Beruflich Dokumente
Kultur Dokumente
This manual deals with the above models as of September 1998. Please
understand that disagreement can take place between the descriptions
i n the manual and actual vehicles due t o change i n design and specifi-
cations. Any change or modifications thereafter will be informed b y
Toyota Industrial Vehicles' Parts & Service News.
GENERAL
BATTERY
OTHER THAN U.S.A.] (1993.1 - 1998.8)
CONTROL ClRCU IT [FOR
IFOR u.s.A.1 (1993.1 -1999.1 )
-
-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8)
MULTI-DISPLAY FUNCTIONS [Fouu.s.A.j (1993.1 - )
-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8)
ELECTRICAL SYSTEM TROUBLESHOOTING [FoRu.s.A.1 (1993.1 -1
MOTOR
/ FRONT AXLE & TRANSMISSION (lgg3.1 - lgg8-l)
FRONT AXLE & DRIVE UNIT (1998-2-1
REAR AXLE (1993.1- 1998.1)
1 A
STEERING
-
-
BRAKE (1998.2- I
BODY & FRAME
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL ]
APPENDIX
GENERAL
Page
EXTERIOR VIEWS ........................... 0-2
VEHICLE MODEL ........................... 0-3
FRAME NUMBER ........................... 0-3
HOW TO USE THIS MANUAL ................ 0-4
EXPLANATION METHOD .......................... 0-4
TERMINOLOGY .................................. 0-5
ABBREVIATIONS ................................. 0-5
LIST OF ABBREVIATIONS AND SYMBOLS .......... 0-6
OPERATIONAL TIPS ......................... 0-7
JACK-UP POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
CIRCUIT TESTER ............................ 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE ................................. 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ....................................... 0-11
TIGHTENING TORQUE TABLE ..................... 0-12
PRECOAT BOLTS ........................... 0-13
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ..................... 0-13
WIRE ROPE SUSPENSION ANGLE LIST ....... 0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ..................... 0-14
COMPONENTS WEIGHT ..................... 0-15
RECOMMENDED LUBRICANTS
AND CAPACITIES ......................... 0-15
LUBRICATION CHART ....................... 0-16
PERIODIC MAINTENANCE ................... 0-17
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................ 0-22
0-2
EXTERIOR VIEWS
VEHICLE MODEL
Battery capacity Voltage
Load capacity Model Control circuit
AH/5HR V
1.0 ton 5FBE10 280 *36 or 48 MCS-IIIA
FRAME NUMBER
Punching
position
5FBE13-10011
5FBE10 5FBE13E10011 (EEC spec.)
1 ton
series
-
(1993.1 1993.9)
5FBE13
(1993.10 -
5FBE130 10011 (EEC spec.)
)
5FBE18-10011
5FBE15 5FBE18E10011 (EEC spec.)
1.5 ton
series
-
(1993.1 1993.9)
5FBE18010011 (EEC spec.)
5FBE18
(1993.10 -
)
2.0 ton 5FBE20-10011
5FBE20
series
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustra-
tion, followed by explanation of cautions and notes summarized as point operations.
--
T = 46.09 48.05
(470 490)
134.00- 35.451
Disassembly Procedure
1 Remove the cover. [Point 11
[Point 11
Disassembly:
J
Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
2. How to read components figures (Example)
(1) The components figure use the illustra-
fl
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of FIG number in parts catalog
each components figure indicates the
Fig. number in the parts catalog.
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to observe them.
Note:
lmportant items of which negligence may cause accidents or matters in operation procedure
requiring special attention.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly RR Rear
Electrical hydraulic power Society of Automotive
EHPS SAE
steering Engineers (USA)
FR Front SST Special service Tool
I-/ Less STD Standard
LH Left hand T= Tightening torque
0PT Option OOT Number of teeth (00)
01s Oversize U/S Undersize
PS Power steering w/ With
RH Right hand
LIST OF ABBREVIATIONS AND SYMBOLS
Symbol Name Symbol Name Symbol Name
BATT Battery FRY Flasher Relay PBsN Snubber Print Board
BZ Buzzer H Horn PLw Working Pilot Lamp
CA Absorber Capacitor IWP Wheel Position Indicator RA Absorber Resistor
CADIP Drivelpump Absorber LBU-~ Back-up Lamp, LH RADIP Drivelpump Absorber
Capacitor LBU-~ Back-up Lamp, RH Resistor
CH Charger LC-L Clearance Lamp, LH PCKI I 2 Check Resistor No.112
CHIF Forward Chime LC-R Clearance Lamp, RH SA Surge Absorber
CHIR Reverse Chime LF-L Flasher Lamp, LH SLL Lequid Level Sensor
CSDIP DriveIPump Current L F - ~ ~Flasher Lamp, LH (Rear) SN1 Sunbber No.1
Sensor LF-R Flasher Lamp, RH SNCI 12 Snubber Capacitor 112
CSps Power Steering Current LF-RR Flasher Lamp, RH (Rear) SNR112 Snubber Resistor 112
Sensor LH-L Head Lamp, LH SSP Steering Pressure Sensor
DADIP Drivelpump Absorber LH-~ Head Lamp, RH SSL Speed Sensor, LH
Diode LR-F Rotaly Forward Lamp SSR Speed Sensor, RH
DCH Charger Diode LR-~ Rotaly Reverse Lamp STH Thermo Sensor
DC-SDD DC-DC Converter & LSAnI2
l Attachment Limit Switch SWAC Accel Switch
Source Drive (Drive) No.112 SWF Flasher Switch
DC-SDP DC-DC Converter & LSB Brake Limit Switch SWH Horn Switch
Source Drive (Pump) LSD Dead Man Limit Switch SWKy Key Switch
DF112 FLY-WHEEL Diode, LSL1/2 Lift Limit Switch No.112 SWL Light Switch
No.112 LSsT Stop lamp limit Switch SWPB Parking Brake Limit
DF314 FLY-WHEEL Diode No.314 L S T - ~ Stop Lamp, LH Switch
DlSP Display L s T - ~ Stop Lamp, RH SWsc Speed Control Switch
DMDlP DriveIPump Motor LST Tilt Limit Switch TF Transformer
DMps Power Steering Motor LT-~ Tail Lamp, LH THR Thermal Relay
DSBu Back-up Direction Switch LT-~ Tail Lamp, RH TM Main Transistor
DSF Forward Direction Switch Lw Working Lamp TMD Main Drive Transistor
DSFo Forward Optional MFL Forward Contactor, LH TMP Main Pump Transistor
Direction Switch MFR Forward Contactor, RH TMps Main Power Steering
DSR Reverse Direction Switch MP Pump Contactor Transistor
F1 Drive Fuse MPS Power Steering Contactor TU Timer Unit
F2 Pump Fuse MRL Reverse Contactor, LH VRAD Accel Drive Variable
F3 Power Steering Fuse MRR Reverse Contactor, RH resistor
F4 Lamp Fuse MScH Charger Magnet Switch VRSP Steering Position Variable
F5 Control Circuit Fuse PBcpu Computer Print Board resistor (Steering
FCH Charger Fuse PBEHPs EHPS Print Board potentiometer)
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks on rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve
in load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil
pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange
the parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean
tools and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassem-
bly. If no tightening torque is specified, tighten the bolt or nut according to the standard
tightening torque table.
Front jack-up
If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with
a bearing plate at least 80 m m long.
Rear jack-up
When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the
weight on the opposite side.
The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle
maintains its balance during jack-up.
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively
according to the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the mea-
sured value should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or
movement.
1. Difference in measurement results with the digital type and analog type
*The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual. Cautions when the polarities are
different between the analog type and digital type are described below.
No continuity
Reverse
I Forward
I
I
NO continuity I
1
Continuity
Reverse shall exist
2 MR
2. Difference i n result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is
used. The resistance of a semiconductor such as a diode varies with the circuit tester power
supply voltage.
The diode characteristics are shown in the figure below.
(m~) The resistance values of the same semiconductor
5 measured with t w o types of circuit testers having
different power supply voltages are different.
Current 4
in This manual describes the results of measurement
forward
direction
with a circuit tester whose power supply voltage is
3.0 V.
2
Variable resistor
Current
flow
I ,-
Resistor
Range: x 10
, (SW 1)
,,
Resistor
41 ,
TEwer
4
(SW2)
Range: x 1
source: 1.5 V
"0 Red 6@
Black
STANDARD BOLT AND NUT TIGHTENING TORQUE
How to judge tightening torque of a standard bolt or nut.
Hexagon
@- Bolt head No.
5 = 5T
6 = 6T
7 = 7T
8 = 8T
Part No.
91611-40625
T L e n g t h (mml
head bolt
Diameter (mm)
0 No mark 4T
Hexagon 4T iameter
No mark
flange bolt
Stud bolt
Two protruding
Part No.
921 32-40614
Length (mm)
Four protruding Diameter (mm)
0-12
I I I I
10 1.25 38 j 400 29 43 1
1
440 j 32
6T I I I
12 1.25 72 1
I
730 1 53
I
79 1810 159
I I
7T
10 1.25 52 i
I
530 j
I
38 58 j
I
590 j
I
43
12 1.25 95 1
I
970 1 70
I
103 1 1050
I
:
I
76
14 1.5 147 j
I
1500 i 108
I
167 ,
11700 j123
16 1.5 226 1 2300
L
1 166 -
I
I
I
- I
I
I -
I
6 1.O 12 i
I
125 j
I
9 l4 1I 145
I
9
8 1.25 29 1
I
300 1 22
I
32 1 330 1I 24
10 1.25 61 j 620 j 45 68 1
I
690 j 50
8T I I I
I I Note:
For toraue check. use the lower limit of the allowable
tighteni;lg torque range. If the bolt moves, retighten it
according to the steps below.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and
tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N-m (kgf-cm) [ft-lbf] Hose inside
of screw diameter
Standard Tightening range m m (in)
7/16 - 20UNF 25 (250) [18.1 1 24-26 (240-270) [17.4-19.51 6 (0.24)
9/16 - 18UNF 49 (500) [36.2] 47-52(480-530) 134.7-38.31 9 (0.35)
314 - 16UNF 59 (600) [43.4] 56-62 (570-630) [41.2-45.61 12 (0.47)
718 - 14UNF 59 (600) [43.4] 56-62 (570-630) [41.2-45.61 12 (0.47)
718 - 14UNF 78 (800) [57.9] 74-82 (760-840) [55.0-60.81 15 (0.59)
1.1116 - 12UNF 118 (1200) [86.8] 112-123 (1140-1250) [82.5-90.41 19 (0.75)
1.5116 - 12UNF 137 (1400) [101.3] 130-144 (1330-1470) [96.2-106.41 25 (0.98)
PF1/4 25 (250) [18.1] 24-26 (240-270) [17.4-19.51 6 (0.24)
PF3/8 49 (500) [36.2] 47-52 (480-530) [34.7-38.31 9 (0.35)
PF1/2 59 (600) [43.4] 56-62 (570-630) 141.2-45.61 12 (0.47)
PF314 118 (1200) [86.8] 112-123 (1140-1250) [82.5-90.41 19 (0.75)
PF1 137 (1400) [101.3] 130-144 (1330-1470) [96.2-106.41 25 (0.98)
WlRE ROPE SUSPENSION ANGLE LIST
Lifting Compres- Suspension Lifting Compres- Suspension
~~~~i~~ Tension
angle sion method angle sion method
-Ll
7
90" 1.41 time 1.00 time
by5
2' A
30' 1.04 time 0.27 time
h0
- 120' 2.00 time 1.73 time
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [lbf]
3. Tilt cylinder front pin 111 lnspect every 170 hours (monthly)
ELECTRICAL SYSTEM
Abnormal sound during revolution I t c t
Loose terminal T c +- t
Insulation resistance M t c
Motor
Brush wear and sliding contact status I c
Loose terminal I C +- C
Terminal loosening I c c t
Operation I c C +-
Wiring clamp
(including Loose connection and taping status I c c c
POWER TRAIN
Oil leak I c c c
TRAVELING EQUIPMENT
Tire air pressure M t c c
STEERING SYSTEM
Play and looseness I t t t
Steering wheel
Function I t t t
Oil leak I t t t
BRAKING SYSTEM
Play and reserve M t t t
Brake pedal
Braking effect I t t t
Pull margin I t t t
Braking effect I t t t
Parking brake
Rod and cable looseness and damage I t t t
lining
Pad wear and damage M
Disk brake wheel wear and damage M
Disk brake lever operating status I t t
Uneven movement I t t t
Oil leak I t c t
Loosening of mounting I +- c C
Back-rest
Deformation, crack and damage I t c t
Lighting
Function and mounting condition I t c c
system
Horn Function and mounting condition I t t c
Direction
Function and mounting condition I t t c
indicator
Instruments Functions I c c c
Hydraulic oil c
Transmission oil
Wheel bearing grease
Master cylinder rubber parts
Wheel cylinder rubber parts
Chain
(Every 3 years)
BATTERY
Page
SERVICE STANDARDS ........................................ 1-2
DISPLAY INDICATION ........................................... 1-2
OVERDISCHARGE ALARM FUNCTION ..................... 1-2
BATTERY COMPARTMENT & MINIMUM
WEIGHT REQUIRED .......................................... 1-3
TROUBLESHOOTING ........................................... 1-4
BATTERY ASSY ................................................... 1-5
DISPLAY INDICATION
1. The display indicates the remaining battery charge
level in 1 0 stages. When the remaining charge drops
to the set level or below, the indication flashes the
warn the timing for charging.
Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on, how-
ever, material handling operation can be performed.
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by re-
ferring to the table below. Always use a case allowing fixation of the battery stopper.
f
38 mm
(1.5 in)
4
Y
-
i
TROUBLESHOOTING
Insufficient charge
Shorting between
service
Deposition of fallen
- acting substance in Dirty terminal or plug-
BATTERY ASSY
REMOVAL-INSTALLATION
Removal Procedure
1 Disconnect the battery plug.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
INSPECTION
1. Electrolyte level inspection
GS battery:
Open the cap and add distilled water if the white line
on the red float is invisible. Add water until the white
line on the float appears and stop addition there be-
cause further addition until the contact between the
float and stopper results in overfilling.
YUASA battery:
Open the cap and add distilled water if the ring of the
red float is dropped. Add water until the float ring
comes into contact with the top portion.
Insufficient electrolyte
Flashing
level
Caution:
Never change the mounting position of the plug with
sensor.
Note:
The electrolyte consumption can be calculated by the following equation:
Consumption (CC) = 5 hour rating capacity x 0.0336 x number of cells x charging frequency
2. Electrolyte inspection
(1) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.
3. Inspection of electrolyte specific gravity
(1) Use a hydrometer and measure the specific gravity
of the electrolyte
Nozzle
Note:
If the insulation resistance is less than 1 MQ, remove
the battery from the vehicle and wash it with water.
Dry the battery case roughly, and measure the insu-
lation resistance again. Install the battery on the ve-
hicle after checking that the insulation resistance is
1 MQor more.
* Battery control table
Prepare the control table for each battery to record and retain the inspection result.
Inspection Electrolyte
Specific Added wa-
date and Inspected cell No. tempera- Remarks Inspector
gravity ter volume
time ture
CONTROL CIRCUIT
(1993.1 - 1998.8)
[FOR OTHER THAN U.S.A.]
[FOR U.S.A.] (1993.1 - 1999.1)
Page
MCS-IIIA CONTROLLER .....................
2-2
GENERAL ........................................ 2-2
SPECIFICATIONS ................................. 2-3
COMPONENTS ................................... 2-4
CONTROL PANEL REMOVAL. INSTALLATION ....... 2-9
CONTACTOR PANEL REMOVAL . INSTALLATION .... 2-10
INSPECTION .....................................2-11
DISASSEMBLY ................................... 2-29
REASSEMBLY .................................... 2-30
PANEL PARTS TIGHTENING TORQUE .............. 2-33
CONTINUITY CHECK WITH CIRCUIT TESTER ....... 2-34
OCL (OVERCURRENT LIMIT) VALUES .............. 2-35
ACCELERATION POTENTIOMETER
ADJUSTMENT ............................ 2-37
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT ............................ 2-38
PARKING BRAKE SWITCH ADJUSTMENT ..... 2-39
MATERIAL HANDLING SWITCH
ADJUSTMENT ............................ 2-40
DIRECTION SWITCH ........................ 2-41
A t the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken t o ensure safety.
When the display is set t o the analyzer (fault analysis) mode, defect detection and functional check of
the main drivelmaterial handling circuit, operating systems, and sensors are performed.
See the Multi-display section (page 3-21 for the diagnosis. See the Multi-display section (page 3-7) for
the analyzer.
Contactor panel
2-8
MF-MR contactor
MP contactor
CONTROL PANEL REMOVAL-INSTALLATION
1 Battery plug 4
5 Connector
6 Wiring
Removal Procedure
1 Disconnect the battery plug.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose,
the control panel elements may be damaged.
CONTACTOR PANEL REMOVAL.lNSTALLATlON
1 Banery plug
2 Toe board
5 Wiring
-
Removal Procedure
1 Disconnect the battery plug.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug.
INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.
As the CPU board and DC-SD boards require battery voltage application, they must be inspected while
being mounted on the vehicle. (Use SST 09240-1 2240-71 .)
Inspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1 Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
Standard
When circuit tester probes are brought into contact with both terminals of CAD or CAP, the pointer deflects
once to the 0 Q side and gradually deflects toward the oo Q side.
If any T M or TMP is found abnormal in inspection replace them (all TMs or all TMPs) as a set.
3- 1. DRD (Direction of Reverse Conductive Diode)
(1 lnspection method
Remove the DRD.
u u
Conduction N o Conduction
When inspecting with the battery installed, disconnect the CN1 17 connector.
Caution:
Always disconnect the battery plug before removing or installing the CPU board or DC-SD board.
Note:
When replacing the CPU board or DC-SD board judged to be causing the trouble as a result of trou-
bleshooting, always measure the applied voltage and resistance at related portions before replace-
ment.
Use SST 09240-12240-71 for the measurement.
CN107
(2) Lists of measurement methods and standards
@ Explanation on list format
+
r Circuit tester ( probe
1
Connector No.
CN102-1
- Connector No.
CN102-9
1
SWKy: ON
Conditions Standard Remarks
L ~ e v eNo.
l
@ Lists
C N 101 connector Basic conditions (battery plug ON.SWKy ON)
CN101-18 I CN101-20
(31, VDD-1 I (NI, GND)
Traveling stop state 4 - 5V
CN101-19 I Unused
CN101-20 Panel N1 Battery plug OFF
(N1, GND) I terminal SW, OFF
on
CN101-21 I CN101-20
Approx. 48 Vl36 V
(13,VBBT) I (N1,GND)
I
CN101-22 I CN101-20
(41, 836 V ) I ( N l , GND)
Approx. 48 Vl36 V Battery voltage
CN102-3 1 Unused
I
I 4 8 V vehicle:
CN102-4 CN102-9 43f 5V
(P8,RCKl) I (N1,GND) 36 V vehicle:
I
I 32f 5V
CN102-5 I CN102-9
(P9,RCKl) I (N1,GND)
Approx. 48 Vl36 V
CN102-6 I CN102-9
ov
(N2, TMS) I (NI, GND)
I
CN102-7 I CN102-9
I Unused Approx. 48 Vl36 V Battery voltage
(41, B36 V ) I (N1, GND)
CN102-8 I CN102-9
(41, D36 V) I ( N l , GND)
Approx. 4 8 Vl36 V Battery voltage
Connector No. o Connector No. Conditions Standard Remarks
CN102-9 Panel N1 Battery plug OFF
on
(NI, GND) terminal SW, OFF
CN102-10 Unused
I 48 V vehicle:
I
CN102-11 I CN102-9 43* 5V
(P8, TMD) (N1, GND) 3 6 V vehicle:
I
I
32 *
5V
CN102-12 I CN102-9
Traveling stop state -5 - - 6V
(92, TMG) I ( N l , GND)
CN103-2 CN103-3
(37, CHOPP +) I (11, GND)
5 * 0.25 V + 5V
I
CN103-3 I Panel N1
(11, GND) I terminal
Battery plug OFF.SWKy OFF on
CN103-4 CN103-3 SW, ON Approx. 4 8 Vl36 V Voltage after
(10, C36V) I (11, GND) SW, OFF OV key switch
CN103-5 I CN103-3
Approx. 1 8 3 V
(15, +30V) I (11, GND)
I
CN103-6 I CN103-3
(30, VDD + 1 (11, GND)
5 * 0.25 V
CN103-7 I CN103-3
*
5 0.25 V
(32, CHOPD + ) 1, GND)
(I
CN103-8 I CN103-3
ov
(11, GND) I (11, GND)
I
CN103-9 I CN103-3
(36, VDP-) I (11, GND)
Material handling stop state 4- 5V
CN103-10 I CN103-3
4- 5v
(38, CHOPP-) I (11, GND)
CN103-11 I CN103-3
ov
(11, GND) I (11, GND)
CN103-12 CN103-3
(13, VBBT) I (1 1, GND)
Approx. 4 8 Vl36 V
CN104-11 I CN104-8
Approx. 4 8 V l 3 6 V
(P2, VBP2) 1 (74, CSD-)
I Battery plug OFF.SWKy OFF
~ ~ 1 0 4 - 1 I2 ~~104-13 Approx. I 10n
Measure with the tester negative Mps contactor
(6' Mps) (I (USA spec..: 68 n)
probe connected to N 104-13.
+
CN104-14 CN104-8
Approx. 4 6 V l 3 5 V
(1, M + ) 1 (74, CSD-)
CN104-15 I CN104-8
Approx. 4 6 V l 3 5 V
(1, M + ) I (74, CSD-)
I
CN104-16 I C N l 0 4 -8 Greater than 0 V and
(76, STHl 1 (74, CSD-) smaller than 5 V
CN1 04-1 7 I CN104-8 Traveling and material handling stop
Approx. 4 8 Vl36 V
(P9, VBP9) 1 (74, CSD-) state
CN104-18 I CN104-8
ov
(74, CSP-) 1 (74, CSD-)
CN104-19 I CN104-8
(72, CSP) 1 (74, CSD-)
Material handling stop state Approx. 1.2 V
CN104-20 I CN104-8
1.2* 0.6 V + 12 V
(73, CSP )+ 1 (74, CSD -)
-
C N 1 0 6 Connector: Basic conditions (Battery plug ON.SWKy ON)
CN106-1 I CN106-2
I Traveling stop state OV
- (82, SSR) 1 (81, SSR)
CN106-2 CN106-1
Traveling stop state OV
(81, SSR) 1 (82, SS,)
CN106-3 CN106-4
Traveling stop state OV
(84, SSL) I (83, SSL)
I
CN106-4 I CN106-3
I Traveling stop state OV
(83. SSL) 1 (84, SSL)
CN106-5 CN106-13 DSFOFF 5 f 0.25V
(45, DSF) 1 (51, GND) DSF ON OV
CN106-6 CN106-13 DSROFF 5f0.25 V
(46, DSR) I (51, GND) DSRON OV
I
CN106-7 I CN106-13 SWAc OFF 550.25 V
(64, SWAc) 1 (51, GND) SWAc ON OV
CN106-8 I CN106-13
3 - 5 v
(53, VRAD + 1 (51, GND)
CN106-9 CN106-13
( , OPTl) 1 (51, GND)
Connector No. * Connector No. Conditions Standard Remarks
I
I 4 8 V vehicle:
CN106-10 I CN106-1 3 Traveling and material handling stop 43 f 5V
(P6, VBP6) 1 (51, GND) state 36 V vehicle:
I
I 32 f 5V
I
I 4 8 V vehicle:
CN106-1 1 I CN106-1 3 Traveling and material handling stop 43f 5V
(P61,VBP61) 1 (51,GND) state 3 6 V vehicle:
I
I 32f 5V
CNlO6-12 I CNlO6-13 LSD OFF 5 * 0.25 V
(67, LSD) 1 (51, GND) LSD ON OV
CN106-13 Panel N1 Battery plug OFF
(51, GND) I terminal SW, OFF
on
CN106-14 CN106-13
(51, GND) (51, GNDl
ov
CN106-15 I CNlO6-13 SWscOFF 5 f 0.25 V
(77, SWsc) 1 (51, GND) SWsc ON OV
CN106-16 I CN106-13 SWpBOFF 5 f 0.25 V
I
(66, SWpB) 1 (51, GND) SWpB ON OV
CN106-17 CN106-13 LSB OFF OV
(65,LSs) 1 (51,GND) LSBON 5 f 0.25 V
CN106-18 I CN106-13 Shall vary smoothly according t o the
(52, VRAD) 1 (51, GND) traveling acceleration state.
-
CN 1 1 1 connector: Basic conditions (Battery plug ON.SWKyON)
CNlll-5 I CNlll-20
Unused
Approx. 4 8 Vl36 V
(10, C36 V ) 1 (NI, GND) OV
CNlll-6 / CNlll-20
5 * 0.25 V
(37, CHOPP + I (N1, GND)
I
5 * 0.25 V
CN111-7 I CN111-20
(35,VDP+) (N1,GND)
CNlll-8 I CNlll-20
Unused - 5V - - 6V
(,-5V) I (N1,GND)
CN111-9 I CN111-20 Approx. 4 8 V l 3 6 V
Unused
(14, VBKY) / (NI, GND) ov
CN111-10 I Unused
CN111-11 CN111-20 SWKyON Approx. 4 8 Vl36 V
(43, K36 V) / (NI, GND) SW, OFF OV
CNIII-I2
CN111-13
/
I
Unused
I
CN111-14 I CN111-20
(11, GND) / ( N l , GND)
Unused OV
CN111-15 Unused
CNlll-16 CNlll-20
Unused OV
(11,GND) f (N1,GND)
CNlll-17 I CNlll-20
Material handling stop state 4 - 5 V
(38, CHOPP-) I (NI, GND)
CNlll-18 CN111-20
(36, VDP-1 I (NI, GND)
Material handling stop state 4 - 5 V
CNlll-19 Unused
Connector No. * Connector No. Conditions Standard Remarks
CN1 1 1-20 Panel N 1 Battery plug OFF
on
(N1, GND) 1 terminal SW,, OFF
CN111-21 I CNlll-20
Unused Approx. 48 Vl36 V
(13, VBBT) I (NI, GND)
I
CNlll-22 I CN111-20 Battery
Approx. 48 V136 V
(41, B36 V) I (N1, GND) voltage
CN112-5 I CN112-9
(PI 5, RCK2) I (Nl, GND)
Approx. 4 8 V136V
CN112-6 I CN112-9
ov
(N2, TMPS) (NI, GND)
CN112-7 I CN112-9
Unused Approx. 4 8 Vl36V
(41, 8 3 6 V) (N1, GND)
I
CN112-8 1 CN112-9
Approx. 4 8 Vl36V
(41, D36 V) 1 (NI, GND)
Unused
CN112-9 PanelN1
Unused Conduction
(NI, GND) I terminal
CN112-10 I Unused
CN112-11
(P14,TMPD) I
CN112-9
(N1,GND)
10 - 25V
- 5 - - 6V
CN 2-1 CN1 2-9
(93, TMPG) I (N1, GND)
Material handling stop state
11. Display
If the cause of a trouble is judged to exist in the display, apply the battery voltage and measure
the voltage at the connector.
REASSEMBLY
Control panel assembly drawing (STD)
(Y
P7
CSD
P2
DF 1
N1 TMD
DCISD b
Control panel assembly drawing (with pump chopper)
(Y)
P7
CSD
P2
DF 1
v
N1 TMD P I 3 P 1 2 CSP TMP D'AP
T?!AiF?d
DClSD board
DCISD b
2-32
Main terminals
M5 2.16 - 2.75 (22 - 28) 11.59 - 2.031
TM-TMP M4 1.18 - 1.77 (12 - 18) 10.87 - 1.301
For installation M5 2.16 - 2.75 (22 - 28) [ I.59 - 2.031
Main terminals M6 3.14 - 3.73 (32 - 38) i2.32 - 2.751
5.10 - 5.69 (52 - 58) i3.76 - 4.201
DF1
For installation M6
Main terminals M6 2.1 6 - 2.75 (22 - 28) [ I.59 - 2.031
13.44 - 14.02 (137 - 143) 19.91 - 10.351
DF3
For installation MI2
DAD-DAP For installation M6 2.16 - 2.75 (22 - 28) f1.59 - 2.031
Heat sink For installation M5 2.13 - 2.75 (22 - 28) 11.59 - 2.031
Terminal set nuts for external connection M8 7.85 - 11.77 (80 - 120) l5.79 - 8.681
(Contactor panel)
Heat sink For installation M5 2.13 - 2.75 (22 - 28) [1.59 - 2.031
Terminal set nuts for external connection M8 7.85 - 1 1.77 (80 - 120) [5.79 - 8.681
Contactor panel
Inspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects t o 0 Q and returns t o 00 Q then.
OCL (OVERCURRENT LIMIT) VALUES
1. Drive circuit OCL value measurement
(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Standard OCL value:
48 V vehicle: 460
3 6 V vehicle: 6 10
;+*: 6 0A A
Ammeter:
5 0 mV, 7 5 0 A
Shunt:
5 0 mV, 7 5 0 A
(2) Judgment method If the measured OCL value is not within the standard range, the current sen-
sor (CS) or CPU board may be defective. Make judgment as follows:
@ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
@ Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON.SWKy ON
Measurement terminals: CN104(9)71 @ - CN104(8) 74 @
Standard: Approx. 1.2V
* Use a digital voltmeter for measurement.
@ Operate the accelerator t o set the speed t o approx. 8 kmlh ( 5 milelh). Read the ammeter
and measure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN104(9)71 @ - CN 104(8)74 @
* Use a digital voltmeter for measurement.
@ Calculation
Measured value C - measured value B = D
Convert the calculated value D according t o the following equation. (Converted value: E)
1V = 100A
@ Judgment
Compare converted value E with measured value A in step @.
*
The current sensor can be judged normal if the result is within 5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.
Pump circuit OCL value measurement
The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.
As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.
ACCELERATION POTENTIOMETER
ADJUSTMENT
Make adjustment in the state of acceleration potentiometer
wlfront toe board.
Standards
LSST a0 n on
10 mm (0.39 in.)
Switch
on-an
an- on
2-39
Standard
A = 26 mm (1.02 in)
Standard
B= 5 - 20 mm (0.20 - 0.79 in)
If the standard is not satisfied, make adjustment by
changing the roller protrusion and mounting position.
C = 26 mm (1.02 in)
Stroke end
DIRECTION SWITCH
REMOVAL-INSTALLATION
Removal Procedure
1 Remove the steering rear cover.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Disassembly Procedure
1 Remove the plate.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operation
[Point 11
Reassembly: Install the microswitches in the correct posi-
tions.
EHPS
INSPECTION (STD)
1. P22-N 1 voltage measurement
Battery plug ON.SWKyON
1 Battery plug
Removal Procedure
1 Disconnect the battery plug.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
EHPS CONTROLLER VOLTAGE MEASUREMENT
When the cause of a trouble is judged t o exist in the EHPS controller, measure the battery voltage and
measure the voltage and conduction at the EHPS controller connector.
CN27
Measurement terminals
-
CN27 Connector Basic conditions (Battery plug ON.SWKy ON)
Forward:
C2E1: - probe - C1: + probe Conduction
DF4 QXIK
Reverse:
C2E1: + probe - C1: - probe co fl
Note:
When shifting to check C2E1-E2 from G2-E2 short connect G2-E2 to avoid the possibility of conti-
nuity on both directions.
Never touch to 6 2 terminal with a naked hand.
REASSEMBLY (EHPS)
T=N.m (kgf-cm)[ft-lbfl
T = 1.47 - 2.94
(15 - 30)
11.09 -
2.171
Steering potentio I
. in)
13.98 - 5.061
Potentio bolt
[,r 2.3\,1,
/ \ )
Monitor No. Potentio voltage
I
Turn the potentio clockwise to increase the po-
tentio voltage.
Turn the potentio counterclockwise to decrease
the potentio voltage.
Steering potentio
Note:
The indicator mark comes on when the potentio voltage is
in a range between 2.3 V and 2.4 V.
First, determine the potentio position for a potentio voltage
of 2.3 V. Then turn the potentio slowly clockwise to search
the indicator mark lighting position.
Page
OPERATION
GENERAL . . .. . . . . .. . . . . . . ... . . . . . . .. . .. . . . . . . . 2A-2
SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . 2A-2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
MAJOR FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5
MAIN CIRCUIT COMPONENTS . . . . . . . . . . . . . . . . . . 2A-8
DRIVE CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . 2A-13
MATERIAL HANDLING CIRCUIT OPERATION . . . . . 2A-17
REPAIR
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-19
COMPONENTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-20
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-35
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-36
PANEL PARTS TIGHTENING TORQUE . . . . . . . 2A-39
CONTINUITY CHECK WITH CIRCUIT TESTER . ... 2A-39
OCL (OVERCURRENT LIMIT) VALUES .... . . . . . . . 2A-40
2. For the control element, a power MOS FET (metal-oxide semiconductor field-effect-transistor)
has replaced the SIT (static induction transistor) that have been used i n the previous models.
Modification has been put into effect from the following frame Nos:
Model Frame No.
5FBE10.13 From 12903
5FBE15.18 From 26973
5FBE20 From 10976
SYSTEM CONFIGURATION
Communication
data
Digital
multi-display
- Key switch
Brake switch
L
System Configuration
1 CPU board
: Material handling chopper (OPT)
I _ _ _ _ _ _ _ _ _ _
Panel Structure
Setting level 1 2 3 4 5 6 7 8
Maximum speed setting (kmlh) 5+1 6fl 7+1 8+1 9+1 10f1 11f1 12+1
Maximum speed setting (mph) 3.2k0.6 3.8k0.6 4.4f0.6 5.0k0.6 5.6f0.6 6.2f0.6 6.8k0.6 7.5k0.6
Material handling option With material handling chopper Without material handling chopper
Controller
Control circuit
Display
Steering
4 potentiometer
Traveling - b
d
accelerator
-
sensor
4
e- Right drive
e- -
--, Main drive -
Speed control swtich motor
DMDR
A A A +
+ circuit +-
Left drive
Current -- motor
Key switch sensor DMDL
SWKY
Material
b Main material handling motor
Fuse F5
handling
circuit - DMP
-
Fuse F2
Battery -
Fuse F1
u
% : Option
MAIN CIRCUIT COMPONENTS
I
I
I
I
N1
In the 5FBE 10-18, drive motors are installed on the left and
right sides to drive the left and right wheels a t the same
time.
Mode I1
In this mode, gate voltage supply to the TMD is
stopped to turn the TMD off.
When gate current supply to the TMD stops, voltage
VDs between D and S of the TMD increases gradually.
At the same time drain current IDdecreases gradually
to cause the TMD to be turned off. The surge voltage
upon turning off is absorbed by CA via DAD.
3. Mode I11
When the TMD is perfectly turned off, the surge ener-
gy stored in CA is discharged through the closed cir-
cuit formed by CA, RA, battery and CA. The surge ener-
gy is discharged as heat at RA and a part returns to the
battery.
4. Mode I V
Indicates the state where the TMD is turned off and the
surge energy in CA is fully discharged.
When TMD is turned off, the counter electromotive
force induced in the motor is circulated through DFI.
The voltage applied to the motor is controlled, with
0-F
c 2 DAD RA
w
Operation of the Main Control Circuit
1. CPU Board
The CPU Board incorporates a microcomputer circuit for processing data from switches, poten-
tiometers, sensors, and other elements and transmitting command signals to the main circuit,
a drive circuit for driving the TMD and TMP, a power source circuit, and a contactor drive circuit.
Shown below is a block diagram of the circuit configuration of the CPU Board.
MPU (Micro Processing Unit) --- Central Processing Unit (CPU)
The MPU processes inputted data (signal)according to the program and transmits the processed
data (signal) to other LSI and boards in the MPU.
The MPU contains.
ROM (Read Only Memory)
A ROM allows fast access to permanently stored data but prevents addition to or modifica-
tion of the data. Programs stored in this type of memory do not dissipate when the power
is turned off.
RAM (Random Access memory)
A RAM allows both access and addition to or modification of the data. The data stored in this
type of memory dissipates when the power is turned off.
I10 (Input/Output) Port
An 110 port is a signal port for an input or output device. Each board receives and sends one
ONIOFF signal.
AID (AnalogIDigital) conversion
Analog signals are converted to digital signals before received by the CPU.
(I!r
tire turning angle between 40" and 80"
% C-
CPU
3. Right turn in forward traveling (tire turning angle over 80")
When the steering wheel is further rotated clockwise, MRRcontactor is set to ON to drive DMDR
in the reverse traveling direction. As the right and left drive motors are driven in the opposite
directions, turning with a small radius is possible.
CPU
4. In switchback braking
In switchback operation, MFLand MRLare changed over to or from MFRand MRRt o apply voltages
in the reverse direction to the left and right motors.
If switchback is attempted when the motor running speed is high, the motor rotating energy
causes a current flow in a route different from the one for ordinary operation to start plugging brak-
ing. The CPU detects the plugging state according t o the potential difference between both ends
of DF2L and DF& t o output the chopper command for plugging braking for same braking.
CPU
MATERIAL HANDLING CIRCUIT OPERATION
The material handling circuit is provided in two types: Standard specification without the material
handling chopper and the option specification with the material handling chopper.
CPU
2. Option specification with the material handling chopper
(1) When the lift lever is operated:
When lift switch No.1 (LSL)is turned on by the lift lever, the MP is closed t o cause the TMP t o
operate the chopper at a predetermined command duty while a current flows through the ma-
terial handling motor as indicated by the arrow in the diagram below.
If the lever is further operated to turn on lift switch No.2 (LSL2),the TMP operates the chopper
at a predetermined command duty greater than when only lift switch No.1 (LSL)is on. Mean-
while the revolving speed of the material handling motor is increased.
As described above, the material handling motor can be operated at two different duty levels.
The duty levels for the two lift switches (LSLand LSL2)can be set independently.
(2) When the tilt lever is operated:
As in lift operation, when the tilt switch is turned on, MP is closed to cause the TMP to operate
the chopper at a predetermined command duty.
Note that only one duty level is available with the tilt lever.
The duty levels for each switch can be set independently.
* The same applies to the attachment operation.
CPU
SPECIFICATIONS (For other than UL-USA-CANADA)
Portion 5FBE1013~15~18
F1 (Drive circuit) 225 A
F2 (Pump circuit) 225 A
Fuses F3 (PS circuit) 50 A
F4 (For lamps) 10 A
F5 (Control circuit) 10 A
TMD (For drive motor) TMMOOI (2 pcs.)
Transistors TMP (For material handling pump: OPT) TMMOOI (2 pcs.)
TMps (For PS: OPT) "'1 M1100H-025
DFI (DM flywheel) PE608N
D F ~ (DM
R flywheel) PE608N
Diodes DF2L(DM flywheel) PE608N
DF3 (PM flywheel: OPT) PE608N
DF4 (PS flywheel) ""1 M1100H-025
CSD (For drive motor) HC-T800V8P12
Current
CSP (For material handling pump: OPT) HC-T800V8P12
Sensor
CSps (For PS: OPT) MBP20A-10MJN
Resistors RA (Absorber) 0.8 Q 220W
MFR.MFL(For forward drive) ME253
MRR.MRL(For reverse drive) ME253
Contactors
MP (For material handling) ME251
MPS(For PS) C48-A1l
N
W
.
.
.L
Control panel (For UL-USA-CANADA)
2A-24
Contactor panel
2A-27
MF-MR contactor
r--- 10
---2 2403
($+ AY
E 8 - H
CY- ~ A Z
BC
L
a
.
- 8 ...J
2403-0688
MP contactor
11
r--- ---2
E0-V
CY-@
8 ..-A
2403-089
INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.
As the CPU boards require battery voltage application, they must be inspected while being mounted
on the vehicle.
Inspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1) Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
Use a resistor of approximately 100 i2 t o discharge CA before you perform the measurement.
Source
3. DFI (flywheel diode No.l), DF2R.DF2L,(flywheel diode No.2 R/L), DF3 (flywheel diode No.3) Dis-
connect the wiring and copper bars from each flywheel diode.
Inspection Circuit tester
Measurement terminals Standard
portion range
Forward
DF 1 Cathode: @ probe - f node:@ probe Approx. 3 kR
direction
DF2R.DF2L R x Ik
DF3 Reverse
Cathode:@ probe - Anode:@ probe m R
direction
4. CA (absorber capacitor)
Disconnect the wiring of the snubber board after discharging the TP9 and TNI with a resistance
of about 100 Q.
Inspection portion Measurement terminals Circuit tester range
CA TP9 - TNI [On snubber board1 S2 x I k
Standard
When circuit tester probes are brought into contact with both measurement terminals, the pointer de
flects once to the 0 Q side and eventually points to rn Q. (The tester indicates m Q because the capacitor is
charged by the tester current.)
5. DAD (drive circuit absorber diode).DAP (material handling circuit absorber diode)
Disconnect the wiring of the snubber board
Inspection Circuit tester
Measurement terminals Standard
portion range
Forward TP9 (cathode)@ probe - TDAD (anode)@ probe Approx. 2.5 kS2
direction
DAD
Reverse TP9 (cathode)@ probe - TDAD (anode)@ probe Approx. 10 kS2
direction
S2 x I k
TP9 (cathode)@ probe - TDAP (anode)@ probe Approx. 2.5 kS2
direction
DAP
Reverse TP9 (cathode)@ probe - TDAP (anode)@ probe Approx. 20 kS2
direction
6. MFR.MFL(forward contactors), MRR.MRL(reverse contactors), MP (material handling pump con-
tactor)
Remove the connectors from the contactors.
Inspection Circuit tester
Measurement terminals Standard
portion range
MFRcoil
MFL coil
Approx. 20 R
MRRcoil Both terminals of the connector of each contactor a x 1
(at 20°C)
MRL coil
MP coil
7. RA (absorber resistor)
Remove the battery and disconnect CN118.
When inspecting with the battery installed, disconnect the PI round connector and the CN100 connec-
tor.
Caution:
Always disconnect the battery plug before removing or installing the CPU board.
Note:
When replacing the CPU board judged to be causing the trouble as a result of troubleshooting, al-
wavs measure the applied voltage and resistance at related portions before replacement.
US; SST 09240-23400-71 (IC clipifor the measurement.
v I
-,
Circuit tester Q probe
Connector pin No.
-
1
CN101-2 ~~10312 Key switch: ON Approx. 48 V
(?3, VB,KY) (NI, N2) Key switch: OFF 0V
1/ 1 I
@ Lists
A: 48V Vehicle
CNlOl Basic conditions (battery plug ON, key switch OFF)
B: 36V Vehicle
Connector No. *Connector No. Conditions Standard Remarks
CN101-1 CN101-3
(75, THC+) (N2, N2) 5 V f 0.25 V
CN101-2 : Unused -
CN101-3 CN101-3
(N2, N2) (N2, N2) Approx. 0 V
CN101-5 -
:
I
CN101-6 Unused
CN105-10
CN105-11 : Cannot be measured with a -
(144, SMTDK) circuit tester
CN105-12 ; Cannot be measured with a -
(143,SDTMK) , circuit tester
CN105-13 Cannot be measured with a -
:
1
(L)
i"
(R)
,
Control panel assembly drawing (For UL-USA-CANADA)
CNlOl CN100
CPU board
Control panel assembly drawing (W/ material handling chopper)
(For UL-USA-CANADA)
2A-43
Contactor panel
ltem Tightening torque N.m (kgf-cm) [ft-lbfl
DF~R.DF~L
Main terminals M5 +
2.5 f 0.5 (25 f 5) [1.8 0.41
For installation M5 2.5 f 0.5 (25 f 5) [I .8 f 0.41
MFR.MFL Main terminals M8 9.8 f 2 (100 f 20) [7.23 f 1.41
MRR.MRL.MP For installation M5 2.5 f 0.5 (25 f 5) 11.8 f 0.41
Heat sink For installation M5 2.5 f 0.5 (25 f 5) [1.8 f 0.41
Set bolts for external connection terminal M8 9.8 f 2 (100 f 20) [7.23 f 1.41
Nuts and bolts for conductive parts
lnspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects to 0 Q and returns to co Q then.
OCL (OVERCURRENT LIMIT) VALUES
1. Drive circuit OCL value measurement
(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Ammeter:
50 mV, 750 A
Shunt:
50 mV, 750 A
(2) Judgment method if the measured OCL value is not within the standard range, the drive cur-
rent sensor (CSD) or CPU board may be defective. Make judgment as follows:
@ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
@ Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON.SWKy ON
Measurement terminals: CN101-9 (71) @ - CN101-11 (74) @
Standard: Approx. 1.2 V
*Use a digital voltmeter for measurement.
@ Operate the accelerator to set the speed to approx. 8 k m l h (5 milelh). Read the ammeter
and masure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN101-9 (71) @ - CN101-11 (74) @
*Use a digital voltmeter for measurement.
@ Calculation
Measured value C - measured value B = D
Convert the calculated value D according to the following equation. (Converted value: E)
1V = 100A
@ Judgment
Compare converted value E with measured value A in step @.
*
The current sensor can be judged normal if the result is within 5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.
Pump circuit OCL value measurement
The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.
As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.
MULTI-DISPLAY FUNCTIONS
-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8)
[FOR U.S.A.] (1993.1 - )
Page
DIAGNOSIS ........................................................ 3-2
GENERAL ......................................................... 3-2
ANALYZER ......................................................... 3-7
GENERAL ......................................................... 3-7
USING THE ANALYZER MODE .............................. 3-9
METHOD FOR SELECTING EACH ITEM .................. 3-12
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM ...................................................... 3-17
MASK FUNCTIONS ........................................... 3-31
PASSWORD INPUT METHOD ............................... 3-33
DIAGNOSIS
GENERAL
The 5FBE Series has the self diagnostic function, which automatically detects errors in the main drive
and material handling circuits, operation systems such as the accelerator, sensors, etc., and sounds
the buzzer while displaying these errors by corresponding error codes on the multi-display.
At the same time, safe operation is ensured by automatic stop of traveling, stop of material handling
and or traveling speed control.
Depending on the trouble only the error code appears on the multi-display. Although the vehicle may
be operated, make necessary repairs as soon as possible.
The self diagnosis mode may be switched to the analyzer (error analysis) mode, in which failure is de-
tected and, the main drive and material handling circuits, each operation system, sensors, etc. are
checked for functions.
Use these functions fully for early detection and elimination of electrical system troubles.
32.s Sh
---
Acceleration potentiometer
A4 Traveling accelerator Traveling stop
abnormality
Temperature sensor
AA CPU board (Display only)
abnormality on CPU board.
Can be enabled or disabled by the display mask function (provided only for the vehicle with deadman switch).
Error
Faulty portion Fault mode Phenomenon in vehicle
code
Acceleration potentiometer
C4 Traveling accelerator Traveling stop
short or opencircuit
Display-MCS communication
Communication failure (Display only)
system
Display-MCS communication
F2 Communication data error (Display only)
system
F7
Charger (on-vehicle type Charging starting failure (Display only)
"5
"6 only)
Steering potentio
F9 Steering potentio Traveling stop
abnormality
Use these functions fully for early solution of troubles in the electrical system.
(2) Testing the connections and insulation defects of wiring and connectors (switch input test)
(3) System check with actual travel and material handling operations (test operation)
3-8
This display is protected by mask functions t o prevent the important internal data from being de-
stroyed by incorrect user operation.
Switching t o the analyzer mode, therefore, requires password entry from the switch panel.
1. Primary password entry
1
[x)
Within 1 0 seconds
Short bleep
If not operated within 10 seconds, the mode returns t o
the ordinary travelinglmaterial handling mode (diagno-
sis mode).
1 Within 10 seconds Keep pressing the switch in the final step for 2 sec-
onds. The intermediate mode screen is displayed.
I
[X [r]
Within 1 0 seconds
:Ztaneousfy.
Note:
beginning.
I Short bleep
lntermediate
Within 10 seconds
Short bleep
4. Analyzer activation
Lighting for 2 seconds followed by
flashing 5 times
The display changes as illustrated and the analyzer is
activated.
Version display
5. Initial display
Flashing
I Transition t o each analyzer mode occurs from this dis-
\ p
I 3 play state.
\ / \
DW/ DW/
1
I-! I-!
1 \ \
[ RnL I
7
I,
I
AnL: analyzer
METHOD FOR SELECTING EACH ITEM
Each item can be selected by adjusting the speedometer display t o the corresponding category and
class numbers.
1. Item selection from analyzer activation state (initial display) (Example: 12)
Step Operation method Display
0 Flashing Indicates the ready
End of analyzer activation state for category
-P
([I
14- 11
- number input.
.-u
V)
-
.-
([I
UU
.-+
-
C
AnL: analyzer
C
I.U
.-0+ llrl
0
-Q)
Q)
To decrease the numeral by 1
V)
C
.-
0
+
0
-Q,
To decrease the numeral by 1
8 @ Press this switch Flashing stops when
V)
rn the class number is
-cu determined t o
0
complete item
selection.
3-13
0
r State of testing a certain item (12)
-P
([I
.-
V)
u
-
.-.-c
([I
C,
c
.-0
C,
( o .Lr D.D ,J
3-14
0
State of testing a certain item (13)
>
-n
m
.-
u
V)
-
.-(C1
.-c
C,
[ o Lr U.L? ,.)
-
COI / I-/
/ / \ \
+
[ run I
V)
a
C,
+
u
" 0 Press this switch t o Returns t o the initial
c Flashing display upon ana-
w set class number 0.
lyzer activation
when class number
0 is set.
i-..rl(01
L E I
AnL: analyzer
@
1. Select the desired item according t o the
$c procedure from "Analyzer activation
a .2 state (initial screen)".
E5
Z$
V) V)
V)
oE
08
a --
5S (I)
SE
l= E
r E
.-3 E
SU
"lE
." 'g
L
a
2%
2:
L .-
3. Ending analyzer mode (transition to diagnosis mode)
Step Operation method Display
0
State of testing a certain item (1 1 ) Category Subcategory
>
-P
([I
.-rn
u
-
.-
(0
.-
C,
-C ESY ( s ~ m p l ~ f ~test-
e d ) 00
C,
rn
al
C,
LC
0
AnL: analyzer
-z>
([I 1
2
8 Press this switch to
a end the analyzer
m mode.
E
-i>m.
I
C
(0
+
0
m
C
W
When the switch in step @ is pressed in step @ (flashing of "nu), the display returns to
display).
a (initial
It is also possible to end the analyzer mode by setting the key switch to OFF.
FUNCTIONAL EXPLANATION OF EACH TEST ITEM
The simple test consists of 3 5 test items ESY-01 t o ESY-35, each with its specific display.
-
Category Subcategory
1. Initial display
/!'0
T
@ Test end
@ Preceding test item
#
Press @: Repeating the same test item
Automatic judgement on
abnormality or defective Check of accelerator switch SW
,,, drive accel-
ESY-15 adjustment of the drive erator potentiometer VRA, and drive acceleration
accelerator by accelerator sensor
operation
Test No. Description
Automatic judgement on temperature on CPU board or judgement based on the
ESY-l difference between the detected temperature value and actual temperature
2 Drive current sensor and pump current sensor zero point check ..................... C1 - E l
ES$-~
1: 0ldes; error
Next test item (1) ESY-xx is displayed with blinking three times on
the hour meter.
RD (2) The error occurrence time and error code are dis-
played on the hour meter and speedometer, re-
spectively.
Preceding test item Time of error duration
Simplified test end Action: lnvestigate the error position by referring to the
troubleshooting.
Test No.: ESY-12 to 1 4
--
played value.
[=) [T) Standard (See page 2-21 .)
**
Retest
VBBTNBKY: Within 1%
VBP9: Within 5%
#
(4) AS the VBKY over 5 4 V cannot be displayed, con-
Simplified test end dact this check only when it is 5 4 V or less.
Preceding test item
Note:
Never tamper with the trimmer potentiometer.
+ '10 #
Actions: @ Check the potentiometer installation state.
@ Check the harness.
@ Replace the potentiometer.
Simplified test end
Preceding test item @) Replace the CPU board.
Test No.: ESY-16
The temperature detected by the thermistor on the CPU board is displayed. The properness of the tem-
perature and voltage range is checked and displayed.
ESY 15
Simplified test end
Next test item (1) ESY-xx is displayed with blinking three times on
the hour meter.
(2) The contactor code is displayed on the hour
meter.
Retest (3) Visually check closing or opening of each contac-
[El tor.
8
3 Check the CPU board.
4 Replace the CPU board.
Category 1 Class 2 Test operation (voltage-current or temperature display)
In the test operation, traveling and/or material handling are possible while monitoring the analog input
value of each sensor.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles to be confirmed.
The error code is displayed when an error occurs and is retained until the error clear switch is pressed.
Indicated upon
\ (4) If an error occurs, the error code is displayed on
Analog input display
switch ON the speedometer and is retained until the error
and steer- Preceding item No. clear switch is pressed.
ing potentio
meter in neutral state
--
Action: lnverstigate the error position and the part show-
ing an abnormal value by referring to the trouble-
shooting procedure.
Next test item
2. Steering potentiometer neutral state check
Traveling while monitoring the traveling speed value input from the speed sensor is possible during the
test operation.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles to be confirmed.
-
,
(kmlh) (kmlh) (kmlh)
Right and left wheels
drive speed display
- Left wheel drive speed
display
Right wheel drive speed
display
Left
+T+hror
and 1 -
1- I
To increase the number by 1 right
Sensor display
being monitored Left /
1-
Past errors (10 items in total) are displayed with the corre-
sponding hour meter readings.
Use this test when the user found an error during operation
but failed in reappearance.
Hour meter reading upon error occurrence (3) The error code is displayed on the speedometer.
Action: lnverstigate the error position by referring to the
troubleshooting procedure.
Diagnosis
monitor end +q
Most recent error display
[El
Uses:
Switch input
test end
- - Buzzer
stop
+Ft
(2) When the buzzer is sounding, stop it by pressing
the stop switch.
Upper switch in the list
3. Shake or apply vibration to the wiring to be checked.
Switch input
(1) The buzzer sounds if shortcircuit occurs.
test end I7 Buzzer
stop
Action: Repair the switch or harness.
Parking brake
Stops warning when
application failure Only when warning When requested by
warning
the parking brake is unnecessary.
warning is the user.
(validlinvalid)
unnecessary. 0
(option input)
Stops warning when a
Battery fluid level battery without Only when warning
warning electrolyte level is invalid.
(validlinvalid) warning terminal is 0
used.
Time of use
Name Function At board Upon
Other
replacement delivery
Name Function
Displays the check result of each vehicle part by
Analyzer the corresponding numeric code.
Locks the switch panel to accept no switch in-
put for other than the password and hour meter
Power control input (locklunlock)
changeover (option), or unlocks the locked
state.
PASSWORD INPUT METHOD
Password list
Primary password Intermediate mode Secondary password Processing
[
,..
I] - IErll 1 Analyzer mode
[Stan
r m ' l
Hour meter start
MCS-IIIA tuning
mode
Z
Press
7'
Simultaneouslv
km -
Unit changeover
mile
Battery
Mounted * Not
mounted
-
Battery fluid level
warning
Valid Invalid
lOl
Irl
- -
Power control input
Unlock Lock
I I
For items described as start in the processing column (analyzer mode, MCS-IIIA tuning mode, tire diameter con-
stant rewrite mode and option input mode), follow the operation procedure described below after inputting the
secondary password. For any other item, processing automatically ends here upon input of the secondary pass-
word.
Note:
Your finger must be used for the panel switch operation.
If sharpened tools are used instead, it would be a cause of damage on switch.
1. Hour meter start
The hour meter does not start counting when a new vehicle is delivered. Always start the hour
meter when the vehicle is delivered from the dealer to each user. See the password list for start-
ing the hour meter.
Note:
Once the hour meter is started, it cannot be stopped. Hour meter starting is necessary also after re-
placement of the meter control board ASSY.
Note:
Items marked "1 are invalid in models without the material handling chopper. (Display appears.)
MCS-IIIA Tuning mode Initial Level Setting List
C1
Braking torque:
Varying the regenerative braking
torque in switchback operation
-
Weak
A
w
Strong
L
C4
Battery charge meter correction:
Correcting the decreasing rate of -----+--
slow Quick
C6
Attachment power control 1:
Varying the pump motor
revolving speed when attachment
-
Low High
switch 1 is ON
C8
Lifting power control:
Varying the pump motor
revolving speed during lifting
-
LOW High
C9
Tilting power control:
Varying the pump motor
revolving speed
-
LOW
a
High
C
CA
Varying the operation timing
(discharge level) for
-
Small o
%
l:
alarm-
Irl
[ol--(xJ--~- [ol
Press
El
Simultaneously
0 ol- [a]
simultaneously press for
2 seconds.
Pr~rnarypassword
Secondary password
@ When the power control select switch is pressed, the tuning mode is indicated by the
speedometer on the display and the power control level indicates the current tuning
level of the mode.
As the tuning mode is changed sequentially (C1 4 C2 -, C3) each time the power con-
trol select switch is pressed, select the desired tuning mode.
@ Carry out tuning by pressing the level setting (up or down) switch.
To increase the tuning level: Press the up switch.
To decrease the tuning level: Press the down switch.
The tuning level is indicated on the display.
If another item is to be tuned in succession, repeat steps @ and 0.
Tuning mode
UP switch
t / \
\\
Power control
select switch select switch 0
-
+ d 1
t
3z.sh
1
1/
Down switch Tuning level Hours used indication
@ Use one of the three methods shown below for returning from the tuning mode.
Press the hour meter select switch to return to the standard display (speed display).
Turn the key switch to the OFF position.
Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
3. Tire diameter coefficient rewriting
The speedometer indication is influenced subtly by the tire type (tire diameter).
Setting for a new vehicle is made according to the tires installed on the vehicle. When tires are
replaced with other tires in a different size (new tires), set the tire diameter constant rewriting.
Also perform this setting when tires are exclusively worn or when special tires are used.
Select any of the three following methods for setting:
Method A: When replaced with new tires in a different size (excluding special tires)
Method B: When replaced with special tires
When the installed tires are worn to make the speedometer indication be felt incorrect.
Method C: When tires are worn to make the speedometer indication be felt incorrect while the
outside diameter of the tire in the new state is known.
lol--m--m- El
@ El El-
m
Press
simultaneously
Simultaneously
press for
[
,..
I]
2 seconds.
@ Select the tire constant from the tire constant table below. i
Tire type
18 x 7 x 8-10PR
Applicable
vehicle model
5FBE10
Tire constant
22
I
Rib lug 18 x 7 x 8-14PR 5FBE13.15 22
18 x 7 x 8-16PR All models 22
Pneumatic tire
18 x 7 x 8-10PR 5FBE10 18
J-lug 18 x 7 x 8-14PR 5FBE13.15 18
18 x 7 x 8-16PR 5FBEl8.20 18
Cushion tire
@) On the display, the speedometer indicates the current tire constant (2 numeral digits)
and the hour meter indicates the tire mark indicator.
Each time the power control select switch is pressed, the 10's digit or 1's digit of the
tire constant blinks alternately. The blinking numeral is incremented or decremented
when the level setting (up or down) switch is pressed. Set the tire constant selected in
step @. (The tire constant can be set between 0 0 and 99.)
To increase the tire constant: Press the up switch. (Increments by 1 each time.)
To decrease the tire constant: Press the down switch. (Decrements by 1 each time.)
/
Power control Hour meter
select switch select switch
\ Indicator
Down switch
@ Select any of the three following methods for returning from the tire constant rewriting
mode:
Press the hour meter select switch to return to the standard (speed) display.
Turn the key switch to the OFF position.
Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
Demonstration mode
Effective * lneffective
*
Primary password Parking brake applica-
acceptance mark
tion failure warning
Effective +,lneffective
*
lo] --=--m-- El
la ' Voltage selection
3,4+48v
TPress P
Simultaneously
simultaneously press for 2 sec. Hours used indication Material handling
chopper
Provided 4+ Not pro-
vided
*
Speed control switch
Set * Reset
These are passwords for option items newly added in the 5FBE series.
As these are set according t o the specifications at the time of new vehicle delivery, no setting is re-
quired unless any change is made.
The items with * are not provided in the vehicle specifications. Although indication on the display ap-
pears, proceed t o the next option item by pressing the power control select switch.
These items should be set in any of the following cases:
When the display board is replaced
When a demonstration is t o be made
When the parking brake application failure warning is t o be reset
(1) Demonstration mode switching effectivetineffective.
For the transportation reason, the condition of the truck before starting the hourmeter has
been so arranged that the parking application failure warning and the simultaneous opera-
tions of the traveling and material handling should be preset to "lneffective".
This condition, however, is changeable to "Effective" by turning the demonstration mode on
the mask function.
This changeover, in especial, in useful for the demonstration of the New Trucks, where the
warning and simultaneous operation are in need.
T
r 4
, 1 4m- End
[ E l - (m)
Demonstration mode : Effective
dEnno
I 5
I
,[-ni m+ End
Pflr - E r PRr - E r
Parking brake applrcation failure alarm : Parking brake application failure alarm :
Effective Ineffective
(Note) Keep the setting at Effective as the ineffective specification is not provided as the vehicle specification.
36 V + 48 V changeover
e
/ *
r d
0 m-l End
'
*
1
4
I
Transition to next option
[m=
48 V + 36 V changeover
P r *
, (01.: End
* r 5
,@ [o)-+ ~ n d
(Note) Keep this setting at Set as speed control switch reset is not provided as the vehicle specification.
MULTI-DISPLAY FUNCTIONS
[FOR OTHER THAN U.S.A.] (1998.9 - 1
Page
DIAGNOSIS ........................................................ 3 ~ - 2
GENERAL ........................................................... 3A-2
ANALYZER ......................................................... 3 ~ - 7
GENERAL .......................................................... 3A-7
USING THE ANALYZER MODE .............................. 3A-9
METHOD FOR SELECTING EACH ITEM .................. 3A-12
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM ...................................................... 3A-17
M A S K FUNCTIONS ............................................ 3 ~ - 3 2
PASSWORD INPUT METHOD ............................... 3 ~ - 3 4
DIAGNOSIS
GENERAL
The 5FBE Series has the self diagnostic function, which automatically detects errors in the main drive
and material handling circuits, operation systems such as the accelerator, sensors, etc., and sounds
the buzzer while displaying these errors by corresponding error codes on the multi-display.
At the same time, safe operation is ensured by automatic stop of traveling, stop of material handling
and or traveling speed control.
Depending on the trouble only the error code appears on the multi-display. Although the vehicle may
be operated, make necessary repairs as soon as possible.
The self diagnosis mode may be switched to the analyzer (error analysis) mode, in which failure is de-
tected and, the main drive and material handling circuits, each operation system, sensors, etc. are
checked for functions.
Use these functions fully for early detection and elimination of electrical system troubles.
3i'.s Sh
--
Acceleration potentiometer
A4 Traveling accelerator Traveling stop
abnormality
*l.Can be enabled or disabled by the display mask function (provided only for the vehicle with deadman switch).
3A-4 4
.
Error Faulty portion Fault mode Phenomena\%
code
Acceleration potentiometer
C4 Traveling accelerator Traveling stop
short or opencircuit
Display-MCS communication
F1 Communication failure (Display only)
system
Display-MCS communication
F2 Communication data error (Display only)
system
F6
Charger (on-vehicle type Charging safety timer
++4 Charging stop
only) operation
*5
F7
Charger (on-vehicle type (Display only)
*4 Charging starting failure
"5 only)
ANALYZER
GENERAL
The 5FBE series has the analyzer for function check and defect detection of the main drive and mate-
rial handling circuits, operating system such as accelerator, and sensors by switching the multidisplay
into the analyzer mode for quick and easy servicing.
Use these functions fully for early solution of troubles in the electrical system.
(2) Testing the connections and insulation defects of wiring and connectors (switch input test)
(3) System check with actual travel and material handling operations (test operation)
3A-8
This display is protected by mask functions to prevent the important internal data from being de-
stroyed by incorrect user operation.
Switching to the analyzer mode, therefore, requires password entry from the switch panel.
1. Primary password entry
Within 10 seconds
Keep pressing the switch in the final step for 2 sec-
onds. The intermediate mode screen is displayed.
Note:
Your finger must be used for the panel switch operation.
If sharpened tools are used instead, it would be a cause of
Keep pressing for 2 sec. damage on switch.
Short bleep
Intermediate
7
I kmlh
lllA tuning mode occurs from this mode.
32.5h
I
]
? //
Hours used indication
1
Within 10 seconds
] p] g~:taneously
Short bleep
4. Analyzer activation
Lighting for 2 seconds followed by
flashing 5 times
The display changes as illustrated and the analyzer is
activated.
\ \ I / / \\
Then the initial display appears.
- DW# DW# If the analyzer cannot be activated by the operation
I
1717- I \ \
above, turn the key switch OFF once and repeat from
the primary password input again. If not activated by
(0 UEr-3.0 ) repeated operation, system abnormality may exist.
*
I
I
I
Version display
5. Initial display
Flash~ng
I
1 Transition t o each analyzer mode occurs from this dis-
\ \ p /
play state.
11
- PI
'
I-/ I-/
I \ \
( flnL A
1,
7
I
AnL: analyzer
.METHOD FOR SELECTING EACH ITEM
Each item can be selected by adjusting the speedometer display t o the corresponding category and
class numbers.
1. Item selection from analyzer activation state (initial display) (Example: 12)
Step Operation method Display
0 Flashing Indicates the ready
End of analyzer activation state for category
-lua 14- 14- number input.
,
.-
V)
-0
-m
.-
D L ! L!
.-
,
C,
-C
AnL: analyzer
s
@ m /.DL!
.-0
C,
[lrl [ RnL I
0
-Q,
a, To decrease the numeral by 1
V)
/ I \ \
c
.-
0
C,
-0
Q,
Q,
To decrease the numeral by 1
V)
0 Press this switch Flashing stops when
V)
-m the class number is
o determined t o
complete item
selection.
3A-13
-m
.-.-+
-C
C
.-0
El
C,
0
- al
a
To decrease the numeral by 1
V)
@ 7Press this switch Flashing stops when
the class number is
-a
V)
H-TJ
ed:::rclass
l number
desired
is dis-
7)
[ ~r DO ..]
determined t o com-
plete item selection.
(2) To select an item in a different category (Example: 13-+New item)
-
State of testing a certain item (13)
>
-
a
n
.-
V)
-
.-([I
.-
C,
[ o ~ Ur . 3 3
-
C
B i0J / / \ \
+J
[ run I
V)
al
C,
w-
u
c
0 Press this switch t o Returns t o the initial
W set class number 0. display upon ana-
lyzer activation
when class number
0 is set.
AnL: analyzer
@
1. Select the desired item according t o the
&c procedure from "Analyzer activation
0 .E!
E t; state (initial screen)".
2%
V) V)
V)
mE
U B
al "
5 Bal
s Ez
-c=
'S
s
0 0
.- +
+J
3-
."E E
"2
5al
3 t;;
2-
a .9
3. Ending analyzer mode (transition to diagnosis mode)
Step Operation method Display
0
State of testing a certain item (11 ) Category Subcategory
>
-n
lu
.-
u
V)
-
.-
lu
.-
C,
' I , \
C,
V)
a
C,
LC
0
c 0 Press this switch Returns t o the initial
w and set class display upon
number 0. analyzer activation
\ \ I ,
when class number
llrl
AnL: analyzer
When the switch in step @ is pressed in step @ (flashing of "n"), the display returns to @ (initial
display).
It is also possible to end the analyzer mode by setting the key switch to OFF.
3A-17
The simple test consists of 37 test itmes ESY-01 t o ESY-37, each with its specific display.
if- if-
ESY-SD-~
----
t
I
/ i '0
@ Test end T@ Preceding test item
#
Press @: Repeating the same test item
ESY-01 Automatic check of main circuits, current and speed sensors etc.
Automatic judgement on
abnormality or defective
Check of accelerator switch SWAc, drive accelerator
ESY-17 adjustment of the drive
potentiometer VRA, and drive acceleration sensor
accelerator by accelerator
operation
Test No. Description
Automatic judgement o n temperature o n CPU board or judgement based o n the
ESY-18
difference between the detected temperature value and actual temperature.
Automatic judgement o n the performance of the controller traveling thermo sensor and
ESY-19
detection of voltage
I Main drive circuit and main pump circuit check ........................................... CO-EO
2 Drive current sensor and pump current sensor zero point check .....................C l v E l
Next test item (1) ESY-xx is displayed with blinking three times on
the hour meter.
(2) The error occurrence time and error code are dis-
played on the hour meter and speedmeter, re-
spectively.
Preceding test itern Time of error duration
Simplified test end Action: lnvestigate the error position by referring to the
troubleshooting.
Test No.: ESY-12 to 16
The voltage at the voltage input terminal is measured and
(0: OK H : NG) displayed.
t
1 \
1. Select the function b y pressing the switch.
Note:
Never tamper with the trimmer potentiometer.
( opm-z.
A
.1 ] /// \
I. Press the switch t o select the function.
Potentiometer voltage
(1) ESY-17 is displayed with blinking 3 times on the
PTA : Accelerator potentiometer hour meter.
Next test Item
fi
1
1 \ (2) The potentiometer type and potentiometer voltage
are displayed on the hour meter.
r=
[ a ] [T)
- -Retest
(3) The speedometer displays whether the potentiome-
ter voltage is within the specified range and wheth-
' 10 i
er the switch onloff state is proper.
83 B-A=C.
4 C=1.4Vormore.
W
Actions: 1 Check the potentiometer installation state.
2 Check the harness.
3 Replace the potentiometer.
4 Replace the CPU board.
Test No.: ESY-18
Temperature sensor check
The temperature detected by the thermistor on the CPU board is displayed. The properness of the tem-
perature and voltage range is checked and displayed.
Preceding test item (1) ESY-xx is displayed with blinking three times on the
Simplified test end hour meter.
dSF I
0
A
I, ESY-34:
ESY-35:
Lift limit switch 2 (LSL2)(Only in vehicle with mate-
rial handling chopper)
Tilt limit switch (LST)
I I ESY-36: Deadman limit switch (LSD)
DS,: Forward s w ~ t c h0: ON
F: OFF
ESY-37: Attachment limit switch (LSArr)
In the test operation, traveling and/or material handling are possible while monitoring the analog in-
put value of each sensor.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to
enable very infrequent troubles to be confirmed.
3 Key switch terminal voltage V Abnormality of voltage detecting circuit (excessive charge
indicator display error)
The error code is displayed when an error occurs and is retained until the error clear switch is pressed.
(1) Select monitor code 10 and set the tire i n the neu-
tral position, and confirm that the parking brake
Error clear indicator mark is displayed.
end
Traveling while monitoring the traveling speed value input from the speed sensor is possible during the
test operation.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed t o en-
able very infrequent troubles t o be confirmed.
,
(kmlh) (kmlh) (kmlh)
Right and left wheels -'
Left wheel drive speed
drive speed display display display
1 (m
elih
/,i (milelhi, display mile/h)b
Right and left wheels Left wheel drive speed Right wheel drive speed
drive speed display display (milelh)
1. Press the switch to select the function.
Display in normal State: 13
Display in error state: error code (1) The test No. is displayed on the hour meter.
A
a (2) The traveling speed or speed sensor input data is
4-
4 displayed on the hour meter.
r 3 (3) When an error occurs, the error code is displayed
( eLr 18.6 h]
on the speedmeter and is retained until the error
?
1 L
? // clear switch is pressed.
I
Speed sensor display
Action: lnverstigate the error position and the part show-
Speed sensor being monitored
ing an abnormal value by referring to the trouble-
+T+hrOr
shooting procedure.
TO increase the number by 1
Left
and 1 -
1- I
right
Test operation Sensor display
end I, clear
being monitored I
Left 1-
Past errors (10 items in total) are displayed with the corre-
sponding hour meter readings.
Use this test when the user found an error during operation
Initial display
but failed in reappearance.
Hour meter reading upon error occurrence (3) The error code is displayed on the speedmeter.
Action: lnverstigate the error position by referring to the
troubleshooting procedure.
Most recent error display
Diagnosis
monitor end ++I LEI
A level line in the battery charge indicator or a level line in the power control level gauge corresponds
to each switch.
f,
-
/
.
0- -7 d'
(0 SL'/ ]
J
Initial display
-O -
Display and switch table
Deadman switch
Speed control switch
(LSD)
(SWsc)
up,)
-
Parking brake limit switch
o Brake switch (LsB)
-Accelerator switch (SW),
1
Attachment limit switch (LSATT)
1. The corresponding part is lit, when a switch is set to
ON.
Uses:
Switch input
test end -
I
Press this switch to display the switch
immediately below on "Display and
Switch Table".
Category 3 Class 3 Switch input test: Momentary interruption test
Type of switch
Switch input
test end
+F+ SW: switch
I
,
stop
"Itage selection Sets the data according Only for 48V When the battery
(36V148V) specification
to the battery voltage. is replaced.
(option input) 0
Enables simultaneous
Demonstration When a
traveling and material
mode demonstration is to
handling operations
(validlinvalid)
before starting the hour be made.
(option input)
meter.
Sets the data such as Vehicle with the
Speed control
speed control switch speed control
switch set
setting which varies switch
(option input)
with the destination. 0
Starts counting by the
Hour meter start
hour 0 0
Name Function
Displays the check result of each vehicle part by
Analyzer
the corresponding numeric code.
Locks the switch panel to accept no switch in-
put for other than the password and hour meter
Power control input (locklunlock)
changeover (option), or unlocks the locked
state.
PASSWORD INPUT METHOD
Password list
Primary password Intermediate mode Secondary password Processing
(is] +
Analyzer mode
piq
Irl
m +
+ I>[ mode PI
( Tire diameter constant
Primary password
acceptance mark El+a.-(]
rewrite mode VI
lo] --=--m-- = {'pqR 7
\
>
Lrr:
L Unit changeover
I-..I] o-
h [o
\/km,h
[T] k m * mile
1 Irl
+
f ?' 3Z.5h
Press Simultaneously &\ I JJ
Battery
El- Mounted * Not
[z] mounted
Note:
Your finger must be used for the panel switch operation.
If sharpened tools are used instead, it would be a cause of damage on switch.
1. Hour meter start
The hour meter does not start counting when a new vehicle is delivered. Always start the hour
meter when the vehicle is delivered from the dealer to each user. See the password list for start-
ing the hour meter.
Note:
Once the hour meter is started, it cannot be stopped. Hour meter starting is necessary also after re-
placement of the meter control board ASSY.
C1
Braking torque:
Varying the regenerative braking
torque in switchback operation
-
Weak
a
Strong
C
C3
after activation:
Varying the initial duty in soft
start of the material handling
-
Small
-
a
Great
C
chopper
C4
Battery charge meter correction:
Correcting the decreasing rate of
battery charge meter reading
slow
- Quick
C
Low No
Maximum traveling speed limiter: limit
speed
C5 Limiting the maximum traveling a
speed
switch 1 is ON
Lifting power control: L OW High
C8 Varying the pump motor 4 •
revolving speed during lifting
C9
Tilting power control:
Varying the pump motor
revolving speed
- LOW
a
w
High
C
Iol--=--[rl-El [ol
Press
Irl
Simultaneously
0 i-[
,..
I]
simultaneously press for
2 seconds.
Primary password
Secondary password
@ When the power control select switch is pressed, the tuning mode is indicated by the
speedometer on the display and the power control level indicates the current tuning
level of the mode.
As the tuning mode is changed sequentially (C1 -, C2 + C3) each time the power con-
trol select switch is pressed, select the desired tuning mode.
@ Carry out tuning by pressing the level setting (up or down) switch.
To increase the tuning level: Press the up switch.
To decrease the tuning level: Press the down switch.
The tuning level is indicated on the display.
If another item is to be tuned in succession, repeat steps @ and 0.
Tuning mode
UP switch
f
t
Power control -
select switch select switch
\ J
3.5 1
Down switch Tuning level Hours used indication
@ Use one of the three methods shown below for returning from the tuning mode.
Press the hour meter select switch to return to the standard display (speed display).
Turn the key switch to the OFF position.
Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
(2) Maximum traveling speed limiter
The maximum traveling speed limit can be selected from the eight levels shown in the following
table.
Set level and corresponding speed limit
Set level 1 2 3 4 5 6 7 8
(3) Display on the battery charge meter (low battery warning and over-discharge warning)
1 2 3 4 5 6 7 8
4 4
60 % 4
70 %
-0- \ \ 1 1 1 battery
4
warning
/Ill\\\
3 lines blinking 3 lines lighting
\ I / 0
80%
iEji&$g:lk'g -
10 lines 2 lines blinking
4 --
blinking
(Over-dis-
charge 10 lines blinking
warning)
I A (Over-discharge
warning)
90 % dis-
charge
0 "I I ''
//I\\\\
battery
warning
I I
A
10 lines blinking
I (Over-discharge
warning)
dis- '
charge (No
warning) warning)
3. Tire diameter coefficient rewriting
The speedmeter indication is influenced b y the tire type (tire diameter).
The speedmeter indication for new vehicles is factory-set according t o the installed tires. Correct
the tire diameter constant i n any one of the following cases:
(1) When the tires are replaces with new tires of a different size
( 2 ) . When using specialized tires
(3) When tires are extremely worn.
Inl--[rl--m-
@
[rl
[rl El-
m
Press
simultaneously
Simultaneously
press for
[,.rl)
2 seconds.
@ Select the tire constant from the tire constant table below.
Applicable
Tire type Tire constant
vehicle model
1 8 x 7 x 8-10PR 5FBE 1 0 22
Rib lug 1 8 x 7 x 8-14PR 5FBE13.15 22
1 8 x 7 x 8-16PR All models 22
Pneumatic tire
1 8 x 7 X 8-10PR 5FBE10 18
J-lug 1 8 x 7 x 8-14PR 5FBE 18.20 18
18 X 7 X 8-16PR 5FBE18 18
Unique track-shoe tire 1 8 x 7 ~ 8 All models 18
1 8 x 6 - 1 2 118CP 5FBE10.13 24
Cushion tire
1 8 x 7 - 1 2 118 5FBE 18.20 24
@ On the display, the speedometer indicates the current tire constant (2numeral digits)
and the hour meter indicates the tire mark indicator.
Each time the power control select switch is pressed, the 10's digit or 1's digit of the
tire constant blinks alternately. The blinking numeral is incremented or decremented
when the level setting (up or down) switch is pressed. Set the tire constant selected in
step a. (The tire constant can be set between 0 0 and 99.)
To increase the tire constant: Press the up switch. (Increments by 1 each time.)
To decrease the tire constant: Press the down switch. (Decrements by 1 each time.)
/
Power control Hour meter
select switch select switch
\ Indicator
Down switch
@ Select any of the three following methods for returning from the tire constant rewriting
mode:
Press the hour meter select switch to return to the standard (speed) display.
Turn the key switch t o the OFF position.
Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
=IpTB
112 of maximum [Cushion tire]
allowable load Set the 112 of maximum allowable load
state, measure dimension A, B in the figure,
and calculate tire constant W by the follow-
ing equation:
W = 0.55A (mm) - 100
(W = 14A (in) - 100)
[Pneumatic tire and unique track-shoe tire]
With a load at 112 of the maximum allowable
load on the fork, measure dimensions A and
B in the figure.
Calculate the tire constant W by the follow-
ing equation:
W = 0.31A (mm) + 0.23B (mm) - 85
(W = 7.9A (in) + 5.8B (in) - 85)
Count fractions of 5 and over as 1 and disre-
gard the rest.
@ Input the primary password and secondary
password. (See method A.)
@ Then, follow steps 3 and 4 in method A.
Use the value calculated from the actually
measured value as the tire constant.
(3) Tire constant rewriting method (method C)
@ Obtain the tire constant as shown below.
Calculate tire wear C by the following equa-
tion:
C = Tire radius in new state - radius of
worn tire
@ Calculate tire constant W by the following
equation:
Worm state 1
W = W' - - C (mm)
2
(W = W' - 12.7 C (in))
W' = Tire constant in new state
@ Input the primary password and secondary
password. (See method A.)
@ Rewrite the tire constant according to steps
3 and 4 in method A by using the tire con-
stant calculated from the tire wear.
Demonstration mode
Effective * lneffective
*
Primary password Parking brake applica-
acceptance mark
tion failure warning
Effective * lneffective
*
lo] ----~-(YJ---
El
El + Voltage selection
36, 4,
TPress P
Simultaneously
simultaneously press for 2 sec. Hours used indication
@
Material handling
chopper
Provided * Not pro-
vided
*
Speed control switch
Set * Reset
#
r +
r=
, l q
m+ End
\ #
[m])[m]
+
& dEnno
Note:
It takes about a second after pressing the select (UP or DOWN) switch until display change.
3A-44
8
I %
r=
1~
m- ~ n d
b #
-[
[Ej F
l
Parking brake application failure alarm :
2 PRr -E r
(Note) Keep the setting at Effective as the ineffective specification is not provided as the vehicle specification.
36 V + 4 8 V changeover
8
/ \
r d
0 l0l-l End
' '4
\ a
Transition to next option
48 V + 36 V changeover
[
36 V specification
qwl 48 V specification
f 1 I b
rm
, 1~ i- I
~ n d
I r \
rm
,@ m- End
1 9
Z a
Transition to next option
[m]
Set + Reset changeover
[ n ]- SLJ SET
(Note) Keep this setting at Set as speed control switch reset is not provided as the vehicle specification.
ELECTRICAL SYSTEM TROUBLESHOOTING
[FOR OTHER THAN U.S.A.] (1993.1 - 1998.8)
[FOR U.S.A.] (1993.1 - )
Page
GENERAL ......................................................... 4-2
TROUBLESHOOTING EXPLANATION ............... 4-2
DRIVE SYSTEM-MATERIAL HANDLING
SYSTEM TROUBLES ...................................... 4-4
WHEN DIAGNOSTIC ERROR CODE IS
DISPLAYED .................................................... 4-4
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (DRIVE SYSTEM) ........................... 4-67
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (MATERIAL HANDLING SYSTEM) .... 4-87
TROUBLESHOOTING-OTHERS ............................. 4-94
TROUBLESHOOTING RELATED TO MULTI-DISPLAY
AND MCS COMMUNICATION SYSTEM ............. 4-95
STEERING SYSTEM TROUBLES ....................... 4-98
DIAGNOSIS ERRORS ........................................ 4-98
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (STD) ........................................... 4-101
WHEN DIAGNOSTIC ERROR CODE IS NOT
. .
DISPLAYED (WIEHPS) .......... .... ............ ......... 4- I03
This troubleshooting is t o pursue the causes of diagnostic errors indicated by the error codes on the
multi-display and other electric troubles for quick repair.
Measuring instruments such as the megger and multimeter (circuit tester) are used for the error check.
Some error items may be checked by the analyzer on the vehicle.
Descriptions in this manual are for the mechanics who have mastered handling of measuring instruments,
can read wiring and connection diagrams accurately and can make actual measurements using the con-
nector drawing.
Please make use of the attached connection diagram, connector drawing and connector terminal ar-
rangement.
TROUBLESHOOTING EXPLANATION
1. Drive system . material handling system troubles
(1 When an error code is displayed:
See the "Diagnosis Errors" section.
(2) When no error code is displayed:
@ Drive system abnormality
See the "When Diagnostic Result is Not Displayed (Drive System)" section.
@ Material handling system abnormality
See the "When Diagnostic Result is Not Displayed (Material Handling System)" section.
2. Trouble shooting-other
See the "Trouble shooting-other" section
IYES 1
OK (approx. 1.2 V) 4
Measure with a
To A on next page 0 CPU board defect circuit tester.
0 Drive motor defect (short circuit)
I
Repair or replace.
lnspection 1
CSD output vqltage check
CN104-7 (71)-
3 Voltage check
CN104-1 (74)-
f t
1
Tester probe ( +
~ o n n e k t o rNo.
Pin No.
4-4
Estimated causes
@ Overheat (continued use with overload)
I
I
Continued use of vehicle with overload
=I
I I
Stop the vehicle and restart traveling 3 0
minutes later. I
I
NO
Inspection 1
Disconnect connector STH and check the -
NG
- 0 Temperature sensor defect
resistance of temperature sensor. (2 kQ or more)
OK (less than 2 kQ)
OK (less than 2 kS2) CPU board defect, or defective contact or disconnection between CN104
+
CPU board
-m-
Estimated causes
@ Temperature CPU board around at 80°C or more
NO
Continued use of vehicle with overload - YES Restart traveling for confirmation after
stopping for 30 minutes
NO
* The CPU temperature sensor is included on the CPU board. CPU board defect is conceivable
when this error code (A21 is displayed.
ERROR CODE A3: ABNORMALLY HIGH BATTERY VOLTAGE
Estimated causes
@ Connection of other than specified battery voltage t o battery plug
I Inspection 1 I
is connect the battery plug, 0 Abnormally high battery voltage.
and measure the battery
voltage. Replace the battery.
I I
OK (69V or less) ,
0
I OK (battery voltage or less)
Related portion
Acceleration potentio meter
+) -
CN25
CN106-8 (53 POTA -
CN106-18 (52 POTA) -
CPU board VRAD
CN106-14 (51 GND) -
- CN106-7 (64 SWAc)
- -
-
imated causes
@ Acceleration potentiometer defect (between 6 4 and 51
I @ Acceleration potentiometer installation adjustment defect I
I @ Accelerator switch wiring short circuit (between CN106-3 and GND) I
I @ CPU board defect I
Is the battery plug connected Is the normal state recovered
YES- YES
while the accelerator pedal is when the accelerator pedal is 0 Normal
depressed? released?
I I
I
1Not lit (switch OFF)
Inspection 1 NG
Individual acceleration poten- -0 Acceleration potentiometer defect
tiometer inspection (always 0 Q)
--
Related portion
I
CN 105-6 (63 LS,,) --
CNl1
CN105-1 ( 6 0 LSL)
-
Lift/
CPU board
CN105-3 (61 LST) - tilt/
CN 105-2 (68 LSu)
- Attachment switch
--
CN106-13 (51 GND)
I
-
1 CN39
Estimated causes
@ Defect of each material handling switch
I-
ANL31: Switch input test
Is each material handling switch
ON or OFF when the 0 To A on next page
(switch ON)
corresponding material handling
lever is not pulled?
Inspection 1 NG
-0 L S L replacement
~
L S L individual
~ check ( 0 Q at switch
OFF)
1 OK
0
1 (00 Q at switch OFF)
Installation readjustment
Inspection 2
LSL individual check
NG
(0 Q at switch
- 0 LSL replacement
OFF)
I OK
(m Q at switch OFF)
0 lnstallation readjustment
Estimated causes
@ Parking brake switch defect
@ Parking brake switch installation adjustment defect
@ Parking brake switch wiring shortcircuit
@ Deadman switch defect
@ Deadman switch installation adjustment defect
@ Deadman switch wiring short circuit or disconnection
@ CPU board defect
- Occurrence of A7 error while
the parking brake is pulled?
YES
NO
NO
Is the error reset
when the parking Occurrence of A7 error while
-
brake lever is pulled the operator sits on the seat?
or the operator sits
on the seat?
I
YES
I
I II
t ANL31: Switch input test
0 Normal
when the parking brake lever is -0 CPU board
pulled? (switch OFF) defect
0 Switch
replacement
switch OFF)
I 1 OK (m Q at switch ON)
0 ~ e f e c t i d einstallation
adjustment
t
Lit
Is the deadman switch turned -0 Defective CPU board
ON or OFF when the operator (switch ON)
] at switch ON)
0 Deadman ;witch installation defect
lnspection 1. Parking brake switch individual check
Parking brake switch individual removal
Standard 0 Q at switch ON
-4Related portion 1
CN 104-1 7 (P9 VBP9)
0 P9
DClSDD board
CN100-1
(41 VBBT)
@ P9 wiring disconnection
Inspection 1
Traveling fuse (F1 ) check
NG - Inspection 3 replacement
After F1
Q)
P2 NG - 0 Short circuit
5 resistance measurement (0a) between P2
N1 wiring and
N1
OK (other than 0 Q)
0 Normal
i
lnspection 2
P2 0 Disconnection in cable between battery and
5 voltage check fuse F1
N1
0
1
To A on next page
OK (battery voltage)
Inspection 4 Disconnection in wiring
CN104-17 -CN103-8 NG
-
0
0 Short circuit between P9 and N1
P9 voltage check (5 Or less) 0 Disconnection between CN104-17 - and
P9
OK
(over 5 V )
1.-
ANL12: Test operation (No.4)
Voltage measurement at
terminal P9
OK (over 5 V)
CPLJ board defect
OK (0 0) -, To inspection 2
NG (co 0) -, F1 replacement -+ To inspection 3
OK (battery voltage)
NG (0 V ) -, Disconnection in battery cable between battery and fuse F1
lnspection 3. P2-N1 resistance measurement
Battery plug OFF
Measurement terminals P2 - N1
Circuit tester range a x 1
Standard Other than 0 f l
CPU board
-m-
DClSDD board
- CN102-12 ( 9 2 TMG)
DAD JL TM v
G
S
CAD ==
.-
@ TM defect
Display of FA, CA or A 8 in
traveling stop state IYES 0 Take the action for A8
P-
Check connector CN101, 1 02
or 103 disconnection or TM o Perform traveling test after correction.
connection loosening.
OK
Inspection 1 NG Inspection 4
Voltage check between P7 and (less = TM Individual check after dis- NG (TM
N1. than 8V) connecting TM wiring copper damage)
bar
OK I
lnspection 2
L
wk- :
Continuity check between TM TM replacement
and DCISDD NG -0 Wiring
I disconnection
0 To A on next page
lnspection 3
Continuity check of wiring 0 Wiring
between CPU and DCISDD disconnection OK Inspection 8
DF1 lndividual check
OK OK
0 CN117orCN118defect
I
lnspection 6
Continuity check between
CN 102-5 DAD cathode (heat 0 Disconnection
sink) and CN102-4 TM(D)
t
0 Drive DCISD defect
lnspection 1. P7-N 1 Voltage check
Battery plug ON, SW, OFF, direction switch OFF, acceleration switch OFF
OK (0Q) + To inspection 3
NG -, Wiring disconnection
lnspection 3. CPU-DCISDD continuity check
Battery plug OFF, SST connection
1 2 3 4 5 6 7 8
+
Between D and S
8 8
D - - S
D + - S-
Between D and S
8 8-+: :aann
D - -
D + -S
S+ : a Q
Anode - - Cathode +
Measurement terminals
Forward:
Reverse: 8
Anode + - Cathode - 8
Circuit tester range h2 x 1K
Forward: Approx. 3 kh2
Standard Reverse: co62
Anode - - Cathode +
Measurement terminals
Forward:
Reverse: 8
Anode + - Cathode -8
Circuit tester range nx IK
Forward: Approx. 6 kQ
Standard Reverse: oo Q
Connector CSD
CSD
Estimated causes
@ Drive current sensor defect
@ Disconnection or defective connector contact between CN104 and traveling current sensor
@ Drive motor defect (short circuit)
@ CPU board defect
NO OK (approx. 1.2 V)
C1 display upon starting 0 CPU board defect
!
Wire continuity
check between NG
CN104 and CSD
I
t
I
(No.0 CSD display)
CDS value = 0 in traveling
YES
0
OK
CSD defect
0
0
1
Disconnection
Contact defect
(OA)
1
0
0
NO (other than OA)
CPU board defect
Drive motor defect 0 CSD defect
I
(short circuit) 0 Drive motor or main circuit wiring defect
Inspection 1. CSD output voltage measurement
Battery plug ON, SWKYON, SST connection
Measurement terminals CN 1 0 4 - 9 0 - CN 1 0 4 - 8 0
Circuit tester range DClO V
Standard Approx. 1.2 V
OK (approx. 1.2 V ) + CPU board defect or drive motor defect (short circuit)
NG (over 2.0 V or less than 0.35 V ) -, CSD defect, or wiring defect
ERROR CODE C4: TRAVELING ACCELERATOR ABNORMALITY
CPU board
1- CN106-18 (52 POTA)
Estimated causes
@ Acceleration potentiometer defect
@ Short circuit or open circuit in wiring between CN106 and acceleration potentiometer
@ Defective contact of CN106 . CN25 and CN26
@ CPU board defect
Not disconected
1
ANL11: ESY-15
(acceleration potentiometer check) 0 To A on next page
Check the potentiometer voltage when the
accelerator pedal is not depressed.
I'
OK (0.1 V or more)
r 11
ANL11: ESY-15
(acceleration potentiometer check) 0 To B on next page
Check the potentiometer voltage when the
accelerator pedal is fully depressed.
1 ANLl 1: ESY-15 1
(acceleration potentiometer check) o Disconnection at CN106-7
Check the potentiometer voltage when the
and disconnection or short
switch is turned from OFF to ON while 1.4 V or more) circuit with other portion at
depressing the accelerator pedal gradually.
CN1 06-8
I'
OK (1.3 V or less)
! * The acceleration potentiorne-
0 CPU board defect
ter is defective i f the switch
is not turned ON.
Inspection 1 Does the acceleration
Disconnect the acceleration - potentiometer resistance vary NO 0 Acceleration
potentiometer and check it from 0 Q to about 2 to 4 kQ
potentiometer
individually. when it is turned?
replacement
YES
\
0 Adjustment defect. Readjust it.
B
Recheck after disconnecting the acceleration
potentiometer connector.
ANL11: ESY-15
NG
(acceleration potentiometer check) = 0 Short circuit of wiring between
Check the potentiometer voltage when the (4.6 V or more) CN106-18 and CN106-8
accelerator pedal is not depressed.
OK (0 V)
lnspection 2
Disconnect the acceleration potentiometer,
and check it individually.
0
1
Adjustment defect. Read just it.
lnspection 1. Individual acceleration potentiometer measurement
Battery plug OFF
Direction
switch
Estimated causes
@ Direction switch abnormality
Discon-
Check if CN106 or CN9 connector is dis- Confirmation test after correction
I nected
connected.
I
1
Not disconnected
1I
ANL31: Switch input test
When the direction lever is operated to 0 Direction switch defect
the forward or reverse position, is the 0 Short circuit or disconnection of wiring
opposite direction also set to ON?
0
I
CPU board defect
ERROR CODE C8: SPEED SENSOR ABNORMALITY
Related portion
CN21
CN106-1 (82SSR-)
Speed sensor
CN106-2 (81 SSR+) - SSR
CN20
] 0 km/h on R side
I
p2
F MRL F
E E
I
D
CAD TM;~
S
N1
0
lnspection 1 DF2R
lnspection 2 DF2L
lnspection 3 DF1
Inspection 4 DAD 0 Repair the part judged NG.
lnspection 5 SN1
I Individual check of each part I
0 Harness pinching
0 CPU defect
0 DCISDD abnormality
The standards for inspection 1 to inspection 4 are the same as the inspection standard for each element.
Inspection 5. SN 1 inspection
Disconnect SN 1 wiring
-
CPU board
internal junction
Estimated causes
@ CPU board defect
DClSDP
Material
handling
panel
CN1 12-4 (PI 4 RCK2)
PI1
CN112-4 (PI 4 RCKP)
0
-D
-
-
- P I5 6 G
CN119 CN117
--
--
CAP
-
.d
@ TMP defect
OK (10 n)
Check disconnection of
each connector and NG
loosening of TMP -0 Material handing oper-
(Disconeected or loosenned 1
ation after correction
connection.
I lns~ection2 I I Inspection 5 I
*PI 3 Remove TMP wiring To A on
$ voltage check copper bar and check
next
N1 TMP individually. page af-
ter TMP
OK (8 V or morel l OK replace-
lnspection 5 ment
lnspection 3
P I1
TMP
resistance To B on
$ continuity check
DCISDD (using SST)
0 Wiring dis-
connection
I measurement
DAP cathode (heat sink)
next
page
I
0
0
l OK (O each)
DCISDD board defect
CPU board defect
0
0
I
OK ( 0 n)
~is'connectCN1 19 and
check the RAP
EQio RAP defect
I individually. 1.
0
1 OK (approx. 1.5 62)
Disconnection between
main circuit and CN117,
CN119
lnspection 1. Pump fuse (F2 check)
Battery plug OFF
Standard 0Q
Measurement terminals ~ 1 3 -0 ~ 1 0
OK (0Q) + To inspection 4
NG (00 Q) + Wiring disconnection
+
Between D and S
8 8
D - - S
D + - S-
Between G and S
8 8-+ : a n
G - -S
G + -S
: Continuity shall exist
OK + To inspection 6
NG -+ To inspection 8
lnspection 6. P I 1-DAP cathode (heat sink) continuity check
Battery plug OFF
lnspection 7. CN 1 1 2-5 - DAP Cathode and CN 1 1 2-4 TMP (D) continuity check
Battery plug OFF
Standard 0n
defect
NG (a Q) +Wiring disconnection
Inspection 8. Individual DF3 measurement
Battery plug OFF, DF1 wiring connection
Measurement terminals
Measurement terminals
OK (forward: approx. 6 kQ, reverse: co Q) + Loosening of DAP wiring or TMP copper bar terminal
NG + Loosening of DAP lead or round terminal
- -
OK (approx. 1.5 Q) Main circuit CN 1 1 7 CN 1 1 9 open circuit
NG (00 Q) RAP defect
+
ERROR CODE E l : MAIN MATERIAL HANDLING CIRCUIT CURRENT SENSOR
ABNORMALITY
Related portion
Connector CSP
Estimated causes
@ Material handling current sensor defect
1
ON
( E l display upon material
handling operation)
0
IoK (approx. 1.2 V )
I ANLI 2: T e n operation
(No. ICSP display)
0 CSP defect
Is the CSP value when the o Main pump motor circuit
material handling lever is not wiring defect
pulled?
IYU
0
l o t h e r than OA
0
I°K
CSP defect
Inspection 1. CSP output voltage measurement
Battery plug ON, S W K ON,
~ and use of SST
Measurement terminals ~ ~ 1 0 4 - 1-
9 0~ ~ 1 0 4 - 1 8 0
Related portion
1CN102-1 JWKY - P1
CN103-13 (14VBKY) CN101-3 (43 K36V)
0 0 -
' '-1
CN103-12 (13 VBBT) CN101-14 CN101-22 (41 B36Y)
DClSDD board
I
///
@ DCISDD defect
Occurrence during traveling YES CN106-12.13 NG
S wiring check -0 Deadman
CN22 switch wiring
defect
NO OK
Lit - Direction
Inspection 2
switch in-
OK
Short-circuit
(switch ON) -0
dividual check in wiring
I
Not lit between
NG CN106 and
(switch OFF)
CN9
0 Direction switch defect 0 CPU board
- - -
1 -- - -
defect
ANL31: Switch input test
SWACcheck with accelerator
Not lit
(switch OFF)
0
t
CPU board defect
Inspection 3
Accelerator switch Short circuit
(switch ON)
individual check in wiring
between
CN106 and
CN25
0 Acceleration circuit 0 CPU board
defect defect
lnspection 1. Deadman switch individual check
Deadman switch removal
OK Momentary disconnection of the line between CN106 and CN22, momentary disconnec-
4
tion of the BIT plug power supply line, DCJSDD defect, or CPU board defect
NG + Deadman switch defect
Related portion
-- -
CN105-1 (60 LSLI) -CN11 Material handling
--
CN106-13 (51 GND) switch No. 1 (LSL)
CPU board
CN39
Estimated causes
@ Material handling switch No. 1 (LSL)defect (open)
0
t
CPU board defect
ERROR CODE EE: MCS RECEIVING DATA ABNORMALITY
Related portion
-
CN 1 CN120
CN 107-2 ( 1 4 2 SDTMA)
Multi-
CPU board display
DlSP
CN107-5 (143 SDTMK)
Estimated causes
@ Multi-display defect
Discon-
CN107 disconnection check, wiring
nected
disconnection check and display side >o Display check after correction
connector check (CN1 and CN120)
0
0
1Not disconnected
-
CN32
Estimated causes1
@ Steering potentiometer (VRSP)
Inspection 1 Inspection 2
CN1 05-9 Steering potentiometer individu-
$ voltage measurement al check
CN106-13
OK
0 Wiring disconnection
\ or short circuit
P2
0
CN117 CN118
-
- I
RAD
-
CN104-17 (P9 VBP9)
CPU
board
-I-
///
-
CN4
-
-
CN103-12 (13 VBBT) CN102-8 (41 D36V) -0SWKY
CN101-21 (13 VBBT)
1
DClSDD board
Estimated causes
@ RAD wiring disconnection
@ RAD defect
@ P9 wiring disconnection
Inspection 1
RAD individual check L
Io
- RAD defect
0 To A on next page
Inspection 2
CN104-17 0 PZ-CN117-CNl18-P9-CN104
$ voltage measurement ,iring defect
CN 103-8 battery voltage)
F
lnspection 3
CN103-12 0 Wiring defect
5 voltage measurement (battery voltage or 0 DC/SDD defect
CN103-8 more)
0
l°K
CPU board defect
lnspection 1. RAD individual check
RAD removal
OK + Approx. 1.5 Q
NG + RAD defect
OK + To inspection 3
NG + P2-CNl17-CNl18-P9-CNl04 wiring deftct
Inspection 3 Battery volatge input check
SWKYOFF, of SST
r-~; I
- I
SWKY
0 0
CN102-1 (43 K36V)
A
CN101-3.4 (15 +30V)
CN101-14 (11 GND)
I
CN103-8 (11 GND)
CPU board
CN103-5 (1 5 + 30V)
///
~ s t i m a t
@ The battery voltage is not applied.
I OK (battery voltage)
lnspection 2
CN102-1 (43 K36V) Key switch defect
5 voltage check Wiring defect
CN102-9 (N1 GND)
OK (battery voltage)
DCISDD 0
Inspection 5 defect
Inspection 3 Inspection 4 0 Wiring
Disconnect CN1 0 3
CN103-5 Disconnect CN107 from CPU defect
(15 +30V) CN103-5 NG CN103-5 NG,(short
$ voltage check
NG (15 +30V) (OV) (15 +30V) ( 0 V) circuit)
CN103-8 (OV) $ voltage check 5 voltage check between
(N11 GND) CN103-8 CN103-8 CNlOl
(N11 GND) (N11 GND). and
CN103
OK OK OK 0 CPU
(approx. 25 V) (approx. 25 V) (approx. 25 V) board
1 1 defect
0 CPU board defect 0 Display defect 0 CPU board defect 0 Display
0 Defective wiring (short circuit) defect
between CN107 and display
0 CPU board defect
lnspection 1. Battery voltage measurement
Battery plug ON
Measurement terminals @I
~ N 1 0 2 ( 1 ) 4 3 @- C N I O ~ ( ~ ) N
CN9
CN106-6 (46 DSR)
Deadman switch
CN106-13 (51 GND) LSD
CN104-14 (1 M + )
.- T
-
T
CN104-3 (2 MFL)
-
Connector MFL
I
CN104-2 (5 MRR) ---
1.
Connector MFR
CN104-4 (3 MRL)
Connector MRL
Estimated causes
@ Battery overdischarge
OK (15 V or more)
YES
(turned ON and OFF)
I S
: ned ON and OFF)
OK (approx. 2 0 Q) -, CPU board defect, wiring disconnection (between CPU board and
MFR.MFL.MRR.MRL contactor)
NG (00 Q) + MFR.MFL.MRR.MRL contactor replacement
4. The vehicle does not move at all. (The MFR*MF~.MR~
and MRLcontactors are
closed. 1
Related portion
1-1 I
.
CPU board
Estimated causes
@ The acceleration potentiometer signal is not input.
CN6
CN106-17 (65 LSB)
Brake switch
CN106-13 (51 GND) LSB
CN25 - I
NG
(Less than 1.3 V in
- 0
0
Acceleration potentiometer defect
Disconnection of wiring between ac-
full acceleration state) celeration potentiometer and CN 106
Not lit
(switch OFF)
Inspection 2 0 Switch
Brake switch (OFF state: replacement
individual check
I OK (OFF state: Q)
I 0
OK
Connector contact defect
Wiring disconnection
c
0
I
Display mask func- I
Inspection 1 NG tion check NG
I P Set correctly.
Drive circuit OCL value (outsidew S 36Vl48V selec-
measurement the tion set as
dard range) specified?
I I
0
1 OK (within the standard range)
CN26
CN25, -
CN106-8 (53 VRAD+)
4Estimated causes I
@ Insufficient acceleration potentiometer signal
The maximum traveling speed is not attained when the speed control switch is ON or the
maximum speed limiter (display mask function tuning mode: C5) is set to enable. (In this
state, the turtose mark is displayed.)
1
OK (1.3 V or more in full
acceleration state)
0 To A on next page
1 ANL31: Switch input test
Speed control switch ON-OFF
check
lp*(switch OFF)
0
0
Speed control switch defect
-
Wiring
CN106-CN105)
defect (speed control switch
] OK (switch ON)
Tire wheel diameter check (See - NG -0 Traveling test after wheel diameter
the mask function) setting (The maximum speed may
not be attained depending on the
/OK tire material and running resistance.)
0 CPU board defect
0 Drive motor defect
7. Excessive braking in switch back operation.
Related portion
Speed sensor
CN106-1 (82 SSR-) SSR
-
-
-- -
CN20
CN106-4 (83 SSL-1 - '
Estimated causes
@ Speed sensor defect, momentary disconnection or short-circuit in speed sensor harness
1'r'
of speed sensor RH and LH.
Inspection 1. 1 ~ - DF2R
0 or DF2L defect
DF2R.DF2L individual check
Measurement terminals
-
CN9
-
I
Estimated causes
@ No direction switch signal input
1 oK 1
I
OK (approx. 20 0)
OK (approx. 20 Q) + CPU board defect, or wiring disconnection (between CPU board and
contactor coil)
NG (00 Q) + MFR-MFLorMRR.MRLcontactor replacement
4-85
7
CN106-15 (77 SWSc)
Speed control
CN106-13 (51 GND) CN 1
Speed sensor RH
CN106-1 (82 SSR-)
SSR
0
1 oK
CPU board defect
speed indi-
cation dur-
ing
traveling at
a constant
speed)
(2) The limited speed is abnormal.
CN21
CN106-2 (81 SSR+)
Speed sensor RH
CN106-1 ( 8 2 SSR-1 SSR
CPU .-
board
CN106-4 (83 SSL + )
Speed sensor LH
CN 106-3 ( 8 4 SSL-) - SSL
L
CN20
Estimated causes
@ Wheel diameter setting error
0
l oK
CPU board defect
speed indi-
cation dur-
ing traveling
at a cons-
tant speed.)
4-87
-
CN11
CN 105-6 (63 LSAnI) -
CN105-1 (60 LSL) -
CN105-3 (61 LST) -
Lift tilt
CN106-13 (51 GND) - attachment
switch
1
CPU
board
-
CN39
-
CN105-2 (68 LSL2)
CN104-15 (1 M + )
CN104-5 (7 MP)
Connector MP
@ F2 fuse open
0 F2 fuse replacement
0 To A on next page
'-
A
- Turned OFF in ap-
Is the MP contactor closed Is it turned on immediately prox 2.5 seconds
when the matenal handling
lever is pulled?
Closed when the material handling
lever is release?
-
To B on this
0
page
I
I I
Not closed
0
1 Turned OFF immediately
Inspection 2
ANL 1 1: ESY-22
MP contactor operation check
NG - MP contactor coil continuity
NG-o MP contactor
(aQ) coil
check
1
OK
1
I
OK (approx. 20 Q)
replacement
1 OK (approx o
OK (approx. 20 Q) -+ CPU board defect, or wiring disconnection (between CPU board and contactor)
NG (aQ) -, MP contactor coil replacement
Inspection 3. Pump motor continuity check
Battery plug OFF, P12-PI3 motor cable disconnection
CNll
CN105-6 ( 6 3 LSATTI) -
CN 105-1 ( 6 0 LSJ -
CN105-3 (61 LST) -
Lift tilt
attachment
CN106-13 (51 GND) - switch
d
CPU
board
-
CN115
CN104-15 (1 M + )
-
CN 104-5 (7 MP)
L
MP Connector
@ F2 fuse open
Inspection 1
F2 fuse continuity check
NG
(00
- 0 F2 fuse replacement
OK (0Q,
Is the MP contactor closed when the Closed 0 Pump motor defect
material handling lever is pulled? 0 Pump motor cable disconnection
Not closed
1
0 To A on next page
P-
ANL31: Switch input test o Material handling switch defect
Check ONIOFF of each
0 Wiring defect (each material handling switch -
CN 105lCN106)
material handling switch
Inspection 2
ANL11: ESY-22 MP contactor
MP contactor coil continuity 0
MP contactor operation check check
I
OK OK (Approx. 20 Q)
1
0 CPU board defect 0 CPU board defect
0 Wiring defect (MP contactor coil - CN110)
Caution:
Never touch the material handling lever during MP contactor operation check.
Otherwise, the pump motor starte to move the mast and fork when the MP contactor is closed.
lnspection 1. F 2 fuse continuity check
Battery plug OFF
OK (approx. 2 0 Q) CPU board defect, or wiring disconnection between CPU board and contac-
-+
tor coil
NG (a Q) -, MP contactor replacement
TROUBLESHOOTING - OTHERS
Battery capacity is not indicated correctly.
YES
YES
0
Adjustment of tuning Adjustment of tuning
mode C 4 mode C 4
0 Adjust toward level 0 Adjust toward level
8. 1.
TROUBLESHOOTING RELATED TO MULTI-DISPLAY AND MCS
COMMUNICATION SYSTEM
ERROR CODE F1: FAILURE IN COMMUNICATION BETWEEN MULTI-DISPLAY AND MCS
I I I
I
I
OK
1
0 CPU board defect
0 Multi-display board defect* * Multi-display board: CPU board for
display
I I I I
OK
OK
Note
Even if error code F5 is displayed when the AC power is connected, charging is possible by pressing
the CHARGE switch. As the count memory for automatic equalized charging is abnomal, automatic equal-
ized charging fails.
ERROR CODE F6: CHARGING SAFETY TIMER OPERATION
AC power is input check. NG
Error
- 0
0
Power service interruption
AC power cable defect
display
OK (200 V)
OK (200 V)
Charger timer test Take a corrective action accord-
NG - ing to the timer test and
troubleshooting.
OK
Fuse (Fch) continuity check NG
0 Blown fuse (Fch)
(00 Q)
- - -
P-
ANL11: ESY-12
CPU port defect
Charging voltage check
'1
0 Transformer defect
ERROR CODE F7: CHARGING START FAILURE
Continue charging as it is. YES Tap changer voltage check
+Charging completed? -
OK (5 V)
! I
OK (5 V ) 0 Timer unit defect 0 Display board defect
0 Harness defect
0
I O
pened
---
>
ex
e
P22
I
b
(U
g-
53
TMps
-
-
I 1
BATT
-
4b
CN27-4 (151. LISFi
- cs, 3ISP
41
PBEHPS i
-
1
@ PS board defect
0
1
To A on next page
Does the PS motor run when the steering
PS board defect
wheel is not operated after SWKYON?
NO
I Inspection 1.
H
(SWKYON)
Does the PS motor run when the steering
CN27(4)151 (harness side-board side)
wheel is operated after SWKYON?
$ Voltage measurement
CN27(5)163
0 V on both harness
side and board side
0
i
J
0
I
CN41 C N 4 3 defect 0
I
CN27 defect 0
t
Wiring disconnection
0 PS controller internal
wiring defect
0 PS board defect
lnspection 1. Display signal voltage check
Battery plug ON, SWKYON, CN27 connection
C27
(C2E1terminal)
OK (battery voltage on both harness side and board side) CN41 C N 4 3 defect, PS controller in-
+
Estimated causes
@ CPU board defect
I @ Direction switch defect I
I @ Mps contactor defect I
I @ Connector and Wiring defect I
@ Parking switch defect
0
0
oK (llon)l
CN42 defect
Wiring disconnection
0 Direction switch defect
0 CPU board defect
0 Parking switch defect
lnspection 1. Main PS circuit voltage measurement
Battery plug ON, SWKYON, CN27 connection
OK (appro~.1 1 0 Q) + CN42 defect, wiring disconnection, direction switch defect, CPU board
defect, or parking switch defect.
NG (co Q) -, Mps contactor defect
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (WIEHPS)
1. The steering wheel is heavy. (The PS motor does not run when the steering wheel
is operated after the SWKYis turned to ON.)
p22
TM,s
ii
+I
CN27-l(43 SWKY)
-CN27-3(161 SSP)
- CN27-2(162 SSP)
- SSP
CN27-5(163 SSP)
&
-
-BATT PB~HP~
7
CN27-4(151 DISP)
CSPS
DISP
b
-
A
@ F3 open
@ PS motor defect
@ PS pump defect
@ PS board defect
@ TMps defect
@ Wiring disconnection
7
Check connector and wiring connections.
NG
%
Recheck by operation after correction.
11
OK
Inspection 1.
NG - 0 Blown F3
CN41 defect
voltage measurement
0 PS controller internal wiring defect
CSpsN1
I 1
OK (battery voltage)
0 To A on next page
Inspection 2. 0 CN41-43 defect
Release the steering wheel. NG 0 PS controller internal wiring defect
TMpsC2E1 - 0 Motor cable connector defect
$ voltage measurement 0 Motor defect (The motor circuit is
CSPSN1 open if the measured voltage is 0 V.)
I OK (battery voltage)
lnspection 3.
Operate the steering wheel t o the stroke
end.
TMpsC2E1
$
CSPSN1
voltage measurement
1 Battery voltage
tLess
than
battery
voltage
0
Motor defect
PS pump defect (The pump or motor
may be seized if the measured voltage
is about half of the battery voltage.)
I
lnspection 4.
CN27(3)161
$ voltage measurement
CN27(5)163 t-
I
o
0
CN27 defect
PS board defect
r-
Inspection 5.
CN27(2)1 6 2
0 Steering pressure switch defect
$ voltage measurement
CN27(5)163
wheel is released
I 1 0 V or more: Voltage when the steering
0 PS circuit TMps defect wheel is operated
0 PS circuit current sensor defect
0 PS board defect
lnspection 1. Main PS circuit voltage measurement (1
Battery plug ON, SWKYON, CN41 C N 4 3 connection
C27
(C2E1 terminal)
C27
(C2E1 terminal)
C27
(C2E1terminal)
OK (approx. 1 2 V) To inspection 5
NG (0V ) + CN27 defect or PS board defect
Inspection 5. Steering pressure switch operating voltage measurement (2)
Battery plug ON, SWKYON, CN27 connection, with steering wheel rotation
OK (2 V or less when the steering wheel is not operated, and 10 V or more when the steering wheel
is operted) -+PS circuit TMps defect, PS circuit current sensor defect, or PS board defect
NG -+Steering pressure switch
4-108
04
Does the motor stop upon SWKYOFF? No Welding of contactor contact.
YES
7
CN27-3061 SSP)
~ ~ 2 7 - 2 ( 1 6 SSP)
2
PBEHPS SSP
CN27-5(163 SSP)
Estimated causes
@ PS board defect
NG
OK =
Inspection 1.
CN27(2)162 NG 0 Steering pressure sensor
$ voltage measurement - 0 Wiring defect
CN27(5)163
OK ( 2 V or less when the steering wheel is not operated, and 10 V or more when the steering wheel
is operated) + PS board defect
NG -, Steering pressure switch defect, or wiring defect
ELECTRICAL SYSTEM TROUBLESHOOTING
[FOR OTHER THAN U.S.A.l(l998.9 - )
Page
GENERAL .................................. 4A-2
TROUBLESHOOTING EXPLANATION ........... 4A-2
LOCATIONS OF TERMINALS AND
CONNECTORS ............................ 4A-3
BEFORE TROUBLESHOOTING ............... 4A-4
DRIVE SYSTEM-MATERIAL HANDLING
SYSTEM TROUBLES ...................... 4A-5
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED ... 4A-5 Em
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (DRIVE SYSTEM) .................... 4A-70
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (MATERIAL HANDLING SYSTEM) ..... 4A-81
TROUBLESHOOTING RELATED TO STEERING
SYSTEM..... ............................. 4A-86
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED ... 4A-86
GENERAL
Only the following items, which have changed due t o use of the MOS controller, are explained here.
For items other than the above, see chapter 4, ELECTRICAL SYSTEM TROUBLESHOOTING, in the
5FBE Repair Manual (CE306).
TROUBLESHOOTING EXPLANATION
Inspection 1 NG
F1 check
C F1 defect
(-Q)
OK (0 s2)
7
Inspection 2 NG
CN101-9 (43)
C
SWKYdefect
$ Voltage check
CN103-2 (N1)
Measure with a circuit tester.
OK (48 V)
1
CPU board defect
\ Repair or replace.
Potential level
/
\ Pin No.
I
Connector No.
LOCATIONS OF TERMINALS AND CONNECTORS
Main measurement terminals referred to in this troubleshooting chapter are located as shown below.
PI2
Provided for models
with a material
handling chopper.
P13
Provided for models
with a material
handling chopper.
Provided for models
without a material
handling chopper.
N1
CN
- TH Temperature sensa
CN101-24(76,THCD)
CPU
board CN101-1(75,THC+) STH
Inspection 1
Disconnect connector CN TH Temperature sensor defect
and measure the resistance of
temperature sensor. (2.2 kQ or more)
1
s:P than 2.2 kQ)
Defective contact or disconnection between CNlOl and temperature sensor
CPU board defect
Inspection 1. Temperature sensor resistance check
Battery plug OFF, connector TH disconnection
OK (less than 2.2 kQ) +CPU board defect, or defective contact or disconnection between C N l O l
and temperature sensor
NG (2.2 kQ or more) + Temperature sensor defect
ERROR CODE A2: CPU BOARD ABNORMAL TEMPERATURE RISE
-
Related portion 1
fO,
- Estimated causes
80°C or more
Temperature measurement + Leave the vehicle unoperated for some
time (about 30 minutes)
NO
1
CPU board defect
The CPU board temperature sensor is included on the CPU board. CPU board defect is
conceivable when this error code (A2: CPU board abnormal temperature rise) is displayed.
ERROR CODE A3: ABNORMALLY HIGH BATTERY VOLTAGE
Related portion
CPU
board
I CN102-11(P2.VBP2) P2
0
~ s t
The charger plug is connected YES * Start charging after connecting the charger
to the controller. plug to the battery side.
NO
YES
The mounted battery is other w Mount the specified battery.
than the specified one.
NO
7
CPU board defect
ERROR CODE A4: ACCELERATION POTENTIOMETER INSTALLATION DEFECT
Acceleration
potentiometer
CN25 CN26.
CN105-6(50,POT-)
CPU
board CN105-l(64,LSAC) VRAD
- -
E s t i
Is the battery plug connected YES c IS the normal state recovered YES
while the accelerator pedal is when the accelerator pedal is Normal
depressed? released?
I I
I ON (Lit)
t
Accelerator switch wiring short circuit (short circuit between 64 and 50)
Inspection 1. Individual acceleration potentiometer inspection
Battery plug OFF, CN26 removal
Lift 2 switch
2 -
Estimated causes
Is the battery plug connecte while YES Recovered to the normal state YES
any material handling lever is when the material handling lever Normal
operated? is released.
-
1
Inspection 2 NG LSL2defect
LSL2individual check
(always 0 Q)
OFF NO^ lit) 1
(Lit) I
OK
Wiring short circuit (Normal state: WQ
of the switch in the Operated state: 0 Q)
Inspection 1 ON position
Individual check on LSL, LST, and Installation adjustment defect
I
NG Each material handling
OK 1
(always 0 Q) limit switch defect
(Normal state: -Q Operated state: 0 Q)
1
Installation adjustment defect
Inspection 1. LSL, LST, and LSAT1individual check
Battery plug OFF, LSL, LST, and LSATl individual removal
lnspection 2. LSL2individual check (only when the material handling chopper is provided.)
Battery plug OFF, LSL2individual removal
CPU
-
board Deadman switch
CN22 CN28
CN103-4(67,LSD)
- -
LSD
- -
Estimated causes
0
t
Normal
ANL3 1: Switch input test
Is the switch turned ON or OFF
when the parking brake lever is
pulled?
lnspection 1
0 Switch
check replacement
t
Lit
Is the deadman switch turned 0 Defective CPU board
ON or OFF when the operator (switch ON)
sits on the seat?
F5
CN104-3(41,VBBT) P1
CPU F1
board CN102-11(P2,VBP2) P2
V
Estimated causes
1 ,
Inspection 1
Drive fuse (FI) check
p-(other than R)F l defect
OK (0 Q)
Voltage measurement at OK
terminals VBBT and VBP2 CPU board defect
(a= VBBT - VBP2) (a = 15 V or less)
Voltage calculation
I (NaG= 15 v or more)
Inspection 2
P2
$ continuity check
CN102-11 (P2) b- Disconnection between CN102 and P2
1 OK (0 Q)
Related portion
F5
-
CN104-3(41,VBBT) P1
CPU
board CN102-2(P11,VBP11)
-
- Estimated causes
Inspection 1 NG
F2 defect
Pump fuse (F2) check
(Any value other than 0 Q)
OK
-
(p = 15 V or less)
CPU board defect
NG
(p = 15 V or more)
1
Inspection 2
P2 NG
c Disconnection between CN102 and P I1
$ continuity check
CN102-2 (PI I) (-Q)
OK (0 Q)
7
Short circuit between P I1 and N1
lnspection 1. Pump fuse (F2) check
Battery plug OFF, fuse (F2) individual removal
ro,
Estimated causes
P8 P1
0
RA
____
I TP9
DAD
TDADo ! LI
n
..
" I I
CN101-14(P8,TMD-D) 0 I
t-
-
TMD l-
C PU CN101-16(92,TMD-G)
I1 CA
board
I- Snubber board
'----------------------------------l,---;
- TN1
CN101-22(N2,TMD-S)
i1
0
N1
a TMD defect (Be sure to check DFI, DF2R, DF2L, snubber board (CAI DAD),
and RA because a defect in any of these may be primary cause of a defective TMD.)
a
@ CPU board-TMD wiring disconnection
@) P8-TDAD wiring disconnection
@ CPU board defect
(If error codes CO and FA are displayed at the same time, give priority to FA.)
CO and C1 displayed
in traveling stop state? P- See the section of troubleshooting of C1
lnspection 1
Remove TDAD round terminals of snubber
board and turn on battery plug. Snubber board defect
TDAD (P8) (less than 15 V or less)
$ voltage check
TNI (NI)
v lnspection 2
(15 V or more)
lnspection 3
Remove CNlOl and TMD wiring- and check
continuity between: NG Wiring disconnection between CPU
(A) CN101-14 - TMD-D
board and TMD
(B) CN101-16 - TMD-G
(C) CN101-22 -TMD-S
(D) CN101-16 - CN101-22
OK
I 1
I
lnspection 4
TMD individual check after
disconnecting TMD wiring
copper bar
OK
I
CPU board defect
I
TMD defect
Conduct inspections 5-10 below the heading "A" on the next page as a defect in DFl1DFZR,
snubber board (CAI DAD), and RA may be a primary cause of a defective TMD.
. .
OK
t
lnspection 6
(perform this check only when NG rn SN1 individual check
CO and C9 are simultaneously
displayed.)
OK
1
lnspection 7 NG
DF2Rand DF2Lindividual C DF2 individual check
check
OK .
Inspection 8 NG C
CA individual check
OK
1
Inspection 9 NG C
DAD individual check
Snubber board defect
4
OK
Inspection 10 NG C RA individual check
RA individual check
OK
1
Driving confirmation test
lnspection 1. TDAD-TN1 voltage check
Snubber board TDAD round terminal disconnection, battery plug ON, key switch ON
--
Snubber board
TN1
TDAD
OK (0 C2)+ To inspection 3
NG ( 4 2 ) -+ Wiring disconnection between P8-TDAD
lnspection 3. Between CPU board-TMD wiring continuity check
Battery plug OFF, CN101-TMD wiring disconnection
A: CN101-14 (P8) [RECI -TMD-D [wiring sidel
B: CN101-16 (92) IRECI - TMD-G [wiring sidel
Measurement terminals C: CN101-22 (N2) [RECI - TMD-S [wiring side1
D: CNIOI-I6 (92) [RECI - CN101-22 (N2) [RECI
Circuit tester range 0 x 1
A: 0 R
1 Standard
OK (standard) 4 To inspection 4
NG (other than standard) 4 CPU board-TMD wiring defect
Standard
Source
OK (standard) + To inspection 6
NG (other than standard) + DFI defect
lnspection 6. SN1 individual check (Conduct this inspection only when CO and C9 are displayed si-
multaneously.)
Battery plug OFF, SN1 wiring disconnection
OK (standard) + To inspection 7
NG (other than standard) + SN1 defect
Inspection 7. DF2R-DF2L individual check
Battery plug OFF, each DF2 wiring and copper bar removal
OK (standard) + To inspection 8
NG (other than standard) -+ DF2 defect
OK (standard) + To inspection 9
NG (other than standard) + Snubber board defect, to inspection 10
lnspection 9. DAD individual check
Battery plug OFF, snubber board wiring disconnection
OK (standard) + To inspection 10
NG (other than standard) + Snubber board defect, to inspection 10
Estimated causes
1 YES
~ a i t eplug
r ~ ON, Key switch ON
CSD output voltage check
CPU board defect
CN101-9 (71) (0.86 V or more
$ voltage check and 2.5 V or less)
CN101-I 1 (74)
Inspection 2
Remove CNlOl and CN CSD. Wire continuity
check: OK c CSD defect
between CN101-7 and CN CSD (wire color: W) (0 Q)
between CN101-9 and CN CSD (wire color: 0)
between CN101-11 and CN CSD (wire color: B)
NG c-Q)
Wiring defect between CN101 and drive current sensor
ANL 11: ESY 21-24 NG
Drive contactor ONIOFF check (not turned ON and OFF)
I
lnspection 3
ANL 11: ESY 21-24
Check voltage between: NG
o P41-N1 with MFRcontactor ON * B
o P51-N1 with MRRcontactor ON (other than
o P4-N1 with MFL contactor ON battery voltage)
o P5-N1 with MRL contactor ON Drive motor defect
1 OK (battery voltage)
Drive motor wiring defect
lnspection 4 lnspection 5
A N L I I : ESY 21,23 Remove P4, P41, P5, P51, P6, P61,
Check voltage between: and P7 and check continuity of
o P7-N1 with MFRcontactor ON (other than drive motor between:
1 o P7-N1 with M Fcontactor
I
~ ON battery voltage)
I P4 - P5
P41 - P51
1 OK (battery voltage)
lnspection 6 NG Inspection 7
Remove CN102 and check NG Contactor
Individual check of
resistance of NG contactor (other than (other than defect
contactor judged NG
MFR... CN102-3 (4) approx. 20 9) - approx. 20 9)
MRR... CN102-5 (5) OK
MFL... CN102-4 (2) (approx. 20 9)
MRL... CN102-6 (3)
T I Main drive circuit connection defect
CN102-1 (1)
_I
(approx. 20 RYI Inspection
Remove CNlOl Drive main
circuit connec-
I $
N1
continuity check
1 OK (0 9)
(42) tion defect
OK (0 9 )+ CSD defect
NG (4-2) +Wiring defect between CNlOl and drive current sensor
lnspection 3. Drive contactor voltage measurement
Battery plug ON, key switch ON, each contactor ON in ANLI 1: ESY 21-24
P41 @ - N 1 with MFRcontactor ON
P51 @ - N1 @ with MRRcontactor ON
Measurement terminals P4 @ - N1 @ with MFL contactor ON
P5 @ - N1 @with MRLcontactor ON
Circuit tester range DC5OV
Standard Battery voltage
P7 @- N1 @ with MFRcontactor ON
Measurement terminals
P7 @- N1 @ w i t h MFL contactor ON
Circuit tester range DC50V
Standard Battery voltage
P4 - P5
P41 - P51
Measurement terminals [Wiring side]
P6 - P7
P61 - P7
Circuit tester range R x l
Standard Approx. 0 R
OK (approx. 20 Q) + To inspection 8
NG (other than approx. 20 R) 4 To inspection 7
lnspection 7. Contactor individual check (to be performed on defective contactors only)
Battery plug OFF, each contactor wiring and copper bar disconnection
CN
- TH Temperature sensc
CN101-24(76,THCD)
CPU
board CN101-1(75,THC+) STH
Estimated causes
Inspection 1
Disconnect CN TH and measure
the resistance of the temperature
sensor.
I NG - Temperature sensor defect
I OK (0 52)
(Less than 2.2 k52)
Wiring defect between CNlOl and temperature sensor
Inspection 1. Temperature sensor resistance measurement
Battery plug OFF, CN TH disconnection
OK (less than 2.2 kQ) +Wiring defect between CNlOl and temperature sensor
NG (2.2 kQ or more) -+ Temperature sensor defect
ERROR CODE C4: TRAVELING ACCELERATOR ABNORMALITY
Acceleration
CN105-2(53,POTA+)
CN105-3(52,POTA)
CPU VRAD
board CN105-6(50,POT-)
CN105-l(64,LSAC) --
Estimated causes
I OK (0.3 V or more) I
I YES
I
t t
Mounting adjustment defect
Check the potentiometer Wiring defect between CPU board
and acceleration potentiometer
OK (4.5 V or less)
(4'6
NG
Inspection 2
CN105-6 (50)
$ continuity check
CN26-1 (50)
- Wiring defect
NG between
CN105 and
(42) acceleration
or more) pottiometer
1 OK (0 SZ)
OK (standard) 4 Mounting adjustment defect, Wiring defect between CPU board and
acceleration potentiometer
NG (other than standard) + Acceleration potentiometer defect
lnspection 2. Continuity check between CN105 and acceleration potentiometer
Battery plug OFF, disconnection between CN26 and CN105
Related portion
CPU CN103-B(46,DSR)
board DS
CN103-17(51,LS-)
- P
Estimated causes
NO
1
CPU board defect
4A-40
-
1 , CN104-l(81,SSR-k)
CN2 1 Speed sensor (right)
SSR
CN104-2(82,SSR-)
i
-
CPU
board CN20 Speed sensor (left)
CN104-6(83,SSL+)
SsL
--
Estimated causes
Related portion
I
CPU
board
+
ANL 11: ESY21-24 NG Replace welded contactor
Check ONIOFF of drive contactors
(Not turned ON and OFF)
lnspection 1
Disconnect CN101
CN101-16 (92)
1 ~ -
Disconnection in wiring between CNlOl and TMD
(-42)
$ continuity check
TMD-G
lnspection 2
Individual SN1 check ING S N l defect
lnspection 3 NG
lndividual DF1 check DFl defect
lnspection 4
lndividual snubber
board check
TDAD - TP9
ke Snubber board defect
OK (standard)
lnspection 5
Individual DF2R, DF2 defect
1OK
CPU board defect
lnspection 1. Continuity check between CNlOl and TMD
Battery plug OFF, CN101 disconnection
OK (0 SZ) -+ To inspection 2
NG ( 4 2 ) -+ Disconnection in wiring between CNlOl and TMD
OK (standard) + To inspection 3
NG (other than standard) -+ SN1 defect
lnspection 3. Individual DF1 check
Battery plug OFF, DF1 wiring and copper bar removal
OK (standard) -+ To inspection 4
NG (other than standard) -+ DF1 defect
Related portion
--- CONTACTOR
CN102-6(3,MRL+) CN MRL---
MRL
- CONTACTOR
--
CN102-12(7,MP+) CN MP ---
MP
-
CN103-2(6,MPS+)
- CONTACTOR
-
CN103-l(1,MPS-) - MOPS
C NTACTOR (without EHPS)
k
SWKY
CN103-14(43,VBKY2) I
0 0
OK (battery voltage)
II
AN L11: ESY21-26
Check each contactor turns ONIOFF I(
OK
(Turned ON and OFF)
- A
lnspection 5
Remove contactor
connectors (MRRand
-
NG
(mQ)
Disconnection
in wiring
MRL)and CN116 and between
lnspection 3 CN116 and
lndividual contactor Contactor check continuity
between contactor contactor
(MFR,MFL, MP, MRR, defect connector
and MRL)check connector and CN116
IOK
CPU board defect
I OK (0 R)
Inspection 6 NG Inspection 8 NG
Disconnection Disconnection
(applicableto models (applicable to models
(mQ) in wiring in wiring
with EHPS) without EHPS)
between CPU between CPU
Remove CN104 and Remove CN103 and
board and board and
CN37 and check CN42 and check
CN37 CN42
continuity between continuity between
CN104 and CN37. CN103 and CN42.
OK (0 R) OK (0 R)
Inspection 7 NG Inspection 9 NG
C Snubber MPSdefect
Individual snubber (applicable to models (mR)
board check (0 R) board defect without EHPS)
TDAD - TP9 lndividual MpScheck
OK (standard) OK (approx. 68 R)
lnspection 2. Continuity check between CPU board and contactor connectors (MFR,MFL, and MP)
Battery plug OFF, contactor connectors (MFR,MFL,and MP) and CN102 disconnection
MFR:CN102-3 (4) [REC] - CN MFR-2(Wire color: W)
MFL: CN102-4 (2) [REC] - CN MFL-2(Wire color: 0)
Measurement terminals MP: CN102-12 (7) [RECI- CN MP-2 (Wire color: Y)
MFR.MFL.MP:CN102-1 (1) [REC] - Each contactor connector-I
(Wire color: R)
Circuit tester range a x 1
Standard 0 i2
OK (0 i2) + To inspection 3
NG (42) + Disconnection in wiring between CPU board and contactor connectors (MFR,MFL,
and MP)
lnspection 3. Individual contactor (MFR,MFL, MP, MRR,and MRL)continuity check
Battery plug OFF, disconnection of each contactor wiring and copper bar
OK (0 Sl) + To inspection 5
NG ( 4 2 ) + Disconnection in wiring between CPU board and CN116
lnspection 5. Continuity check between contactor connectors (MRRand MRL)and CN116
Battery plug OFF, disconnection of contactor connectors (MRRand MRL)and CN116
OK (0 Q) + To inspection 3
NG ( 4 2 ) -t Disconnection in wiring between CN116 and contactor connector (MRRand MRL)
lnspection 6. Continuity check between CPU board and CN37 (applicable to models with EHPS)
Battery plug OFF, disconnection of CN104 and CN37
OK (0Q) + To inspection 7
NG (ooQ) + Disconnection in wiring between CPU board and CN37
lnspection 7. Individual snubber board check
Battery plug OFF, disconnection of snubber board wiring
Inspection 8. Wiring check between CPU board and CN42 (applicable to models without EHPS)
Battery plug OFF, disconnection of CN103 and CN42
OK (0 0)+ To inspection 9
NG (-Q) + Disconnection in wiring between CPU board and CN42
Inspection 9. Individual MpScheck (applicable t o models without EHPS)
Battery plug OFF, disconnection of CN42
- Estimated causes
- Estimated causes
Related portion
PI4 P1
0
RA
, ----- - --- - -- -- - -__--- - - --- - -- - -- - -
''---I TP9
DAP
L I .. 'I I
CN101-15(P14,TMP-D)
t-
CPU CN101-4(93,TMP-G)
I1 CA
board
TN1
CN101-23(N2,TMP-S)
4I
0
N1
-
P
Estimated causes
a TMP defect (Be sure to check DF3, snubber board (CA, DAP), and RA because a defect in any
of these may be a primary cause of a defective TMP.)
@ Snubber board defect
@ Wiring defect between CPU board and TMP
@ Wiring defect between PI4 and TDAP
@ CPU board defect
It is possible that "WJmaterial handling chopper" is selected in the display option setting although
the vehicle is not provided with a material handling chopper. Change the display option setting to
"Without material handling chopper".
(IfEO and FA are displayed at the same time, give priority to FA.)
Check if the snubber board NG
Correct the problem and recheck
and TMP connection wiring
I is loosened.
I
1
Inspection 1 NG
board defect
Remove TDAP round terminal v or les>)
'(i5
of snubber board and turn on
battery plug.
TDAP (PI4)
$ voltage check
TNI ( N I )
I OK (15 V or more)
v l e m
lnspection 2
and TDAP
Wiring defect between PI4 and TDAP
lnspection 3
Remove CNlOl and TMP wiring and check NG Wiring defect between
continuity between:
* CPU board and TMP
(A) CN101-15 and TMP-D
(B) CN101-4 and TMP-G
(C) CN101-23 and TMP-S
(Dl CN101-4 and CN101-23
(D) 0 0
lnspection 4
Remove TMP wiring CPU board defect
copper bar and check
I TMP individually. I
1
NG
TMP defect
Conduct inspections 5-8 below the heading "A" on the next page, as a defect in TMP, DF3, snubber
board (CAI DAD), and RA may be a primary cause of a defective TMP.
lnspection 5
Individual DF3 check 1~ DF3 defect
lnspection 6
lndividual CA check
lnspection 7
lndividual DAP check
lnspection 8
Individual RA check 1 ~ RA defect -
I oK
Material handling confirmation test
lnspection 1. TDAP - TN1 voltage measurement
Disconnection of TDAP round terminals on snubber board, Battery plug ON, key
switch ON
Measurement terminals
TDAP (P14) @[wiring side] - TN1 (N1)0
[on snubber board]
Circuit tester range DC50V
Standard 15 V or more
OK (0 Q) -+ To lnspection 3
NG ( 4 2 ) -+ P14 - TDAP wiring defect
lnspection 3. CPU board - TMP continuity check
Battery plug OFF, CN101.TMP wiring disconnection
A: CN101-15 (P14) [RECI -TMP-D [wiring sidel
B: CN101-4 (93) [REC] - TMP-G [wiring sidel
Measurement terminals C: CN101-23 (N2) [RECI -TMP-S [wiring sidel
D: CN101-4 (93) [REC] - CN101-23 (N2) [REC]
Circuit tester range R x l
A: 0 R
B:OR
standard C: 0 Q
D:R
..
OK (standard) -+ To lnspection 4
NG (other than standard) + CPU board - TMP wiring defect
Source
OK (standard) -+ To lnspection 6
NG (other than standard) -+ DF3 defect
OK (standard) -+ To lnspection 7
NG (other than standard) -+ Snubber board defect, to lnspection 8
lnspection 7. Individual DAP check
Battery plug OFF, snubber board wiring disconnection
OK (standard) -t To lnspection 8
NG (other than standard) -t Snubber board defect, to lnspection 8
CPU CN101-lO(72,CSP)
board CSP
CN101-12(74,CSP-)
Estimated causes
It is possible that "WJmaterial handling chopper" is selected in the display option setting although
the vehicle is not provided with a material handling chopper. Change the display option setting to
"Without material handling chopper".
lnspection 3
ANLI 1: ESY-25 - B
PI2 - N1 voltage check with MP contactor NG (other than battery voltage)
closed
Pump motor defect
I
T
lnspection 4
OK (battery voltage)
pump motor wiring defect
t
lnspection 5
NG (-a)
1 OK (battery voltage)
B
lnspection 6 lnspection 7
Remove CN102 and MP contactor Contactor defect
check resistance of (other than
MP contactor approx. 20 R) approx. 20 R )
CN 102-12 (7)
resistance
-
measurement OK (approx. 20 R)
CNI02-1 (1)
lnspection 8
Remove CNlOl
CN101-25 (N2)
$ continuity check
-NG
(-R)
Defective wire connection of material handling main circuit
N1
I OK (approx. O R )
lnspection 2. Wiring continuity check between CNlOl and material handling current sensor
Battery plug OFF, CN CSP-CN101disconnection
OK (0 Q) + CSP defect
NG (42)-t Wiring defect between CNlOl and material handling current sensor
lnspection 3. Material handling contactor voltage measurement
Battery plug ON, key switch ON, closing of MP contactor in ANLI 1: ESY-25
Related portion
Direction switch
Estimated causes
Lit Inspection 2
'- OK
Direction switch in-
- -0 Short-circuit
(switch ON)
dividual check in wiring
ING
Not lit between
(switch OFF) CN106 and
CN9
0 Direction switch defect 0 CPU board
1 defect
Not lit
(switch OFF)
0
t
CPU board defect
Inspection 3
Accelerator switch Short circuit
(switch ON) in wiring
individual check
0
7
Acceleration circuit
defect
0
between
CN106 and
CN25
CPU board
defect
lnspection 1. Deadman switch individual check
Deadman switch removal
OK -+ Momentary disconnection of the line between CN106 and CN22, momentary disconnec-
tion of the BIT plug power supply line, CPU board defect
NG --+ Deadman switch defect
CNll
CN103-lO(60,LSL)
Lift switch
CN103-17(51,LS
CPU
board
CN103-11(68,LSL2) CN39
--
Lift 2 switch
-
CNl I connector
disconnection check P- Correct the problem and recheck
OK
1
CPU board defect
4A-74
Related portion
Multi-display
CN1 CN120
CN105-12(143,SDTMQ
CPU
board CN105-13(142,SDTMA) DISP
L -
-
- Estimated c a u s e s s
a Multi-display defect
NG
CN105, CN 1, and CN120 disconnection check t Correct the problem and recheck
OK
T
Inspection 1 NG t Wiring disconnection between CPU
CN105 and CN120 removal and (-Q) board and multi-display
CN105 - CN120 wiring continuity check
-
OK (0 SZ)
7
CPU board defect
Multi-display defect
Inspection 1. Disconnection in wiring between CPU board and multi-display
Battery plug OFF, CN 105.CN120 disconnection
CN 104-3(41,VBBT)
CN103-16(41,VBBT2)
4P
SWKY
CPU F5
board CN104-4(43,VBKY) I PI
0 0- 0
CN103-14(43,VBKY2)
CN101-3(N2,N2)
I N2
0
- Estimated causes
NG
Battery check Correct the problem and recheck
, 1 OK (battery voltage)
1
1
OK (battery voltage)
1I OK
board
1 OK (battery voltage)
I
(battery voltage)
Display defect
lnspection 4
Wiring disconnection between key switch and CPU board
CN103-14 (43)
either connector pair)
CN103-16 (41)
voltage check
CN103-4(67,LSD) -
CN22
-
Deadman switch
IF
--
CN6 Brake switch
CPU
board
CN103-13(65,LSB)
LSB
-
Y-
Acceleration
potentiometer
CN105-2(53,POTA+)
CN105-3(52,POTA)
CN105-6(51,POT-) VRAD
CN105-l(64,SWAC)
h -
Estimated causes
@ Battery overdischarge
@ No input of direction switch signal
@ No input of deadman switch signal
@ Accelerator switch defect or wiring disconnection between accelerator switch and CPU board
@ Brake switch defect or wiring disconnection between brake switch and CPU board
@ CPU board defect
ANL2: AID test NG * Battery overdischarge
VBP2 voltage measurement
I
(less than 20 V)
OK (20 V or more)
*r
lnspection 1 NG lnspection 3
Remove contactor Wiring Remove CN102 and CN116 CPU board
connectors (MFR.MFL) disco~ection and check continuity -CN116
and CN102 Contactor between CPU between: wiring
connectors - CN102 board and CN102-5 (5) - CN116-7 (5) disconnection
wiring continuity contactor CN102-6 (3) - CN116-9 (3)
check connectors CN102-1 (1) - CN116-3 (1)
I
lnspection 2 NG lnspection 4 NG
Contactors (MRR contactor Remove contactor -Wiring
MFL.MRR.MRL) (-a defect connectors (MRRMRL)and (-0) disconnection
individual check CN116 Wiring continuity between
check between CN116 and
contactor connectors contactor
and CN116 connectors
4
CPU board defect
OK (0 Q) -t To lnspection 2
NG (42) -c Wiring disconnection between CPU board and MFR.MFLcontactor connectors
OK (0 Q) -+ To lnspection 4
NG ( 4 2 ) -+ Wiring disconnection between CPU board and CN116
OK (0 Q) + To lnspection 2
NG ( 4 2 ) + Wiring disconnection between CN116 and MRR.MRLcontactor connectors
3. Normal speed control fails.
(The vehicle does not accelerate, attain the maximum traveling speed, or move.
(MFR.MFL.MRR.MRL contactors can be closed.))
o The maximum traveling speed is not attained unless the power control value of the display
mask function tuning mode C5 is set to "8". If the traveling speed control setting indicator for
2-speed appears on the display, the vehicle also does not achieve its maximum traveling
speed.
o The indication on the speedometer depends on the wheel diameter setting. Make sure that the
tire size setting matches the actual wheel diameter of the vehicle.
CN104-1(81,SSR+)
~
-~ 2Speed
1 sensor (right)
CN104-2(82,SSR-) SSR
L
SSL
CPU
board
- CNlO3-13(65,LSB)
CN6 Brake switch +
LSB
- CN103-17(51,LS-)
LU u
Acceleration
- CN105-2(53,POTA+)
potentiometer
CN105-3(52,POTA)
CN105-6(60,POT-) VRAD
---
CNI05-l(64,LSAC)
1 YES
I
-
ANL2: A I D test NG Acceleration potentiometer defect
Acceleration potentiometer voltage fiWiring defect between
measurement ( X C < = 1.3 V) acceleration potentiometer and
CPU board
I
- Related portion
CN102-8(P6,VBP6) CN116-1(P6,VBP6) O
- CN102-g(P61,VBP 7
LA
P61
0
CPU
- CN104-l(81,SSR-t) -
CN21 Speed sensor (right)
CN104-6(83,SSL+) -
CN20 Speed sensor (left)
CN104-7(84,SSL-) SSL
7-
Estimated causes
lnspection 1
Remove CN102, P6, and P61 CN 102 - P6 wiring disconnection
Checkwiring continuity between: CN102 - P61 wiring disconnection
CN 102 - P6
CN102 - P61
Inspection 2
DF~L.DF~R D F ~ L . D F defect
~R
individual check
D F ~ or
L D F ~ installation
R adjustment defect
CPU board defect
lnspection 1. CPU board - P6aP61 wiring continuity check
Battery plug OFF, CN102*P6.P61disconnection
OK (0 R ) -+ To lnspection 2
NG (042) + CN102.P6.P61 wiring disconnection
lnspection 2. D F ~ R . Dindividual
F~~ check
Battery plug OFF, DF2R.DF2Lindividual wiring disconnection
OK (standard) -+ D F ~ R . Dinstallation
F~~ defect, CPU board defect
NG (other than standard) + D F ~ R . Ddefect
F~~
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED
(MATERIAL HANDLING SYSTEM)
1. The pump motor does not run.
(1) When material handling chopper is provided (option)
-
Related portion
CN103-lO(60,LSL)
CN103-6(61,LST)
CN103-5(63,LSATl)
CNll
Lift switch
Tilt switch
Attachment 1 switch
CPU
board
--
L
,
CN103-1l(68,LSLZ) CN39
Lift 2 switch
I
It is possible that "Wlmaterial handling chopper" is selected in the display option setting al-
though the vehicle is not provided with a material handling chopper. Change the display option
setting to "Without material handling chopper".
, OK
(ONIOFF)
Pump motor defect
CPU board defect
4A-89
GN 11
CN103-lO(60,LSL) -
CN103-6(61,LST)
Lift switch
CN103-5(63,LSATl) Tilt switch
Attachment 1 switch
CN103-17(51,LS-)
C PU
board --
CNMP' -
MP contactor
-
- Estimated causes.
0
ANL31: Switch input test
Check ONIOFF of each Installation adjustment defect in each
defect
material handling switch.
OK
(neither ON/OFF) material handling switch
Wiring defect between CPU board and
each material handling switch
I
A
Not closed
A
Inspection 1
Remove CN102
CN102-12 (7)
NG
(other
- Inspection 2
MP contactor
individual check
NG
(other than
- MP contactor defect
t
I Inspection 3
Remove CNlOl
CN101-25 (N2) Defective wire connection of material handling main
$ continuity check circuit
N1
1 OK (0 a)
OK (approx. 20 Q) + To lnspection 3
NG (other than approx. 20 Q) + To lnspection 2
-7
TMPS
-
CN1
CN120
-
1
-I
-I
- -
DlSP
PBEHPS
- P23
O
N1
a P B Edefect
~ ~ ~
@ Multi-display defect
@ CNI, CN27, CN41, CN43, CN120 connection defect
@ TMps defect
1
lnspection 1
PBEMPsdefect
I NG (0V)
CN32
- Steering potentiometer
CN1054(55,POTST+)
CPU CN105-5(56,POTST)
board VRSP
CN103-17(51,LS-)
-
@ Open or short circuit of wiring between CPU board and steering potentiometer
@ CN103, CN105, or CN32 connection defect
@ CPU board defect
lnspection 1
Remove CN103, CN105, and CN32 and check wiring continuity of
(A) CN105-4 -CN32-1,
(B) CN105-5 - CN32-2,
(C)CN105-5 - CN103-17,
(D)CN105-4 - CN103-17,
(El CN105-4 - CN105-5,
(F)CN103-17 - CN32-3.
(B) -m
-m
1
1 Wiring defect between CPU board and steering potentiometer
lnspection 2
Steering NG
D Steering potentiometer defect
potentiometer
individual check
! oK
CPU board defect
lnspection 1. Wiring continuity check between CPU board and steering potentiometer
Battery plug OFF, CN103.CN105.CN32 disconnection
Steering potentiometer
OK (standard) + To lnspection 2
NG (other than standard) -+Wiring defect between CPU board and steering potentiometer
Related portion
CPU
board
--
imated causes
@ RA defect
@ P I - RA - CN100 - P9 - CPU board wiring disconnection
@ CN100, CN118 connector connection defect
@ CPU board defect
@ Snubber board defect
lnspection 1
Remove CNlOl Wiring disconnection between CPU board and P9
P9 (TP9 located at the
upper part of T N I )
$ continuity check
CN101-26 (P9)
Inspection 2 RA defect
Remove P I round terminal (other than P I - RA - CNlOO wiring defect
and CNlOO 0.8 52)
P1
$ continuity check
CN100-2 (P9)
OK (approx. 0.8 R)
A
Inspection 3 Snubber board defect
Individual snubber
board inspection
OK (0 Q) -t To lnspection 2
NG (-& 4 CPU
#I ) - P9 wiring disconnection
board
SPECIFICATIONS
Vehicle type
48V specification vehicle 36V specification vehicle
Item
TYpe DC series-wound open type 4-
Nominal voltage V 48 36
Rated output kw 3.3 x 2 e
Insulation class F H
Brush size mm 1 4 x 40 x 32 e
(width x length x thickness) (in) (0.55 x 1.57 x 1.26)
Number of brushes 4 c
COMPONENTS
Removal Procedure
1 Remove the battery ASSY.
(See page 1-5 "Battery Assy Removal.lnstallation".)
9 Disconnect the inlet hose and high pressure hose from the control valve.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operation
[Point 1I
[Point 21
Disassembly Procedure
1 Remove the disc brake.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Measure the insulation resistance between each motor cable and motor case.
Standard: 3 MQ or more
Field coil continuity inspection. Terminals to be measured: E and F
Standard: 0 Q (circuit tester range: 0)
5-7
Point Operations
[Point 1 I
Undercut depth
[Point 21
Inspection: Install the armature and brushes. Attach a
spring scale to the brush spring and measure
the spring force on the instant when the spring
departs from the brush.
Spring force
5FBE10,13 5FBE15,18,20
Standard 11.8 N (1.2 kg) 12.6 Ibl t
Inspection: Measure the insulation resistance between the
brush holder and bracket.
Standard: 1 MQ or more
[Point 31
[Point 41
PUMP MOTOR
GENERAL
SPECIFICATIONS
Vehicle type
48V specification vehicle 36V specification vehicle
Nominal voltage V 48 36
Rated output kw 8 6.1
Insulation class F H
Brush size rnm 14 x 4 0 x 32
4-
(width x length x thickness) (in) (0.55 x 1.57 x 1.26)
Number of brushes 4 c
COMPONENTS
Removal Procedure
1 Remove the battery hood.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1I
2 Brushes
Disassembly Procedure
1 Raise the brush cover.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Measure the insulation resistance between each motor cable and motor case.
Standard: 1 MQ or more
Field coil continuity inspection. Terminals to be measured: E and F
Standard: 0 Q
5-14
Point Operation
[Point 1I
1 Standard
5FBE10,13
80 mm (3.15 in)
5FBE15,18,20
t
Mica
Limit 75 mm (2.95 in) t
[Point 21
Inspection: Install the armature and brushes. Attach a
spring scale to the brush spring and measure
the force on the instant when the spring de-
parts from the brush.
Spring force
5FBE10,13 5FBE15,18,20
Standard 11.8 N (1.2 kg) i2.6 Ibl t
-
Inspection: Measure the insulation resistance between the
brush holder and bracket.
Standard: 1 MQ or more
[Point 31
[Point 41
SPECIFICATIONS
Vehicle type 48V specification 36V specification EHPS specification
vehicle vehicle vehicle
Permanent magnet +
Type C
type enclosed motor
Nominal voltage V 48 4- 36/48
Rated output kw 0.75 0.66 0.710.9
Insulation class F c c
Brush size mm 8 x 3 0 x 25 C 4-
(width X thickness x length) (in) (0.31 x 1.18 x 0.98)
Number of brushes 2 c c
Removal Procedure
1 Remove the side cover RH.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Measure the insulation resistance of each motor cable and motor unit before starting disassembly.
Standard: 1 Ma or more
_..
....//
. ...._. /'
Disassembly Procedure
1 Remove the PS contactor.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Measure the insulation resistance between each motor cable and motor case.
Standard: 1 MQor more
Point Operations
[Point 1I
[Point 21
[Point 31
Page
GENERAL ............................................................. 6-2
SPECIFICATIONS ................................................. 6-3
COMPONENTS ..................................................... 6-3
TRANSMISSION .................................................. 6-4
REMOVAL.INSTALLATI0N ..................................... 6-4
DISASSEMBLY .INSPECTION.REASSEMBLY ............. 6-6
FRONT AXLE ........................................................ 6-9
DlSASSEMBLY.INSPECTl0N.REASSEMBLY ............. 6-9
GENERAL
SPECIFICATIONS
Item 5FBElO 5FBE13 5FBE15 5FBE18
Overall gear ratio 17,48 4- 4- 4-
COMPONENTS
TRANSMISSION
REMOVAL-INSTALLATION
I 1 Transmission oil
I
Removal Procedure
1 Drain transmission oil.
3 Remove drive motors LH and RH. (See Drive Motor Removal on page 5-4.)
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Fill transmission oil to the level plug position
Right side: 1.7 Q (0.45 USgall
Left side: 1.8 Q (0.47 USgal)
Standard vehicle: Hypoid gear oil SAE 85W-90
Insulated vehicle: Hypoid gear oil SAE 75W-80W
Front wheel hub nut tightening torque: 107.87-147.10 N.m (1100-1500 kgf-cm)
179.59-108.53 ft-lbfl
Point Operations
[Point 1 I
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat liquid gasket (Three Bond 1215 or equivalent) on the transmission cover mating face before
reassembly.
Fill MP grease 0.490N (50 g) [O. 110 Ib] in the hub cap. Use MIL-G-3278-A only in the case of insu-
lated model 45s.
Transmission cover set bolt tightening torque: 29.42-44.13 N.m (300-450 kgf-cm) [21.71-32.56 ft-
Ibf]
Check the clearance between the tip end of the speed sensor and the gear. If it is not within the
standard, adjust it by changing the washer.
Standard: 0.5-2.5 mm (0.020-0.098 in)
Point Operations
[Point 1 I
[Point 21
[Point 31
[Point 41
Disassembly Procedure
1 Jack up the vehicle and remove the front wheels.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Fill MP grease 0.490N (50 g) [0.110 Ib] in the hub cap. Use MIL-G-3278-A only in the case of insu-
lated model 45s.
Front wheel hub nut tightening torque: 107.87-147.10 N-m (1100-1500 kgf-cm) 179.59-108.53 ft-
Ibf]
Point Operations
[Point 1I
Page
GENERAL .......................................................................... 6 ~ - 2
SPECIFICATIONS ............................................................ 6 ~ - 2
COMPONENTS ................................................................6 ~ - 3
FRONT AXLE & DRIVE UNIT ..................................... 6 ~ - 4
REMOVAL.INSTALLATION ............................................. 6A-4
DISASSEMBLY.REASSEMBLY ........................................ 6A-6
6A-2
GENERAL
SPECIFICATIONS
Item 5FBE 10 5FBE13 5FBE15 5FBE18 5FBE20
Overall gear ratio 17.48 + + + +
Removal Procedure
1 Remove the mast ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 11
DISASSEMBLY.REASSEMBLY
T = N.m (kgf-cm) [ft-lbfl
Disassembly Procedure
1 Remove the speed sensor.
3 Remove the gears (33T and 63T-16T) and axle shaft. [Point 21
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 11
[Point 21
I
*
Grease
I
1.
2.
Fill grease to the transmission case as shown.
3. Install the axle shaft ASSY, 33T gear and adjust nut.
4. Adjust the axle shaft preload by tightening the adjust
nut.
Standard: 110-150N(11-15kgf)[24-33lbfl
Note:
See that the adjust nut lock bolt hole aligns with the
33T gear lock hole. If not, adjust at the minimum
tightening side.
w 5.
6.
Install a new lock bolt.
SST
Note:
Install the 16T gear side bearing when installing
the 16T gear to the transmission case.
I [Point 31
SST I
Disassembly: Using SST, remove the bearings.
SST 09950-40010
[Point 51
Page
REAR AXLE ASSY .............................................. 7-2
GENERAL ........................................................... 7-2
SPECIFICATIONS ................................................ 7-4
COMPONENTS ................................................... 7-4
REMOVAL.INSTALLATION ................................... 7-5
DISASSEMBLY .INSPECT10NmREASSEMBLY ............ 7-7
REAR AXLE HUB ................................................ 7-9
REAR AXLE ASSY
GENERAL
1.0 and 1.3 ton series, and cushion vehicles of 1.O, 1.3, 1.5 and 1.8 ton series
7-3
COMPONENTS
Removal Procedure
1 Remove the battery hood.
4 Remove the cylinder. (See Steering Cylinder ASSY Removal on page 8-1 5 . )
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Rear wheel hub nut tightening torque: 107.87-147.10 N-m (1100 - 1500 kgf-cm)
-
[79.59 108.53 ft-lbf]
Point Operations
[Point 1 I
Standard
1 tonseries: 69 - 1 3 7 N ( 7 - 1 4 k g ) [ 1 5 - 3 1 Ibl
1.5 ton series: 7 8 - 147 N (8 - 15 kg) [ I8 - 33 Ibl
In case of 1 ton series Measure at the center of the rear axle in the 1 ton se-
ries, and at the hub bolt in the 1.5 ton series.
Disassembly Procedure
1 Remove the hub cap.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Fill MP grease in the hub cap. Use MIL-G-3278-A only in the case of the insulated model 45s.
Axle shaft side: 0.785 N (80 g) t0.176 Ibl
Axle shaft wheel side cap: 0.2452 N (25 g) [0.0551 Ibl
Rear wheel hub nut tightening torque: 107.87 - 147.10 N.m (1100 -
1500 kgf-cm)
[79.59- 108.53 ft-lbfl
7-8
Point Operations
[Point 1I
[Point 21
[Point 21
Removal Procedure
1 Jack up the vehicle and remove the rear wheel.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Fill MP grease in the hub cap. USE MIL-G-3278-A only in the case of the insulated model 45s.
Axle shaft side: 0.785 N (80 g) [O. 176 Ibl
Axle shaft wheel side cap: 0.2452 N (25 g) [0.0551 Ibl
Rear wheel hub nut tightening torque: 107.87-147.10 N m (1100-1500 kgf-cm)
179.59-108.53 ft-lbf]
7-10
Point Operations
[Point 1 I
[Point 21
Page
GENERAL ........................................................................ 7 ~ - 2
SPECIFICATIONS ............................................................7A-3
COMPONENTS ............................................................ 7A-4
REAR AXLE HUB ........................................................7A-5
REMOVAL-INSTALLATION ............................................ 7A-5
REAR AXLE ASSY .......................................................... 7 ~ - 8
REMOVAL.INSTALLATION ..............................................7A-8
7A-2
GENERAL
Pneumatic single tire
-. . .
-- -
--- -- -
--- ..
SPECIFICATIONS
Item 5FBE10 5FBE13 5FBE15 5FBE18 5FBE20
TYpe Full floating C C t C
Tire size 18 X7-8 10PR 18 X 7-8 14PR 16X 6-8 10PR C 16 X 5-10 112
Tire inflation pressure
780 (8) [1101 880 (9)[1301 780 (8) [1101 +
kPa (kgf/cm2)[psi]
COMPONENTS
REAR AXLE HUB
REMOVAL-INSTALLATION
T = N-m (kgf-cm) [ft-lbfl
Removal Procedure
1 Jack up the vehicle and support it by wooden supports.
5 Remove the bearing outer lace from the rear axle hub. [Point 31
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 11
[Point 21
[Point 31
Grease
[Point 41
Removal Procedure
1 Remove the counter weight.
4 Set the rear axle t o straight ahead condition, remove the steering cylinder set bolt, and slide the
cylinder. (See Section 8.)
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1I
- -
Standard: 10 20 N-m (100 200 kgf-
cm) [7.2 14.5 ft-lbf]
-
After adjustment, firmly stake the lock nut
with a punch. (2 places)
[Point 21
[Point 31
[Point 41
Reassembly: U s i n g SST, i n s t a l l t h e u p p e r b e a r i n g
outer lace.
SST 09130-30200-71
Note:
Be careful so as not to damage the rear axle ASSY.
GENERAL
Tilt steering
-
Operating range ( 6 O )
Full forward tilt
Full backward tilt
Steering valve
8-3
COMPONENTS
Steering wheel
Steering post
Hydrostatic steering valve
Drag link & steering piping
Steering cylinder
I I
SPECIFICATIONS
Vehicle model
5FBE10,13,15,18,20
Item - -
Diameter mm (in) 380 (14.96)
Steering wheel
Play mm (in) 20 - 4 0 (0.78 - 1.57)
Power steering type Hydrostatic power steering
Delivery cclrev (cu-in) 6 9 (4.21)
Hydrostatic
Relief valve set pressure
kPa (kgf/cm 2 ) [psi]
7850 - 8530 (80 - 87) [ I140 - 12401
steering valve
Maximum input torque
1 18 (12) 1871
N.m (kgf-cm) Ift-lbfl
Relief valve type Built-in type
-
HYDROSTATIC STEERING VALVE ASSY
REMOVAL.lNSTALLATlON
Removal Procedure
1 Remove the rear toe board.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Disassembly Procedure
1 Remove the fitting. [Point 11
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 11
[Point 21
[Point 31
Port face
Drive Reassembly: Set the concave portion of the rotor set star
in parallel.
Pin '\
[Point 51
[Point 61
STEERING WHEEL
REMOVAL-INSTALLATION
Removal Procedure
1 Remove the horn button.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
8-12
Point Operation
[Point 1I
Removal Procedure
1 Remove the steering wheel. (See Steering Wheel Removal-Installation on page 8-11 .)
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Disassembly Procedure
1 Remove the snap ring.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
8-15
Removal Procedure
1 Remove the rear panel.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operation
Front
[Point 1I
t
Installation: Install and adjust the steering potentio. See
I Steering potentio
page 2-50 for the adjustment method.
[Point 21
1. While pushing the cylinder with a force of 98 N (10 kg) [22 Ibl in the direction of G, eliminate the
backlash between the rack and pinion to 0.
2. While keeping the state above unchanged, temporarily tighten bolts (to about a half of the spec-
ified torque) in the order of A to D. Then retighten them to the specified torque.
Set by aligning the spring pin (on pinion side) and the punch mark (on rack side). (To obtain the tire
neutral position).
Spring pin
F
Punch mark
Disassembly Procedure
1 Remove the steering cylinder end.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat hydraulic oil on each part before reassembly.
Use new O-rings, U-packings and dust seals at the time of reassembly.
Point Operation
[Point 1 I
Page
GENERAL ........................................................... 9-2
SPECIFICATIONS ............................................... 9-3
COMPONENTS ................................................... 9-3
DISC BRAKE ....................................................... 9-7
REMOVAL.INSTALLATION ................................... 9-7
DISASSEMBLY.INSPECTION.REASSEMBLY ............ 9-8
DISC BRAKE ADJUSTMENT ................................. 9-10
BRAKE PEDAL .................................................... 9-11
REMOVAL-INSTALLATION ................................... 9-11
BRAKE PEDAL ADJUSTMENT .............................. 9-12
MASTER CYLINDER ........................................... 9-13
REMOVAL.INSTALLATION ................................... 9-13
DISASSEMBLY.INSPECTI0N.REASSEMBLY ............ 9-14
PARKING BRAKE ................................................ 9-15
REMOVAL.INSTALLATION ................................... 9-15
AIR BLEEDING FROM BRAKE SYSTEM ............. 9-17
9-2
GENERAL
Disc brake
SPECIFICATIONS
Item 5FBE10-18
Foot brake type Hydraulic disc brake
Parking brake type Lever type
Diameter 200 (7.87)
Brake wheel mm (in)
Thickness 9.5 (0.374)
2
Area cm 28.8 x 2
Brake pad
Thickness mm (in) 5 (0.197)
Wheel cylinder inside diameter mm (in) 19.05 (0.75)
Master cylinder inside diameter mm (in) 19.05 (0.75)
COMPONENTS
Parking brake
9-4
Brake pedal
9-5
Brake pipe
9-6
Disc brake
9-7
DISC BRAKE
REMOVAL.INSTALLATI0N
Removal Procedure
1 Remove the RR toe board and FR toe board.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the brake system.
Check the brake fluid quantity and never fail to add if insufficient.
3
Disassembly Procedure
1 Remove the spring. [Point 11
2 Remove the cotter pin, pin, lever ASSY No. 3 and lever ASSY No. 4.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
9-9
[Point 21
2. Adjust the clearance between the brake wheel and each pad equally on the (a) and (b) sides by
turning adjusting bolt @I.
Clearance: Between 0.4 m m (0.01 57 in) and 1.1 m m (0.0433 in) at the ends of pads
A A
BRAKE PEDAL
REMOVAL.INSTALLATION
Removal Procedure
1 Remove the master cylinder pin.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
9-12
Adjust bolt
Removal Procedure
1 Drain brake fluid from the reservoir tank.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the brake system.
Check the brake fluid quantity, and add without fail if insufficient.
9-14
DISASSEMBLY-INSPECTION-REASSEMBLY
Disassembly Procedure
1 Remove the clevis.
3 Remove the snap ring, push rod and piston stop plate.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
PARKING BRAKE
REMOVAL.INSTALLATI0N
Removal Procedure
1 Disconnect the parking brake wire. [Point 11
Installation Procedure
The installation procedure is the reverse of the removal procedure.
9-16
Point Operations
[Point 1 I
Adjustment: Adjust to 4 to 6 notches at the center of the lever when operated with a force of 294 N
(30 kg) 166 Ibl.
Check if the displacement of the A portion is within 3 mm (0.12 in), and make adjustment by means of
@ and @ if the standard is not satisfied.
AIR BLEEDING FROM BRAKE SYSTEM
1. Bleed air from the master cylinder.
Note:
While bleeding air from the brake system, be careful not to let the brake fluid in the reservoir tank
become insufficient.
Always use genuine brake fluid (SAEJ-1703 DOT-3).
While one person pumps the brake pedal several times and keeps it in the depressed state, another
person should loosen the breather plug for air bleeding until no bubble is seen in the discharged
brake fluid.
BRAKE
(1998.2 - )
Page
GENERAL ..........................................................................9 ~ - 2
SPECIFICATIONS ............................................................9 ~ - 3
COMPONENTS................................................................9A-4
DISC BRAKE .....................................................................9 ~ - 7
REMOVAL-INSTALLATION.............................................. 9A-7
DISASSEMBLY.INSPECTI0N . REASSEMBLY ............... 9A-8
DISC BRAKE WHEEL INSPECTION ...........................9 ~ - g
BRAKE ADJUSTMENT..................................................g ~ - l o
AIR BLEEDING FROM BRAKE SYSTEM ..................g ~ - 1I
BRAKING FORCE INSPECTION.................................. ~ A - I I
MASTER CYLINDER (1998.2 - 2000.3) ..................9 ~ - 1 2
REMOVAL-INSTALLATION.............................................. 9A-12
DISASSEMBLY-INSPECTION-REASSEMBLY ................. 9A-13
MASTER CYLINDER (2000.4 - 1 ................................9 ~ - 1 4
REMOVAL.INSTALLATION............................................. 9A-14
DISASSEMBLY.INSPECTION .REASSEMBLY ................ 9A-15
PARKING BRAKE ............................................................9A-17
REMOVAL-INSTALLATION............................................9A-17
BRAKE PEDAL .................................................................9A-19
REMOVAL.INSTALLATI0N..............................................9A-19
ADJUSTMENT .................................................................9A-20
GENERAL
Disc brake
SPECIFICATIONS
Item 5FBE10-20
Foot brake type Hydraulic disc brake
Parking brake type Lever type
Diameter 200 (7.87)
Brake wheel m m (in)
Thickness 9.5 (0.374)
Area cm2 28.8 X 2
Brake pad
Thickness m m (in) 5 (0.197)
Wheel cylinder inside diameter m m (in) 19.05 (0.75)
Master cylinder inside diameter m m (in) 19.05 (0.75)
COMPONENTS
Parking brake
Brake pedal
Brake master cylinder
Brake pipe
9A-6
Disc brake
DISC BRAKE
REMOVAL-INSTALLATION
Removal Procedure
1 Remove the rear and front toe boards.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the brake system.
After installation, adjust the disc brake (see page 9A-10) and the parking brake (see 9A-18).
Disassembly Procedure
1 Remove the springs. [Point 11
2 Remove the cotter pin, pin, lever ASSY No. 3 and No. 4.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, bleed air (see page 9A-11) and adjust the brake (see 9A-10).
9A-9
[Point 21
2. Bleed air from both left disc brake ASSY RH and LH.
(1) Bleed air, one side at a time, in the same manner
as above.
I Stopping distance 1
(ft) 5.0 (16.4)
or less
1 + I C I + I e I
2. If the braking force is insufficient, check for poor pad contact, contamination of pad or rotor by
foreign matter, leakage of brake fluid and invasion of air.
9A-12
Removal Procedure
1 Drain brake fluid from the reservoir tank.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the brake system.
Disassembly Procedure
1 Remove the clevis. [Point 11
3 Remove the snap ring, push rod and piston stop plate.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operation
[Point 1 I
Removal Procedure
1 Drain brake fluid f r o m the reservoir tank.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the brake system.
DISASSEMBLY-INSPECTION-REASSEMBLY(2000.4 - )
Disassembly Procedure
1 Turn the boot up and remove the snap ring.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 11
Installation:
Temporarily set the push rod length to the illustrated dimen-
sion, and make readjustment after installation.
[Point 21
Installation:
Apply rubber grease on the piston cup and whole periphery
of the cup before reassembly.
9A-17
PARKING BRAKE
REMOVAL-INSTALLATION
Removal Procedure
1 Remove the spring.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
L
I
[Point 11
Inspection: 1. Check the parking lever moving distance when an operation force of 294 N (30
kgf) [66 Ibf] is applied to the center of the parking lever knob.
Standard: 4 - 6 notches
Removal Procedure
1. Remove the master cylinder pin.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
9A-20
ADJUSTMENT
Standard: 135 - -
140 mm (5.31 5.51 in)
BODY FRAME
COMPONENTS
Frame & Weight
Battery hood
5201
(EC SPEC ORS U.S.A)
91651-41026
FL
Instrument panel & floor
BATTERY HOOD
I
Removal Procedure
1. Release the battery hood catch.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
BALANCE WEIGHT
REMOVAL-INSTALLATION
Removal Procedure
1. Remove the rear cover.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
COMBINATION METER
The combination meter has the diagnostic (self-diagnosis) function and analyzer (fault analysis) func-
tion in addition t o general display such as the traveling speed, battery charge and hour meter indica-
tions.
\
Multiway hour meter
I I
Display
Switch panel
I I
Disassembly Procedure
1. Remove the cover sheet.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
MATERIAL HANDLING SYSTEM
Page
NATURAL DROP TEST ..................................... I1-2
NATURAL FORWARD TILT TEST .................... I 1-2
OIL LEAK TEST ................................................. I1-3
NATURAL DROP TEST
1. Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 to 1.5 m (40 to 6 0
in), and stop the motor.
2. Gently tilt the mast fully forward and turn the key switch
off. After 5 minutes, disconnect the oil control valve and
return hose. Measure the oil leakage amount in one
minute by placing a measuring cylinder at the fitting.
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
TILT CYLINDER
1. Set the mast in the vertical position with the standard
load on the fork. Lift the fork by about 50 cm (20 in)
and turn the key switch off.
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
MAST (1993.1 -- 1994.1)
Page
V MAST ASSY ................................................. 12-2
COMPONENTS .................................................. 12-2
REMOVAL . INSTALLATION ................................ 12-5
DISASSEMBLY . INSPECTION . REASSEMBLY ..... 12-6
LIFT BRACKET .................................................. 12-7
REMOVAL . INSTALLATION ................................ 12-7
DISASSEMBLY . INSPECTION . REASSEMBLY ...... 12-8
CHAIN ............................................................... 12-9
REMOVAL . INSTALLATION ................................ 12-9
CHAIN INSPECTION ........................................... 12-1 1
CHAIN ADJUSTMENT ........................................ 12-1 1
FORK ................................................................. 12-12
REMOVAL ......................................................... 12- 1 2
INSTALLATION .................................................. 12- 1 2
INSPECTION ...................................................... 12-1 2
MAST ADJUSTMENT ....................................... 12-13
V-SV MAST ...................................................... 1 2- 1 3
FV MAST .......................................................... 12-19
FSV MAST .................................................... 12-25
LlFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) ............ 12-31
MAST (1994.1 ^. 1
Page
V MAST ASSY ................................................. 12-32
COMPONENTS ................................................. 12-32
MAST DISASSEMBLY.
1NSPECTION.REASSEMBLY ............................. 12-38
LlFT BRACKET DISASSEMBLY .
lNSPECTlON.REASSEMBLY (1994.1 - 2000.5) .. 1 2-40
LlFT BRACKET DISASSEMBLY
INSPECTION .REASSEMBLY (2000.6 - ) ........... 1 2-42
MAST ADJUSTMENT ........................................ 12-44
CHAIN .............................................................. 12-54
INSPECTION ..................................................... 12-54
REASSEMBLY .................................................. 12-54
ADJUSTMENT .................................................. 12-55
FORK ................................................................ 12-55
..................................................... 12-55
INSPECTION
SV MAST ASSY ........................................ I2-56
COMPONENTS .............................................. 12-56
MAST ADJUSTMENT ........................................ 12-58
FV MAST ASSY ........................................ I2-62
COMPONENTS ............................................. I2-62
MAST ADJUSTMENT ........................................ 12-64
FSV MAST ASSY ............................................. 12-68
COMPONENTS ................................................ 12-68
MAST ADJUSTMENT ........................................ 12-70
LlFT CYLINDER ROD SHIM
ADJUSTMENT ............................................... 12-74
12-2
V MAST ASSY
COMPONENTS
REMOVAL . INSTALLATION
Removal Procedure
1 Disconnect the chain.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Coat MP grease on the inner surfaces of the bushing and cap at the mast support and on the tilt
cylinder front pin before reassembly.
It is necessary to inspect uneven motion of lift cylinders and make necessary adjustment when
any of the mast ASSY, outer mast, inner mast and lift cylinders is replaced (See page 12-31).
Install the mast support bushing with the greasing port facing upward.
12-6
Point Operations
[Point 1 I
7 Pull out the outer mast from the bottom side of the inner mast.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
LIFT BRACKET
REMOVAL . INSTALLATION
Note:
Remove the lift bracket before lift bracket roller replacement or shim adjustment.
I
Removal Procedure
1 Set the mast in the neutral position and fully lower the fork.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
DISASSEMBLY INSPECTION REASSEMBLY
Disassembly Procedure
1 Remove the backrest.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1I
CHAIN
REMOVAL . INSTALLATION
Removal Procedure
1 Remove the adjusting nut and nut on the mast side.
Installation Procedure
The installation procedure in the reverse of the removal procedure.
Note:
Tighten (in parallel) to prevent twisting as against the chain wheel.
12-10
0
0
0
0
Outer mast Front lift cylinder Outer mast Front lift cylinder Front lift cylinder
[Point 1I
Installation:
CHAIN ADJUSTMENT
1. Place the vehicle on a flat ground and set the mast in
the vertical position.
3. Turn the adjusting nut (on the lift cylinder side) so that
the fork bottom surface is about t o come into contact
with the ground surface without slackening the chain.
4. Check that the chain tensions are equal on the left and
right sides.
FORK
REMOVAL
1. Raise the fork approximately 2 0 0 mm (7.88 in).
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1. Fork inspection points
Note:
If the fork tips misalignment exceeds the maximum al-
lowance, check individual fork for bending, play at the
mounting section, and the warping of the lift bracket finger
bar.
MAST ADJUSTMENT
V-SV MAST
Mast Lift Roller Adjustment (V-SV)
lnner mast
$J
Outer mast
Measure with this rolling face
in close contact.
These -rollers
Bring into contact
.8mm(0-0.031 in)
ere the roller is
closest)
1. Measure the gap with the mast overlap at near 500 mm (19.69 in).
2. Shift the inner mast to one side to bring the roller into contact with the outer mast. The gap on
the opposite side between the inner mast and the side of the roller at the position where they are
the closest shall be 0 to 0.8 mm (0 to 0.031 in).
4. After the adjustment, the inner mast shall move smoothly in the outer mast.
Outside diameter
Mast roller Seal color Remarks
m m (in)
0 0
Outer mast 94.5 -0.2 (3.720 -0.007) Black
0 0
114.5 -0.2 (4.508 -0.007) Black
Inner mast o o
11 5.1 -0.2 (4.531 -0.007] Blue Oversize
Measure with this rolling face
in close contact.
1. Measure the gap with the mast overlap at near 500 mm (19.69 in)
2. Shift the inner mast to one side t o bring the roller into contact with the outer mast, and adjust the
clearance between the roller and mast on the opposite side at the closest position to 0 to 0.8 mm
( 0 to 0.031 in)
4. After the adjustment, check if the inner mast moves smoothly in the outer mast.
Lift Bracket Lift Roller Adjustment (V.SV1
Front
1
Middlellower lift roller
100 mm (3.93 in)
Upper side roller ring into contact
Outer mast
1. Make adjustment where the center of the side roller in the upper part of the lift bracket is 100 mm
(3.93 in) above the top end of the inner mast.
2. Upper lift rollers need no adjustment as they are fixed in position by snap rings.
3. For the center and lower lift rollers, shift the lift bracket to one side t o bring the rollers into contact
with the mast, and adjust the clearance between the roller and mast on the opposite side to 0 to
0.8 mm ( 0 to 0.031 in) at the position where the roller is the closest to the mast.
4. Adjust the upper side rollers after adjusting the middle and lower rollers. Bring the side roller into
contact with the mast on one side, and adjust the clearance between the side roller and inner mast
to 0 to 0.6 mm (0 to 0.024 in).
5. After the end of adjustment steps 3 and 4, the lift bracket shall move smoothly along the overall
length of the mast.
12-16
2. With the inner mast in contact with the outer mast roller, adjust the clearance between the mast
strip and mast to 0.5 to 1.0 mm (0.020 to 0.039 in)
SV Mast Assy
Components
12-19
FV MAST
Components
Outer Mast and lnner Mast Roller Adjustment (FV)
@
in close contact.
the closest)
1. Shift the inner mast to one side to bring the roller into contact with the outer mast. The gap on
the opposite side between the roller and outer mast at the position where they are the closest shall
be 0 to 0.5 mm ( 0 to 0.020 in).
2. Turn the bolt for adjustment, and lock the bolt by the nut when the gap is adjusted to an appropri-
ate level. The mast gap, however, shall be even on the left and right sides.
3. See the roller list for roller selection. As a rule use oversize rollers (No.2). Use No.1 rollers only
when the mast inside width is small.
4. After the adjustment, the inner mast shall move smoothly in the outer mast.
5. See the table below for the mast overlap at the time of adjustment.
These rollers
Outer m
1. See the table on the preceding page for the mast overlap at the time of adjustment.
2. Shift the inner mast to one side to bring the roller into contact with the mast. The gap on the oppo-
site side between the roller side face and mast at the position where they are the closest shall be
0 to 0.5 mm ( 0 to 0.020 in).
3. Turn the bolt for adjustment. When the appropriate gap is obtained, lock the bolt by the nut.
4. See the list below for the roller to be used.
5. After the adjustment, the inner mast shall move smoothly in the outer mast.
If the bottom recessed roller bolt is overtightened to obstruct smooth mast or lift bracket movement,
loosen the nut and return the bolt a little.
Make readjustment after moving the mast or lift bracket a few times.
As the roller does not retract by loosening of the bolt only, always move the mast or lift bracket a few
times before making readjustment.
12-23
1. Make adjustment with the center of the lift bracket upper side roller at 100 mm (3.9 in) from the
top of the inner mast.
2. The upper and center lift rollers need no adjustment because they are stopped by snap rings.
3. For the lower lift rollers and side rollers, shift the lift bracket to one side to bring the roller into
contact with the mast, and make shim adjustment for a clearance of 0 to 0.5 mm (0 to 0.020 in)
between the mast and the roller on the opposite side where the roller is the closest.
4. After the adjustment, check for smooth movement of the lift bracket.
12-24
.-C
The roller must contact the inner mast
2. With the inner mast in contact with the outer mast roller, adjust the clearance between the mast
strip and mast to 0.5 to 1.0 mm (0.020 to 0.039 in)
FSV MAST
Components
12-27
1. Shift the middle mast to one side to bring the roller into contact with the mast. The gap on the
opposite side between the roller side face and mast at the position where they are the closest shall
be 0 to 0.5 mm (0 to 0.020 in).
2. Turn the bolt for adjustment. When the appropriate gap is obtained, lock the bolt by the nut.
The mast gap, however, shall be even on the left and right sides.
4. After the adjustment, the inner mast shall move smoothly in the middle mast.
5. See the table below for the mast overlap at the time of adjustment.
Maximum fork height Overlap No. Outside diameter mm (in) Seal color
5500 or less 450 (17.72)
6000 500 (19.69) 11 5.1 -0.2 4.531 -0.007 Blue
6500 or more 600 (23.62)
Middle Mast and Outer Mast Rollers Adjustment (FSV)
lnner Mast and Middle Mast Upper Rollers Adjustment (FSV)
These roller
Outer
Middle mast
Bring into c
re the roller is
1. See page 12-27 for the mast overlap at the time of adjustment.
2. Shift the middle mast to one side to bring the roller into contact with the mast. The gap on the
opposite side between the mast roller side face and mast at the position where they are the closest
shall be 0 to 0.5 mm (0 to 0.020 in).
3. Turn the bolt for adjustment. When the appropriate gap is obtained, lock the bolt by the nut.
The mast gap, however, shall be even on the left and right sides.
5. After the adjustment, the inner mast shall move smoothly in the outer mast.
0.5 m m
-0.020 in)
here the roller is
e closest)
2. Upper lift rollers need no adjustment as they are stopped by snap rings.
3. For lower lift rollers and side rollers, shift the lift bracket to one side to bring the roller into contact
with the mast, and make shim adjustment for a clearance of 0 to 0.5 mm (0t o 0.020 in) between
the roller and mast on the opposite side where the roller is the closest.
4. After the adjustment, check for smooth movement of the lift bracket.
12-30
2. With the inner mast in contact with the outer mast roller, adjust the clearance between the mast
strip and mast to 0.5 to 1.0 mm (0.020 to 0.039 in)
1. Inspection
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with alomost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast, Set the SST to the outer mast
tie beam, and lower the inner mast until it reaches the
SST.
SST 096 10-22000-7 1
(2) Remove the set bolt of the cylinder rod end on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7)Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 mm (0.020 in)
1.0 mm (0.039 in)
12-32
V MAST ASSY
COMPONENTS
12-35
REMOVAL-INSTALLATION
Removal Procedure
1 Set the mast vertical and lower the fork to the bottom position.
4 Remove the lift bracket. (Raise the inner mast until it comes off from the lift bracket, and slowly
move the vehicle in the reverse direction to depart from the lift bracket. Then stop the engine.)
[Point 21
5 Disconnect the overflow hose and high pressure hose. (Lower the inner mast to the bottom posi-
tion and operate the lift lever several times to release the residual pressure in the lift cylinder be-
fore disconnecting the hoses.)
Note:
Apply MP grease on the interior surface of the mast support bushing, inner surface of the mast sup-
port cap and tilt cylinder front pin.
Mast support cap set bolt tightening torque:
T = 68.65 - -
107.87 N.m (700 1100 kgf-cm) [50.65 - 79.59 ft-lbf]
If any of the mast ASSY, outer mast, inner mast and lift cylinder is replaced, it is necessary t o in-
spect and adjust uneven motion of the lift cylinder. See the lift cylinder rod shim adjustment section
(on page 12-74) for the inspection and adjustment method.
Adjust the chain tension. (See page 12-55.)
Point Operations
[Point 1I
[Point 21
[Point 31
Disassembly Procedure
1 Remove the hose cover.
3 Remove the cylinder rod end set bolt and disconnect the rod end. [Point 11
5 Remove the cylinder bottom set bolts and remove the lift cylinder.
6 Slide the inner mast in the lowering direction and remove the lift rollers.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1I
[Point 21
Shim
Disassembly: Take a note on the number of cylinder sup-
port shims used.
Disassembly Procedure
1 Remove the lift rollers. [Point 11
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Back rest set bolt tightening torque T = 99.54 - 184.86 N-rn(1015 - 1885 kgf-crn) [73.44 -
136.38 ft-lbf]
12-41
Point Operations
[Point 1I
[Point 21
[Point 31
Wls~deroller
Disassembly Procedure
1 Remove lift rollers. [Point 11
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1 I
Disassembly:
SST 09950-40011
Vehicle without side rollers:
Disassembly:
Remove upper roller after removing the roller stop plate.
Reassembly:
Install each roller with the side chamfered with greater ra-
dius facing outward.
Reassembly:
Bring the stop plate into contact with the roller inner ring.
Minimize the clearance between the plate and pin by shim
insertion.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
[Point 21
Reassembly:
Install the side roller in the correct direction.
The side chamfered with a greater radius of the roller shall
be on the front side of the vehicle.
12-44
lnner
Outer mast
mast
This roller
Bring into contac
Standard clearance A = 0 -
0.8 mm
-
(0 0.031 in)
Shim thickness: 0.5 and 1.O mm
(0.020 and 0.039 in)
I
Shim (3) Distribute the shim thickness equally t o the left and
right rollers. (See the "mast roller removal.installa-
tion" section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
This roller
6-Zr
Outer mast
Inner mast
Standard clearance B = 0 -
0.8 mm
I I
-
(0 0.031 in)
Shim thickness: 0.5-and 1.0 mm
(0.020 and 0.039 in)
I (3) Distribute the shim thickness equally to the left and
right sides. (See the "mast roller removal.installa-
tion" section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
Mast Roller Removal.lnstallation
Shim
Lift Bracket Roller Adjustment (1994.1 - 2000.5)
bracke;
Inner mast
Standard clearance C = 0 -
0.8 mm
-
(0 0.031 in)
Shim thickness: 0.5 and 1.O mm
(0.020 and 0.039 in)
(4) Distribute the shim thickness equally to the left
and right sides. (For the shim replacement pro-
cedure, see the lift bracket disassembly section
on page 12-40.)
(5) Install the side rollers.
Outer mast
lnner mast
Lift bracket
Inner mast
(1) Bring the center of the lift roller in the upper part of the lift
bracket to 100 mm (3.94 in) from the top of the inner
mast.
Standard
- -
Lower lift roller: C = 0 0.8 mm (0 0.031 in)
- -
Middle lift roller: D = 0 0.8 mm (0 0.032 in)
(3) Adjust the upper lift rollers after adjusting the middle and
lower lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect the lift roller
clearance on the opposite side where the roller side face
is closest to the mast.
Standard
Upper lift roller: D = 0 - 0.6 mm (0 - 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness.
(4) After the adjustment, see that the lift bracket moves
smoothly along the overall length of the mast.
, Upper lift roller
12-51
Inner
::s;lt
mast bracket
( i b i
lnner
mast bracket
Standard:
-
C = 0 0.8 mm (0 - 0.031 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness.
(6) After adjusting the middle and lower lift rollers, bring the
side roller on one side into contact with the outer mast
and measure on the opposite side the clearance between
the side roller and inner mast surface.
Standard:
-
D = 0 0.6 mm (0 - 0.024 in)
If the standard is not satisfied, make adjustment by
changing the side roller shim thickness.
(7) Distribute shims equally to the left and right side. (See
Lift Bracket Disassembly-lnspection-Reassembly sec-
tion for the side roller installation method. Shim replace-
ment is possible on the vehicle.)
(8) After the adjustment, see that the lift bracket moves
smoothly over the entire length of the mast.
Mast Strip Adjustment
Note:
When inspecting the chain elongation, use the SST
above and inspect without removal from the vehicle.
Standard chain link pitch
15.88 mm (0.6252 in) (Type: BL534)
REASSEMBLY
Cot
Sketch
Pin
Install with the cotter pin on the Install with the cotter pin on the Install with the cotter pin on the
vehicle center side. vehicle center side. vehicle front side.
1 Tighten nuts @ and a.Tightening torque T = 49.03 - 78.45 (500 - 800 kgf-cm)
-
i36.18 57.88 ft-lbf]
2 Tighten nut @
Cram Clamp
Sketch
0 0
0
0 0
The clamp is used only for the SV
mast.
12-55
ADJUSTMENT
1 Place the vehicle on a flat ground, and set the mast in the vertical position.
2 After moving the fork up and down several times without a load, check that the chain tension on
the left and right sides are equal.
3 Turn the adjusting nut so that the fork bottom surface is about to come into contact with the
ground surface without slackening the chain.
4 Check the chains for equal tension on the left and right sides.
REMOVAL
1. Loosen the set bolts (OPT) for preventing the fork from
loosening.
Note:
Always set the lever for preventing the fork from loosening
in the horizontal position after it is used.
4. Unlock after lifting the fork stopper pin, and shift the
fork blades one by one to the center.
INSPECTION
1. Inspect the fork.
Note:
If the tip end limit misalignment is exceeded, inspect the
bend, fork mounting looseness and lift bracket finger bar
distortion for each blade.
12-56
SV MAST ASSY
COMPONENTS
12-58
lnner
Outer
mast
Standard clearance A = 0 - -
0.8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm ( 0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast move smoothly in the outer mast.
This roller
Inner mast
Standard clearance B = 0 - -
0 . 8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally t o the left and right sides. (See the mast roller removal.
installation section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
12-60
k't
into contact
Outer mast
Inner mast
Standard clearance C = 0 -
0.8 mm (0 0.031 in) -
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) Distribute the shim thickness equally to the left and right sides.
(5) Adjust the upper and lower side rollers after adjusting the middle lift rollers. Bring the side roller
on one side into contact with the mast side surface and adjust the clearance between the side
roller and inner mast surface to the following value by inserting the side roller shim.
Standard clearance D = 0 -
0.6 mm (0 0.024 in) -
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
( 6 ) Distribute the shim thickness equally to the left and right side rollers.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
Mast Strip Adjustment (SV)
FV MAST ASSY
COMPONENTS
12-64
lnner
Outer mast
mast
This roller
Standard clearance A = 0 - -
0.8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm ( 0.020 and 0.039 in)
(3) Distribute the shim thickness equally t o the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
This roller
fi
Outer mast
Inner mast
Standard clearance B = 0 - -
0.8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
12-66
bracket
Standard clearance C = 0 -
0.5 mrn (0 0.020 in) -
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) Distribute the shim thickness equally t o the left and right sides.
(5) Adjust the side rollers after adjusting the lower lift rollers. Bring the side roller on one side into
contact with the mast side surface and adjust the clearance between the side roller and inner
mast on the opposite side t o the following value by inserting the side roller shim:
Standard clearance D = 0 -
0.6 mm (0 0.024 in) -
Shim thickness: 0 . 5 and 1.0 mm (0.020 and 0.039 in)
(6) Distribute the shim thickness equally t o the left and right side rollers.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
12-67
F
Outer mast
Middle mast
lnner mast
This ioller
1. lnner mast roller and middle mast lower roller clearance adjustment
(1) Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast and the mid-
dle mast, and adjust the clearance between the roller side face and mast at the closest position
on the opposite side to the following value by inserting the inner mast roller shim and middle
mast lower roller shim, respectively.
Standard clearance A = 0 - -
0.8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm ( 0.020 and 0.039 in)
(3)Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
For the lift bracket roller adjustment procedure on trucks without side rollers, see pages 12-49
to 12-50.
This roller
2. Outer mast roller and middle mast upper roller clearance adjustment
(1 Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the inner mast and middle
mast, and adjust the clearance between the roller and mast at the closest position on the op-
posite side t o the following value by inserting the outer mast roller shim and middle mast upper
roller shim respectively.
Standard clearance B = 0 - -
0.8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally t o the left and right sides.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast and the
middle mast moves smoothly in the outer mast.
12-72
Lift bracket
Standard clearance C = 0 -
0.5 mm (0 0.020 in) -
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) Distribute the shim thickness equally t o the left and right rollers.
(5) Adjust the side rollers after adjusting the lower lift rollers.
Bring the side roller on one side into contact with the mast side surface, and adjust the clear-
ance between the side roller and inner mast side surface t o the following value by inserting the
side roller shim:
Standard clearance D = 0 -
0.6 mm (0 - 0.024 in)
Shim thickness: 0.5 and 1.0 mm (0.020 - 0.039 in)
(6) Distribute the shim thickness equally t o the left and right sides.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
12-73
1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simulta-
neously with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of
the inner mast shakes at the time of stopping. To
correct this, add shims to the cylinder that stops
first.
2. Adjustment method
(1 Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches
the SST.
SST 09610-22000-7 1
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)
CYLINDERS
Page
LIFT CYLINDER ASSY (1993.1 ^. 1994.1) ..... 13-2
GENERAL .......................................................... 13-2
SPECIFICATIONS ............................................... 13-2
COMPONENTS .................................................. 13-3
REMOVAL . INSTALLATION ................................ 13-4
DISASSEMBLY . INSPECTION . REASSEMBLY ...... 13-6
TILT CYLINDER ................................................. 13-8
GENERAL .......................................................... 13-8
SPECIFICATIONS ............................................... 13-8
COMPONENTS .................................................. 13-9
REMOVAL . INSTALLATION ................................ 13-10
DISASSEMBLY . INSPECTION . REASSEMBLY ...... 13-12
LIFT CYLINDER ASSY (1994.1 ^. ) ............... 13-14
GENERAL .......................................................13-14
SPECIFICATIONS ............................................... 13-14
COMPONENTS .................................................. 13-15
REMOVAL.INSTALLATION .................................. 13-16
DISASSEMBLY INSPECTION-REASSEMBLY
(1994.1.2000.1) ........................................ 13-18
13-2
SPECIFICATIONS
Cylinder type Single-acting type
Cylinder bore m m (in) 45 (1.77)
Piston rod outside diameter mm (in) 35 (1.38)
Piston stroke m m (in) 1 5 0 0 (59.06)
Piston seal type U packing
Rod seal type U packing
13-3
COMPONENTS
6501
CB
p r m r
I 02 K Al
I
m i
91611-41040
01 (RH)
6501 -038C
13-4
REMOVAL . INSTALLATION
Removal Procedure
1 Remove the chain and chain wheel.
3 Disconnect the cylinder rod end, and set the SST. [Point 11
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Adjust the lift chain tension equally on the left and right sides.
Repeat full stroke lifting and lowering without any load to bleed the air and check if movements are
normal.
After the movement check, inspect the hydraulic oil level.
If a part of the lift cylinder ASSY, etc. is replaced, it is necessary to check and adjust uneven move-
ments of lift cylinders. See page 12-31 for the inspection and adjustment methods.
13-5
Point Operations
[Point 1I
2 2
3 8 3
1 Overflow hose
LH RH
Disassembly Procedure
1 Remove the overflow hose.
Reassembly Procedure
The reassembly procedure is the reverse of the disassmbly procedure.
Note:
Before reassembly, coat hydraulic oil on each part.
Replace O-rings, U-packing and dust seals with new ones at the time of reassembly.
Coat liquid packing (08833-00080) on the threaded portion of the cylinder cover before reassembly.
Point Operations
[Point 1I
[Point 21
TILT CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double acting
Cylinder bore mm (in) 7 0 (2.76)
REMOVAL . INSTALLATION
Removal Procedure
1 Slightly hoist the mast.
Note:
Check if the rod joint length is the same as that at the time of removal.
Raise the fork by approx. 200 mm (7.87 in). Inspect and adjust the forwardlbackward tilt angle.
Put a match mark (with red paint) on the joint and rod.
Slowly tilt the mast a few times to check movement.
Check the hydraulic oil level, and add if insufficient.
Coat MP grease where the front and rear pins are inserted.
Tilt the mast fully forward and backward to confirm no uneven movements between the left and right
sides.
Point Operations
[Point 1I
Disassembly Procedure
1 Remove the rod joint.
2 Remove the top cover, and extract the rod wlpiston. [Point 11
Note:
Coat hydraulic oil on each part before reassembly.
Replace O-rings, U-packings and dust seals with new ones at the time of reassembly.
Coat liquid packing (08833-00080) on the threaded portion of the cylinder cover.
when installing the rod guide, wrap the threaded portion of the piston rod thinly with vinyl tape and
slowly insert the rod to prevent sealing parts from being damaged.
Point Operations
[Point 11(1993.1 - 2000.1)
Disassembly.Reassembly: SST 09620-10110-71
[Point 21 (2000.2 - )
[Point 31
[Point 41
SPECIFICATIONS
Cylinder type Single-acting type
Cylinder bore mm (in) 4 5 (1.77)
Piston rod outside diameter mm (in) 35 (1.38)
Piston seal type U packing
Rod seal type U packing
With flow regulator valve (RH)
Others
With safety down valve (LH)
13-15
COMPONENTS
13-16
REMOVAL-INSTALLATION
1 Lift bracket
Removal Procedure
1 Remove the lift bracket. (See removal procedure steps 1 t o 4 in mast removal-installation section
on page 12-35.)
2 Remove the cylinder rod end set bolt and cylinder bottom set bolt.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Perform the following operations after installing the lift cylinder:
Repeat lifting and lowering to stroke ends without load to bleed the air and t o check normal opera-
tion.
After the operation check, check the hydraulic oil level and add oil if insufficient.
Inspect t h e lift cylinders for uneven movements and make adjustment if necessary. (See t h e lift
cylinder r o d shim adjustment section on page 12-74.)
Point Operations
[Point 1I
Removal: Hoist the inner mast (middle mast) and set the
SST to the inner mast (middle mast) tie beam.
SST 09610-22000-71
[Point 21
DISASSEMBLY-INSPECTION-REASSEMBLY (1994.1 - )
Note:
Oil will leak if the U packing or dust seal at the rod guide portion is defective.
Natural drop will occur if the U packing at the piston portion is defective.
Disassembly Procedure
1 Remove the cylinder cover.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Do not install dry parts but apply hydraulic oil before reassembly.
Apply liquid packing (08833-00080) on the threaded portion of the cylinder cover before tightening.
Cylinder cover tightening torque T = 284.39 - -
421.69 N.m (2900 4300 kgf-cm) [209.82 - 311.11
ft-lbf]
Point Operations
[Point 1I
[Point 21
112 pitch
-- --
Displacement between front
and rear gears
SPECIFICATIONS
Vehicle type
5FBE10.13-15 5FBE18.20
Item
Removal Procedure
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Coat paste lubricant containing molybdenum disulfide on the pump spline before installation.
Clean the surface for mounting the fitting to prevent damage on the O-ring.
Point Operations
[Point 1I
Disassembly Procedure
1 Remove the cover. [Point 11
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Wash the parts, blow them with compressed air and reassemble them after applying hydraulic oil.
Always use new seals after disassembly.
14-6
Point Operations
[Point 1 I
[Point 21
Limit:
Contact trace exceeding half of the circum-
ference
TEST PROCEDURE
Note:
A bench test is required for a strict inspection, but it is impossible in an actual service. Install the oil
pump on the actual vehicle and judge the properness of the oil pump state by checking the cylinder
operation.
3. Raise the hydraulic oil temperature t o 50-55OC (122-1 3 1 OF), and measure the lift cylinder full stroke
operation time calculate the lifting speed.
FV.FSV Masts
Lifting speed mm/s
Vehicle model No load Loaded
FV FSV FV FSV
5FBE10 390 (77) 460 (91) 240 (49) 280 (55)
5FBE13 390 (77) 460 (91) 230 (45) 260 (51)
5FBE15 390 (77) 460 (91) 220 (43) 240 (47)
5FBE18 350 (69) 410 (81) 190 (37) 220 (43)
5FBE20 350 (69) 410 (81) 190 (37) 220 (43)
POWER STEERING PUMP ASSY
GENERAL
SPECIFICATIONS
Pump type TCP-031 -C
COMPONENTS
Rear tor board . front
Removal Procedure
1 Remove the side cover RH.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Coat paste lubricant containing molybdenum disulfide on the oldham joint before installation.
OIL CONTROL VALVE
Page
GENERAL ........................................................... 15-2
SPECIFICATIONS ................................................ 15-3
HYDRAULIC CIRCUIT ......................................... 15-3
COMPONENTS .................................................... 15-4
OIL CONTROL VALVE ASSY ............................. 15-5
REMOVAL.INSTALLATION .................................... 15-5
DISASSEMBLY.INSPECTION.REASSEMBLY ............. 15-6
RELIEF PRESSURE ADJUSTMENT ..................... 15-8
OIL CONTROL VALVE LINK ............................... 15-9
COMPONENTS .................................................... 15-9
15-2
GENERAL
Oil Control Valve Sectional View (in Neutral State)
HYDRAULIC CIRCUIT
COMPONENTS
15-5
Removal Procedure
1 Remove the rear toe board and front toe board.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Check the hydraulic oil level, and add oil to the specified level if insufficient.
Coat grease on the oil control valve lever link.
DISASSEMBLY INSPECTION REASSEMBLY
Note:
Select a clean location for operation.
As every component part is finished with high precision, carefully operate during disassembly to pre-
vent any damage.
T=N.m (kgf-cm) [ft-lbfl
Disassembly Procedure
1 Remove the seal holder.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Before reassembly, thoroughly wash each part, blow compressed air and coat hydraulic oil.
15-7
Point Operations
[Point 1I
1 Remove the plug (9116- 18UNF-2B)on top of the oil control valve, and install an oil pressure gauge.
Oil pressure gauge: Pressure resistance at 19610 kPa (200 kgf/cm2, 2840 psi) or more.
Note:
Follow the same procedure as that for lifting.
Tilt the mast fully backward when measuring the hydraulic pressure.
SST LIST
Section
Part Name
2 2A 4 5 6 6A 7 7A 8 9 9A 12 13 15
Part No.
Illustration
Transfer bearing
09316-12010
replacer
0
L) ., , ,, 09523-36010
Rear axle hub
guide tool
0
0 09527-17011
Rear axle shaft
bearing remover
0
Differential
09550-5501 1
replacer set
0
Steering wheel
09609-20011 0
puller
4 09717-20010
09950-40011
Brake shoe
return spring
remover
Universal
0 0
(09950-40010)
puller
0 0 0 0
&@ p o : .
(09950-20017)
/ \
*$5 09950-40010 Puller B set 0 0
lsbe*%d*
@ OOQO,,
09950-60020 Replacer B set 0 0
09370-10410-71
nut remover
s* 09430-12240-71
Rear axle shaft
bearing replacer
0
09610-10160-71
09610-22000-71
Joint pin
09810-20172-71 0 0
remover
16-4
CONTROLLER
@ and @ represent the positive (red) probe and negative (black) porbe of the circuit tester
All models from January 1993 to August 1998
U.S.A. specifications as from September 1998
CPU board & DC-SD board See text (page 2-1 8)
PS controller See text (page 2-47)
Display See text (page 2-28)
F1 (Drive fuse) A 225 (48 V spec.) 275 (36 V spec.)
F2 (Pump fuse) A 225 (48 V spec.) 275 (36 V spec.)
F3 (Power steering fuse). A 50
F4 (Lamp fuse) . A 10
F5 (Control circuit fuse) A 10
D O s@ 00
TM-TMP - 0 0 So 00
conduction Q Do GO 00
When the tester probes are brought into contact with the
CADCAP conduction Q CAD and CAP terminals, the pointer initially diflects, then
(Tester range Qx IK) gradually returns until it finally indicates co.
(As CAD and CAP is charged by the current from the tester.)
MFR.MFL.MRR.MRL.MP
Coil resistance n 20 (20°C) (68OF)
(Tester range Qx 1)
RADaRAP resistance
(Tester range Qx 1)
n 1.5~
A ~ O U
DO-S@ 3
.=a
TM D.TMP kR D@-G@
[Tester range: R x 1kl DO-G@ Ca
oo
GO-S@
GO-S@ m
Forward
Cathode @ - Anode @ : Approx. 3
DFI.DF~R.DF~~.DF~ kR direction
[Tester range: 52 x Ik l Reverse
cathode @ - node @ : 00
direction
When the tester probes are brought into contact with
On the CA terminals, the pointer initially deflects,
CA kR
snubber board then gradually returns until it finally indicates R.
[Tester range: R x Ik] (The pointer indicates m R because the capacitor
TP9-TN1
is charged by the current from the tester.)
Forward TP9 (Cathode)@ probe - TDAD (Anode)@ probe:
DAD kR direction Approx. 2.5
[Tester range: R x 1kl Reverse TP9 (Cathode)@ probe - TDAD (Anode) @ probe:
direction Approx. 10
Forward TP9 (cathode)@ probe - TDAD (Anode) @ probe:
DAP kR direction Approx. 2.5
[Tester range: R x Ik l Reverse TP9 (Cathode)@ probe - TDAD (Anode) @ probe:
direction Approx. 20
MFR.MFL.MRR.MRL.MPcoil resistance R
[Tester range: 52 x Ikl Approx. 20 (20°C)
RA kR
Approx. 0.8
[Tester range: R x Ik l
OCL value (Drive circuit) A 460
Tightening torque N.m(kgf-cm) [ft-lbfl
Control panel
M5: 2.5 f 0.5 (25 f 5) i1.8 f 0.41
Main terminal -
TM D.TMP M4: 1.5 f 0.5 (15 + 5) i1.1 f 0.41
For mounting M5: 2.5 + 0.5 (25 f 5) [ I .8 + 0.41
Main terminal M5: 2.5 f 0.5 (25 f 5) [1.8 f 0.41
DF1 . DF3
For mounting M5: 2.5 f 0.5 (25 f 5) [1.8 f 0.41
Heat sink For mounting M5: 2.5 f 0.5 (25 f 5) [ I .8 f 0.41
Set nut for external connection terminal M8: 9.8 f 2 (100 f 20) [7.23 f 1.41
Controler panel
Main terminal M5: 2.5 f 0.5 (25 f 5) 11.8 f 0.41
DF~R.DF~~
For mounting M5: 2.5 f 0.5 (25 f 5) 11.8 f 0.41
Accelerator Potentio-Meter
Clearance between accelerator link 1.0 mm (0.039 in) Switch must be turned off.
stopper and bracket 2.0 mm (0.079 in) Switch must be turned on.
Tightening torque for set-screw N.m(kgf-cm)[ft-lbf] 1.57 - 2.35(16- 2 4 ) [ 1 . 1 6 - 1.741
Non-manipulation 0
Switch ON, OFF (Continuity) Q
With manipulation 00
MOTOR
)rive Motor
Armature coil insulation resistance More than 1 MQ
Commutator outside Standard 8 0 (3.15)
diameter mm (in) Limit 7 5 (2.95)
Standard 1 .O (0.09)
Undercut mm (in)
Limit 0.3 (0.01 2)
1
Field coil conduction Q
E- F 0
(Tester range Q x 1K)
Field coil insulation
Yoke E-F More than 1 MQ
resistance
Standard 32 (1.26)
Brush length mm (in)
Limit 1 4 (0.55)
Brush pressure N (kg) [Ibl 11.8 (1.2) i2.61
I Brush holder insulation resistance 1 More than 1 MQ I
Pump Motor
Armature coil insulation resistance More than 1 Mi2
Commutator outside Standard 8 0 (3.1 5)
diameter mm (in) Limit 7 5 (2.95)
Standard 1.O (0.039)
Undercut mm (in)
Limit 0.3 (0.01 2)
Field coil conduction 62
E- F 0
(Tester range 62 x 1K)
I
Yoke * E-F More than 1 M62
Standard 3 2 (1.26)
Brush length mm (in)
Limit 1 4 (0.55)
I Brush ~ressure N (ka) llbl I 11.8 (1.2) 12.61
Brush holder insulation resistance More than 1 M62
REAR AXLE
735 (7.5) [I071 (1.O ton) (1993.1 1998.1) -
780 (8) [I 101 (1.0 ton) (1998.2 -1
Rear tire air pressure kPa (kgf/cm2) [psi] 880 (9) [I301 (1.3 ton)
834 (8.5) I1211 (1.5, 1.8 ton) (1993.1 -
1998.1)
780 (8) [I101 (1.5, 1.8, 2.0 ton) (1998.2 -1
69 -
137 (7 -
14) [15 - 311 (5FBE10, 13)
Rear axle ASSY starting force N (kg) [Ibl 78 - 147 (8 - -
15) 118 331 (5FBE15, 18,201
Rear axle hub starting force N (kg) [Ibl 49 - 7 8 ( 5 - 8) [ I 1 - 181
Tightening torque N.m (kgf-cm) Ift-lbfl
Rear wheel hub nut 1 107.87 - 147.10 (1100 - 1500) 179.59 - 108. 531
STEERING
Play of steering wheel mm (in) 20 - 4 0 (0.79 - 1.57)
Relief valve set pressure kPa (kgf/cm2) [psi] 7850 - 8530 (80 - 87) [ I140 - 12401
Tightening torque N.m (kgf-cm) [ft-lbfl
Steering valve screw 254.97 - 284.39 (2600 - 2900) i188.11 - 209.821
Steering Cylinder
Standard 55 (2.17)
Steering cylinder bore mm (in)
Limit 55.35 (2.1791)
BRAKE
Foot Brake
Standard 5 (0.197)
Brake pad thickness m m (in)
Limit 1 .O (0.039)
Disk brake wheel
m m (in) Limit 8.5 (0.335)
thickness
Disk brake wheel runout m m (in) Limit 0.12 (0.0047)
Brake Pedal
Brake pedal height (without pad) mm (in) 135 - 140 (5.31 - 5.51
Brake pedal play mm (in) 10 * 3 (0.39 * 0.12)
Parking Brake
Number of parking brake lever notches 4- 6
(operating force) (294 N (30 kg) [66 Ibl)
Deviation of cable fixture m m (in) Within 3 (0.12) (1998.2 -1
MATERIAL HANDLING SYSTEM
Natural drop mm (in)/15 min 90 (3.54)
Natural forward tilt mm (in)/15 min 30 (1.18)
Lift cylinder oil
leak amount
(all lift port)
6 - 16 (0.37 - 0.98)
Oil leak cc (cu-in)/min
test Tilt cylinder oil
leak amount
(total of lift and tilt)
14 - 34 (0.85 - 2.07)
cc (cu-in)/min
MAST
Fork
-
CYLINDER
Lift Cylinder
Standard 45 (1.77)
Lift cylinder bore mm (in) V mast
Limit 45.20 (1.7795)
Lift cylinder rod Standard 35 (1.38)
V mast
diameter mm (in) Limit 34.92 (1.3748)
Lift cylinder rod bending limit mm (in) 2.0 (0.079)
Tilt Cylinder
?
Standard 70 (2.26)
Tilt cylinder bore mm (in)
Limit 70.35 (2.7697)
Standard 30 (1.18)
Tilt cylinder rod diameter mm (in)
Limit 29.92 (1.1780)
Tilt cylinder rod bending limit mm (in) 1 .O (0.039)
Tightening torque N.m (kgf-cm) [ft-lbfl
Tilt cylinder cover 219.67 - 407.96 (2240 - 4160) f162.06 - 300.981
Piston rod joint set bolt 60.90 - 1 13.17 (621 - 1 1 54) i44.93 - 83.491
Castle nut 225.55 - 284.39 12300 - 2900) I1 66.41 - 209.821
OIL PUMP
Body inside diameter mm (in) Limit 39.180 (1-54252)
Body interior surface damage depth
Limit 0.1 (0.004)
mm (in)
Side bush inside diameter mm (in) Limit 19.123 (0.75287)
Side bush axial length mm (in) Limit 14.77 (0.581 5)
Center bush inside diameter mm (in) Limit 19.123 (0.75287)
Center bush axial length mm (in) Limit 29.68 ( 1 .I
685)
Gear shaft diameter mm (in) Limit 18.935 (0.74547)
TAB
TAB REC
-
TAB REC
43
REC
TAB REC
TAB REC
aCN
TAB
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TA B REC
TAB REC
--
TAB REC
Ct'
TAB REC
N O P C J N O P C J .
1161G-R .I5V I161G-RCN27-3
2 162 G-Y SSP 2 162 G-Y CN27-2 TAB REC
3 163 G-8 GNO 3 163 G-8 CN27-5
N22-
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TAB REC
TAB REC
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CN22 &
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TAB REC
TAB REC
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TAB REC 2 1 ps 2 1 NI 15-1
TAB REC
TAB REC
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TAB REC
I152 B 1 I52 B CNI-12
CN37
(Joint connector)
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TAB REC
2 V B FAN 2 V W 1-1
TAB REC
TAB REC
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TAB REC
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3 P9 RAD
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TAB REC
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CN3 1-6 N30-I 0 ~ ~ 3 0 - 2
N34-5 CN30-5 CN34-2
m w w (Nl. W)
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0417-5 LF-L 0465-7 CN65-2
( 109. BR) (110. GR) (17.BR) u&H
JOINT PORTION OF FR PILLAR HARNESS Display, charge panel joint
A
CN30-5
CN30-9N&- 13-5
cN23-2% N24- 2
CN1 6- 4 CN7-1 CN 00-3 CNI- 14
(41. Y ) (N1. W - 8 ) (N1. W - B ) ( 110.R
CN16-3
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CN5-I
(101. R)
CN32-2 A N I05-9
( 5 6 R-G) f!lAl
JOINT PORTION OF MAIN HARNESS
CONNECTOR DRAWING [FOR OTHER THAN U.S.A.] (1998.2 - 1998.8)
TAB REC
TAB REC
TAB REC
77 G-Y CNl-8
TAB REC
TAB REC
N O P C J
1 1 60 1 G-W I LS r
2 1 61 1 G-R I LS r
REC
1 N1 W J14
FRY 2 110 GR J15
FRY 3 43 L CN304
TAB REC
TAB REC
8.W LS Y.G CN106-17
2 51 R-L LS s 2 51 R.L CN37-16
TAB REC
TAB REC SSL
TAB REC
SSR
TAR REC
B CN106-16
2 51 B SW ?. 51 R-L CN37-7
REC
- JL
TAB REC
TAB REC
TAB REC
TAR REC
TAB REC
TAR REC
9 M ACCEL
TAB REC
REC
- SWn
2 162 - SSP
3 161 - SSP OUT CN105-9
51 8 GND
SSP
CN33
TAB REC
TAB REC
107
TAB REC
104 LT-R 104 CN30-2
2 N1 B GND
TAB REC
~ N O ~ P ~ J C 1I
1 108 R-Y CN8-2
2 104 G-R CN37-20
R-G
4 43 BY CN1W-2
51 R-L CN37.19
TAB REC
152 SLL 152 CN1-12
TAB REC
CN37
(JOINT CONNECTOR)
TAB REC
P21 DM P21 FET
P22 W FET
REC
TAB REC
102 LH-R
TAB REC
102 LH-L 102 CN17.3
TAB REC
P21 FET
TAB REC
TRANS
TAB REC
TAB REC
TAB REC
l 1 132 1 V-R I TU I 1 4 1 132 1 Y-R ICN120-5 AC7i.7 CNW-1
2 95 L THR
REC
TAB REC
TAB REC
TAB REC
NO[ P I C I J
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P I 1 7-ZfJ
TAB REC
CN12-1
CN316ECN30-3
CN31.2 f i C N 3 3 . 2
CN31.6 CN30-10 CN30.2 CN34-1 CN333 CN34-5
CN30-5 CN34-2
cN34-6'A
Lf.RR CN3D1
CN30.9
LF.LR
LF-RR
CN31.3
CN34.3
CN12-2 CN3M
ACN3O-8
CN31-4
CN14.3
b CN51-2 CN18.3
b CNU-2 CN13-4 LF-R CN13-5
( I 1O.GR)
LF-R
($
CNl8-1 CN18-2 CN1-1 CNl-l
@ CNlm-19 CNlm-9
CN41 CN17-5
CN16-4
A (41.Y)
CN7.1
C N 2 3 . 2 S
CNI
(N1.W-0)
CN17.1 &'cw.2 CN24-2
C~13.1
CN1-14
(NI.W-0)
CN30-9-&CNl3.5
(1 10.GR)
CN35-2 P I TERMINAL
-&
CN3-1
CN16-3
A CN51
(1Ot.R)
CN32-2 A
(56.R-G)
CN1059
CN16.1
(Pl.0)
CNl6.2
REC
TAB REC
NO P C J lc8 SW F 108 R-Y CN13-4.CN301
3 108 G SWF 109 G-Y CN17d.CNS10
2 120 B DSFO
3 103 G DSBU
4 40 W-0 DSR CN103.0
5 45 W-BR DSF CN103-7
6 43 R DSFO.DSBU
REC
IUI U
REC
77 G-Y CN1.8
TAB REC
TAB REC
N O P C J
1 60 G-W LS L 1 60 G.W CN103-10
2 61 GR LS T 2 61 G-R CNlOJs
3 1)3 GY LS ~ r r 3 -
63 -
0-0 -
CN103-5
4 51 R-L COM -
4 51 R-L CN37-5
TAB REC
NO P C J
REC
REC
REC
BW LS.
2 51 R-L LS
TAB REC
NO P I C 1 J I INO I P I C I J
TAB REC
TAB REC
N O P
i ;i
1 1 ~ 1 0 3
C J
LF-R 1NO P
1 1 ~ 1 0 8~
I C
~
1
~ C
J
N l 1 3 4
SSR
2 110
1 ;1 1 ;1
NI
104
LF-R
LC-R
LGR 1 1 1 1 1
2 110
Nl
104
CN13-5
cN13-1
CN13-2
1
TAB REC
TAB REC
103 R-W CN309.CNg-3
NO P C J
1 101 R CN5-1
F4 2 P1 B
4 41 Y CUC1,CUlW-16
TAB REC
N O P C J NO1 P 1 C J
TAB REC
NO1 P C J
TAB REC
N O P C J NO P C J
REC
TAB REC
TAB REC
TAB REC
TAB REC
TAB REC
TAB REC
2 51 - Ls cs
W
2
I N1 0 GND
5 103 LEU-R
6 108 G LF-RR
TAB REC
TAB REC
J
2 56 R-6 J6
TAB REC
TAB REC
152 SLL 152 CN1-12
TAB REC
TAB REC
56 OVT 56 CN105-5
51 8 GND
TAB REC
J
W{ TAB REC
TAB REC
WlW-1
TAB REC
NO P C J
TAB REC
2 PU W DM-
2 1 N1 W LH-R 95 THR
TAB REC
TAB REC
102 W-L 102 CN17-3 NO P I C ] J I NO P C J
2 N1 W LH-L N1 W JO
TAB REC
TAB REC
CN61-1
CNS1
2 95 L CN€€-2 TU
TAB REC
NO P C J
TAB REC
NO P C J
1 U W
2 V R TRANS
4 W B 4 W TRANS
TAB REC
NO P I C / J N O P C J
TAB REC
I . o ~ P-
I -C I J I h o l P / C / J ]
1 143 - SDTMK 1 143 R-Y CNl-6
TAB REC
1 - I C / 0 / P l C I J 1
TAB REC
CONNECTOR DRAWING [FOR U.S.A.] (1993.1 - 1998.11
TAB REC
@JJ
CN -
TAB REC
TAB REC
TAB REC
N O I P I C I J
11411 - 1 An TAB REC
TAB REC
@CN15 &
TAB REC
2 51 SW 2 51 R CN37-7
TAB REC
TAB REC
2 108 Y
3 109 0
25 @
REC
TAB REC
TAB REC
TAB REC
-
-
TAB REC
- -
TAB REC
TAB
TAB REC
TAB REC
TAB REC
TAB REC
REC
TAB REC
TAB REC
N O I P I C ( J
2 1 ~ l1 e l cur
32
TAB REC
2 56 Y
3 51
@j
REC
TAB REC
TAB REC
TAB REC
N O j P I C I J N O I P I C I J
I 11021 Y I CN17-3
CN37 111021 W 1
2 1 N l l U I
LK
LK 2 1 N l l U 1 J9
(Joint connector)
CN
@g
TAB REC
TAB REC
TAB REC
TAB REC
2 51 LSL2 2 51 R CN37-6
CN4 1
TAB REC
N O I P I C I J
2 1 NI I B 1 Shunt
TAB REC TAB REC
TAB
TAB REC
E P C J ycP C J
I P I 5 GP Ullt? I P I 5 GR RAP
2 P 2 GR 01118-1 2 P 2 GR RAD
3 P 9 GR UllCl 5 P9 GR PAD
mlpt REC
2 P9
TAB
l E kNl:7-2]
W PAD 2 I P9 1 GI) ICNI 17-3
TAB REC
CN13-1 CN17-I CN14-1 CN 1 4-2
CN18-I CN 1 8-2
LF-L C N 7-5
~ LF-L
( 109. BR) ( I 10, GR)
FR pillar harness joint
CN34-6
LF-R BcN30-1
( 104. G )
g3
~ ~ 3 0 - 9
LF-
-'
( 103. 0)
CN34-3
CN12-2
CN30-8
(N1. W )
CN 1 7-4 CN30-4
N37-1
(109. P ) (43.L)
CN 1 00-4
CNI-lfiC~7-I
JI
CN13-1
CN10 0 - w 2 4 - 2 ~ ~ 1 3 - 1 R~~ CN 17-5
CN3O-lI&N13-5
CN3- 1
TAB REC
N o I P I C I J
BR CN120.19 l 1 17 1 BR I CN107.6
2 104 G-R CN120.10 CN8
3 144 R.G CN120.12
R CN120.9
5 51 R.L CN2.2
6 143 R.Y CN120.1
REC
Wl
N O P C J
7 141 R.W CN120-2
1 43 L CN37-11
8 77 G.Y CN2.3
2 108 2 108 BR CN30.1
3 109 SWr 3 109 P CN30.10
W-B CNl20-20
TAB REC
TAB REC
TAB REC
2 110 FRY
FRY
CN
TAB REC
TAB REC
l N O l INOI
P I c l J I
1 108 BR J25
2 110 GR J26
3 N1 W CN13-1
G
*I
LC-R 4 104 CN13-2
TAB REC
1101 P l c l J 1
2 51 B sw,
TAR RFC
TAB REC
TAB
REC
1 ~ 0 1P I C I J 1
TAB REC
TAB REC
120 R-W CHI
N1 B CHI
TAB REC
NO^ P I C I J I I N OP~I C I J I
TAB REC
TAB REC
TAB REC
OUT CN105-9
51 B GND 51 CN37-18
TAB REC
107 Lw 107 CN30-7
N1 W L w L a.B z
N O P
1 1 67
TAB
C
1 . I
J
LSar I!%E~ 3 103 0 B,
TAB REC
104 CN30.2
REC
CN37
(JOINT CONNECTOR)
TAB REG
TAB REC
TAR RFC
LSU CN105.2
2 51 R LSL2
TAB REC
P21 FET F3ta-
TAB REC
TAB REC
TAB REC
102 LH a 102 CN13-3
2 N1 W LH a
TAB REC
102 LH L 102 CN17-3
2 N1 W LH
TAB REC
SDTMK
GND
1-
TAR REC
2 141 - SMTOA
MRR
. MFL
- MRL
10 . MP
TAB REC
RAP
CN13-1 CN17-1 CN14.1 CN14.2
CN14-3
d.2 CN51-2 C~(8.3 CN52.2 CN13.4 LF-R ~~13.5
95 LF.R
CN18-1 CNl8-2
J2-j
CN17-4
(109.BR)
LF-L CN17-5 95
(1 1O.GR)
LF-L
CN31-6
5 CN30.10 CN302
5 CN34-1
CN3l.5
CN33-3
CN30.3
CN2d-5
CN31-2
CN30.5
CN12-1
CN33.2
CN34-2
(109.P) (104.G) (103.01 (N1.W)
N c
LF-RR
~~30.1
CN30-9
LF-LR
'fc
LF-RR
CN31-3
CN3-3
CN12-2 CN24.4
A
CN30-8
CN31-4
4
CN17-4
CN30-6 -&
CN30.4
CN1.2
CN37-1
CNB-3 CN30-10 CN1W-2
(1OO.P) (43.L)
cN13.n
CN1W.4 CN13-1 CN17-5
$
CN3.1
CN4-1 CN7-1 c~lw.3 CN24-2
CN16-4
?I
(41.Y)
CN1W-1
CNZ3.2
(N1.W)
CN30-5
CNl-1
IN1.W)
"
CN17-1
1&cN13-5
(11 O.GR)
CN16-3
A(101.R)
CN51
P 1 TERMINAL
cN16.1& cN16-2
CN23.1
5 CN303
CN30-1
ACN13-4
CNB-2 CN3-3A
CN17-3
CN13-3
(P1.0) (103.0) (108,BR) (102.Y)
TAB REC
TAB REC
NO P C J NO P C J
1 17 BR CN120-19 1 17 BR CNlE-18
2 104 G CN120-10 2 4 3 L .I8
3 144 GR CN120-12 3 144 GR CNlE-11
TAB REC
N O P C J
TAB REC
NO P C J NO P C J
TAB REC
TAB REC
2 111 SL CN3C-E
TAB REC
TAB REC
[ N O ~ P I C IJ I [ N O ! P I C I J 1
TAB REC TAB REC
NO P C J
TAB REC
SSL CN104-7
2 83 B SSL 2 83 0 CN1046
TAB REC
1 NO
1 ~108
2
P
110
1 1
C J
LF-R
LF-R
1E
NO
2
P
110
C J
CN13-5
l
IN,OI~; 1
TAB
SSR
J 1 1~ ~ 1 1 REC
c
GR CN104-2
1
TAB REC
NO P C J NO P C J
TAB REC
~NOIPIC! J ~NOIPICI J
TAB REC
2 PI 0 F5
TAB REC
~ N 103
, O R-W
I P ~ C ~ I ~ N
103
, O ~ P
CN30-3
I ; J~ 1
TAB REC
REC
TAB REC
NO P C J NO P C J
TAB REC
NO P C J NO P C J
1 1 1 1
Nl
104
LGL
LGL
1 1 1 1 1
Nl
104
CNl7-1
CN17-2
1
TAB REC TAB REC
NO P C J
4 1 53 1 - I ACCEL
CN33
TAB REC
2 162
TAB
- SSP 2 162
REC
CN19-2
I
mi 120 G-Y CN30-6
1 1 I-I 1 1 ;I I I
3 161 - SSP 3 161 R CN19-1
DISP CN1-11
163 SSP 163 CN19-3
151 151
I W I 1 4 1 5 1 6 /
TAB REC
TAB REC
TAB REC
TAB REC
56 IWP 58 G 514
3 51 B IWP 51 R CN37-19
TAB REC
1 1 2 1 3 1 1 4 1 5 1 0 1 [ 6 1 7 1 [ / I 9 I 10 CN103-1
11 12 13 14 15 16 17 18 19 20
REC
TAB REC
N P J
TAB REC
N O P C I J N O I P ~ C I J
TAB REC
NO P C J J
TAB REC
1 51 B LSD
2 67 Y LSD CN22-2
TAB REC
TAB REC
BW EL2 CN103-11
2 51 R-L EL2 2 51 R CN37-6
TAB REC
NO P C J
TAB REC
P21 FET F21
TAB REC
3 P B 8 R4
CNtlJ
a v mrls
, * m CNW
TAB REC
~ N ~ ~ P IJ C ]I ) d o I P I C I J 1
TAB REC
WI
11 142 - SDTMA
CN105
TAB REC
TAB REC
h 0 l P / C / J 1 I N O ~ P I C / J 1
DIRECTIONALCONTROL PEDAL
DEAD MAN BRAKE BACK-UP BUZR
CHI-F&R
CN31-1
Ecm CN12-1
q A
CN30-E
A.
CN31-5 CW-2 ~ c w 2 CN31-3
cN304 CN34-3
c m 2 CN34-1 CN12-2 CN34-4 CN31-4
CN33-3 CN344 CN30-5 CN34-2
(104.G) (103.0) (N1,W (110,GR) (H1.SL)
044-1
%
(41,Y)
cN1w3
CN1W CN1OO-l
& H
(N1 .W)
CN30-5
'323-2
CN13-1
H
(N1,w
CN17-1
J2
Cbi30.9 &CNw
l
(ll0,QR)
CN16-4 A
(101,R)
CN51
CN1-2 CNB-3
CNl6-I +cN16-2
CN103-14
CN30-1
CN13-4
CN8-2
CN8-3
4
CN17-4
CNYJ-10
CN118-I CN104-4 CN37-1
(103.0) (108.BR) (109.P)
143.L)
IP1.O)
CN17-3 CN352
J
+
J
,
CN3-3 CNl3-3 CN105.5 CN32-2
(102.Y) 156.6)
CNlOl CN102
No. P No. P
MCS-Ill A CHECK SUB-HARNESS (SST 09240-12240-71)
CONNECTOR DRAWING ON INSPECTION SIDE.
CNlOl CN102
CNlll CN112
CPU BOARD & DC/SD BOARD CONNECTOR DRAWING (Harness side)
[FOR OTHER THAN U.S.A.] (1998.2 - 1998.8)
-
[FOR U.S.A.] (1998.2 1999.1)
CNlOl CN102
No. P No. P
1 - 12 -
2 - 13 -
3 15 14 11
4 15 15 -
5 10 16 11
6 32 17 33
7 30 18 31
8 - 19 -
43 22
CNlll
No. P No. P No. P No. P
1 35 9 36 1 4 11 P2
2 37 10 38 2 5 12 6
3 11 11 11 3 2 13 1
4 10 12 13 4 3 14 1
5 15 13 14 5 7 15 1
6 30 14 31 6 75 16 76
7 32 15 33 7 - 17 P9
8 11 16 11 8 74 18 74
9 71 19 72
10 73 20 73
No. P No. P
1 82 . 11 P61
2 81 12 67
3 84 13 51
4 83 14 51
5 45 15 77
6 46 16 66
7 64 17 65
8 53 18 52
MCS-Ill A CHECK SUB-HARNESS (SST 09240-12240-71)
CONNECTOR DRAWING ON INSPECTION SIDE.
CN 101 CN102
CNlll CN112
CPU BOARD CONNECTOR DRAWING (Harness side)
[FOR OTHER THAN U.S.A.] (1998.9 - )
[FOR USA- UL- CANADA 1 (1999.2 - )
CONNECTING DIAGRAM [FOR OTHER THAN U.S.A.] (
CNI 1
CN29
warnicg chime
Contactor panel
Joint
..,.-
111 111 111
laa
CNI 1 8 I _.__ I
CONNECTING DIAGRAM [FOR OTHER THAN U.S
CNl l
CNI
AC PLUG
CONTACTOR PANEL
CHI-FBR
FORWARD AND
BACK.UP CHIME
CONTROL PANEL
-
--
CN107 CN105
CONNECTING DIAGRAM [FOR OTHER THAN U.S.A. UL. CANADA] (1998.9 - )
U i L Y FOR C W A S P E C SW 0
CNl
CNll
CN52
(EnPSl (EMPSI DM 0s
CONT CN43
BAT
CONTROLPANEL
16-58
CNI I
CN3
C
-- - - --- - - -- -
, When EHPS ia not provided
P21 h 1
Contactor PS
CN42
Joint connector
CONNECTING DIAGRAM [FOR U.S.A.] (1998.2 - 1999.1)
.--
I I I FOR LOkD WNDLNG
CHWPEII I @ CN13
(EHPS) IEHPS) DM .,
CONT ,
BATT IEHPSI
SEAT
I STD Veh~cle
i
CONNECTING DIAGRAM [FOR U.S.A. UL. CANADA] (1999.2 - )
ONLY FOR W I S P E C .
9 CNl
f
CN1
CNll
COKIACTOR PANEL
1 STD
F?
WIRING DIAGRAM [FOR OTHER THAN U.S.A.] (1993.1 - 1998.1)
WIRING DIAGRAM [FOR OTHER THAN U.S.A.] (1998.2 - 1998.8)
pe CP"
TF TRWORMER DS -
- OIRECSION SWITCH, s*CK.UP
iJ TIMER UNIT -
W A D-
VARI-OHM. ACCEL. D R M 3
-
-
lR LIMITSWITCH.LIFT NO.1R
MS IAGNETSWITCH.WARGER
CSM
CAPACITOR. I\BSORBER
CURRENTSENSOR.DRNEPUMP
--
LS
SW
L I M ~ S W I T M . D WMIW
SWITCH ACCEL
L STa LIUIP STOP Fn
F, FUSE.P"MP
P R I M WARD. COMPUTER
1 FOR EHPSLESS 1
PB PRINT WARD. EHPS SSP SENSOR, SEERING PRESSORE Pt PILOTLIUIP, WORKING WZZER
ST+
YL
SENSOR.THERM0
L LAMP. HE40 RH
L LAMP, CLEAMNCI L t
.+
TRANSSTOR. MAIN. PUMP L U M P FLASHER RH lRE4Rl RCKIR RESISTOR.CHECK ( R
L LAMP FLASHER LH
v
VRAO VARI-OHCC ACCEL DRIVE
OSFO
---"
nspl.
JOIRECTION
-- --
L S I/~~LIMIT
~
--
SWITCH.
SYITCK
-
l n r R r r T r n N SYTTCH.
- -
LIFT.
FORWARO OPTIONAL
- ACK-UP
B
NO. 1 1 2 1 T2+I 1 1
CUL .*"
OISP
.so" W
am
ON
1
L-
CMIa
ILAMP.
I
CHIME.
BACK-W,RH
REVERSE
FRY IRELAY.
FLASHER
SA ISLIRGE ABSORBER
I I
OISP IDISPLAY LAMP. CLEARANCE L H
I
I I
TM TRANSISTOR MAlN hlpr CONTACTOR W W E R STEERING
1 -
LS - IR UMITSWTTCH. UFT, K) 1R
LS UMITSWFCH. TILT
OFlR DIODE. FLVWHEEL. NO.1R
BIl7 BIlTERV
I CHWRMRSE
W P ,H W M H w
W P , CLEAPANCE Ln m RELAY,iU8HER
SI SUffiE*BSOBER
SN1 SNUBBER.NO.1
MOTOR. WWER STEERING
mP INOIUTOR. WHEEL W m O N
CONTACTOR.PUMP (ONLY M R U W O A SPEC.)
TRANSTOR. WIN. ORNE CONTACTOR. WWER STEERING U P , -HER Ln ( R W )
L q P ( V I R K Y U STERRNO W m O N . N 3 1
TW\HSISXXL WIN, PUMP W P , -HER M (REAR) RCKlR RESISTORCHECK 1R
L
1 I
DS DIRECTION S M E H . REVERSE