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FOREWORD
This manual mainly describes the development objectives of new Toyota forklift
7FBEF15 to 20 models, outlines of main component units, structures and functions of
new mechanisms and other technical features.
Please read it carefully for sales and service activities.

This manual has been edited for the vehicles launched into the market in May
2003.
Any later change shall be informed through Toyota Industrial Equipment Parts &
Service News.
Please refer to the repair manual and parts catalog for the matters necessary
for servicing.
TOYOTA Material Handling Company

A Division of TOYOTA INDUSTRIES CORPORATION

SECTION INDEX
NAME SECTION
GENERAL 0
DEVELOPMENT OBJECTIVE 1
ELECTRICAL SYSTEM 2
POWER TRAIN 3
TRAVELING, STEERING AND BRAKE SYSTEMS 4
INSTRUMENTS 5
FRAME AND AUXILIARY EQUIPMENT 6
MATERIAL HANDLING AND HYDRAULIC SYSTEM 7
SAS CONTROL SYSTEM 8
OUTLINE OF MAJOR OPTIONS 9
APPENDIX 10

0-1
GENERAL
Page 2
VEHICLE EXTERIOR VIEWS ...................................... 0-2
3
MODEL LINEUP .............................................................. 0-3
0
3

0-2
VEHICLE EXTERIOR VIEWS

■ Vehicle exterior views
Front View
Rear View

0-3
MODEL LINEUP
■ Vehicle model lineup
Payload
New model Previous model Voltage 2
(L.C. 500 mm)
1.5 ton 7FBEF15 5FBE15 48V 3
1.6 ton 7FBEF16 − 48V
1.8 ton 7FBEF18 5FBE18 48V 0
2.0 ton 7FBEF20 − 48V
L.C.: Load center 3

0-4

1-1
DEVELOPMENT OBJECTIVE
Page 2
DEVELOPMENT OBJECTIVE ..................................... 1-2 3
FEATURES (SELLING POINTS) ................................ 1-3
MAJOR DIFFERENCES BETWEEN NEW AND
PREVIOUS MODELS ................................................. 1-9 1

1-2
DEVELOPMENT OBJECTIVE
■ Development objective
Toyota 5FBE series, 1,500-kg to 1,800-kg three-wheel, counter battery type forklift have favorably been
accepted by a large number of customers thanks to their ease of use and reliability since the model
change in 1993.
After the model changes by competitors in later years, however, disparities in specifications and
equipment compared to 7FB series and 7FBR series have been pointed out.
Growing environmental concerns in the market, on the other hand, has been adding to the importance of
battery vehicles.
■ Development concepts
Optimum material handling operation matching each customer's needs by making the most of
1
the features of AC-motor drive system.
Adoption of the SAS (mast control and steering synchronizer) developed in the 7 series and
2 highly evaluated in the market for realization of high stability comparable with that of the 7
series.
Easier ingress and egress by adoption of the open step, small-diameter steering wheel and tilt
3
steering with memory.
Addition of 1,600- and 2,000-kgf models to the 1,500- and 1,800-kgf models in the previous
4
series.
The AC drive system, especially was implemented in 1999 ahead of other companies by consolidation of
our time-tested technologies. Its features have fully been utilized not only in performances but also in
operating feel.
We propose these models as three-wheel counter battery forklift trucks without an equal in performance
and operating feel.

1-3
FEATURES (SELLING POINTS)

■ Major selling points
The greatest feature of the new models is adoption of the AC motor drive system. New features of the 7FB
series have also been adopted in many places.
2
1. Adoption of AC Motor Drive System 3
What is AC motor drive system?
The conventional DC motor drive system uses a controller for battery current chopping (ON and OFF)
to control the motor power by changing the chopping ratio to realize from inching at the time of starting
up to the maximum power.
The controller in the AC motor drive system converts the battery current to a three-phase alternate
current, whose sine wave form (frequency and waveform height) varies to control the motor power.
1
The table below compares the motor voltage, motor structure and the controller between the AC
system and DC system.
Comparison between the DC and AC systems
Motor voltage Motor structure Controller
Motor
Mean voltage
Commutator Brush M
Battery
ON ON ON
Con-
troller
DC
sys-
tem Microcomputer
Battery voltage Motor voltage
control
Contactor
• Conversion from battery DC • Need of brush and commu- • Relatively easy by mean DC
voltage into the mean volt- tator maintenance voltage control
age by the chopper • Complicated structure • Need of contactor for rotat-
ing direction change
Sine wave Motor

Stator core Stator coil
Con-
troller
Battery M
Battery voltage
AC
sys-
tem 1 Phase Microcomputer
Motor voltage control
• Conversion from battery DC • No brush and commutator • Conversion from DC into

voltage into the AC voltage (maintenance-free) three-phase AC by the mod-
by the controller • Compact and lightweight ule
• No need of contactor for
rotating direction change

1-4
Features of AC motor drive system

The table below shows three major features of the AC motor drive system. The AC motor drive system
has already been adopted in the industrial world by making the most of these features.
System feature Product feature
Realization of higher performance in the same
1 Simple, compact motor structure
product size
Realization of new control by three-phase Realization of new performance and feel thanks
2
AC control to wider motor control range
Reduction of maintenance cost for motor brush
3 No motor brush and contactor
and contactor
It has been known to worldwide forklift engineers that the AC motor drive system, as stated above, is a
very excellent system for battery forklift trucks.
Selling points of the new models fully utilizing these features are explained below.
2. Power Select Function
The performance best matching the operator can be selected by single switch operation.
The traveling performance in loaded state is improved in new models by making the most of the
simple, compact structure of the AC motor. One switch selects any of the following modes.
• Mobility-preference mode featuring the shortest cycle time (H mode)
• Efficiency-preference mode for short cycle time and long working hours (P mode)
• Operation-hour-preference mode featuring the longest operation hours with the performance
equivalent to that of previous models (S mode)
To satisfy individual customer requirements, a power control select function is provided for setting the
traveling mode by selection from six modes including H, P and S.
The operation efficiency is greatly improved by selection of the optimum performance for each
customer need like H mode selection for a job requiring the power and performance or S mode
selection for continuous operation for many hours.
Power select function
[7FBEF15]
Cycle time
(sec/cycle) [H mode] :Fixed mode
85
[P mode]
90
Previous model
[S mode]
95
180min 220min 260min 300min Operation time

(DIN 4PzS 440L)

1-5
Especially, the loaded traveling and material handling performances in the H mode have been
improved over 30%. As a result, our 30-m operation cycle time has been shortened by about 10% or
more.
1.5 ton
2
3
Lifting speed
mm/sec
65%UP
NL610 600
FL430
540
480 480 420
1
350
280
260
NL: No load
FL: Full load
H mode P mode S mode 5FBE15 STILL
Traveling speed
Km/h
NL16.5 30%UP
16.0
FL15.0 15.0 14.0
14.0 13.5
12.5 12.5
11.5
NL: No load
FL: Full load
H mode P mode S mode 5FBE15 STILL R20
Cycle time Operation time

(TOYOTA 30m operation cycles) (DIN 4PzS 440L, TOYOTA 30m operation cycles)
270
sec/cycle 11%UP min
95 95
240 230
85
91 185
H mode P mode S mode 5FBE15 H mode P mode S mode 5FBE15

1-6
3. Improved Efficient Operation Hour

The accelerator-off regeneration system is added to the AC drive system for longer operation
compared to the previous models. The power up function is also adopted for longer efficiency
operation hours.
Power keep function
(Setting to the P mode at the Efficiency-preference and the S mode for Operation-hour-preference)
The power keep function has been developed as the new control in new models for maintaining the
discharged battery performance by making use of the wider motor control range of the AC motor drive
system.
• The efficiency operation hours allowing operation without feeling performance degradation
is improved by 40% by adoption of the power keep function and extension of the operation
hours.
• The number of operation cycles without feeling performance degradation is also improved by
40%.
This new function actually improves the operation efficiency at each customer greatly.
Full load performance Low remaining battery charge warning

1.1 New model
Battery usage
1
limit range
0.9
Decrease in
performance
0.8 Previous model Lift interruption
25%UP
0.7
0% 20% 40% 60% 80% 100%
Previous model (1.5t) Battery discharge level (%)
Efficiency operation hour:2H20m
(440AH/5hr)
40%UP
Previous model (1.5t:S mode)

Efficiency operation hour:3H20m
(440AH/5hr)
However, note that efficient operation becomes hard when the battery level indicated by the battery
charge indicator becomes one bar (battery discharge to about 90%).
1.5 ton
min
350 52% UP
270 17% UP
230
7FBEF15 7FBEF15 5FBE15

S mode S mode
(DIN 5PzS550L) (DIN 4PzS440L)

1-7
4. Easy Ingress/Egress and Dwelling Ability

Easy Ingress/Egress
An open step is provided for easy ingress/egress.
The tilt steering is also provided with a memory as on the 7FB series to allow full forward tilting of the
steering column to ensure smoother ingress/egress.
Step height
Step height
Step height 545mm
430mm (21.5in)
(16.9in)
New model Previous model

Dwelling Ability
Compared to previous models, the head clearance is increased by 25 mm (0.98 in) to 1,025 mm (40.4
in).
5. Maintenance Cost Reduction
Maintenance items specific to battery vehicles are as follows:
1) Addition of distilled water for battery
2) Pump motor brush replacement
3) Pump contactor replacement in controller
4) Drive motor brush replacement
5) Drive contactor replacement in controller
Since the AC motor has no brush and contactor as explained earlier, brush replacements are
unnecessary. Depending on the operating conditions at each customer, the annual maintenance cost
can be reduced as much as 80%.
The newly adopted acceleration-off regeneration system regenerates the electrical braking energy
upon accelerator pedal release during traveling in the battery by making the most of the wider motor
control range of the AC motor drive system. This accelerator-off regeneration system not only extends
the operation hours and improves the running stability by electrical braking but also reduces the brake
load and lining wear for less brake maintenance cost.

1-8
6. Safety Functions
The new models are installed with the SAS safety functions adopted on the 7FB series to ensure
equivalent safety. Though the safety functions are summarized below, refer to the SAS Control
Equipment section for further details.
Safety Function List
Safety control Functional outline
Decreases the front tilt angle at a high fork height
Active mast front tilt angle control or under a heavy load, and increases it at a low
fork height or under a low load.
Retards the backward tilting speed at a high fork
Active mast backward tilt speed control
Mast height, and increases it at a low fork height.
con- If the key switch is in the OFF position, the lift
trol Key-lift interlock operation is disabled even when the material han-
dling lever is operated.
Forward tilting by pressing the button causes the
Automatic fork leveling control mast to be stopped automatically when the fork is
leveled.
The steering knob is not shifted during full
Steering synchronizer (EHPS)
hydraulic power steering.
EHPS: ELECTRONICALLY CONTROLLED FULLY-HYDRAULIC POWER STEERING
On three-wheel battery counter vehicles, the automatic control rear stabilizer is not provided because
of no rear wheel swing mechanism.
7. Anti-rollback
A function for easy starting on a slope (reduction of rollback on a slope) is provided.
8. Model Series
The 1.6- and 2.0-ton models have been developed anew to enrich the model line-up.
The 1.0- and 1.25-ton models have been discontinued.
Capacity (kgf)
1000 1250 1500 1600 1800 2000
7FBE
5FBE
: Continuation : New
9. Maximum battery capacity

The battery compartment length in the longitudinal direction has been widened by 87 mm on the 1.5-
ton model and 193 mm on the 1.8-ton model to accept the same DIN-size batteries for the STILL R20
on all series models.
Capacity (kgf)
1500 1600 1800 2000
7FBE 5PzS550L 6PzS660L 6PzS660L 6PzS660L
5FBE 4PzS440L 4PzS440L

1-9
MAJOR DIFFERENCES BETWEEN NEW AND PREVIOUS MODELS

−:Not applicable
New models Previous models
Item Applicable Applicable
models models
1385 mm 1.5 ton 1295 mm All models
Wheel base
1490 mm 1.6 to 2.0 ton − −
General 1070 mm 1.5 to 1.8 ton 1075 mm All models
Overall width
1125 mm 2.0 ton − −
Overall height 1980mm All models 1950mm All models
Drive motor AC: 4.9 kW × 2 All models DC: 3.3 kW × 2 All models
Motor Pump motor AC: 9.2 kW All models DC: 8 kW All models
PS motor − − DC: 0.75 kW All models
Traveling, material
Traveling/material
Main controller handling and steer- All models All models
Controller handling control
ing control
Steering controller − All models Contactor type All models
Steering synchro-
Steering system All models FHPS system All models
Traveling sys- nizer, EHPS system
tem Parking brake lever Parking brake lever
Parking brake lever All models All models
ratchet type ratchet type
18 × 7−8 1.5 to 1.8 ton 18 × 7−8-14PR 1.5 ton
Front tire
200/50-10 2.0 ton 18 × 7−8-16PR 1.8 ton
Tires
15 × 4.1/2-8(dual) 1.5 to 1.8 ton
Rear tire 16 × 6-8-10PR(dual) All models
16 × 6-8(dual) 2.0 ton
Mast control
• Active mast front
tilt angle control
• Mast backward
All models − −
SAS equip- tilt angle control
SAS specifications • Automatic fork
ment
leveling control
• Key-lift interlock
Steering synchro-
All models − −
nizer EHPS
Head clearance 1025mm All models 1000mm All models
Frame
Step height 430mm All models − −
Auxiliary Rear combination High-mount embed-
All models Add-on type All models
equipment lamp ded type

1-10

2-1
ELECTRICAL SYSTEM
Page 2
BATTERY .......................................................................... 2-2
3
MOTORS ........................................................................... 2-4
MAIN CONTROLLER .................................................... 2-10

2-2
BATTERY
■ General
1. Battery Compartment and Necessary Weight
When purchasing the battery locally, always adjust the weight to satisfy the minimum weight 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)
STD
7FBEF16 to 20 738 (29.1) ↑ ↑ 985 (2172)
7FBEF15 630 (24.8) ↑ ↑ 830 (1830)
R/O
7FBEF16 to 20 738 (29.1) ↑ ↑ 985 (2172)
R/O: Battery roll-out specifications
X
th
ng
Le
Height
Z
Y
Width

2-3
2. Battery Specifications
No batteries are provided.
Please use the batteries conforming to DIN 43 531A.
Use 320A connectors.
2
3
RIGHT LEFT
2
180
(7.1)
(9.8)
250
FRONT
-+
320A
CONNECTOR
3. Battery List
The table below shows recommended batteries.
Refer to the general description for batteries with regard to the minimum required weight.
DIN 43 531A
Installed battery Battery case
Vehicle models Voltage Capacity Dimensions mm (in)
Supplier Model
[AH/5HR] length width height
5PzS550L 550 630 (24.8) 830 (32.7) 627 (24.7)
VARTA
5PzS600Hx 600 ↑ ↑ ↑
24CYQ5 500 ↑ ↑ ↑
7FBEF15 48 OLDHAM
24CYH5 550 ↑ ↑ ↑
5PzS500 500 627 (24.7) ↑ ↑
CHLORIDE
5PzS550H 550 ↑ ↑ ↑
6PzS660L 660 738 (29.1) 830 (32.7) 627 (24.7)
VARTA
6PzS720Hx 720 ↑ ↑ ↑
24CYQ6 600 ↑ ↑ ↑
7FBEF16 to 20 48 OLDHAM
24CYH6 660 ↑ ↑ ↑
6PzS600 600 735 (28.9) ↑ ↑
CHLORIDE
6PzS660H 660 ↑ ↑ ↑

2-4
MOTORS
Drive motor
■ General
1. A compact, high-performance, maintenance-free AC induction motor optimum for battery forklift trucks
has been newly developed as the drive motor.
2. The motor is maintenance-free because it has no brush.
■ Specifications
Rated output Size
Voltage Mass
Vehicle model (kW) Type Diameter × Length
(V) kg (lb)
(60-min rating) mm (in)
7FBEF15 to 20 48 4.9 3-phase AC φ180 (7.1) × 227 (8.9) 37 (82)
■ Drive motor features

The induction motor (see the figure below) developed for the new models this time has the following
features:
• The drive unit is integrated with the motor (built-in structure) to attain a compact size.
• The iron core shape and winding are optimized for motor efficiency improvement.
• A high-precision rpm sensor for direct detection of the motor speed is adopted to realize elaborate
functions such as power select and power keep.
• A motor temperature sensor is adopted to ensure stabilized output and to prevent burning due to
overloaded use.
■ Caution
Depending on the use at each customer (continuous heavy-load operation for example), the vehicle
performance may temporarily be dropped to protect the controller and motor from overheating. This is due
to restriction of the current to the motor as a result of specified temperature detection by the temperature
sensor built in the controller or the motor. This is not an abnormality. Since the respective warning appears
on the monitoring display, stop the operation and restart after the warning indication disappears.
Length
Drive unit Field core

Field winding
Rpm sensor bearing
Diameter Rotor

2-5
■ Structure and principle of AC induction motor

The AC induction motor has no brush and commutator unlike the conventional DC motor, so there is no
sliding part. It, therefore, has the following features:
1. The motor size can be reduced by dimension L for the brush and commutator if the output is the same.
2. In the size is same, the core size can be increased by dimension L for the brush and commutator, 2
resulting in a higher output.
3. Because of less number of parts and no sliding part, it features high reliability and efficiency. For new 3
models, a new AC induction motor best suitable for forklift trucks has been developed and adopted.
AC motor (for new models) DC motor (for previous models)
Field core
Field core Field winding Field winding Brush Commutator
Rotor L
Rotor
The rotor consists of the core made up of piled thin electromagnetic steel plates through the grooves in
which aluminum conductor bars pass. Both ends of conductor bars are shorted by end rings on both sides
of the core as illustrated in (b) below. When the bars and end rings are taken off, the shape is like a cage
for a squirrel or mouse as shown in (c) below. It is therefore called a cage rotor.
(a) Core
End ring
(b) Rotor ASSY
Conductor bar
(aluminum conductor bar)
End ring
(c) Cage rotor

2-6
■ Motor operation principle

Right-hand screw rule and Fleming's rule are to be explained here before explanation on the motor
operation principle.
1. Right-hand screw rule
Raise the thumb of the right hand with other fingers Direction of
folded. When the thumb is placed in the current current
flowing direction in this state, the magnetic field is Magnetic
generated vertically to the thumb or in the direction of field
the folded fingers. Magnetic
field
Direction of
current
2. Fleming's right-hand rule

Place a linear substance in freely movable state on a Direction of
fixed material as shown at right. If the linear Magnetic field
Magnetic
substance is moved in the illustrated direction when
field
the magnetic field is generated as illustrated, an emf
current is generated in the illustrated direction. Direction of
motion
Direction of
current
Magnetic field
Direction of
Direction of motion
current
3. Fleming's left-hand rule

Place a linear substance in freely movable state on a Direction of force
fixed material as shown at right. If a current flows in Direction of
the fixed material when the magnetic field is Magnetic Magnetic field
generated as illustrated, a force is applied to the linear field
substance in the illustrated direction.
Direction of
Magnetic field current
Direction of
force
Direction of
current

2-7
Operation principle
1. When a current flows in a fixed direction in the field winding as shown below, magnetic field is
generated around the field winding as illustrated according to the right-hand screw rule and magnetic
poles (N and S poles) are generated.
2. Clockwise rotation of the magnetic poles here is the same as counterclockwise rotation of rotor bars.
3. A current is induced in each rotor bar in the illustrated direction according to Fleming's right-hand rule.
4. The induced current in each rotor bar generates a clockwise force according to Fleming's left-hand
rule.
5. A rotating torque is generated by the electromagnetic force as explained above. The rotating speed of
the rotor is slightly less than that of the filed poles.
6. Actually, the outer field winding does not move. The sine wave of each phase of the three-phase
alternate current generates a rotational magnetic field to generate a rotating torque of the rotor.
Rotational Rotational
direction direction Field winding
magnetic magnetic
Field winding of pole Magnetic field
of pole
N pole Direction
of current
Direction of
current induced
Direction in the bar
of force
Magnetic
field
Direction Rotational
of force direction of
cage rotor
Direction
S pole of current
Current flow from the rear to the front Magnetic field
Current flow from the front to the rear
Rotational direction Rotor (Field winding)
magnetic of pole

2-8
7. The rotational magnetic field is as explained below.

(1) Assume that three coils are placed on the outer side the rotor. When these three coils (a1-a2, b1-b2
and c1-c2) are connected and a three phase alternate current flows, the magnetic flux varies as
shown in the figure below to generate a 2-pole rotational magnetic field. The rotating magnetic field
makes one turn in one cycle of the three-phase AC. Since the field rotates once in one cycle of the
three-phase AC, the inner rotor also makes one turn.
Current (i) t1 t2 t3 t4
ic ia ib ic
c1
b2
a2 a1 Time (t)
ia
b1 c2
ib S S
N N
S S
N N
(2) See the internal structure of the motor. Six coils in three pairs are placed on the outer side of the
rotor. When the six coils (a1a1' - a2a2', b1b1'-b2-b2' and c1c1'-c2c2') are connected in three
phases to receive a three-phase alternate current, the magnetic flux varies as shown in the figure
below to generate a four-pole rotational magnetic field. In this case, the rotational magnetic field
makes a 1/2 turn in one cycle of the three-phase AC. In a motor with three phases of magnetic field
(using six coils in three pairs), the inner rotor can generate twice as much torque as was in the case
of a single-phase motor (using three coils).
Current (i) t1 t2 t3 t4
ia ib ic
c2 b1’
a1’ a1
ia
b2 c1’ Time (t)
c2’ b1
a2 a2’
b2’ c1 ib
S N S
N
ic S S
N N N N
S S
N N S
S

2-9
Pump motor
■ General
1. An AC induction motor most suitable for compact, high-performance, maintenance-free battery forklift
trucks is adopted newly as the pump motor just like the drive motor.
2. The motor output is increased by making use of the induction motor to improve the performance both
in loaded and unloaded states.
3. The motor is maintenance-free because of no brush.
Length
Diameter
Field core Field winding
Rpm sensor
bearing
Rotor
■ Specifications
Rated output Size
Voltage Mass
Vehicle model (kW) Type Diameter×Length
(V) kg (lb)
(5-min rating) mm (in)
7FBEF15 to 20 48 9.2 3-phase AC φ180 (7.1) × 290 (11.4) 31 (68)

2-10
MAIN CONTROLLER
■ General
AC System
This controller is multi-functional making use of most advanced electronic technologies such as inverter
control using a microcomputer, the function for CAN communication between the main controller and the
drive/pump motor driver, and the function for communication with multi-screen display.
The power select and power keep functions have been realized by making use of the AC motor drive
system features.
The traveling/material handling performance can be selected from H, P and
Power select function
S modes by operating the buttons.
The operating performance is maintained even when the battery discharge
Power keep function proceeds for longer, efficiency operation (only when the P or S mode is
selected).
AC and DC power system output

characteristics with fully charged battery
AC motor maximum output
Torque
Torque
AC power system output
AC power system output
characteristics with discharged battery
characteristics
DC power system output DC power system output
characteristics characteristics with
(DC motor maximum output) discharged battery
Rpm Rpm
The AC motor realized greater output than the DC motor in the same size.
The AC motor drive system output characteristics are determined by the combination of the alternate
current and frequency output from the controller.
Optimum combinations for multiple characteristics are mapped and stored in the controller for power
selection by map switchover.
The output characteristics of the DC motor drive system, on the other hand, are determined by the
controller output voltage itself. The characteristic of the motor itself when the battery voltage is applied
(chopper duty: 100%) is the maximum output. The performance, therefore, drops as the battery voltage
decreases.
On the other hand, the AC motor drive system maintains the performance by changing the AC current and
frequency combination according to the battery discharge level. The power keep function is thus realized.

2-11
■ Controller configuration
Traveling/Material Handling Controller System Configuration
Drive Drive motor thermo-sensor

Traveling
AC Drive rpm sensor
AC driver
motor
Drive Drive motor thermo-sensor

Traveling
AC AC driver Drive motor rpm sensor
motor
Direction switch
Traveling accelerator potentiometer
Battery Brake switch
Main
controller Tire angle sensor
Material handling switch
Pump
Material Solenoid valve
AC motor
handling
AC driver Display
Pump motor thermo-sensor
Pump motor rpm sensor
Traveling/material handling controller

2-12
Internal Configuration of Traveling/Material Handling Controller
Battery
Traveling/material handling controller
Main controller
CPU board Power supply
contactor
Cooling fan
CPU Drive
Sensors and I Traveling AC driver AC
switches /
RAM motor
O
ROM
Drive
I AC
/ Traveling AC driver
motor
O CAN
I/O
EEPROM Material handling
Pump
AC driver
AC motor
Display Solenoid
drive Lift solenoid valve
circuit
Tilt solenoid valve
Steering synchronizer
solenoid valve
Comfortable operability is CANBus

realized by making fine Controller Area Network
control using microcomputer. Bus
CPU
Central processing unit
(Central Processing Unit)
ROM
Read-only memory (Contains the control program.)
(Read-only Memory)
RAM Memory allowing reading and writing (The contents are
(Random Access Memory) erased when the power is turned off.)
EEPROM
Electrically programmable memory (Contains the data
(Electrically Erasable, Programmable
required for control and error codes.)
Read-only Memory)
I/O
Input/output interface
(Input/Output)
CANI/O
(Controller Area Network Input/Output CAN input/output interface
interface)

2-13
■ Major controller functions

1. Two traveling motor control
Two independent AC drive systems are adopted for controlling the motors for front wheels LH and RH.
The outputs from motors LH and RH are controlled according to the steering angle for smooth
operation.
2. Accelerator-off regeneration braking
Regeneration braking is provided to regenerate the electrical braking energy into the battery when the
accelerator pedal is released during traveling. This will extend the operable hours, lengthen the brake
lining life and realizes easy, stable traveling with engine-brake-like feel. This function is active even
when the direction switch is in the neutral position.
3. Brake Pedal Regeneration Braking
Regeneration braking also functions upon ordinary braking to extend the operable hours and lengthen
the brake lining life. This function is active even when the direction switch is in the neutral position.
4. Switch-back regeneration braking
Regenerating braking also functions at the time of switch-back operation.
Smoother operation feel is obtained than on previous models.
5. Power keep function
The performance is maintained even when battery discharge proceeds for longer efficiency operation
hours. (Only when the P or S mode is selected.)
6. Power select function
The traveling/material handling mode is selectable from H, P and S by button operation on the multi-
screen display.
7. Power control select function
The traveling/material handling performance mode setting and performance setting to other than H, P
and S are possible by operation on the multi-screen display.
8. Auto-off function
If the vehicle is left with the key switch kept at the ON position, the controller forcibly turn the key
switch off for power saving. To use the vehicle again, turn the key switch to OFF and ON.
9. Deadman Switch Function
Traveling is disabled while the operator is not on the seat.
10. Anti-rollback function
The anti-rollback function is provided for easier starting on a slope.
11. Traveling speed limiter
The traveling speed is limited to the maximum level set with the multi-screen display.
12. Thermal protector
The temperature sensor installed in each controller/motor informs the operator of temperature rise to
the specified level by indication on the multi-screen display and restricts the controller output for
protection.
13. Remaining battery charge calculating function
The battery voltage drop by discharge is detected and calculated by the controller for indication of the
remaining charge on the multi-screen display.
14. Diagnosis function
Any abnormality in the operating systems like the motor driver and accelerator or any sensor
abnormality is detected for indication by respective code on the multi-screen display, and a necessary
action is taken.
15. Analyzer function
When the multi-screen display is in the analyzer mode, defective part detection and functional check of
each operating system and motor driver are possible.
16. Over-discharge warning function
When the remaining battery charge drops below the specified level, it warns on the multi-screen
display and material handling during traveling is disabled. This function protects the battery and inform
the operator of the need to charge the battery.

2-14
17. Return-to-neutral function

When the direction lever is in the forward or reverse position or when the key switch is turned on while
the accelerator pedal is depressed, traveling is disabled unless the direction lever and accelerator
pedal are returned to their neutral positions.
18. Parking brake ON alarm
An alarm tone sounds when traveling is attempted without releasing the parking brake.
19. Parking Brake OFF Warning
Warning alarm sounds if the operator leaves the seat without applying the parking brake.

3-1
POWER TRAIN
Page 2
DRIVE UNIT...................................................................... 3-2
3

3-2
DRIVE UNIT
■ Difference from previous models
The drive unit size has been reduced by changing the train of gears from that on previous models, and the
motors LH and RH are arranged transversely on the same axis.
■ General
1. The drive unit adopted for new models has transversely installed traveling motors similarly as on
previous models.
2. Changing the gear train from the previous 4-axis, 3-stage to the 2-axis, 2-stage reduction mechanism
with semi-built-in traveling motors has reduced the drive unit size.
3. Hypoid gear oil (API: GL-4, SAE: 75W-85W) is adopted as the common lubricant for all models (same
as for previous models).
■ Structure
Gears
• First-stage reduction adopts the helical gear featuring high transmission efficiency.
• Second-stage reduction adopts the planetary gear featuring high space efficiency.
Reduction ratio New models Previous models
All models 27.040 17.482
■ Drive unit structural drawing
Drive motor
First axis
(Motor input shaft)
Helical gear
Planetary gear
Second axis
(Front axle shaft)

4-1
TRAVELING, STEERING AND BRAKE SYSTEMS
Page 2
ACCELERATOR .............................................................. 4-2
3
REAR AXLE ..................................................................... 4-3
TIRES ................................................................................. 4-4
STEERING ........................................................................ 4-6
BRAKE .............................................................................. 4-10

4-2
ACCELERATOR
■ Standard Pedal
The accelerator is mounted on the front protector bracket.
A plastic pedal is adopted as on the conventional models for smooth start in depression.
The pedal effort is decreased from 1.5 kg to 0.7 kg by revising the accelerator structure.
■ D2 pedal (option)
The accelerator pedal and the direction switch are integrated.
This pedal allows quick, smooth control of the vehicle speed and changeover between forward and
reverse traveling directions. The traveling direction can be changed without freeing one hand from the
steering wheel.

4-3
REAR AXLE
■ General
Double tires are installed as the standard feature for rear wheels of all vehicle models for longer tire life.
2
3

4-4
TIRES
■ General
1. Pneumatic shaped cushion (PSC) tires are adopted as standard tires.
The table below shows standard tires.
2. Pneumatic tires are adopted optionally for the 1.5- to 1.8-ton models.
3. See the OPTION LIST for details of the optional tires.
Standard Tire Setting List
Front tire
Vehicle Tire pressure
Type Tire size Rim size
model kPa(kgf/cm2)[psi]
7FBEF15 PSC 18×7-8/4.33 SOLID 4.33R-8 −
7FBEF16 PSC 18×7-8/4.33 SOLID 4.33R-8 −
7FBEF18 PSC 18×7-8/4.33 SOLID 4.33R-8 −
7FBEF20 PSC 200/50-10/6.50 SOLID 6.50F-10 −
Rear tire
Vehicle Tire pressure
Type Tire size Rim size
model kPa(kgf/cm2)[psi]
7FBEF15 PSC 15×41/2-8/3.00 SOLID 3.00D-8 −
1/2
7FBEF16 PSC 15×4 -8/3.00 SOLID 3.00D-8 −
7FBEF18 PSC 15×41/2-8/3.00 SOLID 3.00D-8 −
7FBEF20 PSC 16×6-8/4.33 SOLID 4.33R-8 −
■ Notes
• Wheels of new models are not interchangeable with those of previous models.
• The allowable load may vary when the tire type is changed. See the load table for details.
• When color tires are adopted, install tire bands because static electricity is likely to be generated in the
vehicle by the use on resin-coated floor or roads with high friction.

4-5
■ Option list
Front Tire
Model
Tire name Tire
specification
Tire size
Wheel
specification
Wheel
size
7FBEF15 7FBEF16 7FBEF18 7FBEF20
Tire
brand 2
FR
U-LUG
Tire
18×7−8/4.33 Sidering 4.33R-8 STD STD STD WATTS 3
U-LUG 200/50-10/
FR Sidering 6.50F-10 STD WATTS
Pneumatic Tire 6.50
shaped cushion J-LUG
FR 18×7−8/4.33 Sidering 4.33R-8 F01B F01B F01B WATTS
Tire
J-LUG 200/50-10/
FR Sidering 6.50F-10 F01B WATTS
Tire 6.50
J-LUG 18×7−8-
FR Sidering 4.33R-8 F01J WATTS
Tire 14PR
Pneumatic
J-LUG 18×7−8-
FR Sidering 4.33R-8 F01J F01J WATTS
Tire 16PR
Pneumatic U-LUG
FR 18×7−8/4.33 Sidering 4.33R-8 F01K F01K F01K WATTS
shaped cushion Tire
nonmarking
white FR
U-LUG
Tire
200/50-10/
6.50
Sidering 6.50F-10 F01K WATTS
4
Rear Tire
Model
Tire
Tire name Tire Wheel Wheel
Tire size 7FBEF15 7FBEF16 7FBEF18 7FBEF20 brand
specification specification size
U-LUG 15×4.1/2−8/
RR Sidering 3.00D-8 STD STD STD WATTS
Tire 3.00
U-LUG
RR 16×6−8/4.33 Sidering 4.33R-8 STD WATTS
Pneumatic Tire
shaped cushion J-LUG 15×4.1/2−8/
RR Sidering 3.00D-8 F41A F41A F41A WATTS
Tire 3.00
J-LUG
RR 16×6−8/4.33 Sidering 4.33R-8 F41A WATTS
Tire
J-LUG 15×4.1/2−8-
Pneumatic RR Sidering 3.00D-8 F41J F41J F41J WATTS
Tire 12PR
Pneumatic U-LUG 15×4.1/2−8/
RR Sidering 3.00D-8 F41K F41K F41K WATTS
shaped cushion Tire 3.00
nonmarking U-LUG
white RR 16×6−8/4.33 Sidering 4.33R-8 F41K WATTS
Tire

4-6
STEERING
Steering system
■ General
Power Steering System
Full hydraulic steering system is adopted as the standard as on the previous models.
The power steering system on the previous models has used an exclusive motor pump to supply hydraulic
oil to the power steering system.
On the new models, the hydraulic oil from the oil pump is shunted by the priority valve to supply hydraulic
oil at an appropriate pressure to each power system.
Solenoid valve
Steering valve
Oil control valve

Oil pump
Priority valve
Rear axle cylinder
Rear axle
Oil tank

4-7
Priority valve
■ Operation
When the key switch is OFF
The spool in the priority valve is located to the left of the control spring.
P (Oil pump)
Spool
Control spring
When no steering operation is performed

Hydraulic oil flows from the pump through the spool to PP and LS pilot line.
As the CF line in the steering valve is shut and the pilot line is drained, internal pressure of CF goes
through inside the spool to PP and to the LH chamber, pushing the spool to the right side of the figure.

4-8
As the spool is pushed to the right side, the EF line circuit opens, allowing almost all the pump discharge to
flow from the EF line to the control valve.
When steering operation is performed

Turning the steering wheel opens the control orifice in the steering valve and opens the CF line.
The lower side pressure of the control orifice goes through the LS pilot line to the RH chamber, generating
the pressure difference with the LH chamber in which the pressure is equal to that of the upper control
orifice. The pressure difference differs depending on the opening of the control orifice (steering speed).
The spool is operated by this pressure difference to divide some pressure from the pump and supply
adequate hydraulic oil to the steering valve.

4-9
Steering system
■ General
The rack and pinion of the turning drive portion in the full hydraulic power steering system are made
compact with integration. Removal and installation of the rear axle including the rack and pinion have
become easier.
Previous
Pinion
PS cylinder
PS cylinder
New model
Pinion
Steering wheel
■ General
1. The steering wheel outside diameter is changed from 380 mm (15.0 in) to 360 mm (14.2 in) for easier
operation.
2. Tilt steering with memory is adopted.
3. Since the steering tilt angle is memorized when the steering column is raised and returned to the
original position, no re-setting is necessary.
4. The steering wheel adjustable angle is widened from 6° on the previous models to 9°.

4-10
BRAKE
Brake pedal
■ General
1. The brake structure is changed from the hydraulic to the mechanical type on all models.
2. The pendant pedal link structure is adopted as on the previous models.
■ The regenerative brake
The regenerative brake sensor use a limit switch not only to improve the sensor system reliability but also
to facilitate maintenance when readjustment of the regenerative brake becomes necessary.
Sensor for regenerative brake
Brake pedal

4-11
Front brake
■ General
Hydraulic parts such as the master cylinder are discontinued by adoption of mechanical disc brake that
has excellent maintainability.
■ Brake specifocations
Foot brake Mechanical disc brake
Type
Parking brake Mechanical disc brake
Brake disc outside diameter mm (in) 203 (8.0)
Brake effective diameter mm (in) 165 (6.5)
Material Semi-metallic phenol resin
Outside diameter: R100 (3.94) × Inside diameter:
Brake pad Dimension mm (in)
R65 (2.56) × Thickness: 6(0.24)
Area mm2 (in2) 3528 (5.47) × 2 × 2
Brake ASSY
Motor & Drive unit
Brake disc

4-12
Parking brake
■ General
The lever type (ratchet type) is adopted as on previous models. The grip portion is shaped for easy
gripping.
Previous model New model
■ Structure
When the brake lever is pulled from position A to position B in the figure below, the disc brake is
mechanically applied through a wire cable.
■ Operation method
1. Grip the knob and pull the lever from position A to
Release button
position B to apply the parking brake.
2. For releasing, throw the lever from position B to
Position A
position A while pressing the release button in the
illustration. Position B
■ Lever operating force

Lever operating force N(kgf) 100~200 (10.2~20.4)
* The figure above is maximized at the position when the lever is pulled about 35° from position A above.

5-1
INSTRUMENTS
Page
MULTIPLE DISPLAY ...................................................... 5-2 2
GENERAL FUNCTIONS ............................................... 5-10
3
DIAGNOSIS ...................................................................... 5-15
MASK FUNCTIONS ....................................................... 5-21

5-2
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

5-3
(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 2
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same
time, the corresponding error code is displayed and buzzer sounds to warn the operator.
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to
3
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
warn the service person. Perform matching by referring to the MATCHING section.
(4) Overheat warning indicator
If the temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or
pump motor rises beyond the specified level, the overheat warning indicator blinks. At the same time,
a buzzer sounds to warn the operator.
When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks.
Display Information
Overheat warning indicator

Display information
C/R
Overheat section
Main controller
5
3 0 / 9 AM DCR Traveling AC driver
11 : 00
S P H
S P H PCR Material handling AC driver
MENU
DM Drive motor
PM Pump motor
Overheat section
Vehicle Operation Restriction when Overheated

Overheat Specifica- Description of control
Mode
section tion Primary control Secondary control Tertiary control
STD · H 1. Character indication and indicator blink
Main
Fisherman P 2. Buzzer for 5 seconds
controller
spec (OPT) S 3. Change to half throttle
STD · H 1. Character indication and indicator blink

Traveling
Fisherman P 2. Buzzer for 5 seconds
AC driver
spec (OPT) S 3. Change to half throttle
Material STD · H 1. Character indication and indicator blink

handling Fisherman P 2. Buzzer for 5 seconds
AC driver spec (OPT) S 3. Restrict material handling output

5-4
Overheat Specifica- Description of control

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

5-5
(5) Battery charge indicator

This indicator indicates the remaining battery charge in 10 stages.
A: Low remaining battery charge warning
The battery charge indicator blinks when the remaining battery charge drops to the set level or below.
When the key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to warn the
operator.
B: Battery overdischarge warning (lift interrupt function)
When the battery charge decreases further below the set level after the remaining battery charge
2
warning, any attempt at traveling or material handling operation will cause all charge indicator
segments to blink and the alarm to sound to warn the operator. In this case, material handling during 3
traveling cannot be performed.
Note:
The level can be set using TUNING function of the mask function. (See page 5-45.)
Low remaining battery charge warning Battery overdischarge warning
3 0 / 9 AM 3 0 / 9 AM
11 : 00 11 : 00
S P H S P H
S P H S P H
MENU MENU
Number of segments corresponding to All battery charge indicator segments blink.

the remaining battery charge.
5
(6) Power select Indicator (traveling and material handling)
A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by
pressing the power select button on the GENERAL screen.
If all symbols are enclosed, control is performed in the original mode (level set on the POWER
CONTROL LEVEL SETTING screen).
(7) Multiple display area
The date and time are normally displayed in this area. This area is also used for various function
settings and error code displays of the diagnosis function.
(8) 2-speed travel speed control
Press this button on the GENERAL screen to set the 2-speed travel speed on and off.
(9) Hour meter selector button
This button changes displayed items of multi-hour meter function. The built-in function is different on
the easy model (standard vehicle) and the all-round model (OPT). (See page 5-9.)
(10) Power select button
The button selects S, P or H mode. The selected mode can be changed each time the power select
button is pressed on the GENERAL screen.
Press the button and hold it for 2 seconds to set the level of each function.

5-6
(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.
Display information
Display information Low temperature section

COL D AM
DCR 11 : 00 COLD DCR Traveling AC driver
S P H
S P H
MENU COLD PCR Material handling AC driver
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
S P H
• Speedometer can not be displayed when wheel 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)

5-7
■ 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

5-8
■ Abbreviations display 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 Traveling AC driver control board
K-DIFF TBD
position 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

5-9
■ General functions
1. General functions 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:
{: General function :Not provided
Model
Functions Easy model All-round model
(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 Traveling or Material handling hour meter  {
meter
function Odometer  {
Lap time meter  {
Trip meter  {
Calendar · clock { {
Battery overdischarge warning { {
Low remaining battery charge warning { {
Overheat warning { {
Low temperature warning { {
Warning func- Parking brake ON warning { {

tion 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).

5-10
GENERAL FUNCTIONS
■ Changing Display
Button (1) Button (2)
2-speed travel speed

ON/OFF setting
GENERAL screen
3 0 / 9 AM
11 : 00 Hour meter display
S P H
S P H selection
MENU
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 S P E E D The easy model does not
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
S P H
screen 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.

5-11
■ Operating procedure of function setting

GENERAL screen
1. 2-speed travel speed on/off selection
Press button (1) for 2-speed travel speed control on/
off. The 2-speed travel speed is on if the indicator 2-speed travel speed indicator
comes on. Button (1)
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 T R I P 1 2 3 4 5. 0
11 : 00 RE S E T 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
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 . 0
S P H S P H
S P H S P H
MENU
Press MENU
button (2)
The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.
Press button (3) on each screen to return to the GENERAL screen.

5-12
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 3 0 / 9 AM
11 : 00
control is performed in the mode set on the Power S P H
S P H
Control Level SETTING screen. MENU
S: Standard mode
P: Power mode
H: High power mode Button (3)
Power select indicator
2-SPEED TRAVEL SPEED LEVEL SETTING screen

The 2-speed travel speed level is set on this screen.
Press button (3) on the general screen for 2 seconds or Blinks upon 2-speed travel Button (1)
more to display the 2-SPEED TRAVEL SPEED LEVEL speed level setting. Button (2)
SETTING screen.
1. Press button (1) to decrease the 2-speed travel speed
level.
2. Press button (2) to increase the 2-speed travel speed 1 5 8
level. S P H
S P H
3. Press button (3) to display the next screen. MENU
2-speed travel speed level Button (3)
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 Button (1) Button (2)
LEVEL SETTING screen to display the OVERSPEED
ALARM SETTING screen.
1. Press button (1) to decrease the traveling speed
setting.
2. Press button (2) to increase the traveling speed
10Km / h
S P H
S P H
setting. MENU
3. Press button (3) to display the next screen.

Button (3)
Traveling speed setting
for overspeed alarm

5-13
POWER CONTROL FUNCTION SELECTION screen

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

S P H
S P H
MENU
2) Press button (2) to select the higher level.

3) Press button (3) to display MATERIAL
Button (3)
HANDLING POWER CONTROL LEVEL
Select "YES" and
SETTING screen.
press button (3)
(2) MATERIAL HANDLING POWER CONTROL
TRAVELING POWER CONTROL
LEVEL SETTING screen
LEVEL SETTING screen
1) Press button (1) to select the lower level.
2) Press button (1) to select the higher level.
3) Press button (3) to display the next screen.
S P H
2. To display the next screen, press button (2) on the
POWER CONTROL FUNCTION SELECTION screen, S P H
S P H
MENU
select “NO” and press button (3); alternatively, press

button (3) on the MATERIAL HANDLING POWER
CONTROL LEVEL SETTING screen. Press button (3)
MATERIAL HANDLING POWER
CONTROL LEVEL SETTING screen
S PH
S P H
S P H
MENU
Press button (3)

CLOCK SET FUNCTION
SELECTION screen

5-14
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 DISPLAY FUNCTION SELECTION screen, select “YES” and press
button (3) to display the CLOCK SET screen.
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).

5-15
DIAGNOSIS
1. When diagnosis is activated, the diagnosis ON
indicator comes on and blinks on the screen and a Wrench symbol
beep sounds to warn the operator that some
abnormality has occurred on the vehicle.
2. Also, up to three diagnosis error codes are displayed A1 1 A1 2 A1 3
1 2 3 4 5 . Oh
on the screen. When the number of error codes S P H
S P H
exceeds three, up to six are displayed on screens. MENU
3. In order to enable battery level checking, battery

charge indicator is displayed during diagnosis error Diagnosis codes
codes display. Abnormality detection time
(Key ON hour meter)
■ Diagnosis code list

Displayed code: Code indicated on the display when an abnormality occurs in the vehicle
Diag memory code: Code indicated on the display when mask function DIAG MEMORY is in use P5-30
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
Communication abnormality from C/R to
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 for-
ward tilt restriction C/R
61-2 61-2 Load sensor: Short circuit
·No automatic leveling
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

5-16
Diag
Displayed Detection
code controller
code
Forward and backward tilt SWs:
63-1 63-1
simultaneously on
·No forward tilt restriction
Forward tilt SW: Short circuit for more than 2
63-2 63-2 ·No automatic leveling C/R
minutes
(Forward tilt disabled)
Backward tilt SW: Short circuit for more than
63-3 63-3
2 minutes
64-1 64-1 Lift solenoid: Open
Interruption of lift sole-
64-2 64-2 Lift solenoid: Short circuit C/R
noid output
64-3 64-3 Lift solenoid: Drive circuit abnormality
65-1 65-1 Tilt solenoid: Open
Interruption of tilt sole-
65-2 65-2 Tilt solenoid: Short circuit C/R
noid output
65-3 65-3 Tilt solenoid: Drive circuit abnormality
·No forward tilt restriction
66-1 66-1 Tilt matching abnormality C/R
·No low lift restriction and
67-1 67-1 Lifting height switch abnormality forward tilt restriction C/R
71-1 71-1 Tire angle sensor: Open Traveling stop, no steer-
C/R
71-2 71-2 Tire angle sensor: Short circuit ing knob synchronizer
72-1 72-1 Steering angle sensor: STS1 abnormality
72-2 72-2 Steering angle sensor: STS2 abnormality No steering knob syn-
C/R
72-3 72-3 Steering angle sensor: STSC abnormality chronizer
72-4 72-4 Steering angle sensor: Open
73-1 73-1 Steering knob synchronizer solenoid: Open
Steering knob synchronizer solenoid: Short
73-2 73-2 Steering knob synchro-
circuit C/R
nizer solenoid output stop
Steering knob synchronizer solenoid:
73-3 73-3
Drive circuit abnormality
Traveling restriction,
74-1 74-1 Tire angle sensor matching abnormality C/R
no steering synchronizer
Restricted traveling out- DCR_LH,

A0-1 DCR main drive circuit overheat
put DCR_RH
Restricted material
A0-2 PCR main drive circuit overheat PCR
handling output
·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

5-17
Diag
Displayed Detection
code controller
code
Restricted traveling out-

A2-1 CPU board overheat C/R
put
Restricted traveling out- DCR_LH,

A2-2 DCR_LH or DCR_RH board overheat
put 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
Material handling dis-
A6-3 A6-3 Tilt switch abnormality C/R
abled
A6-5 A6-5 Attachment switch 1 abnormality
AA-1 AA-1 CPU board thermo-sensor abnormality C/R
Restricted traveling out-
AA-2 AA-2 DCR_L board thermo-sensor abnormality DCR_LH
put
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 to
AD-1 AD-1 Traveling disabled C/R
C/R (1)
Traveling disabled
Communication abnormality from DCR_L to (when AD-4 and AD-6
AD-2 AD-2 C/R
C/R (2) occur at the same time,
MB not turned on)
Communication abnormality from DCR_R to
AD-3 AD-3 Traveling disabled C/R
C/R (1)
Traveling disabled
Communication abnormality from DCR_R to (when AD-2 and AD-6
AD-4 AD-4 C/R
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)

5-18
Diag
Displayed Detection
code controller
code
AF-1 AF-1 CPU abnormality (1) ·Traveling disabled
AF-2 AF-2 CPU abnormality (2) ·Material handling dis-
C/R
AF-3 AF-3 CPU abnormality (3) abled
AF-4 AF-4 CPU abnormality (4) ·Power steering disabled
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
Restricted traveling out- DCR_RH
put
C2-2 C2-2 Drive motor 1 thermo-sensor abnormality DCR_LH
C2-3 C2-3 Drive motor 2 thermo-sensor abnormality DCR_RH
DCR_LH main drive circuit thermo-sensor
C3-1 C3-1 DCR_LH
abnormality Restricted traveling out-
DCR_RH main drive circuit thermo-sensor put
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 Restricted traveling out- DCR_LH
C8-2 C8-2 Drive motor 2 rpm sensor abnormality put DCR_RH
CB-1 CB-1 MB contactor abnormality C/R
(solenoid off)
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 PCR
abled
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)

5-19
Diag
Displayed Detection
code controller
code
EF-1 EF-1 EEPROM abnormality (1) Operate under the default
C/R
EF-3 EF-3 CPU abnormality Display only
Communication abnormality from C/R to dis-
F1-1 F1-1
play (1)
Display only Display
Communication abnormality from C/R to dis-
F1-2 F1-2
play (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
H3-1 *1 H3-1 Attachment 1 potentiometer abnormality (1)
Attachment 1 operation
Attachment 1 potentiometer neutral abnor- C/R
H3-4 *1 H3-4 stop
mality
Attachment 1 potentiometer matching
H3-5 *1 H3-5
abnormality
Attachment 2 potentiometer neutral abnor- C/R
H4-4 *1 H4-4 stop
mality
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)
abled
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)
abled
H5-5 *1 H5-5 Lift solenoid drive circuit abnormality
abled

5-20
Diag
Displayed Detection
code controller
code
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)
abled
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)
abled
H6-5 *1 H6-5 Tilt solenoid drive circuit abnormality
abled
H7-1 *1 H7-1 Attachment 1 a3 solenoid abnormality (1)
stop
abled
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)
abled
Attachment 1 solenoid drive circuit abnor- Material handling dis-
H7-5 *1 H7-5
mality abled
stop
abled
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)
abled
Attachment 2 solenoid drive circuit abnor- Material handling dis-
H8-5 *1 H8-5
mality abled
H9-1 *1 H9-1 Unload valve solenoid open
H9-2 *1 H9-2 Unload valve solenoid short Material handling dis-
C/R
Unload valve solenoid drive circuit abnor- abled
H9-3 *1 H9-3
mality
*1: Only on the vehicle with the mini lever (OPT).

5-21
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 by
Tuning 
and material handling functions. *2 customer
Specification Sets each vehicle option and other {
 
setting specifications. *1 *2 · *3
Each control
Enables or disables each control {
function  
function. *2 · *3
enable/disable
Option
set Hour meter {
Starts the hour meter count. { 
start *3
Enables or disables the demo
Upon new
mode. (Material handling prohibi-
Demo mode   vehicle
tion during traveling for vehicle
demonstration
delivery)
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

5-22
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 5-23.)

5-23
■ Password
Notes 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 Ve D* . * C* .
11 : 00 T L * . * TR* . * 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 3 0 / 9 AM
11 : 00 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 Response from the vehicle

1 Press buttons (1) and (2) at the same time. A short beep sounds.
Press button (1) (in 10 seconds after pressing button (1) and
2 A short beep sounds.
(2))
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 A short beep sounds.
of password input)
5 The VERSION screen is displayed automatically.
After displaying the VERSION screen for 3 seconds, the MASK MENU screen appears auto-
6
matically.

5-24
Operation on MASK MENU screen

Caution:
Unlike the analyzer function selection on of previous models, display of test screen does not
prohibit the vehicle’s ordinary operation.
1. Input the password on the general screen (see page 5-23) 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 setting screen for each function.
(1) ANALYZER screen
This screen displays the vehicle’s electrical system operating status and the error code detected by
the controller.
(2) TUNING screen
Performs fine adjustment of traveling and material handling control.
(3) OPTION SET screen
Matches the controller or display control according to the set option or control.
(4) MATCHING screen
This screen is for updating the sensor output voltage stored in the controller (output voltage values
from the SAS function and mini lever function sensors in the standard vehicle condition).
(5) WHEEL DIA screen
Updates the tire information in the controller to correct the speed and trip meter display.
(6) END screen
GENERAL screen can displayed from this screen.
Press button (3) on this screen to display the GENERAL screen.
As an alternative method, turn the key switch to OFF when any screen is displayed to display the
general screen.
Version screen GENERAL screen

Button (2)
Button (1) Press Button (3)
= ME NU= = ME NU=
1 . ANAL YZ ER 6 . END
S P H S P H
S P H S P H
MENU MENU
Button (3)
Press Button (1) or Press Button (1) or

(2) to switch screen. (2) to switch screen.
= ME NU= = ME NU=
2 . T U N I NG 5 . WH E E L D I A
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.
= ME NU= = ME NU=
3 . OP T I ON SE T 4 . MA T C H I N G
S P H S P H
S P H S P H
MENU
Press Button (1) or MENU
(2) to switch screen.

5-25
■ 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 voltage 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.

5-26
Analyzer menu screen list

*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 code 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
I/O MONITOR1 material handling AC driver board tempera-
I/O 1-6 TBP: +25
2 (Voltage/ ture: °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 Voltage after MB contactor: V
Traveling AC driver 1 DC_BUS voltage: V
I/O 1-12 VBBD: 50/50
Traveling AC driver 2 DC_BUS voltage: V
Material handling AC driver DC_BUS voltage:
I/O 1-13 VBBP: 50
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)
I/O MONITOR2 LSB: 1 Brake switch: 0 (OFF), 1 (ON)
I/O 2-3
3 (Traveling LSD: 1 Seat switch: 0 (OFF), 1 (ON)
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: mph or km/h

5-27

Meaning
L: −.−− −.−− 1− Lift switch: 0 (OFF), 1 (ON)
Lift lever angle 1 sensor voltage: V
I/O 3-1 *1 Lift lever angle 2 sensor voltage: V
L:0.90 3.50 10 Lift raise switch: 0 (OFF), 1 (ON)
Lift lower switch: 0 (OFF), 1 (ON)
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)
I/O MONITOR3 Attachment 1 lever angle 1 sensor voltage: V
(material handling I/O 3-5 *2 Attachment 1 lever angle 2 sensor voltage: V
4
system and mast A1:0.90 3.50 01 Attachment 1 raise switch: 0 (OFF), 1 (ON)
control) Attachment 1 lower switch: 0 (OFF), 1 (ON)
A1 (SOL):−.−− Unused
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)

5-28

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)
I/O MONITOR4 (150)
5 (Steering Deviation of steering angle knob position
control) 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
ACTIVE TEST (0) signal:
6 0 (normal), 1 (error)
(operation test)
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)

5-29
Operation procedure
1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Check that “1. ANALYZER” is displayed 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

5-30
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.
Operation Procedure
1. Display the ANALYZE MENU screen. Button (1)
2. Check that “1. DIAG MEMORY” is displayed and
press button (3) (enter). Past diagnosis codes are ANALYZER MENU screen Button (2)
displayed sequentially starting with the newest one.
3. Functions of buttons on the 1. DIAG MEMORY screen
are as follows:
= AN L ME NU=
1 . D I AG ME MOR Y
Button (1): Unused S P H

S P H
Button (2): Unused

MENU
Button (3): Displays past diagnosis codes

*: Button (3)
• Press button (3) on the DIAG-10 screen to display the Press button (3)
ANALYZER MENU screen.
• When no error codes are displayed on the screen and
the hour meter time is “0.0h”, it indicates that no error I A 1
codes are stored in the memory. A1 1 1 2 3 4 5 . 6 h
S P H
• Other screen cannot be displayed from DIAG S P H
MENU
MEMORY screen. Display ANALYZER MENU screen

to display other screen.
*: For the details of diagnosis error codes, see Key ON hour meter
DIAGNOSIS CODE LIST on P5-15. Press button (3)
I A 2
A1 2 1 2 3 4 5 . 6 h
S P H
S P H
MENU
Press button (3)
I A 3
0 . 0 h
S P H
S P H
MENU
No error occurrence
is indicated Press button (3)
I A 1 0
0 . 0 h
S P H
S P H
MENU
Press button (3)

ANALYZER MENU screen

5-31
Vehicle Abnormalities Not Stored in Diagnosis 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 for- warning indicator
1
ward or reverse position and the vehicle travels blinks
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. (Warns even when Short beeps
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 5-45.) 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 posi- Short beeps
tion.
Material handling lock (OPT):
When the operator leaves the seat while operat-
• Beep
5 ing the mini lever and then sits down again, a No display
Short beeps
buzzer sounds to warn the operator and the mate-
rial 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)

5-32
I/O monitor
This function displays the analog input voltage from each
Activated Detected error code
of traveling, material handling and SAS sensors. at present
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 code on the screen. 
+ 2 5 / + 2 5
S P H
S P H
MENU
Description of activated function
I/O monitor 1
This function displays the temperature of each electrical functional part and the voltage at the respective
terminal.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press button (2).
3. Check that “2. I/O MONITOR1” is displayed and press Button (1)
button (3) (enter). I/O monitor function (1) is activated ANALYZER MENU screen Button (2)
and I/O 1-1 to I/O 1-13 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR1 screen = AN L ME NU=
are as follows:
S P H
S P H
Button (1): Unused MENU
Button (2): Unused

Button (3): Displays I/O 1-1 to I/O 1-13 screens Button (3)
sequentially Press button (3)
*: Press button (3) on the I/O 1-13 screen to display the
ANALYZER MENU screen. (1) I/O 1-1 screen
Other screen cannot be displayed from I/O MONITOR1
screen.
Display ANALYZER MENU screen to display other
I / O1 1
screen. T HCD + 2 5 / + 2 5
(1) I/O 1-1 screen S P H

S P H
MENU
THCD: Main drive circuit (1) (2) temperature (°C)

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

S P H
S P H
MENU
displayed.
• Checks if the temperature measurement function is
• The temperatures at the time of measurement are Press button (3)
displayed. I/O 1-3 screen

5-33
(3) I/O 1-3 screen

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

MENU
Temperature of the pump motor is displayed.

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

displayed.
(7) I/O 1-7 screen Press button (3)
(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
functioning properly. S P H
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
V B 4 8 5 0 . 0
S P H
S P H
MENU
Press button (3)

I/O 1-9 screen

5-34
(9) I/O 1-9 screen

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

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

S P H
displayed.
MENU
Standard: 48 V
Press button (3)
VBBP: Main pump motor circuit voltage (V) (11) I/O 1-11 screen
Voltage of the main pump motor circuit is displayed.
Standard: 48 V
I / O 1 1 1
V BMB 5 0
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)


5-35
I/O monitor 2
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing
control.
Operation procedure
2. Press button (2) twice.
3. Check that “3. I/O MONITOR2” is displayed and press
button (3) (enter). I/O monitor function (2) is activated
4. Functions of buttons on the I/O MONITOR2 screen
are as follows: Button (1)
Button (1): Unused
ANALYZER MENU screen Button (2)
Button (2): Unused
Button (3): Displays I/O 2-1 to I/O 2-6 screens
sequentially
= AN L ME NU=
*:Press button (3) on the I/O 2-6 screen to display the 3 . I / O MON I TOR 2
ANALYZER MENU screen. S P H

S P H
MENU

screen.
Display ANALYZER MENU screen to display other Button (3)
screen Press button (3)
(1) I/O 2-1 screen (1) I/O 2-1 screen
POTA: Accelerator potentiometer voltage (V)
A: When the accelerator pedal is released
(SWAC: OFF) 
P O T A 0 . 7 1 S WA C 0
Standard: 0.3 to 2.4 V S P H
S P H
B: Standard voltage when the accelerator pedal is MENU
depressed to its stroke end

Standard: 1.7 to 4.7 V
B - A = 1.4 V or above Press button (3)
SWAC: Accelerator switch I/O 2-2 screen
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.

5-36
(2) I/O 2-2 screen

Direction switch inspection.
I/O 2-1screen
DSF: Forward traveling switch
DSR: Reverse traveling switch
Button (2)
Indication Button (1)
Operation (2) I/O 2-2 screen
DSF DSR
Forward traveling 1 (=ON) 0 (=OFF)
Neutral 0 (=OFF) 0 (=OFF) 2 >
< I / 0 2
DS F 0 DSR 1
S P H
Reverse traveling 0 (=OFF) 1 (=ON) S P H
MENU
Operate the direction lever to judge switch ON/OFF

quality. Button (3)
Press button (3)
(3) I/O 2-3 screen
• LSB: Brake switch inspection (3) I/O 2-3 screen
When the brake pedal is released
LSB: 1 = ON
When the brake pedal is depressed 
L SD 1
LSB: 0 = OFF S P H
S P H
Operate the brake pedal to judge switch ON/OFF

MENU
quality.
• LSD: Deadman seat check
When the seat is occupied Press button (3)
LSD: 1 = ON (4) I/O 2-4 screen
When the seat is not occupied
LSD: 0 = OFF
Take or leave a seat to judge switch ON/OFF 
quality. SS D1 3 0 0 0 [ 3 0 0 0 ]
S P H
S P H
(4) I/O 2-4 screen

MENU
SSD1: Drive motor 1 rpm [target rpm]

Inspect the rpm sensor while the vehicle is
traveling.The rpm of the drive motor increases Press button (3)
according to the speed increase. (5) I/O 2-5 screen
(5) I/O 2-5 screen
SSD2: Drive motor 2 rpm [target rpm]
Inspect the rpm sensor while the vehicle is traveling. 5 >
< I / 0 2
SS D2 3 0 0 0 [ 3 0 0 0 ]
The rpm of the drive motor increases according to the S P H

S P H
speed increase.
MENU
(6) I/O 2-6 screen

SPD: Traveling speed (km/h) Press button (3)
Check the traveling speed while the vehicle is jacked
(6) I/O 2-6 screen
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 quality. S P D 1 0 . 0
S P H
S P H
MENU
Press button (3)


5-37
I/O monitor 3
This function displays the ON/OFF status of material handling and mast control switches and analog input
voltages from sensors.
Operation procedure
2. Press button (3) three times.
3. Check that “4. I/O MONITOR3” is displayed and press Button (1)
button (3) (enter). I/O monitor function (3) is activated ANALYZER MENU screen Button (2)
4. Functions of buttons on the I/O MONITOR3 screen = A N L ME NU=
are as follows: 4 . I / O MON I T OR 3
S P H
Button (1): Unused. S P H
MENU
Button (2): Unused.

Button (3): Displays I/O 3-1 to I/O 3-13 screens Button (3)
sequentially Press button (3)
*: Press button (3) on the I/O 3-13 screen to display the (1) I/O 3-1 screen
ANALYZER MENU screen. Standard models
screen.
Display ANALYZER MENU screen to display other 
screen L : . . 1
S P H
S P H
(1) I/O 3-1 screen

MENU
Standard models
L: Lift switch inspection Mini lever models (OPT)
When the lift lever is in the UP position
L: −.−− −.−− 1− = ON
When the lift lever is in the neutral or DOWN position 
1 . 0 0 3 . 0 0 1 0
L: −.−− −.−− 0− = OFF S P H
S P H
Operate the lift lever to judge ON/OFF quality. MENU
Mini lever models (OPT)

L: Lift lever angle 1 sensor voltage (V)
Lift lever angle 2 sensor voltage (V) Press button (3)
Lift raise switch (0=OFF, 1=ON) (2) I/O 3-2 screen
Lift lower switch (0=OFF, 1=ON) Standard models
Judge the raise and lower input quality by lift lever
operation.

Lift lever angle 1 Lift lever angle 2 L ( SO L ) : .

S P H
S P H
sensor voltage sensor voltage MENU
Raising 1.1 to 2.3 V 2.2 to 3.5 V

Lowering 0.4 to 1.6 V 2.9 to 4.2 V
(2) I/O 3-2 screen 

L ( SO L ) : 0 . 3 5
Standard models S P H
S P H
L (SOL): Unused MENU

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

5-38
(3) I/O 3-3 screen

Standard models I/O 3-2 screen
T: Forward and backward tilt switch inspection Button (2)
(3) I/O 3-3 screen Button (1)
Forward Backward
Operation Display Standard models
tilt switch tilt switch
Forward tilt T: −.−− −.−− 10 1 (=ON) 0 (=OFF)
Neutral T: −.−− −.−− 00 0 (=OFF) 0 (=OFF) 
. 1 0
Backward tilt T: −.−− −.−− 01 0 (=OFF) 1 (=ON)

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

Mini lever models (OPT) Mini lever models (OPT) Button (3)
T: Tilt lever angle 1 sensor voltage (V)
Tilt lever angle 2 sensor voltage (V)
Forward tilt switch (0=OFF, 1=ON) 
Backward tilt switch (0=OFF, 1=ON) T : 1 . 0 0 3 . 0 0 1 0

S P H
S P H
Judge the forward and backward tilt input quality by lift MENU
lever operation.
Tilt lever angle 1 Tilt lever angle 2
Press button (3)
sensor voltage sensor voltage
(4) I/O 3-4 screen
Forward tilt 1.1 to 2.3 V 2.2 to 3.5 V Standard models
Backward tilt 0.4 to 1.6 V 2.9 to 4.2 V
(4) I/O 3-4 screen 4 >

< I / O3
T ( SO L ) : .
Standard models S P H
S P H
MENU
T (SOL): Unused
T (SOL): Tilt proportional valve solenoid current (A) Mini lever models (OPT)
Judge the output quality to the tilt proportional valve
solenoid by tilt lever operation.
Standard: 0.3 to 0.85 A (Lever operated) 
0 . 3 5
S P H
(5) I/O 3-5 screen

S P H
MENU
Standard models
A1: Attachment 1 lever inspection
When the attachment 1 lever is ON Press button (3)
A1: −,−− −,−− 1− = ON (5) I/O 3-5 screen
When the attachment 1 lever is in the neutral position Standard models
A1: −,−− −,−− 0− = OFF
Operate the attachment 1 lever to judge ON/OFF
quality. 
. 1
3-way and 4-way mini lever models (OPT) S P H
S P H
A1: Attachment 1 lever angle 1 sensor voltage (V)

MENU
Attachment 1 lever angle 2 sensor voltage (V)

Attachment 1 raise switch (0=OFF, 1=ON) 3-way and 4-way mini lever models (OPT)
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
Attachment 1 lever Attachment 1 lever S P H

S P H
MENU
angle 1 sensor volt- angle 2 sensor volt-

age age
Raising 1.1 to 2.3 V 2.2 to 3.5 V Press button (3)
Lowering 0.4 to 1.6 V 2.9 to 4.2 V I/O 3-6 screen

5-39
(6) I/O 3-6 screen

I/O 3-5 screen
Standard models
A1(SOL): Unused Button (2)
(6) I/O 3-6 screen Button (1)
3-way and 4-way mini lever models (OPT) Standard models
A1 (SOL): Attachment 1 proportional valve solenoid
current (A)
Judge the output quality to attachment (1) proportional 
valve solenoid by attachment 1 lever operation. A 1 ( S OL ) : .
S P H
Standard: 0.3 to 0.85 A (Lever operated) S P H
MENU
(7) I/O 3-7 screen

Standard models, 2-way and 3-way mini lever Button (3)
models (OPT) 3-way and 4-way mini lever models (OPT)
A2: Unused
4-way mini lever models (OPT)
A2: Attachment 2 lever angle 1 sensor voltage 
A 1 ( S OL ) : 0 . 3 5
Attachment 2 lever angle 2 sensor voltage S P H
S P H
Attachment 2 raise switch (0=OFF, 1=ON)

MENU
Attachment 2 lower switch (0=OFF, 1=ON)

Judge the forward and backward tilt input quality by tilt Press button (3)
lever operation. (7) I/O 3-7 screen
Standard models
Attachment 2 lever Attachment 2 lever 2-way and 3-way mini lever models (OPT)
angle 2 sensor angle 2 sensor
voltage voltage
Raising 1.1 to 2.3 V 2.2 to 3.5 V 
.
S P H
Lowering 0.4 to 1.6 V 2.9 to 4.2 V

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

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

A 2 ( S OL ) : .
S P H
S P H
MENU
4-way mini lever models (OPT)

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

I/O 3-9 screen

5-40
(9) I/O 3-9 screen

SWTK: Automatic fork leveling cancel switch
inspection I/O 3-8 screen
0 = OFF
Button (2)
1 = ON
Button (1)
Operate the tilt knob switch to judge ON/OFF quality. (9) I/O 3-9 screen

SSP: Pump motor rpm [target rpm] 
Inspect the rpm sensor during the actual material S WT K : 0
S P H
handling operation. Check that the pump motor rpm

S P H
MENU
increases according to the material handling speed

increase. Button (3)
(11) I/O 3-11 screen Press button (3)
MH: Lifting height switch inspection (10) I/O 3-10 screen
Combination of lifting height switch ON/OFF
Lifting MH1 MH2-1
Indication
height switch switch 
2 0 0 0 [ 2 0 0 0 ]
S P H
Low lifting S P H
10− 1 (=ON) 0 (=OFF) MENU
height
High lifting
01− 0 (=OFF) 1 (=ON)
height Press button (3)
Change the lifting height to judge ON/OFF quality. (11) I/O 3-11 screen
POTT: Tilt angle sensor voltage (V) 
Check the input voltage of tilt angle sensor controller MH : 1 0
Standard when the mast is in the vertical position:

S P H
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 (12) I/O 3-12 screen

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)

5-41
I/O monitor 4
ON/OFF state of knob steering synchronizer and other switches and the analog input value from each
sensor are indicated.
Operation procedure
Button (1)
2. Press button (2) four times.
3. Check that “5. I/O MONITOR4” is displayed and press ANALYZER MENU screen Button (2)
button (3) (enter). I/O monitor function (4) is activated
time button (3) is pressed. = A N L ME N U =
5 . I / O MO N I T OR 4
4. Functions of buttons on the I/O MONITOR4 screen S P H
S P H
are as follows:
MENU
Button (1): Unused

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

S P H
MENU
screen.
Press button (3)

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.
STSC sensor turns on when the actual value is 80 on
the I/O 4-2 screen. 159
0
1
80

5-42
(2) I/O 4-2 screen

K-POS: Actual value of knob position (target) I/O 4-1 screen
Actual value:
Knob position computed by the controller from the Button (2)
steering angle sensor signal. Button (1)
(2) I/O 4-2 screen
Target value:
Knob position computed by the controller from the tire
angle sensor signal. 
K POS 1 5 9 1 5 0
S P H
S P H
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 the steering wheel clockwise and decreases
when turning it counterclockwise. 159
0
1
80
(3) I/O 4-3 screen

• K-DIFF: Deviation of steering angle knob position I/O 4-2 screen
Difference between target and actual values at I/O
4-2. Button (2)
• SOL: Steering synchronizer solenoid (3) I/O 4-3 screen
Button (1)
0 = OFF
1 = ON
Operate the steering wheel to check that the steering 
synchronizer solenoid turns on when there is K D I FF 1 0 0 SOL 0
S P H
deviation of steering angle knob position. S P H
MENU
(4) I/O 4-4 screen

TIRE: Tire angle sensor voltage (V) Button (3)
Operate the steering wheel to check the variation in Press button (3)
voltage. (4) I/O 4-4 screen
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)


5-43
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
2. Press button (2) five twice.
3. Check that “6. ACTIVE TEST” is displayed and press
Button (1)
button (3) (enter). ACTIVE TEST function is activated
and ACT-1 to ACT-3 are displayed sequential every ANALYZER MENU screen Button (2)
4. Functions of buttons on the ACTIVE TEST screen are
as follows: = AN L ME NU=
Button (1): Forced ON 6 . ACT I VE TE ST

S P H
S P H
Button (2): Forced OFF MENU
Button (3): Displays ACT-1 and ACT-3 sequentially

*:Press button (3) on ACT-3 screen to display the Button (3)
ANALYZER MENU screen. Press button (3)
Other screen cannot be displayed from ACTIVE TEST (1) ACT-1 screen
screen.
screen. < ACT 1 >
F AN : ON / O F F ( 4 8 )
(1) ACT-1 screen S P H

S P H
FAN: Fan (Fan voltage (V))

MENU
Forcibly output the ON/OFF signal to check the fan

operation and display visually.v
• Press button (1) to select ON. Press button (3)
→ Fan rotates and fan voltage is displayed. (2) ACT-2 screen
• Press button (2) to select OFF.
→ Fan stops rotating and fan voltage is displayed.
Note: < ACT 2 >
K S OL : ON / O F F ( 0 )
Be sure to open the battery hood and remove the side S P H
S P H
cover to check the fan operation. MENU
(2) ACT-2 screen

KSOL: Steering knob synchronizer solenoid Press button (3)
1: Signal check line ON (error)
0: Signal check line OFF (normal) ACT-3 screen
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

5-44
(3) ACT-3 screen

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

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

5-45
■ Tuning
General
This function performs fine adjustment of traveling and material handling controls.
When the use requests to limit the maximum speed or weaken the regenerative braking force, each setting
can be performed on the TUNING screen in the procedures same as power control level setting.
59 tuning items are prepared including spares.
Tuning items list
Tuning Level ( : Initial setting position)
Item
No. 1 2 3 4 5 6 7 8
Switchback regenerative breaking torque:
1 Changes the regenerative braking torque at Weak Strong
switchback.
Acceleration OFF regenerative breaking torque:
2 Changes regenerative breaking torque when Weak Strong
acceleration is OFF.
Battery warning setting level: Slow
Changes the activation timings of low remaining Disabled
3 Fast
battery charge warning and battery
overdischarge warning. (See page 5-50.)
Battery charge indicator correction:
Slow Fast
4 Corrects decreasing rate of battery charge decrease decrease
indicator.
Traveling speed limiter: Low High
5 speed None
Adjust the maximum traveling speed. speed
Attachment power control No.1:
Low High
6 Changes the pump motor output for when speed speed
attachment switch No.1 is ON.
Tilt power control:
Changes the pump motor output for when Low High
7 speed speed
the tilt switch is ON.
(The SAS function mast control speed is not limited.)
Attachment power control No.2: *1
Low High
8 Changes the pump motor output for when speed speed
attachment switch No.2 is ON.
Auto-off function activation time: Long
9 Short None
Sets the time for activating auto-off function.
10 Spare
11 Spare
12 Spare
*1: 4-way mini lever models (OPT)

5-46

Item
No. 1 2 3 4 5 6 7 8
Lift lowering adjustment (1):
20 Adjusts solenoid output current at the beginning Small Large
of lift lowering operation.

21 Slow Fast
Adjusts inching speed during lift lowering operation.

22 Adjusts the maximum solenoid output current during Small Large
lift lowering operation.

23 Weak Strong
Adjusts acceleration during lift lowering operation.

24 Weak Strong
Adjusts deceleration during lift lowering operation.
Lift raising adjustment (1):

25 Adjusts solenoid output current at the beginning of Small Large
lift raising operation.

26 Slow Fast
Adjusts inching speed during lift raising operation.

lift raising operation.

28 Weak Strong
Adjusts acceleration during lift raising operation.

29 Weak Strong
Adjusts deceleration during lift raising operation.
Forward tilt adjustment (1):

forward tilt operation.

31 Slow Fast
Adjusts inching speed during forward tilt operation.

forward tilt operation.

33 Weak Strong
Adjusts acceleration during forward tilt operation.

34 Weak Strong
Adjusts deceleration during forward tilt operation.
Backward tilt adjustment (1):

backward tilt operation.

5-47

Item
No. 1 2 3 4 5 6 7 8

36 Slow Fast
Adjusts inching speed during backward tilt operation.

backward tilt operation.

38 Weak Strong
Adjusts acceleration during backward tilt operation.

39 Weak Strong
Adjusts deceleration during backward tilt operation.
Attachment 1 lowering adjustment (1):

lowering operation of attachment 1.
41 Adjusts inching speed during lowering operation of Slow Fast
attachment 1.
43 Adjusts acceleration during lowering operation of Weak Strong
attachment 1.
44 Adjusts deceleration during lowering operation of Weak Strong
attachment 1.
Attachment 1 raising adjustment (1):
raising operation of attachment 1.
46 Adjusts inching speed during raising operation of Slow Fast
attachment 1.
48 Adjusts acceleration during raising operation of Weak Strong
attachment 1.
49 Adjusts deceleration during raising operation of Weak Strong
attachment 1.
51 Adjusts inching speed during lowering operation of Slow Fast
attachment 2.

5-48

Item
No. 1 2 3 4 5 6 7 8
53 Adjusts acceleration during lowering operation of Weak Strong
attachment 2.
54 Adjusts deceleration during lowering operation of Weak Strong
attachment 2.
56 Adjusts inching speed during raising operation of Slow Fast
attachment 2.
58 Adjusts acceleration during raising operation of Weak Strong
attachment 2.
59 Adjusts deceleration during raising operation of Weak Strong
attachment 2.

5-49
TUNING Screen Operating Procedure

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

5-50
TUNING 1 Button (1) Button (2)

This function sets the tuning level of the standard TUNING MENU screen
functions.
Operation procedure = T U N ME N U =
1. Display the TUNING MENU screen. 1 . T UN I NG 1
S P H
2. Check that “1. TUNING1” is displayed and press

S P H
MENU
button (3) (enter) to display TUNING level setting

screen. Button (3)
3. Press button (3) to display the tuning item desired to Press button (3)
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows: < T UN >
NO . 1
1 5 8
Button (1): Tuning level down S P H

S P H
MENU
Button (2): Tuning level up

Button (3): Enter (to the next item screen)
Press button (3)
*: Press button (3) on the TUNING No.12 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
< T UN >
setting screen of TUNING1. Display TUNING MENU
1 5 8
NO . 2
screen to 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

5-51
TUNING 2 LIFTV
This function changes the tuning level of the lift lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display “2.TUNING2 LIFTV” Button (1)
and press button (3) (enter) to display TUNING level TUNING MENU screen Button (2)
setting screen.
3. Press button (3) to display the tuning item desired to
be set. = T U N ME N U =
2 . T UN I NG 2 L I F T V
4. Functions of buttons on the TUNING level setting S P H
S P H
screen are as follows: MENU
Button (1): Tuning level down

Button (2): Tuning level up Button (3)
Button (3): Enter (to the next item screen) Press button (3)
Other screen cannot be displayed from each level < T UN >
NO . 2 0
1 5 8
setting screen of TUNING2 LIFTV. Display TUNING S P H

S P H
MENU screen to display other screen. MENU
Press button (3)
< T UN > 1 5 8
NO . 2 1
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

5-52
TUNING 3 TILTV
This function changes the tuning level of the tilt lever.
Operation procedure
2. Press button (1) or (2) to display “3.TUNING3 TILTV” Button (1)
Button (2)
and press button (3) (enter) to display TUNING level TUNING MENU screen
setting screen.
3 . T UN I NG 3 T I L T V
S P H

NO . 3 0
1 5 8
setting screen of TUNING3 TILTV. Display TUNING S P H

S P H
Press button (3)
< T UN > 1 5 8
NO . 3 1
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

5-53
TUNING 4 ATT1V
This function changes the tuning level of the attachment 1 lever.
Operation procedure
2. Press button (1) or (2) to display “4.TUNING4 ATT1V” Button (1)
and press button (3) (enter) to display TUNING level Button (2)
TUNING MENU screen
setting screen.
4. Functions of buttons on the TUNING level setting 4 . T UN I NG 4 A T T 1 V
S P H
screen are as follows: S P H
MENU

Other screen cannot be displayed from each level
< T UN > 1 5 8
setting screen of TUNING4 ATT1V. Display TUNING NO . 4 0
MENU screen to display other screen.

S P H
S P H
MENU
Press button (3)
< T UN > 1 5 8
NO . 4 1
S P H
S P H
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

5-54
TUNING 5 ATT2V
This function changes the tuning level of the attachment 2 lever.
Operation procedure
2. Press button (1) or (2) to display “5.TUNING5 ATT2V” Button (1)
and press button (3) (enter) to display TUNING level TUNING MENU screen Button (2)
setting screen.
5 . T UN I NG 5 A T T 2 V
S P H

NO . 5 0
1 5 8
setting screen of TUNING5 ATT2V. Display TUNING S P H

S P H
Press button (3)
< T UN > 1 5 8
NO . 5 1
S P H
S P H
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

5-55
■ 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
Sets the data according to the destina-
OPT-4 DESTI * J Japan I than
tion. 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
OPT-7  Not used    
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.

5-56
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 function of the options. T OF F AM
11 : 00
• When the controller board is replaced, it is S P H
S P H
necessary to reset it according to the vehicle MENU
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.
Meaning of indication 30/ 9 AM
S AS OF F 11 : 00
T-OFF: TILT CONT (active mast front tilt angle S P H
S P H
control) is disabled. MENU
SAS-OFF: SAS (SAS control) is disabled.
Operation 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
Button (3): Enter (to the next item screen)
*: 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.

5-57
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)

5-58
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)

5-59
■ 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

5-60
Before matching
Vehicle should be in the “Standard state” for matching.
“Standard state” means the vehicle satisfies the following conditions:
1. Tire pressure check
Make sure that the tire pressure is at the specified V mast
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°).
3. No-load vertical condition check 500 mm
Signal voltage of the load sensor in no-load state is (19.7 in)
stored. Make sure that the following conditions are
met. FV•FSV mast
• 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 100mm
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 travel position check

Signal voltage of the tire angle sensor in tire straight Within 50 mm (2.0in)
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
right sides
the vehicle to stay within 50 mm (2.0 in) to the left and

right of the line.
5 m (16 ft)
Operation 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

5-61
*: 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 ( . ) .
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
MENU MENU
Press button (3)

5-62
■ 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.
Operation procedure for tire constant setting
1. Input the password on the general screen (see page
5-23) to display the MASK MENU screen.
2. Press button (2) four times to display “5. WHEEL DIA” MASK MENU screen
and press button (3) (enter) to display the tire constant
setting screen.
3. Press button (1) or (2) to set the desired tire constant = ME N U =
5 . WH E E L D I A
and press button (3) (enter) to display the MASK S P H
S P H
MENU screen. MENU
4. Functions of buttons on the tire constant setting

screen are as follows: Button (3)
Button (1): Decreases the tire constant. Press button (3)
Button (2): Increases the tire constant.
Button (3): Enter and display MASK MENU screen
WH E E L D I A
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

6-1
FRAME AND AUXILIARY EQUIPMENT
Page 2
BODY FRAME ................................................................. 6-2
3
INSTRUMENT PANEL AND
ADJACENT PORTION ............................................... 6-8
AUXILIARY EQUIPMENT ............................................. 6-10
FUSES ............................................................................... 6-13

6-2
BODY FRAME
Frame
■ General
(1) (4)
(3) (2)
(1) Round-type front stay (3) Cautions for jacking up

(2) Side cover (4) Cautions for hoisting the vehicle
1. Round-type front stay

• The newly adopted round-type front stay facilitates
ingress/egress.
2. Elimination of side covers

• Side covers on previous vehicles are eliminated and replaced with structural members to strengthen
the lower portion of the frame.

6-3
3. Cautions for jacking up

• A jack-up point is provided at the bottom of the
frame to the rear of the front tire.
• The jack-up point is provided within a range of 150
mm (5.9 in) from the fender. Jack up the vehicle at 2
the specified jack-up point.
• Do not attempt to perform service work when the
vehicle is jacked up. Always place wood blocks, etc.
3
under the vehicle before starting the work.
• For jacking up the rear side, see the WEIGHT
section.
150 mm
(5.9 in)
4. Cautions for hoisting the vehicle

Hoist the front of the vehicle at the mast and the
rear at the head guard similarly as for previous
models.
6
Weight
■ General
1. Compared with previous models, each new model vehicle has a weight of novel design.
2. Jack up the vehicle at the points illustrated below:

6-4
Battery hood
■ General
1. A press-integrated hood wholly covers the top of the battery. This hood opens up fully for the ease of
battery maintenance and replacement.
2. Use the notch of the head guard to replace the battery from the right-hand side of the vehicle.
■ Battery hood opening/closing procedure

Caution:
When opening/closing the battery hood, hold the handle on the right-hand side of the hood.
(1) Set the mast in vertical position.
(2) Pull the lock release lever.
(3) Tilt the steering post forward.
(4) Open the battery hood.
(1)
(4)
(3)
Lock release
lever
(2)

6-5
■ Battery hood locking device

• To fix the battery hood securely for operation, a locking device and a catch are provided on the front end
of the hood.
• The locking device automatically locks the hood when closed as a fail safe locking mechanism. The
catch prevents looseness of the hood by means of cushion rubber. 2
3
Catch
Locking device
Damper stay
1. Damper stay is adopted as a standard part to reduce the hood opening/closing force.
2. When fully open, the stay is automatically locked. To close the hood, release the lock with a finger. 6
Push this and

release the lock
Side hoods
1. Stamped side hoods are adopted to create a simple and clean product image.
2. Simply open the battery hood only for daily inspection and battery fluid addition.
3. For battery replacement, the side hoods on both sides can be removed or installed in one-touch action
without using a tool.

6-6
Step
1. An open step is adopted for the new model. The step height is much reduced compared to previous
models for easier ingress/egress.
2. The top surface of the step is designed for both slip-resistance and easier cleaning.
Step height
mm (in)
H1 H2
Previous model 545 (21.5)
New model 430 (16.9) 545 (21.5)

H2
H1
Toe board
1. Toe board is divided into the front and rear sections.
2. The front toe board is attached with the accelerator pedal and fixed onto the frame with bolts.
3. The rear toe board allows one-touch installation/removal using a positioning pin.
4. For hydraulic oil and other daily inspection, simply remove the rear toe board.
Accel pedal
FR Toe boad
RR Toe boad
Positioning pin

6-7
Floor mat
The new model is provided with a floor mat on top of the toe board.
Seat
■ General
A seat switch function is added to the Grammar seat favorably accepted on the 7FGF25 series.
A fabric seat (Grammar) is adopted optionally.
■ Major Features
1. ORS function
Operator protection system: Decreases critical damage to the upper body of the operator in case of
unexpected rollover of the vehicle.
2. Side wings with holes
• Restrain the operator in an emergency.
• Assist grip function for ingress
3. Seatbelt installation as standard equipment
ELR (emergency lock retractor) type
4. Reclining function
Tilting range: 5 ° each in the forward and backward directions
5. Dial type operator's weight adjustment mechanism
Knob position on the front side of the seat
Operator’s weight adjustment function: 50 to 130 kg
6. Built-in seat switch
7. Bull mark

6-8
INSTRUMENT PANEL AND ADJACENT PORTION

■ Layout near operator’s seat
(1)
(2)
(7)
(9) (10) (11) (12)
(8)
R
(13) (14)
Pattern of shift
Center of steering
(3) (4) Center of vehicle
(6)
(5)
(17)
Layout of Pedal
(18) (16)
(15)
D2 Pedal (OPT)
No. Name No. Name

(1) Parking lever (10) Control lever (for tilting)
(2) Horn SW (11) Control lever (for attachment)
(3) Direction lever (12) Control lever (for attachment) (optional)
(4) Turn signal SW (13) Brake pedal
(5) Key SW (14) Accelerator pedal
(6) Lamp SW (15) D2 pedal (optional)
(7) Steering wheel (16) Tilt steering lock lever
(8) Seat (17) Rear work light SW (optional)
(9) Control lever (for lifting) (18) Tilt steering lock release lever
* SW: Switch

6-9
Instrument panel
■ General
1. Novel design is realized with resin molding.
2. The instrument panel consists of 2 halves using sturdy and environmentally friendly polypropylene as
the material.
3. The downsized instrument panel improves the ease of ingress/egress.
LH Instrument panel RH Instrument panel

6-10
AUXILIARY EQUIPMENT
■ Direction switch
1. Difference from previous models
The direction switch is the same as that installed on the 7FGF25 series.
2. Direction lever
(1) The direction switch is of the lever type easily operable with fingers as on the 7FGF25 series.
(2) The direction switch is positioned on the left-hand side as a standard component.
(3) Since the D2 pedal (OPT) has a built-in switch, no direction lever is provided.
Direction switch
Forward
Fr
Neutral F
N N
R
Backward Rr

6-11
■ Lights
1. List of lights
Type of light Specifications Bulb
(1) Head light OPT Same as on the previous model 40W
10W(Clearance, upper)
(2) Front combination light OPT Same as on the previous model
25W(Flasher, lower)
High-mount, transverse rear combi- 25W(Flasher, outer)
nation lights are installed as stan- 25W/10W
(3) Rear combination light OPT dard components for improved (Stop/tail, center)
visibility, damage prevention and 25W(Reverse, RH only
design. inside)
The rear working light is of a large
(4) Rear working light OPT square type. 40W
(red pilot lamp provided)
The new model operates on 48 V and not compatible with engine-driven forklifts.
(2) (1) (3) (4)

6-12
2. Light switch
Light switch is positioned on the right-hand side of the steering column for improved operability.
Two-stage light switch turns the side clearance lights and taillights ON and OFF in the first stage and
the headlights, side clearance lights and tail lights ON and OFF, in the second stage.
Turn signal switch
Light switch
Switch for rear working

light (OPT)
Turn signal switch (W/ auto return function)

H
T
R
OFF
Neutral
N OFF
L Light switch

6-13
FUSES
■ Installed positions
Fuses F1 and F4 to F6 are installed in the controller box located under the rear right-hand section of the
vehicle. F1 is of the module type while F4 to F6 are of the blade type. Previously independent F1 for
traveling and F2 for material handling are integrated as F1 fuse for traveling and material handling.
F1
A view F4 F5 F6
A view
■ Name (Applicable function) and capacity
7FBEF15 to 20
F1 For traveling/material handling 500A

F4 For lights 10A
F5 For control circuit 10A
F6 SAS, for solenoid 10A
■ Cautions for fuse replacement

When replacing any fuse, always be sure to disconnect the battery plugs and discharge overall
capacitor by applying a resistance of approx. 100Ω to between P3 and N2.

6-14

7-1
MATERIAL HANDLING AND HYDRAULIC SYSTEM
Page 2
V MAST ............................................................................. 7-2
3
FV MAST ........................................................................... 7-3
FSV MAST ........................................................................ 7-4
MATERIAL HANDLING SPEED.................................. 7-5
LOAD BACKREST & FORK ........................................ 7-6
TILT CYLINDER .............................................................. 7-7
OIL PUMP ......................................................................... 7-8
OIL TANK .......................................................................... 7-9
OIL CONTROL VALVE .................................................. 7-10
MATERIAL HANDLING LEVER .................................. 7-19
HYDRAULIC CIRCUIT ................................................... 7-20
MAST INTERCHANGEABILITY.................................. 7-21
A4 PIPING......................................................................... 7-22 7

7-2
V MAST
■ General
1. The vehicle is installed with the V mast as the standard component.
2. The mast installation method is changed from that for the previous models to reduce the lost load
center (distance from the front axle center to the fork front).
3. A mast for 2.0 tons is newly provided.
■ Major improvements
1. Improved mast durability
Mast durability has been improved by reducing the torsional force applied to the mast rails by changing
the tilt bracket construction. In addition, the outer middle beam is discontinued to reduce the lost load
center while retaining sufficient mast durability.
2. Front visibility
Unique front visibility vision is retained by using the mast rail and finger bars similarly as on previous
models.
3. Chain
The mast chain size for the 1.5- to 1.8-t masts remains unchanged. The size for the 2.0-t mast is the
same (BL634) as on the 7FBMF 20 and 25 models.
4. Lift cylinder
The lift cylinder for the 1.5- to 1.8-t masts is the same as that for the 7FBMF16 and 18. The lift cylinder
for the 2.0-t mast is the same as that for the 7FBMF20 and 25.
5. Lift cylinder piping
The basic structure of the piping for the 1.5- to 1.8-t masts remains unchanged. The safety down valve
is of the same inline type as on the Previous models except for an additional fitting for the pressure
sensor.
The basic structure of the lift cylinder for the 2.0-t mast is the same as that for the 1.5- to 1.8-t masts.
6. Lift roller
The mast rollers for the 1.5- to 1.8-t masts are the same as those for the 7FBMF16 and 18.
The mast rollers for the 2.0-t mast are the same as those for the 7BMF20 and 25.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity 1.0 ton 1.3 ton 1.5 to 1.8 ton 2.0 ton
New model − − 355(14.0) 370(14.6)
Previous model 380(15.0) 385(15.2) 385(15.2) −

7-3
FV MAST
■ General
1. The FV mast is optionally available.
2. The mast installation method is changed from that on previous models to reduce the lost load center
2
(distance from the front axle center to the fork front).
3. A mast for 2.0 tons is not provided. 3
1. High mast durability
Same as that of the V mast.
2. Front visibility
Unique front visibility vision is retained by using the mast rail and finger bars similarly as on previous
models.
3. Chain
Same as that for the V mast.
4. Lift cylinder
The lift cylinder remains unchanged from that for the 7FBMF16 and 18.
The basic lift cylinder piping is the same as that for previous models.
The same in-line type safety down valve as that for the previous models is used except for an addition
of the fitting for a pressure sensor.
6. Lift roller
Same as for the V mast.
mm(in)
7
New model − − 355(14.0) 370(14.6)
Previous model 380(15.0) 385(15.2) 385(15.2) −

7-4
FSV MAST
■ General
1. The FSV mast is optionally available.
2. The mast installation method is changed from that for the previous model to reduce the lost load center
(distance from the front axle center to the fork front).
3. A mast for 2.0 tons is newly provided.
1. High mast durability
Same as for the V mast.
2. Front visibility
Unique front visibility is retained by using the mast rail and finger bars similar to those on previous
models.
3. Chain
The mast chain for the 7FBEF15 to 18 is the same in size as that for previous models. The chain
(BL634) for the 7FBEF20 is the same in size with that for the 7FBMF20,25.
4. Lift cylinder
The mast lift cylinder for the 1.5- to 1.8-t models remains unchanged from that for the 7FBMF16 and
18. The mast lift cylinder for the 7FBEF20 is the same as that for the 7FBMF20,25.
The basic piping structure remains unchanged for the 1.5- to 1.8-t models. The flow regulator position
has been changed to shorten the lost load center (distance between the center of the front axle to the
front edge of the fork).
The pressure sensor piping is connected to the piping between RR cylinders.
The basic lift cylinder piping structure for the 2.0-t model is the same as that for the 1.0- to 1.8-t
models.
6. Lift roller
Same as that for the V mast.
mm(in)
New model − − 395(15.6) 415(16.3)
Previous model 410(16.1) 415(16.3) 415(16.3) −

7-5
MATERIAL HANDLING SPEED

List of material handling speeds
V-mast FSV-mast
mm/s (fpm)
FV-mast
2
Vehicle model
No load Load No load Load No load Load 3
H 610 (120) 430 (85) 560 (110) 400 (79) 560 (110) 400 (79)
Lift P 540 (106) 350 (69) 490 (96) 330 (65) 490 (96) 330 (65)
7FBEF15
S 480 (94) 280 (55) 430 (85) 270 (53) 430 (85) 270 (53)
Lower ALL 550 (108) 500 (98) 450 (89) 480 (94) 420 (83) 480 (95)
H 610 (120) 420 (83) 560 (110) 390 (77) 560 (110) 390 (77)
Lift P 540 (106) 340 (67) 490 (96) 320 (63) 490 (96) 320 (63)
7FBEF16
S 480 (94) 260 (51) 430 (85) 250 (49) 430 (85) 260 (51)
Lower ALL 550 (108) 500 (98) 450 (89) 480 (94) 420 (83) 480 (94)
H 610 (120) 390 (77) 560 (110) 380 (75) 560 (110) 380 (75)
Lift P 540 (106) 320 (63) 490 (96) 310 (61) 490 (96) 310 (61)
7FBEF18
S 480 (94) 250 (49) 430 (85) 240 (47) 430 (85) 240 (47)
Lower ALL 550 (108) 500 (98) 450 (89) 480 (94) 420 (83) 480 (94)
H 500 (98) 340 (67) 470 (93) 320 (63) − −
Lift P 450 (89) 280 (55) 420 (83) 270 (53) − −
7FBEF20
S 400 (79) 220 (43) 360 (71) 210 (41) − −
Lower ALL 500 (98) 500 (98) 450 (89) 480 (94) − −
7

7-6
LOAD BACKREST & FORK

LOAD BACKREST
■ General
1. The backrest is installed as standard equipment.
2. The same flat steel type backrest as on the 7FBMF25 series is adopted.
3. The backrest-less option is selectable for all masts.
7FBEF15 to 18
Outside width of load backrest mm (in) 970 (42.1) 1070 (42.1) 1220 (48.0) 1520 (59.8)
Forkbar width mm (in) 920 (36.2) 1020 (40.2) 1170 (46.1) 1470 (57.9)
Height of
load backrest 1220 (48.0) STD − − −
mm (in)
STD: Standard, − : Not available
7FBEF20
Outside width of load backrest mm (in) 970 (42.1) 1070 (42.1) 1220 (48.0) 1520 (59.8)
Forkbar width mm (in) 920 (36.2) 1020 (40.2) 1170 (46.1) 1470 (57.9)
Height of
load backrest 1220 (48.0) − STD ● ●
mm (in)
STD: Standard, ●: Available as option, − : Not available
FORK
■ General
1. The fork is the same as that for the 7FBMF25 series.
2. The standard fork color is black. Orange color is provided optionally.
3. The forkless option is provided for all masts as on the Previous models.
Fork length mm (in)

Fork width Fork thickness
Vehicle model 800 1000 1100 1200 1400
mm (in) mm (in)
(31.5) (39.4) (43.3) (47.2) (55.1)
7FBEF15 to 18 80 (3.2) 40 (1.6) STD ● ● ● ●
7FBEF20 100 (3.9) 40 (1.6) − STD ● ● ●
STD: Standard, ●: Available as option, − : Not available

7-7
TILT CYLINDER
General
1. The tilt cylinder is newly provided for the 7FBEF series.
2. The screw type front joint is changed to a welded rod type.
3. The front pin for fixing the mast to the tilt cylinder is changed to an eccentric pin. It allows fine
adjustment of the backward tilt angle and uneven lifting.
4. FR and RR installation points use clevis structure.
5. The internal structure is the same as that for the 7FBMF25 series.

7-8
OIL PUMP
■ General
1. The external gear pump is the same in basic structure as that on previous models.
2. The conventional double gear pump is replaced with a single gear pump for noise reduction.
3. To improve the lifting speed, the pump capacity has been increased.
Vehicle model 7FBEF15 to 20

Oil pump name Single gear pump
Oil pump type TMG1A21A3H5-L (Shimadzu)
Drive system Direct motor drive
Delivery
l (US gal) /min 30.8 (8.14)
(at a pumping rate of 1,500 rpm)
Theoretical delivery cm3 (in3) /rev 21.9 (1.34)

7-9
OIL TANK
■ General
1. An independent resin tank is separately bolted on to the frame.
2. It is installed on the front frame.
3. The oil injection and level can be checked easily by removing the toe board.
4. The return filter is located under the front toe board.
Breather
Level gauge & cap
Return filter
Oil tank
■ Other hydraulic parts

1. Oil tank cap
• A rubber male-female type cap is adopted.
• A separate breather is adopted for downsizing.
• Check the oil level by holding the cap end in contact with the retainer opening as illustrated.
Retainer
2. Breather
To ensure prevention of oil leakage from the breather, an off-cap structure is adopted. (40-µ mesh)

7-10
OIL CONTROL VALVE

■ General
Mast control valves are provided anew.
They are as follows:
• A check valve and a solenoid valve are installed in the tilt circuit to control mast tilting operation.
• A check valve and a solenoid valve are installed in the lift circuit, and a key-lift interlock function is
added to prevent the fork from lowering when the lift lever is erroneously moved to the down side while
the key is in the OFF position.
• The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt.
■ Appearance
Forward tilt switch
Backward tilt switch
Lift look release bolt

Tilt solenoid
Lift solenoid
The newly installed check valve for locking the lift circuit enables lowering when unlocked at key
ON. The tilt circuit locking check valve is unlocked to enable tilting only when the tilt lever is
operated in the forward tilt direction with the key switch in the ON position.
■ Specifications
Unit: MPa (kgf/cm2) [psi]
Lift 17.2 (175) [246]
Relief pressure
Tilt 13.7 (140) [195]

7-11
■ Functional description
General
1. This vehicle is equipped with the key-off lift lock function using a solenoid valve provided in the lift
circuit similarly as on the 7FB10-J35 series.
2. Since tilt lock is electrically controlled by the solenoid valve installed in the forward tilt circuit, the
conventional tilt lock valve has been discontinued.
3. Since the flow is controlled by pump motor revolution similarly as on the 7FB10-J35 series, no solenoid
valve is provided on the control valve side.
Lift circuit
1. During lifting (lift solenoid valve: ON)
(1) When the lift lever is operated in the lifting direction, the lift spool moves to the left in the figure.
Then, the pump pressure compresses the spring at the lift load check valve to open the valve.
(2) The pump pressure is led to the lift logic valve. The pressure compresses the spring at the lift logic
valve to open it.
(3) As the result, the pump pressure is led to the C1 port to extend the lift cylinder and raise the fork.
Check valve
Solenoid valve
C1
Logic valve
Lift spool
Lift cylinder
Pump port Lift load check valve

7-12
2. During lowering (lift solenoid valve: ON)

(1) When the key switch is turned ON, the lift solenoid valve is turned on. The poppet moves to the
right side in the figure to open the check valve. Then the hydraulic oil at the lower portion of the lift
cylinder flows through the C1 port to the lower side of the logic valve and the solenoid valve, and to
the upper side of the logic valve and the lift spool.
(2) Therefore, the relation of the pressures when the spool is stationary with the key switch ON will be
as follows: C1 pressure = Logic valve upper side pressure = Logic valve lower side pressure.
(3) Then operating the lift lever to the lowering side pushes the lift spool to the right in the figure and
opens the circuit between the C1 and tank ports. Since part A of the logic valve has an orifice, the
hydraulic oil between the lower side of the logic valve and the spool flows to the tank port.
Meanwhile, the hydraulic oil at the C1 port does not flow down quickly because it is choked by the
logic valve orifice.
Part A
Logic valve upper side Check valve Poppet

Orifice
Solenoid valve
C1
Logic valve
Logic valve lower side
Tank port
Lift spool
Lift cylinder

7-13
(4) From the result of (2), differential pressure relations stand as follows when the lift lever is operated:
C1 pressure > Logic valve upper side pressure = Logic valve lower side pressure.
(5) Then the C1 port pressure acts on the logic valve to move it downward in the figure because of the
difference in area between a and b of logic valve part A. The pressure opens the logic valve and the
main circuit of the C1 port and the tank port to cause the fork to be lowered.
Part A
a
b
Logic valve upper side Check valve
Solenoid valve
C1
Logic valve
Tank port
Lift spool
Lift cylinder

7-14
3. Lowering operation with key-OFF (key-off lift lock)

Operating the lift lever to the lowering side when the key is turned OFF, the lift spool moves to the right
side. Since the solenoid valve is OFF then, the hydraulic oil in the lower part of the logic valve does not
flow to the tank port because of the check valve in the solenoid valve. Thus no pressure difference is
generated between the C1 port and the lower part of the logic valve. Consequently, the logic valve
remains closed. Since the C1 port and the tank port circuits are cut off, the fork does not go down even
when the lift lever is operated in the downward direction when the key switch is turned OFF.
Check valve
Solenoid valve
C1
Logic valve
Tank port
Lift spool
Lift cylinder
Pump port

7-15
4. Emergency circuit (emergency lowering circuit)

(1) The emergency circuit is provided in consideration of a circumstance where for some electrical
reason the solenoid valve fails to function. This refers to bypassing the hydraulic circuit that links
the lift logic valve lower side to the lift spool. This bypass circuit is provided with a needle valve,
which is normally shut off with the needle pushed in with a bolt. This bolt is locked with a lock nut.
(2) The lowering operation is as follows:
1) Loosen the lock nut.
2) Turn the hexagonal bolt to loosen it. (A turn is sufficient.)
3) Operate the lift lever toward the lowering side to lower the fork. The lowering speed is set at
approximately the same rate as for normal lowering.
4) When the lowering is completed, tighten the bolt and the nut according to the instructions given
in the repair manual.
(3) When the lift is manually lowered, hydraulic oil in the lower part of the cylinder, which is led to the
lower side of the lift logic valve, is also led to the needle valve on the emergency circuit. When the
lowering is manually operated, the hydraulic oil led to the needle valve is now led to the tank port,
generating a differential pressure between C1 port and the logic valve lower side same as in
normal circumstance. This causes the logic valve to open. It also opens the main circuit from C1 to
the tank port, allowing the hydraulic oil in the lower part of the cylinder to flow to the tank port.
Bolt Solenoid valve
Nut
C1
Needle valve
Logic valve
Emergency circuit
Tank port
Lift spool
Lift cylinder
Pump port

7-16
Tilt circuit
1. Mast backward tilting (Solenoid valve: OFF)
(1) When the key switch is turned ON and the tilt lever is operated to the backward tilting direction, the
tilt spool is pulled and moves to the left side in the figure.
(2) Then the hydraulic oil in the pump port flows through the spool and compresses the tilt logic valve
spring to open the valve.
(3) As the result of (2), the circuit connecting the pump port and the C3 port is opened. Since the C3
port is connected to the RH chamber of the tilt cylinder, the pump pressure is applied to contract the
tilt cylinder.
(4) On the other hand, when the tilt spool moves to the left side in the figure, the circuit connecting the
C2 port and the tank port opens. C2 port is jointed to the LH chamber of the tilt cylinder.
(5) The action in step (3) applies the pump pressure to the RH chamber of the tilt cylinder.
Consequently, the hydraulic oil in the LH chamber of the tilt cylinder is led from the C2 port to the
tank port through the control valve spool as if pushed by the piston inside the tilt cylinder.
Tilt cylinder
C2 C3
Check valve
Tilt spool
Solenoid valve
Tank port
Tilt logic valve

Pump port

7-17
2. Mast forward tilting (solenoid valve: ON)

(1) When the key switch is turned ON and the tilt lever is operated in the forward tilting direction, the tilt
spool is pushed and moves to the right side in the figure.
(2) Then, the circuit connecting the pump port to the C2 port opens. Since the C2 port is connected to
the LH chamber of the tilt cylinder, the pump pressure is applied to the LH chamber of the tilt
cylinder through the C2 port.
(3) Meanwhile, the tilt solenoid valve is turned ON when operated for forward tilting. The poppet in the
solenoid valve moves to the right side in the figure to open the check valve. Then the hydraulic oil in
the RH chamber of the tilt cylinder flows through the C3 port, right side of the logic valve, the
solenoid valve, the left side of the logic valve and the tilt spool to the tank port.
(4) Then, part A of the logic valve forms an orifice. Therefore, the hydraulic oil is led from the right side
of the logic valve to the spool and then to the tank port, and the hydraulic oil at the C3 port flows
gradually to the right side of the logic valve because of restriction by the orifice at logic valve part A.
Tilt cylinder
Part A
Logic valve right side

C2 C3 Check valve
Poppet
Orifice
Logic valve right
Tilt spool side
Solenoid valve
Tilt logic valve

Tank port
Tilt spool constriction

Pump port

7-18
(5) As the result of (4) above, differential pressure relations stand as follows when the tilt lever is
operated for forward tilting: C3 pressure > Logic valve left side pressure = Logic valve right side
pressure.
(6) Here, because of the difference in area between a and b of the logic valve, the pressure at the C3
port generates a greater force that pushes the tilt logic valve to the right side in the figure. It opens
the logic valve and the main circuit is connected from the C3 port to the tank port.
(7) The choke valve at the tilt spool prevents abrupt forward tilting caused by a load to the mast
forward tilting side when the tilt lever is operated.
Tilt cylinder
Part A
a
b
C2 C3 Logic valve right side
Check valve Poppet
Logic valve right

Tilt spool
side
Solenoid valve
Tilt logic valve

Tank port
Pump port
3. Forward tilt operation at key-OFF (key-OFF tilt lock)

Operating the tilt lever to the forward tilting side when the key switch is turned OFF, the tilt spool moves
to the right in the figure. The hydraulic oil at the C3 port is led to the right side of the tilt logic valve, but
it is cut off by the check valve in the solenoid valve ahead because the tilt solenoid valve is OFF.
Therefore, no pressure difference is generated between the C3 port and the right side of the logic
valve. Consequently, the logic valve does not open. Thus the mast does not tilt forward if it is
attempted while the key switch is OFF because the circuit between the C3 port and the tank port is
closed.
Tilt cylinder
Logic valve right side

C2 C3
Check valve
Logic valve right

Tilt spool side
Solenoid valve
Tilt spool constriction

Tank port
Pump port

7-19
MATERIAL HANDLING LEVER

■ Differences from previous models
1. To improve serviceability, cotter pins are replaced with β pins for installing the control valve lever rods,
control levers and the control valve spool.
2. Tilt knob switch is arranged on the knob of the tilt lever.
4th Automatic fork leveling switch

3rd
Tilt
Lift
-pin

7-20
HYDRAULIC CIRCUIT
■ Hydraulic circuit
1. Resin tank is adopted to reduce contamination, and the standard adoption of the return filter promotes
protection of hydraulic devices.
2. The return filter is arranged under the front toe board.
3. The following figure shows the function of the hydraulic circuit:

7-21
MAST INTERCHANGEABILITY
■ Mast interchangeability by vehicle model
1. Interchangeability within new model series
Mast type
Vehicle model
V FSV FV
7FBEF15 to 18 ❍ ❍ ❍
7FBEF20 ❍ ❍ ×
❍: Mast interchangeable between respective model groups
×: Not available
2. Interchangeability with previous models
No interchangeability
3. Interchangeability with 7FBMF25 series
No interchangeability

7-22
A4 PIPING
■ A4 Piping setting list
Mast
Type of
Oil control valve Piping number 7FBEF15 to 18 7FBEF20
piping
V FSV FV V FSV
A405 Four valves 0 ❍ ❍ ❍ ❍ ❍
A410 Three valves 2 ❍ ❍ ❍ ❍ ❍
A430 Four valves 2 ❍ ❍ ❍ ❍ ×
A450 Four valves 4 ❍ ❍ ❍ ❍ ❍
❍: Available
×: Not available
FV mast is not available for the 7FBEF20.
■ A4 Piping layout
1. Following the discontinuation of outer mast middle beam, the piping for the outer mast portion has
been modified.
2. The piping of inner and middle masts remains basically unchanged from 7FBMF25 series.
■ Free lift
The free lift of the FV mast without backrest decreases as indicated in the table when the A4 piping is
installed. This is because the pulley for the A4 piping is installed on the front cylinder.
mm (in)
Vehicle model
Mast
7FBEF15 to 18 7FBEF20
FV -125 (-4.9) −
■ Termination Types
The termination and piping at the lift bracket are the same as on the 7FBMF25 series.
7FBEF15 to 18 7FBEF20
Piping type Mast Mast
V FSV FV V FSV
A405 STD NONE NONE NONE NONE NONE
STD CTR RH SIDE RH SIDE CTR RH SIDE
A410
OPT − CTR CTR − CTR
STD CTR RH SIDE RH SIDE CTR RH SIDE
A430
OPT − CTR CTR − CTR
STD CTR RH & LH SIDE RH & LH SIDE CTR RH & LH SIDE
A450
OPT − CTR & LH SIDE CTR & LH SIDE − CTR & LH SIDE
CTR: center termination
RH SIDE: right-hand side termination
CTR & LH SIDE: center and left -hand termination
RH & LH SIDE: right-hand and left-hand side termination
−: nonavailable

8-1
SAS CONTROL SYSTEM
Page 2
SAS CONFIGURATION ................................................. 8-2
3
MAST CONTROL............................................................ 8-5
STEERING SYNCHRONIZER FHPS ......................... 8-8

8-2
SAS CONFIGURATION
■ General
The SAS (System of Active Stability) has been developed with the following concepts:
(1) To develop forklift trucks that can be clearly distinguished by customers from other makes in
respect to both “safety” and “engineering”.
(2) To pursue “carefree material handling”.
■ Targets of sas control
Active Mast Function Controller (1) Longitudinal stability is improved by adopting

the mast forward tilt angle control.
(2) Mast backward tilt angle speed control is
adopted to prevent load from falling.
(3) Automatic fork leveling control is adopted to
improve operating efficiency.
(4) Key-lift interlock is adopted.
Active Steering Synchronizer Characteristics of turning and straight traveling is

with FHPS improved by developing FHPS
FHPS:Full Hydraulic Power Steering
■ SAS System configuration

Sensors are installed in various places on the vehicle to detect the vehicle movement and send signals to
the controller. Signals are controlled by the controller and output to respective actuators for action.
Input Output
control Actuator
T K T Integral control valve
Lifting height switch

K Steering synchronizer
Tilt angle sensor solenoid
T•K LCD display
Controller
Forward tilt limit switch

• Diagnosis
Backward tilt limit switch
Tilt knob switch
Load sensor
Traveling speed sensor
Steering angle sensor
Tire angle sensor
T:Active mast function controller

K:Active steering Synchronizer

8-3
■ Names and functions of respective parts

1. Names of parts
(1)
2
(5) 3
(2)
(10)
(3) • (4)
(11)
(12)
(13)
(6)
(8)
(7)
8
(9)
(1) Lifting height switch (8) Tire angle sensor

(2) Tilt angle sensor (9) Integral control valve
LCD display
(3) Forward tilt switch (10)
• diagnosis
(4) Backward tilt switch (11) Steering angle sensor
(5) Tilt knob switch (12) Steering synchronizing solenoid valve
(6) Load sensor (13) Main controller
(7) Traveling speed sensor

8-4
2. Functions of respective parts

Input side (to the controller)
Name Functions
Detects whether the signal is for low or high lifting height. The limit
(1) Lifting height switch switch provided on the outer mast side detects the height of inner
mast.
Detects the mast tilt angle. This sensor at the front protector on the
(2) Tilt angle sensor upper side of RH tilt cylinder detects the mast tilt angle from the tilt
cylinder that rotates around the rear pin as the axis of rotation.
Detects the forward tilt operation of the tilt lever. The limit switch
(3) Forward tilt switch provided to the tilt spool of the oil control valve detects forward tilting
movement when the tilt lever is operated.
Detects the backward tilt operation of the tilt lever. The limit switch
(4) Backward tilt switch provided to the tilt spool of the oil control valve detects backward tilt-
ing movement when the tilt lever is operated.
A switch for automatically leveling the fork when it stops and for
(5) Tilt knob switch
slowing down the backward tilt speed at a low lift.
Detects the load with a pressure sensor provided to the lift cylinder
(6) Load sensor
hydraulic circuit.
Detects the traveling speed from the motor revolution with a sensor
(7) Traveling speed sensor
provided to the drive motor.
Detects the tire angle based on the center shaft turning angle with
(8) Tire angle sensor
the sensor at the top of the rear axle center shaft.
Detects the steering wheel position with the sensor provided under
(11) Steering angle sensor
the steering wheel.
Output side (of the controller)

Name Functions
Two solenoids are provided to the integral control valve.
• The heck valve and the solenoid valve installed to the tilt circuit
control the tilting action of the mast.
(9) Integral control valve • The check valve and the solenoid valve on the lift circuit add the
key-off lift lock function to prevent the fork from lowering if the lift
lever for lowering is actuated by mistake while the key is turned
OFF.
If SAS function has any error, wrench symbol mark on the display
blinks, simultaneously buzzing alarm. In addition, an error code indi-
cates abnormal point.
(10) LCD display
SAS system always requires an initialization (matching) when an
SAS function-related service is provided. In this case, initialize the
system using the display. (See the section for the display)
The solenoid valve is installed to the correcting valve. The solenoid
valve is actuated by a command sent from the controller to open/
Steering synchronizing
(12) close the correcting valve. Opening-closing of the correcting valve
solenoid valve
adjusts the hydraulic oil flow rate to the rear axle cylinder to correct
offset of the knob position.

8-5
MAST CONTROL
■ General
Mast control includes the following functions:
1. Mast forward tilt angle control
2
Mast forward tilt angle control automatically controls the possible forward tilt angle of the mast
according to the state of the load and lifting height. It reduces the hazards of falling cargo or vehicle tip- 3
over if the tilt lever is carelessly operated for forward tilting.
2. Mast backward tilting speed control
Automatically reduces the mast backward tilting speed to prevent the load from breaking loose when
the lifting height is high [about 2 m (6.6 ft) or above.] For low lifting height, tilting speed can be reduced
by tilting the mast backward while keeping the tilt lever knob switch pressed.
3. Automatic fork leveling control
When operated for forward tilting with the tilt lever knob switch pressed, the fork automatically stops in
level position (with the mast in vertical position). This function is convenient for connecting/
disconnecting fork during cargo loading/unloading.
4. Key-off lift lock
The fork does not lower if operated for lift lowering (the lift lever is operated to the lowering side) when
the key switch is turned OFF. This function sharply reduces natural drop or forward tilting.
■ Schematic diagram of control block
Lift lever
Key-switch Tilt konb switch
Lifting height switch
Tilt angle
sensor
Tilt limit switch
Oil control valve

8
Tilt cylinder
Tilt solenoid
Load sensor PS
Lift solenoid
Controller
Pump motor

8-6
■ Descriptions of activation
Mast forward tilt control (forward tilt angle control)
(1) Possible forward tilting angle varies as shown in the figure below according to the lifting height and
load:
Light load (no load) Intermediate load Heavy load

Possible forward tilt angle
No restriction for
High lift height
forward tilt angle
Low lift height No restriction for front tilt angle
Low lift height

Maximum
Forward tilt
angle 5° High lift height
Forward tilt
(Approx 1°)
Mast vertical
Load Heavy
(2) If cargo is raised tilted forward for low lifting height, the stop position may come to the forward tilt
side than the control angle. Do not raise the cargo with the mast tilted forward same as previous
model.
(3) When the low load cargo is at the fully raised position, residual pressure from relief stop is detected
by the pressure sensor as high load, subsequently controlling the forward tilt angle. To enable
further forward tilting, lower the cargo slightly from the fully raised position and relief the pressure.
(4) When installing a heavy attachment to a specialty model, etc., the mast forward tilt control may not
be provided.
Caution:
• Don’t place overconfidence with the mast forward tilt control function.
• Although the forward tilt angle is reduced according to the load and lifting height, this does not
guarantee that the cargo does not fall or vehicle does not tip over under any conditions.
• Never tilt the mast forward from the vertical position with the cargo raised same as previous
model. Or the longitudinal stability will be degraded to cause the hazard of falling even under
allowable load.
• Never use the forward tilt control for any work.
Backward tilting speed control
(1) Controls (delays) backward tilting speed for high lifting irrespective of the load. In addition,
controlled speed continues if the cargo reaches the low lifting height from the high lifting height
while backward tilting is actuated.
(2) For low lifting height, the tilting is in full speed without any control irrespective of the load. Actuating
backward tilt with the tilt lever knob switch pressed controls (delays) the backward tilting speed as
long as the switch is pressed.
(3) When the lifting height enters low level from high level during backward tilting, the tilting speed is
controlled (delayed) as long as the tilt knob switch is pressed. Tilting reaches full speed (no speed
limit) when the tilt knob switch is not pressed.

8-7
Automatic fork leveling control

Operating the fork for forward tilting from the backward tilt position with the tilt lever knob switch pressed
stops the fork automatically in level position (with the mast in vertical position). The conditions vary as
follows depending on the lifting height and the load.
Actuation will be as indicated below when the mast is operated for forward tilting from the backward tilted
position with the tilt lever knob switch pressed:
Not loaded Loaded
High lifting height (Approx. 2m or Stops with the mast held in
Does not tilt forward
more) vertical position
Stops with the mast held verti-
Low lifting height (Less than approx. Stops with the mast held in cal or tilted backward by about
2m) vertical position 1 degree depending on the
load.
• Pressing the tilt lever knob switch during forward tilting with high lifting height and load stops
forward tilting, but the hazard of falling is present depending on the conditions of the road
surfaces, etc. Never use this function for the purpose of any work.
• In the case of a vehicle with attachment, automatic fork leveling control poses a hazard if the
lever stroke is set to maximum during high lifting.
• In the case of a specialty model installed with heavy attachment, etc., the automatic fork leveling
control may not be provided.
Key-off lift lock
1. Integral control valve has been newly designed for mast control, and the lift hydraulic circuit is modified
accordingly.
2. Lowering is disabled if the lever is operated for lowering when the key switch is turned OFF.
3. Since the lift lock solenoid valve is provided to the lift hydraulic circuit, the solenoid valve remains
closed while the key switch is turned OFF, preventing the lowering if the lift lever is operated for
lowering. To lower the fork, turn the key switch ON and operate the lever for lowering.
Possible vehicle weight for installing the mast control
When installing a heavy attachment, etc. to a specialty model, the mast forward tilt angle is set to approx.
1 degree. No automatic fork leveling control is provided for high lifting height.
Upper limit of additional ATT weight (kg)
Vehicle model Lifting height Lifting height Lifting height Lifting height
3000 mm or 3300 to 4000 4300 to 5000 5500 to 6000
below mm mm mm
7FBEF15 700 550 500 400
7FBEF16 700 550 500 400
7FBEF18 700 550 500 450
7FBEF20 800 700 600 500

8-8
STEERING SYNCHRONIZER FHPS

■ General
1. The steering angle sensor located at the lower side of the steering wheel and the tire angle sensor
provided to the upper part of the center shaft turning detect the steering angle and the tire angle
respectively and correct offset relation, if any, of both angles by opening the solenoid valve.
2. To correct the offset relation, the controller sends command to the solenoid valve to form a bypass
circuit to return part of hydraulic oil to be supplied to the PS cylinder to the tank. This system retains
relation between the steering knob position and the tire angle at a prescribed level.
3. Correction may not be made for safety reason depending on the traveling speed and other conditions.
4. If the knob position should be offset after maintenance service, etc., the steering position will be
automatically corrected by turning the key switch ON and turning the steering wheel to lock-to-lock.
■ Schematic diagram of control block
Steering knob
Vehicle speed sensor
Steering wheel angle sensor
DM DM
P R
T L
Solenoid valve
Main controller
Tire angle sensor

9-1
OUTLINE OF MAJOR OPTIONS
Page 2
FISHERMAN SPECIFICATION ................................... 9-2
3
MASTLESS ...................................................................... 9-3
ATTACHMENT LIST ....................................................... 9-4
DRIVE-IN RACK SPECIFICATION ............................. 9-8
MINI LEVERS................................................................... 9-9
BATTERY ROLL-OUT SPECIFICATION .................. 9-23

9-2
FISHERMAN SPECIFICATION
■ General
1. The fisherman specification improved in rust prevention as compared with standard vehicles is
provided anew. Please recommend it for such cases shown below.
• For use in marine product industry
• For frequent use on wet ground
• For use in a humid environment
• For transportation of salty or other water tanks involving water splashing onto the vehicle
• For use in an environment where ground surface is constantly wet with salty water
• For use in an environment involving splashing of oxidizing fluid (such as hydrogen peroxide or
sodium hypochlorite)
• For use in an environment where a snow-melting agent such as calcium chloride is used
2. Since the fisherman specification has poorer heat radiation because of the waterproof structures of the
drive and pump motors, the rate of operation should be kept at about 60% compared to standard
vehicles.
Depending on the type of operation (such as continuous heavily loaded operation), the vehicle
performances may be temporarily reduced for protecting the controllers and motors from overheating.
The motor current limiting function that is activated upon detection of the specified temperature by the
sensor built in each controller or motor causes this. This is not an abnormality. Since an alarm
indication is given on the monitoring display, suspend operation for some time and restart after
disappearance of the alarm indication.
■ Items and contents
The following items have been changed from those on the standard vehicles.
Item Content
Drive/Pump motor Waterproof type
Brake switch Waterproof type
Under the Front-Protector cover
Covers
Tilt cylinder hole cover
Anti-rust roller
Mast
Fully oil charged lift cylinder
Tilt cylinder Tilt cylinder boot
Rust preventive treatment
Bolt
(Covers, Tilt pin)

9-3
MASTLESS
■ General
Mastless vehicles are available optionally.
2
• These are without the mast ASSY, lift bracket, backrest and fork.
• The high-pressure hose from the mast to the control valve is not provided. The control valve fitting is
attached with a blind plug.
3
• The tilt cylinder is for the FSV mast. The pin for fixing the tilt cylinder on the mast is not provided.
• The name plate punched with the model, frame No., manufacturing year, front tread, tire size, tire
pressure, voltage, battery weight and rated load is riveted in the same position as on the standard
model.
• A spare nameplate punched with the model, frame No., manufacturing year, voltage, battery weight and
rated load is supplied with the vehicle.
Note:
• Always install the 7FBEF series mast for SAS manufactured by Toyota as described on the
repair manual.
• SAS matching is a must after mast installation.
• Refer to the table in the mast specification section for the allowable load to be punched on the
nameplate (except when the side shifter is installed).

9-4
ATTACHMENT LIST
SIDESHIFTER
ATT
E811 E811A E811B E911 E911A E911B
NAME
OPT
D910 D911 D912 D900 D902 D903
CODE
INTEGRATED INTEGRATED HOOKED ON HOOKED ON
MODEL INTEGRATED
+A430 +A450
HOOKED ON
+A430 +A450
7FBEF15 ● ● ● ● ● ●
7FBEF16 ● ● ● ● ● ●
7FBEF18 ● ● ● ● ● ●
7FBEF20 ● ● ● ● ● ●
●: Provided
Note:
The sideshifter includes center termination.
Hooked on sideshifter (CASCADE)
■ General
• A detachable sideshifter (Cascade) is provided.
• The basic structure remains unchanged from that for previous models.
• It can be installed on the V, FSV and FV (1-t series) masts.
• The shifter fork bar width is the same as the fork bar width on the vehicle.
Front view of detachable sideshifter

9-5
■ Specifications
7FBEF15 to 18 STD: Standard ●: Available as option
Fork bar width mm (in) 920 (36.2)
Catalog No. 55F-SS-A890 2
Assembly weight kg (lb) 50.3 (111)
3
Effective thickness mm (in) 59.0 (2.32)
Max. sideshift mm (in) 200 (7.87)
Series STD
7FBEF20 STD: Standard ●: Available as option

Fork bar width mm (in) 1020 (40.2) 1170 (46.1) 1470 (57.9)
Catalog No. 55F-SS-A891 55F-SS-A930 55F-SS-A932
Assembly weight kg (lb) 53.5 (2.11) 59.0 (2.32) 88.3 (3.48)
Effective thickness mm (in) 59.0 (2.32) ← ←
Max. sideshift mm (in) 200 (7.87) ← ←
Series STD ● ●
■ Others
1. Fork & Backrest
The fork and backrest are the same as those of the standard vehicles. Series options can be used as
they are.
2. A4 Piping
The E9 attachment includes the A4 piping as shown in the table below.
E9-code A4-type
E911 A410
E911A A430
E911B A450
9
3. Control Lever Layout
The control lever layout remains unchanged. The operating directions are also the same.

9-6
Integral sideshifter
■ General
• The sideshifter integrated with the lift bracket is provided.
• The basic structure remains unchanged from that for previous models.
• It can be installed on V, FSV and FV (1-t series) masts.
• The allowable load and load center are the same as those on standard vehicles.
Rear view of integral sideshifter
Stroke Stroke
Fork bar width
■ Specifications
7FBEF15 to 18 STD: Standard
Fork bar width mm (in) 920 (36.2)
Max. sideshift mm (in) 200 (7.87)
Series STD
7FBEF20 STD: Standard ●: Available as option

Fork bar width mm (in) 1020 (40.2) 1170 (46.1) 1470 (57.9)
Max. sideshift mm (in) 200 (7.87) ← ←
Series STD ● ●

9-7
■ Others
1. Fork & Backrest
The fork and backrest are the same as those of the standard vehicles. Series options can be used as
they are.
2. A4 Piping
The E8 attachment includes the A4 piping as shown in the table below.
E8-code A4-type
E811 A410
E811A A430
E811B A450
3. Tire chain installation

There is no optional tire chain installation structure.
4. Control lever layout
The control lever layout and operating directions are the same as on previous models.

9-8
DRIVE-IN RACK SPECIFICATION

■ Structure (Differences from Standard Model)
The head guard, front stay and rear pillar shapes are different, and the seat position is moved by 36 mm
toward the center of the vehicle.
LOAD
C
B
mm (in)
A B C D
780 (30.7) 1156 (45.5) 1883 (74.1) 780 (30.7)
■ Unallowable Optional Attachments

Lights (FR·RR combination lamps, etc.)
4-way control valve, piping, etc.
■ Others
The assist grip and headlamps are not installed.
The mast backward tilting angle is up to 5°.

9-9
MINI LEVERS
■ General
The electromagnetic oil control valves for mast control with mini levers are newly provided as options.
They are as follows:
• A check valve and an electromagnetic proportional valve are installed in the tilt circuit to control the mast
tilting operation.
• A check valve and an electromagnetic proportional valve are installed in the lift circuit for key-off lift
interlock to prevent the fork from lowering in case the down lift lever is touched erroneously while the
key is OFF.
• The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt.
■ Appearance
Connection with actual machine components
Hydraulic pump
Port P Port C2 Tilt cylinder bottom side
(hydraulic fluid supply source)
Port T1 Tank Port C3 Tilt cylinder rod side
Port T2 Tank Port C4 Actuator
Port C1 Lift cylinder bottom side Port C5 Actuator
Pressure detection port
Port P static pressure detection Pressure reducing valve static
G1 G2
port pressure detection port
C1
G2
C3
P
C5
C2
C4
T1
G1
T2
■ Specifications
Unit: MPa (kgf/cm2) [psi]
Mini rever
Lift 17.2 (175) [246]
Relief pressure
Tilt −

9-10
■ Explanation of Operation
Material handling valve
1. Pressure compensation mechanism
When pressure compensation mechanism is ON
When solenoid C1 is euergized and non-leak valve is closed, the pressure compensation mechanism
operates as follows:
Pressure oil flowing from port P flows from chamber (a) through orifice A to chamber (b), then flows
through orifice B to chamber (c).
The opening aperture of oil passage E is determined by the equilibrium of chamber (b), chamber (c)
and spring 1.
This controls the oil pressure of chamber (a) at a fixed pressure higher than the oil pressure in
chamber (c).
Pressure oil that has flowed through the pressure reducing valve flows to chamber (f), then flows
through orifice D to chamber (e).
The pressure oil in chamber (c) flows into chamber (d) and the pressure compensation valve is
operated by the equilibrium of chamber (c), chamber (d) and spring 2.
This controls the oil pressure of chamber (d) at a fixed pressure higher than the oil pressure in
chamber (e).
Chamber (d) and chamber (c) are connected by orifice C, so they have the same oil pressure, and the
pressure differential between chamber (a) and chamber (f) is kept constant by operation of the unload
valve and the pressure compensation valve.
This pressure differential is detertimed by spring 1 and spring 2.
When the oil pressure in chamber (a) becomes high, the oil drains from the pilot relief valve of the
unload valve.
Accordingly, the maximum oil pressure of chamber (a) is detertimed by the installation load of spring 3.
Pressure compensating function (sectional view of inlet section)
Main flow/excess flow
Pilot flow
Unload valve Spring 1
E A (a) B
Port T1 Port P
(c)
(b) When the pilot relief valve is opened
When the pilot relief valve is closed
(f)
Spring 3
(e)
C Solenoid C1
(d)
Non-leak valve
Pressure compensation valve

Spring 2

9-11
When pressure compensation mechanism OFF

When solenoid C1 is not energized and the non-leak valve is open, the pressure oil from chamber (c)
flows through orifice Q, then returns to the tank via chamber (g). Now chamber (c) has the same
pressure as the tank, so all the pressure oil from port P returns to the tank via part E.
When the pressure compensating mechanism is inactive (sectional view of inlet section)

Pilot flow
E
Port T1 Port P
(c)
(g)
Solenoid c1
Q Non-leak valve

9-12
2. When material handling is not operated (spool in the neutral position)

When a pressure is applied from the port P
The pressure compensating mechanism is inactive because solenoid c1 is not activated.
When the pressure compensating mechanism is inactive (sectional view of inlet section)

Pilot flow
E
Port T1 Port P
(c)
(g)
Solenoid c1
Q Non-leak valve

9-13
Backpressure leak reduction mechanism

Port C1 of the lift cylinder is connected to the bottom of the lift cylinder, and port C3 of the tilt cylinder is
connected to the rod side of the tilt cylinder.
When load pressure from port C1 and port C3 is applied, leakage to chamber (i) and chamber (j) is
controlled by H and I on the seat.
Leakage of pressure oil that flowed to the lift lock check valve and pressure oil that flowed to the tilt
lock check valve is controlled by land part J and land part K respectively.
This reduces natural drop and natural forward tilt.
Backpressure leak reduction mechanism (sectional view of lift section)
Pilot flow
H
Port C1
J
(i)
Tilt lock check valve
Backpressure leak reduction mechanism (sectional view of tilt section)
I Pilot flow
Port C3
K
(j)
Tilt lock check valve

9-14
3. Hydraulic pressure mechanism for solenoid proportional valve

The pressure oil that has had its pressure reduced by the pressure reducing valve flows to chamber
(h), then flows through passage 4 and the filter to become the pilot pressure to each solenoid.
The pressure of the oil is determined by the set load on spring 4.
Hydraulic pressure mechanism for solenoid proportional valve
Pilot flow
Electromagnetic proportional valve Electromagnetic proportional valve
4 Tilt section
Lift section
Filter
(h)
Inlet section
Spring 4 Reducing valve

9-15
4. Load sensing mechanism

The pressure compensation valve, unload valve and sensing circuit are part of pressure compensation
operation.
When the spool strokes, chamber 7 connects to each cylinder port.
Sensing pressure is the cylinder pressure, which gives feedback to the pressure compensation valve.
When sensing pressure + pressure of spring (2) = pressure of chamber (d) and chamber (c), the
pressure compensation valve moves to the equilibrium position.
The pressure differential between the sensing pressure and chamber (d) and chamber (c) becomes
the pressure of spring (2).
The pressure of chamber (d) and chamber (c) is applied to the unload valve, then the unload valve
moves to the equilibrium position, when pressure of chamber (e) and chamber (c) + pressure of spring
(1) = P port pressure.
The pressure differential between chamber (d) and chamber (c) and P port pressure becomes the
pressure of spring (1).
The force of spring (1) and spring (2) is now constant, so the pressure differential is constant, and
sensing pressure + force of spring (1) +force of spring (2) = P port pressure.
Load sensing mechanism

Pilot flow
Lift spool Tilt section (2nd spool)
Lift section (1st spool) Tilt spool
Inlet section Attachment section (3rd spool)
Attachment spool
LS check valve 7

9-16
5. Lift UP operation
When the lift lever is pushed to the UP side, solenoid b1 is energized and the solenoid proportional
valve moves to the right. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (k) on the left side, and the lift spool moves to the right side.
The volume of oil that flows to chamber (k) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check, then flows
through part L and chamber 7 to move the lift lock check valve, and then flows to the port C1 and the
bottom of the lift cylinder.
The select valve does not operate at this time, so the select valve becomes simply a check valve.
The pressure differential between chamber (a) and chamber 7 is kept constant by the pressure
compensation mechanism and the load sensing mechanism, so the volume of pressure oil supplied to
port C1 is determined by the opening aperture of part L irrespective of the load.
Lift UP operation (lift section)

Inlet section Pilot flow
Load check
Tilt section Lift logic valve

(a)
Section S-S
Port C1
Lift spool
Logic selection valve
(k) S S
Spring 5
Solenoid b1 Solenoid a1
Electromagnetic proportional valve 7 8 10 Electromagnetic proportional valve

9-17
6. Lift DOWN operation

When the lift lever is pushed to the DOWN side, solenoid a1 is energized and the solenoid proportional
valve moves to the left. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (m) on the right side, and the lift spool moves to the left side.
The volume of oil that flows to chamber (m) is proportional to the distance the lever is operated.
The pressure oil from chamber (m) flows through 11 into chamber (o) and shifts the select valve to the
left.
Then the pressure oil operating on port C1 flows through orifice F and enters the select valve.
The circuit is configured with the select valve and chamber (u) connected, so the pressure oil of the
select valve flows through part M and then flows from chamber (g) to the tank.
Accordingly, C1 holding pressure opens the lift lock check valve and the oil flows from C1 to the tank.
Lift DOWN operation (lift section)
Pilot flow Lift logic valve
M
Port C1 F
Lift spool
5
Spring 6 Logic selection valve
(o)
11
(m)
(g)
Solenoid a1
Solenoid b1
If, due to a malfunction, you want to lower the mast without moving the lift spool, opening the
emergency DOWN valve will configure the circuit as shown in the diagram and the mast will descend.
Lift emergency down (lift section)

Port C1
Emergency down valve
(g)

9-18
7. FORWARD tilt operation

When the tilt lever is pushed to the FORWARD side, solenoid a2 is energized and the solenoid
proportional valve moves to the left. Then the pressure oil controlled by the pressure reducing valve
flows to chamber (p) on the right side, and the tilt spool moves to the left side.
The volume of oil that flows to chamber (p) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check, then flows from
port C2 to the bottom of the tilt cylinder.
Pressure oil flowing to chamber (p) enters chamber (n), and shifts the select valve to the left.
The circuit is configured so that oil from the tilt cylinder rod side flows from port C3 through the tilt lock
check valve and chamber (y) to chamber (g).
This generates a pressure differential before and after orifice G, and the shifting of the tilt lock valve to
the right causes the oil on the tilt cylinder rod side to return to the tank.
FORWARD tilt operation (tilt section)

Tilt section
Pilot flow
Load check
Attachment section
Section T-T
(a) (y) G Lift logic valve
Port C2 Port C3
Tilt spool
Spring 7
T T (n)
(g)
(p)

9-19
8. REAR tilt operation

When the tilt lever is pushed to the REAR side, solenoid b2 is energized and the solenoid proportional
valve moves to the right. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (w) on the left side, and the tilt spool moves to the right side.
The volume of oil that flows to chamber (w) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check and shifts the tilt
lock check valve, then flows from port C3 to the tilt cylinder rod side.
The select valve does not operate at this time, so the select valve becomes simply a check valve.
The pressure differential between chamber (a) and chamber 7 is kept constant by the pressure
compensation mechanism and the load sensing mechanism, so the volume of pressure oil supplied to
port C3 is determined by the opening aperture of part O irrespective of the load.
REAR tilt operation (tilt section)
Tilt section Main flow/excess flow

Pilot flow
Load check
Attachment section
Section U-U
(a) O Lift logic valve
Port C2 Port C3
Tilt spool

(w) U U
Spring 8
7

9-20
9. Attachment operation
When you operate the attachment lever, solenoid b3 is energized and the solenoid proportional valve
moves to the left. Then the pressure oil controlled by the pressure reduction valve flows to chamber (r)
on the left side and the spool moves to the right side.
Now the oil from chamber (s) drains out from 10 via the solenoid proportional valve.
The flow of the pressure oil after this is the same as for tilt operation.
Attachment operation (attachment section)
Tilt section Main flow/excess flow

Pilot flow
Load check
Outlet
Section V-V
Attachment spool
(a) Port C4 Port C5
(s)
(r) V V Spring 9
10

9-21
■ Mini Lever Structure

Mini levers strongly desired in the US market are provided as options.
• The material handling levers positioned above the instrument panel on previous models are installed on
the right front side of the seat and the lever stroke and operating force are decreased for easier
operation with less fatigue.
• Since they are single-axis levers independent for the forward and backward directions like the manual
levers on previous models, previous model operators can easily handle new models.
• The automatic fork leveling switch is installed behind the tilt lever. When the button is pressed once, the
operated state is stored mechanically by the lock mechanism in the switch for automatic leveling of the
fork at the time of stopping. Pressing it again releases locking to return to the original state without
automatic leveling. (See the mast control section for further details of the function.)
• The lever box position can be adjusted in the longitudinal direction. Loosen the lever box fixing knob, set
the box in the position desired by the operator, and tighten the knob for fixing.
• Levers are guarded all around.
• Material handling operation is disabled while the operator leaves the seat.
Arm pad
Fork automatic
leveling switch
Tilt lever Lift lever
Guard
Att lever

9-22
■ Armrest Structure
• An armrest is provided for alleviating the right arm fatigue during traveling and material handling lever
operation.
• The arm pad to be in contact with the arm and palm are made of soft urethane foam to fit the arm and
palm softly.
• The armrest is fixed on the battery hood to be independent from seat sliding operation. A tall operator
with long arms and legs can obtain the best operating position by sliding the seat backward, and an
operator with short arms and legs by sliding the seat forward.
• The armrest height can be adjusted. Loosen the armrest fixing knob, set the armrest at the desired
height and tighten the knob again.
• Every operator can select the best position for lever operation.
Driver’s position
Large operator
Medium operator
Small operator
Armrest fixing knob
Front-to-rear adjusting knob Height adjusting knob

9-23
BATTERY ROLL-OUT SPECIFICATION

■ General
• Provided for all models.
■ Structure
Battery roll-out vehicles have different frame structure from the standard vehicle as they replace battery
from the RH side.
The batteries are the same as those for standard vehicles.
The following indicate main structure:
A Battery stopper
Part A
Metal roller guide and rollers can be installed under the battery. They enable battery replacement with
ease without using the tool.
Roller guide (steel) Rollers
FR
RH

9-24
■ Battery replacement procedure

Follow the steps below when removing the battery:
(1) Open the battery hood.
(2) Raise the battery stopper to unlock.
(3) Turn the battery stopper. Slide the battery to remove it.
Installation procedure is the reverse of the removal procedure.
Open/close the battery hood following the same steps as the standard vehicle.
(1)
(3)
(2)

10-1
APPENDIX
Page 2
CAUTIONS FOR RECEIVING ORDERS................... 10-2
3
MAJOR SPECIFICATIONS .......................................... 10-3
FRAME NUMBER ........................................................... 10-5
TWO-PLANE DRAWING OF THE VEHICLE ........... 10-6
ELECTRIC WIRING DIAGRAM (VEHICLE
INSTALLED WITH OPTIONAL PARTS) ................ 10-9
10

10-2
CAUTIONS FOR RECEIVING ORDERS

■ Cautions for selling forklifts to customers in the marine product industry
1. Selling the standard vehicles to customers who handle fresh fish, pickles or tanned hides involving
possible salt water splashing onto vehicles may result in troubles of electrical parts such as motors.
Please sell the fisherman specification vehicles to a customer whose working conditions apply to any
of the following:
Conditions
• Transportation of salty or other water tanks involving possible water splashing onto the vehicle
• Vehicle being washed with salty water after the operation
• For use in an environment where the ground surface is constantly wet with salty water
• For use in an environment where the vehicle is possibly wetted with oxidizing fluid (such as
hydrogen peroxide or sodium hypochlorite)
• For use in an environment where calcium chloride or other snow-melting agent is used
2. Attention should be paid for use in such industrial sectors as marine product processing, pickling,
leather tanning and fertilizer production.
■ Cautions for Vehicle Modification
1. Note
These forklifts use high-precision electronic devices. It is, therefore, necessary to pay sufficient
attention to prevent adverse influence on electronic devices when any auxiliary electric equipment not
specified by the manufacturer is to be installed.
2. Caution
When selecting any auxiliary electric equipment of other than the specified manufacturers for
installation on your forklift, check for abnormal surge* or noise generation beforehand and also pay
attention to the installation method.
If it is unknown whether the auxiliary equipment generates any surge, please consult with the auxiliary
equipment manufacturer.
*: Surge refers to local application of a high voltage instantaneously in a part of an electrical circuit due
to a sudden change in the current flowing in the circuit.
3. Other general supplementary advice
(1) Precautions for each type of auxiliary electric equipment are as follows:
1) Auxiliary equipment with built-in inductive load such as a motor or solenoid
Connect a reflux diode across the inductive load.
Connect a surge absorber across the ON/OFF switch.
2) Auxiliary equipment such as a buzzer or chime that generates sound
Use an electronic buzzer instead of a contact-type buzzer or chime.
3) Auxiliary equipment including a high voltage discharge circuit such as an igniter
Since this type is likely to generate a noise, always install after confirming no noise generation.
(2) Precautions about wiring are as follows:
1) Lay the harness for the auxiliary equipment as far from each vehicle harness as possible.
2) Do not branch a power or signal line from any portion in the vehicle harnesses. Connect the
power line for example from an option connector terminal or directly from the battery terminal.
3) The power supply for auxiliary equipment should be provided independently if possible.
(3) Others
1) Install the static straps when installing the non-marking or smooth non-marking tires.

10-3
MAJOR SPECIFICATIONS
7FBEF15, 7FBEF16
Item
7FBEF15
Vehicle model
7FBEF16
2
Standard lifting height
Free lift
mm (in)
mm (in)
3000 (118)
150 (5.9)
3000 (118)
150 (5.9)
3
Mast tilt angle Forward / Backward 5 / 6.5 5 / 6.5
Overall length mm (in) 2695 (106.1) 2795 (110.0)
Body length (to the front of fork) mm (in) 1895 (74.6) 1995 (78.5)
Total width mm (in) 1070 (42.1) 1070 (42.1)
Main Mast raised mm (in) 3920 (154) 3920 (154)
Total
dimen-
height Mast lowered mm (in) 1980 (78) 1980 (78)
sions
Wheel base mm (in) 1400 (55.1) 1505 (59.3)
Front wheel mm (in) 915 (36.0) 915 (36.0)
Tread
Rear wheel mm (in) 175 (6.9) 175 (6.9)
Ground clearance mm (in) 85 (3.3) 85 (3.3)
Vehicle weight (without battery) kg (lbs) 1885 (4156) 1775 (3914)
Minimum turning radius mm (in) 1540 (60.6) 1640 (64.6)
Rated load kg 1500 1600
Load center mm (in) 500 (24) 500 (24)
Traveling speed No load km/h (mph) 16.5 (10.2) 16.0 (9.9)
(forward) Load km/h (mph) 15.0 (9.3) 15.0 (9.3)
Perfor- Traveling speed No load km/h (mph) 16.5 (10.2) 16.0 (9.9)
mance (reverse) Load km/h (mph) 15.0 (9.3) 15.0 (9.3)
No load mm/s (fpm) 610 (120) 610 (120)
Raising speed
Load mm/s (fpm) 430 (85) 420 (83)
Lowering No load mm/s (fpm) 550 (108) 550 (108)
speed Load mm/s (fpm) 500 (98) 500 (98)
Front wheel 18×7−8/4.33 18×7−8/4.33
Tire size
Travel Rear wheel 15×4.1/2-8/3.00 15×4.1/2-8/3.00
device Foot brake Mechanical Mechanical
Parking brake
Voltage V
Manual
48
Manual
48
10
Battery (STD)
Capacity Ah/5HR 550 660
Voltage V 48 48
Battery (High)
Drive Type AC induction type AC induction type
unit Drive motor Output kW 4.9×2 4.9×2
Control device Transistor inverter Transistor inverter
Type AC induction type AC induction type
Pump motor Output kW 9.2 9.2

10-4
7FBEF18, 7FBEF20
Vehicle model
Item
7FBEF18 7FBEF20
Standard lifting height mm (in) 3000 (118) 3000 (119.5)
Free lift mm (in) 150 (5.9) 125 (4.9)
Mast tilt angle Forward / Backward 5 / 6.5 5 / 6.5
Overall length mm (in) 2800 (110.2) 3080 (121.3)
Body length (to the front of fork) mm (in) 2000 (78.7) 2080 (81.9)
Total width mm (in) 1070 (42.1) 1125 (44.3)
Main Mast raised mm (in) 3920 (154) 3920 (154)
Total
dimen-
height Mast lowered mm (in) 1980 (78) 1980 (78)
sions
Wheel base mm (in) 1505 (59.3) 1505 (59.3)
Front wheel mm (in) 915 (36.0) 915 (36.0)
Tread
Rear wheel mm (in) 175 (6.9) 205 (8.1)
Ground clearance mm (in) 85 (3.3) 85 (3.3)
Vehicle weight (without battery) kg (lbs) 1895 (4178) 2215 (4884)
Minimum turning radius mm (in) 1645 (64.8) 1710 (67.3)
Rated load kg (lbs) 1750 2000
Load center mm (in) 500 (24) 500 (24)
Traveling speed No load km/h (mph) 16.0 (9.9) 15.5 (9.6)
(forward) Load km/h (mph) 14.5 (9.0) 14.0 (8.7)
Perfor- Traveling speed No load km/h (mph) 16.0 (9.9) 15.5 (9.6)
mance (reverse) Load km/h (mph) 14.5 (9.0) 14.0 (8.7)
No load mm/s (fpm) 610 (120) 500 (98)
Raising speed
Load mm/s (fpm) 390 (77) 340 (67)
Lowering No load mm/s (fpm) 550 (108) 500 (98)
speed Load mm/s (fpm) 500 (98) 500 (98)
Front wheel 18×7−8/4.33 200/50-10/6.50
Tire size
Travel Rear wheel 15×4.1/2-8/3.00 16×6-8/4.33
device Foot brake Mechanical Mechanical
Parking brake Manual Manual
Voltage V 48 48
Battery (STD)
Voltage V 48 48
Battery (High)
Drive Type AC induction type AC induction type
unit Drive motor Output kW 4.9×2 4.9×2
Type AC induction type AC induction type
Pump motor Output kW 9.2 9.2

10-5
FRAME NUMBER
■ Frame number punching location
2
3
Frame No. punching

position
■ Frame number punching format
Vehicle Model Punching format Vehicle Model Punching format

10
7FBEF15 7FBEF15 10011 7FBEF16 to 20 7FBEF20 10011

10-6
TWO-PLANE DRAWING OF THE VEHICLE
C
D
H
A
E
G
F
Fr Rr
S T
I
J
K
R
M
L
P Q
N O

10-7
mm (in)
Vehicle model
Position
7FBEF15 7FBEF16 7FBEF18 7FBEF20
A 1070 (42.1) 1070 (42.1) 1070 (42.1) 1125 (44.3)
B 900 (35.4) 900 (35.4) 900 (35.4) 990 (39.0)
C 915 (36.0) 915 (36.0) 915 (36.0) 915 (36.0)
D 180 (7.1) 180 (7.1) 180 (7.1) 225 (8.9)
E 80 (3.1) 80 (3.1) 80 (3.1) 100 (3.9)
F 1670 (65.7) 1720 (67.7) 1730 (68.1) 1825 (71.9)
G 1540 (60.1) 1640 (64.6) 1645 (64.8) 1710 (67.3)
H 175 (6.9) 175 (6.9) 175 (6.9) 205 (8.1)
I 3920 (154.3) 3920 (154.3) 3920 (154.3) 3920 (154.3)
J 3000 (118) 3000 (118) 3000 (118) 3000 (118)
K 1970 (77.6) 1970 (77.6) 1970 (77.6) 1970 (77.6)
L 150 (5.9) 150 (5.9) 150 (5.9) 125 (4.9)
M 40 (1.6) 40 (1.6) 40 (1.6) 40 (1.6)
N 800 (31.5) 800 (31.5) 800 (31.5) 1000 (39.4)
O 1895 (74.6) 1995 (78.5) 2000 (78.7) 2080 (81.9)
P 355 (14.0) 355 (14.0) 355 (14.0) 370 (14.6)
Q 1400 (55.1) 1505 (59.3) 1505 (59.3) 1505 (59.3)
R 1980 (78) 1980 (78) 1980 (78) 1980 (78)
S 5° 5° 5° 5°
T 6.5° 6.5° 6.5° 6.5°

10-8

10-9
ELECTRIC WIRING DIAGRAM (VEHICLE INSTALLED WITH OPTIONAL PARTS)

(P2,G) CPR
F6 ACCEL
VRAD
P1 MB P2 F1 P3 - + LIFT TILT ATT1 ATT2 SW MH1
SW AC
TILT LEVER LEVER LEVER LEVER
SW K
VRAT VRAL1 VRAL2 VRAT1 VRAT2 VRAAT11 VRAAT12 VRAAT21 VRAAT22 SW TK DS F DS R LS B LS PB LS D
(P1,B) F5 (41,BR) - + - + - + - + - + - + - + - + - +
SPL
-
MB
F4 (101,Y)
+
(55,W-G)
(20,W-G)
(25,G-W)
(51,R-W)
(29,W-R)
(28,B-W)
(24,P-W)
(52,GR)
(53,R-G)
(22,G-R)
(44,Y-G)
(44,Y-G)
(21,P-G)
(27,Y-G)
(46,G-Y)
(65,Y-G)
(41,BR)
(58,BR)
(70,BR)
(59,Y-R)
(23,B-R)
(45,W)
(43,B-Y)
(26,B-Y)
(51,R-L)
(51,R-L)
(91,GR)
(18,O)
(56,G)
(30,O)
(64,R)
(66,R)
(31,P)
(2,R)
(57,L)
(67,L)
(1,V)
(90,O)
TR Y HR Y LS ST
(116,LG) (115,P)
VBKY
VBBT
B48V
VBMB
VBMB
CPR
MB+
MB-
POT-
SWAC
POTA
POTA+
SPL
SPL+
POTTA
POTTA+
POT-
POTL1
POTL2
POTL+
POTT1
POTT2
POTT+
POTAT11
POTAT12
POTAT1+
POTAT21
POTAT22
POTAT2+
LEDTK
LS-
SWTK
DSF
DSR
LSB
LSPB
LSD
SWLE
LSL+
LSTF+
LSTR+
LSAT1+
LSAT2+
MH2-1
MH1
OPTO
SWL SWL
T HS HM
PB CPU
(104,G-R)
(102,R-G)
(107,R-B)
(111,R-L)
BATT N2
KEYSTART
DS BU DS FO
CANGND
48V
SOLST+
SOLST-
SMTDK
SDTMK
SDTMA
SMTDA
POTH+
FANR+
SOLP+
SOL1+
SOL2+
SOL3+
SOL4+
SOLb1
SOLa1
SOLa2
SOLb2
SOLa3
SOLb3
SOLa4
SOLb4
FANR-
SOLP-
N2
GNDD
CANH
POTH
CANL
STSC
FAN1
FAN2
FAN3
FAN4
FAN5
FAN6
STS1
STS2
D15V
POT-
FAN-
FAN-
L C-L L T-L L H-L LW L ST
LS-
-L
(130,Y)
(131,Y)
(132,Y)
(133,Y)
(134,Y)
(135,Y)
(N2,W-B)
(330,GR)
(36,G-W)
(51,R-W)
(14,B-W)
(312,G-W)
(42,GR)
(146,W)
(141,W-R)
(3,W-R)
(11,G-B)
(34,G-Y)
(39,Y)
(39,B)
(13,R-Y)
(144,G-R)
(143,R-G)
(6,R-G)
(317,G-Y)
(329,B-O)
(51,R-L)
(10,R-L)
(145,B)
(147,Y)
(7,B-G)
(8,P-G)
(316,R-Y)
(313,R-Y)
(142,R-B)
(35,B-L)
(4,B-R)
(314,L)
(9,Y-B)
(16,R)
(12,P)
(5,Y)
L C-R L T-R L H-R L ST
-R
+ -
FAN
EX
FAN
EX
SST
VRAH
TIRE ANGLE SOL Lb1 SOL La1 SOL Ta2 SOL Tb2 SOL ATa3 SOL ATb3 SOL ATa4 SOL ATb4 SOL P
SOL ST
(103,R-W)
RT
(120,Y-R)
FR Y R
SWH
(110,GR)
SA SWF
L BU
(87,W-G)
(88,W-G)
(84,W-R)
(77,B-W)
(81,B-W)
(75,G-R)
(79,G-R)
(86,P-G)
(89,Y-G)
(83,B-R)
(85,R-L)
(76,BR)
(80,BR)
-R
(78,P)
(82,P)
(109,G-Y)
(108,R-Y)
SSP SSD1 SSD2

CUPON
CUPID0
CUPID1
CANTRP
KEYSTART
CANH
CANL
CANGND
SSP-,TP-
TP+
SSP+
SSP1
SSP2
CUDON
CUDID0
CUDID1
CANTRD
KEYSTART
CANH
CANL
CANGND
SSD1-,TD1-
TD1+
SSD1+
SSD11
SSD12
CUDON
CUDID0
CUDID1
CANTRD
KEYSTART
CANH
CANL
CANGND
SSD2-,TD2-
TD2+
SSD2+
SSD21
SSD22
BZ
(48,P)
P14 P7 P71
LF LF (U) (U) (U)
-LR -RR
P15 P8 P81
(V)
AMP STMP
(V)
AMD1 STMD1
(V)
AMD2 STMD2
H
P16 P9 P91
L F-L L F-R (W) (W) (W)
CUP CUD1 (LH) CUD2 (RH)
N2
N1 N1
N1
FANEX FAN, EXHAUST, CONTROL UNIT

FOR STD(MINI LEVER LESS)
MSCH STT SLL GNDD
MB CONTACTOR, BATTERY
AC-R +15V
VRAD VARI-OHM, ACCEL, DRIVE AC-S SMTDK
VRAT VARI-OHM, TILT DS F DIRECTION SWITCH, FORWARD LCD SDTMK
LS L LS TF LS TR LS AT1 LS AT2 SDTMA
DISP
VRAH VARI-OHM, TIRE(HANDLE) DS R DIRECTION SWITCH, REVERSE SMTDA
DS FO DIRECTION SWITCH, FORWARD OPTIONAL
CHGLED1
CHGLED2
CHGLED3
CHGLED4
N1
CHGSW1
CHGSW2
CHGSW3
48V
VRAL1 VARI-OHM, LIFT, NO.1 DS BU DIRECTION SWITCH, BACK-UP
BATT BATTERY VRAL2 VARI-OHM, LIFT, NO.2 LS L LIMIT SWITCH, LIFT NOTE)
THIS DRAWING SHOWS
(60,W-G)
(60,W-G)
(63,P-W)
(63,P-W)
F1 FUSE, DRIVE VRAT1 VARI-OHM, TILT, NO.1 LS TF LIMIT SWITCH, TILT FR

(61,G-R)
(61,G-R)
(51,R-Y)
(62,B-R)
(62,B-R)
F4 FUSE, LAMP VRAT2 VARI-OHM, TILT, NO.2 LS TR LIMIT SWITCH, TILT RR

CASE OF FULL OPTION.
F5 FUSE, CONTROL CIRCUIT VRAAT11 VARI-OHM, ATTACHMENT1, NO.1 LS AT1 LIMIT SWITCH, ATTACHMENT NO1
LS-
LSL+
LSL
LSTF+
LSTF
LSTR+
LSTR
LSAT1+
LSAT1
POTL2
POTL+
POTT2
POTT+
POTAT12
POTAT1+
POTAT21
POTAT22
POTAT2+
LSAT2+
F6 FUSE, FAN&SOLENOID VRAAT12 VARI-OHM, ATTACHMENT1, NO.2 LS AT2 LIMIT SWITCH, ATTACHMENT NO2
VRAAT21 VARI-OHM, ATTACHMENT2, NO.1 LS ST LIMIT SWITCH, STOP LAMP
LCD DISP LCD DISPLAY VRAAT22 VARI-OHM, ATTACHMENT2, NO.2 LS B LIMIT SWITCH, BRAKE LW LAMP, WORKING PB CPU
SOLP+
SOLT+
SOLL+
SOL3+
SOL4+
SOLa1
SOLb2
SOLa3
SOLb3
SOLa4
SOLb4
SOLP-
SOLT-
SOLL-
AM D1 MOTOR, DRIVE 1 LS PB LIMIT SWITCH, PARKING BRAKE L F-LR LAMP, FLASHER LH (REAR)
FOR D2 PEDAL
AM D2 MOTOR, DRIVE 2 CU D1 CONTROL UNIT, DRIVE 1 LS D LIMIT SWITCH, DEADMAN L F-RR LAMP, FLASHER RH (REAR)
AM P MOTOR, PUMP CU D2 CONTROL UNIT, DRIVE 2 L F-L LAMP, FLASHER LH 43(B-Y) 51(R-Y)
(3,W-R)
(6,R-G)
(7,B-G)
(4,B-R)
CU P CONTROL UNIT, PUMP SWAC SWITCH, ACCEL L F-R LAMP, FLASHER RH

SOLST SOLENOID, STEERING PB CPU PRINT BOARD, COMPUTER SWK SWITCH, KEY L ST-L LAMP, STOP LH DS BU DS FO DS F DS R
SOLL SOLENOID, LIFT SWL SWITCH, LIGHT L ST-R LAMP, STOP RH
SOLT SOLENOID, TILT CPR RESISTOR, CURRENT PROTECT SWF SWITCH, FLASHER SOL L SOL T
SOLLa1 SOLENOID, LIFT, a1(DOWN) RT TERMINATING RESISTANCE SWH SWITCH, HORN L BU-R LAMP, BACK-UP RH
103(R-W) 120(Y-R) 45(W) 46(G-Y)
SOLLb1 SOLENOID, LIFT, b1(UP) SST SENSOR, STEERING SWTK SWITCH, TILT KNOB HR Y RELAY, HEAD LAMP
SOLTa2 SOLENOID, TILT, a2(FRONT) SPL SENSOR, PRESSURE LIFT SWMH1 SWITCH, HEIGHT NO.1 TR Y RELAY, TAIL LAMP
SOLTb2 SOLENOID, TILT, b2(REAR)
SOLATa3 SOLENOID, ATTACHMENT, a3 SSD1 SENSOR, SPEED, DRIVE 1 L H-L LAMP, HEAD LH BZ BUZZER
SOLATb3 SOLENOID, ATTACHMENT, b3 SSD2 SENSOR, SPEED, DRIVE 2 L H-R LAMP, HEAD RH
SOLATa4 SOLENOID, ATTACHMENT, a4 SSP SENSOR, SPEED, PUMP L C-L LAMP, CLEARANCE LH SA SURGE ABSOBER
SOLATb4 SOLENOID, ATTACHMENT, b4 STMD1 SENSOR, TEMPRETURE, DRIVE 1 L C-R LAMP, CLEARANCE RH H HORN
SOLP SOLENOID, PRESSUR STMD2 SENSOR, TEMPRETURE, DRIVE 2 L T-L LAMP, TAIL LH FR Y RELAY, FLASHER
STMP SENSOR, TEMPRETURE, PUMP L T-R LAMP, TAIL RH

Published by
TOYOTA Material Handling Company

A Division of TOYOTA INDUSTRIES CORPORATION
1st Printing: May 2003
Pub. No. CE335-CD
Printed in JAPAN

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< Tillbaka till Servicemanual 7FBEF 15-20 Index

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Please read it carefully for sales and service activities.

TOYOTA Material Handling Company

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VEHICLE EXTERIOR VIEWS

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FEATURES (SELLING POINTS)

Sine wave Motor

• Conversion from battery DC • No brush and commutator • Conversion from DC into

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Features of AC motor drive system

180min 220min 260min 300min Operation time

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Cycle time Operation time

H mode P mode S mode 5FBE15 H mode P mode S mode 5FBE15

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3. Improved Efficient Operation Hour

Full load performance Low remaining battery charge warning

Previous model (1.5t:S mode)

7FBEF15 7FBEF15 5FBE15

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4. Easy Ingress/Egress and Dwelling Ability

New model Previous model

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9. Maximum battery capacity

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MAJOR DIFFERENCES BETWEEN NEW AND PREVIOUS MODELS

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Compartment dimensions mm (in) Minimum required battery

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■ Drive motor features

Drive unit Field core

Rpm sensor bearing

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■ Structure and principle of AC induction motor

(b) Rotor ASSY

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■ Motor operation principle

2. Fleming's right-hand rule

3. Fleming's left-hand rule

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7. The rotational magnetic field is as explained below.

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AC and DC power system output

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Drive Drive motor thermo-sensor

Drive Drive motor thermo-sensor

Traveling/material handling controller

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Internal Configuration of Traveling/Material Handling Controller

Comfortable operability is CANBus