsdon CN9 klipps bort

och ersätts av ett 6-pol AMP hylsdon.
Original
kablage till
Kablage A22601-002 F&B spak
Kopplingsdon
Kopplingsdon Kopplingsdon
AMP 6-pol (hylsor)
AMP 6-pol AMP 6-pol
(stift) (hylsor)
Kablage A22600-002
F&B brytare
Kopplingsdon
AMP 6-pol (stift)
Tillägg för OPS (fr.o.m 2006)

Toyota 7FBEF 15-20

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Toyota 7FBEF 15-20

Încărcat de

Drepturi de autor:

Formate disponibile

TOYOTA 7FBE13, 7FBEF13-20

New Model Features < Tillbaka till Index

VEHICLE EXTERIOR VIEW

7FBEF18 7FBEF20 10011

HOW TO USE THIS MANUAL

DISASSEMBLY · INSPECTION · REASSEMBLY

2. How to read component figures (Example)

Item New unit Conventional Conversion rate*1 (1 [conventional unit] = X [SI

Wooden block or stand

HOISTING THE VEHICLE

WIRE ROPE SUSPENSION ANGLE LIST

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

MEMBER WEIGHTS - 7FBEF15-20

TOWING THE VEHICLE

MEMBER WEIGHTS - 7FBE10-20

TOWING THE VEHICLE

ELECTRICAL PARTS INSPECTION

2) Digital circuit tester

STANDARD BOLT & NUT TIGHTENING TORQUE

Hexagon Bolt with two

Hexagon Bolt with two

No mark 4T Nominal diameter

Stud bolt Length

TIGHTENING TORQUE TABLE

Nominal Hexagon Hexagon

N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Hydraulic oil level by lifting height

To 3000 mm Capacity 14 (3.70) 17 (4.49) 

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

To 6000 mm Capacity 18 (4.75)  19 (5.01)

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

1. Mast strip 8. Steering rack and pinion gear

Inspection timing Every 6 Every 3 Every 6 Every 12

Inspection timing Every 6 Every 3 Every 6 Every 12

Inspection timing Every 6 Every 3 Every 6 Every 12

Inspection timing Every 6 Every 3 Every 6 Every 12

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

Rear view Rear reflection status I ← ← ←

Inspection timing Every 6 Every 3 Every 6 Every 12

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Pos Kontroll av: Pos Kontroll av: Pos Kontroll av:

0:0 Grupp 0, Hel maskin 3:0 Grupp 3, Bromsar/hjul 5:9 Fartreglage

BATTERY COMPARTMENT AND REQUIRED WEIGHT

Compartment dimensions mm (in) Minimum required battery

Compartment dimension Minimum required bat-

Battery Indicate level Low Remaining Battery Charge Warning 6

Plate corrosion Sulfation Plate warpage and ative substance freeing

Deposition of freed Fouled terminal or

Short circuit Electrolyte leakage and reduction Loosened or corroded connection

2. Battery electrolyte specific gravity inspection

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

* How to use the hydrometer

3. Insulation resistance inspection

1. Insulation resistance measurement

Measurement terminals Controller side of battery plug-body

Connectors to which SST 09240-24300-71 is applicable

(2) Measurement method and standard list

Connector No. Connector No. Conditions Standard Remarks

Connector No.⇔Connector No. Conditions Standard: Remarks

Connector No.⇔Connector No. Conditions Standard: Remarks

Connector No.⇔Connector No. Conditions Standard: Remarks