7FBEU15-20 OPS Repair Manual CU341

FOREWORD

This manual describes the explanation and service procedures concerning the modified portions of the Toyota Battery Forklifts 7FBEU15, 18, 20. For the portions not described herein, please refer to the New Model Features and Repair Manuals shown below.

This repair manual contains the information on the vehicles manufactured as of

October 2005. Please understand that the description herein may not be applicable to the vehicles produced thereafter. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles’ Parts & Service News.

The performance values described herein are for standard vehicles under our specified test conditions. Since the conditions (weather, road surface, maintenance and operation) are different in actual use, the values will vary accordingly.

<Reference>

New Model Features and Repair Manuals related to this manual are as follows:

{

NEW MODEL FEATURES

7FBEU15, 18, 20 (Pub. No. PU315)

{

REPAIR MANUAL

7FBEU15, 18, 20 (Pub. No. CU330) Vol. 1

7FBEU15, 18, 20 (Pub. No. CU331) Vol. 2

Service Information Bulletins affecting Models

(30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32

Service Information Bulletin

1 SIB MA06-001 - 7FBCU Option Menu Changes

2 SIB CC06-001 - A5 Error Code Additional Information

3 SIB RA06-002 - Tie Rod Change

4 SIB FA06-003 - Front Axle Hub Change

5 SIB FA06-002 - Changes to Reamer Bolt Torque

6 SIB RA04-001 - New Tie Rod End Design

7 SIB MA05-009 7FBEU Option Set Menu Changes

8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload Specification)

9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion

10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks

11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust

12 SIB DU05-004 - Reduction Gear Change

13 SIB ST99-001R - Recommended Special Service Tools

14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting

15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting

16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32)

17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55)

18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32)

19 SIB FA05-001 - Gear Case Change (7FBCU35-55)

20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20)

21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~20

22 SIB CE05-001 Key Switch Change (All Models)

23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20)

24 SIB CE05-008 7FBEU Voltage Conversion

25 SIB CC05-011 Low Battery Voltage / Performance Reduction

26 SIB CC05-007 MB Contactor Cover (7FBEU15-20)

27 SIB ST06-001 - Recommended Special Service Tools

28 SIB CE05-006 Pump Motor Cooling Fan

29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit

30 SIB MA07-005 - Maintenance Indicator Changes

31 SIB RA07-001 Rear Axle Flange Change

32 SIB HS07-001 Addition of Back-Tilt Lock Valve

33 SIB CE06-005R - Display Battery Replacement

34 SIB CE06-005R Display Battery Replacement

35 SIB FA07-001R Front Axle Shaft Change

36 SIB CC07-004 - Tuning No. 14 Information

37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section

38 SIB CC08-003R Inching While Braking Option (Tuning Level 13)

39 SIB DU08-001R 7BNCU Drive Unit Repair Correction

40 SIB ST08-001 Recommended Special Service Tools

41 SIB CE08-002R Battery Connector Bracket

42 SIB HS08-002 Addition of OPSS Back-tilt Lock Valve



43 SIB CC08-010 7FB10-J35 Programming Changes

44 SIB Option Setting and Tuning Modes (7FB Models)

45 SIB BR09-001 7FB Repair Manual Corrections

46 CC09-001 7FB Revision of Repair Manual

47 CC09-003 Error Codes 31-1, 31-2 and 31-3

48 DU09-003 Gear Case Bolt Torque Change

49 CC09-004 5F and 5G codes

50 DM09-001 Drive, Pump and Steer Motor through Bolt Torque

51

DM09-002 Pump Motor Cable Clearance

52 CC10-001 Flashware v4.2

53 HS10-001 7FBEU Steering Circuit Hydraulic Schematics

54 SIB CE10-004 8FBC(H)U Voltage Conversion

55 SIB ST10-001 Measuring Parking Brake Force on 8FBC(H)U Trucks

56 SIB BR10-001 Stainless Steel Deadman Switch Mounting Screws

57 SIB CC10-005 v3.1 Software Update for Auxiliary Functions

58 SIB MA10-002 8FBCU Tuning Modes Explained

59 SIB CE10-006 7FBEU Motor Sensor Bearing Change

60 SIB CE10-007 8FBCU Height Selector Information

61 SIB CE10-008 8FBCU Shock Sensor Information

62 SIB MA10-003 8FBCU Auto Speed Control Information

63 SIB MA10-004 8FBCU Touch Pad Information

64 SIB MA10-006 AC Motor Controller Change

65 SIB CE11-001 Clamp Release Interlock (Mini Lever Units)

66 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin

67 SIB FA11-001 7FBEU Front Axle Repair Kits

68 SIB CC11-004 8FBCU Tuning No.1 Explained

69 SIB CE11-002 8FBCU Horn Wires Breaking

70 SIB CE11-003 Clamp Release Interlock (Standard Lever Units)

71 SIB DM11-002 7BNCU New Auxiliary Motor and Pump

Technical News Brief

1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal

Option, Over Heating Diagnosis, and 7FBCU Voltage Specs

2 TNB - 2004-07 - Hydraulic oil change

3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange

4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump

5 TNB - 2006-05 - Plate to Prevent Chain Rollback

6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates

7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure

8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage



9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display

10 TNB - 2006-09 - 7-Series Electric ROM Write

11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention

12 TNB-2006-03 - 7FBEU Counterweight Squeaking

13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure

14 TNB-2008-10 7BNCU Steer Sensor Alignment Tool

15 TNB-2008-16 Dual Contactor (Units with Pump Chopper)

16 TNB-2009-04 7FBEU Static Strap Update

Hotline Tech Tips

1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels

7FBCU

2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU gradeability; 7FBCU CB1 and CB2

3

HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on

7FBEU and 7FBCU

4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential

Oil Level

5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing

6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU

Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction Mode and Lift Interrupt

Settings

7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement

8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 2

9 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers

10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon

11

HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel

12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures;

7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse Replacement

13

HTT-2006-01 - 7 Series Electric Lift Truck Erratic Display; 7FBE Drive Unit Part Numbers

14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes

15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-3

16 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement

17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm

18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption

19 HTT-2006-07 - 7FBEU Slow Motor Speed

20 HTT-2006-08 - 7FBEU E2-1 Error Code

21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N

22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes

23 HTT-2006-11 - 7FBCU Drive Transistors



24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor

25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install

26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added

27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU

28 HTT-2007-04 - Class 1 gear case oil

29 HTT-2007-05 - 7FBCU Gear Case Sealing

30 HTT-2007-06 - Steer Cylinder change

31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil

32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting

33 HTT-2007-09 - Repair Manual 322

34 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors

35 HTT-2007-11 - CU322 Repair manual clarification, 7FBEU 31-1, 31-2, 31-3

36

HTT-2007-12 - Class 1 Alarm with OPSS

37 HTT-2008-01 - Class I Gear Noise

38 HTT-2008-02 - Drive Unit Part Numbers, EF-1 & EF-2 Error Codes, Flashware Cable for

39 HTT-2008-03 - 7FBE Error Codes 64-2 & H9-2, 7FBCU15-55 A8, A1 & C3 Error Codes,

40 HTT-2008-04 - No Display with EZ Pedal, (30)7FBCU15-32 Complaint of Low Top Speed

41 HTT-2008-05 - 7FBCU20-32 Battery Slide out Field Installation Kit, (30)7FBCU15-55 Drive

42 HTT-2008-06 - 7FBE Front Hub Induction Hardening and Drive Axle Clattering

43 HTT-2008-07 - 7FBCU15-25 Inspecting the EHPS Transistor

44 HTT-2008-08 - 7FBE Internal Gear Hardened

45 HTT-2008-09 - (30)7FBCU15-32 Error Code C0-(1-6)

46 HTT-2008-10 - 7FBE Drive Axle Connector Rod Adjustment

47 HTT-2008-11 - Using The SST Tools In Diagnosing Board Issues and UL Ratings

48 HTT-2008-12 - Diagnostic Tips

49 HTT-2009-01 - Slow Lowering or Incorrect Staging During Lowering

50 HTT-2009-02 - C2-2 or C2-3 Error Codes and Trouble Shooting Error Codes H9-1,2,3 Or 64-

1,2,3

51 HTT-2009-03 - Static Strap Mounting and Lift Interrupt Settings

52

HTT-2009-04 - Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters

53 HTT-2009-05 - Error Codes After Card Replacement

54 HTT-2009-06 - Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On

55 HTT-2009-07 - Slow Travel Speed

56 HTT-2009-08 - Occurrence of Error Code AO-4

57 HTT-2009-09 - Jerky Travel at Slow Speeds

58 HTT-2009-10 - Gear Case Bolt Torque Increase

59 HTT-2009-11 - A5 Error Code On 7FBE and 7FBC Forklifts With OPSS, 5F and 5G Codes for the 7BNCU Model Forklifts

60 HTT-2009-12 - 7FBCU Transistor Test Procedure & Speed Sensor Check

61 HTT-2010-01 - FE-4, E2-2, E2-4 Error Codes

62 HTT-2010-02 - Switch Adjust, RF Interference on AC Trucks



63 HTT-2010-03 - Documenting 7FBCU Brake Inspection and Adjustment During PDI,

Flashware v4.2

64 HTT-2010-04 - Class I Brush Warning Option 14, 7BNCU Diode Replace Instructions

65 HTT-2010-05 - Class I 7FBEU Front Axle Repair Kits

66 HTT-2010-06 - Class I AC Drive Motor Over Current Limit Checks, SAS Manual Lowering

Valve

67 HTT-2010-07 - 8FBCU Slow Travel or Surging Hydraulics, Setting Time/Date

68 HTT-2010-08 - 8FBCU Display, Main CPU and Changing Voltage

69 HTT-2010-09 - 8FBCU Measuring Parking Brake Force, 7BNCU Software v3.1

70 HTT-2010-10 - 8FBCU Service Information Bulletins

71 HTT-2010-11 - 8FBCU Slow Attachment Speeds, Seat Switch Failures

72 HTT-2010-12 - 8FBCU Travel Alarm in Both Forward and Reverse

73 HTT-2011-01 - Speed Limit Adjustment on 8FBCU

74 HTT-2011-02 - Class I-VI Common Electrical Acronyms, 7FBEU Error Codes 72-1, 72-2 or

Missing Manager's Functions

75 HTT-2011-03 - Class I 8FBCU Slow Lowering w/Standard Levers

76 HTT-2011-04 - Class I 8FBCU H Power Mode, 7FBEU RPM Sensor Bearing Damage

77 HTT-2011-05 - Class I Adding Electrical Devices,

78 HTT-2011-06 - Class I Battery Option/Type

79 HTT-2011-07 - Class I 7FBCU35-55 Using SST3 On CN112

80 HTT-2011-08 - Class I 8FBCU Tuning No. 1, Back to Basics Troubleshooting

81 HTT-2011-09 - Class I Important SIBs

82 HTT-2011-10 - Class I 8FBC(H)U Controller Software Change

83 HTT-2011-11 - Class I Adding Forward Travel Alarm

84

HTT-2011-12 - Class I C1-2 Error Codes, Hyd Oil Maint and Diagnosing Intermittent

Complaints

85 HTT-2012-01 - Class I 8FBCU Relief Valve Structure, Using DVOM to Check Voltage Drop

SECTION INDEX

NAME

GENERAL

OPS & IMPROVEMENTS

BODY

APPENDIX

SECTION

2

3

0

1

0-1

GENERAL

Page

PERIODIC MAINTENANCE ............................... 0-2

OPS SYSTEM .................................................... 0-2

GENERAL ...................................................................

0-2

CHANGES FOR INSTALLATION OF

OPS FUNCTION ......................................................

0-3

SYSTEM CONFIGURATION AND

OPERATION PRINCIPLE ........................................

0-3

DISPLAY ............................................................ 0-5

GENERAL ...................................................................

0-5

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

0-2

PERIODIC MAINTENANCE

Comparison with Former Edition: Repair Manual, Pub. No. CU330, Page 0-22

Change:

INSPECTION METHOD

I : Inspection. Repair or Replacement if required.

M : Measurement. Repair or Adjustment if required.

T : Retightening C : Cleaning L : Lubrication

Inspection timing

Every

6 weeks

Every

250 hours

Every

3 months

Every

500 hours

Item

SAFETY DEVICES, ETC.

Loosening and damage of mounting

SEAT Seat belt damage and function

Seat switch function

OPS Function I

I

I

I

←

←

←

←

Every

6 months

Every

1000 hours

Every

12 months

Every

2000 hours

←

←

←

←

←

←

←

←

OPS SYSTEM

GENERAL

The OPS (Operator Presence Sensing) System is equipped as the standard feature on all models.

The switch installed on the seat detects the operator, and when the operator is not seated in the normal operating position (operator’s seat), the OPS system interrupts the traveling power and restricts load handling operation.

When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding the buzzer (pi-)* for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turning off the seat switch. When the controller detects malfunction, the display indicate the diagnosis error code.

*: The buzzer sounds only export model.

S P H

0-3

CHANGES FOR INSTALLATION OF OPS FUNCTION

1.

Change in return-to-neutral function

When the key switch or seat switch is turned ON with the direction lever in the forward or reverse position or the accelerator pedal depressed, traveling is disabled unless the direction lever and accelerator pedal are returned to the neutral positions.

SYSTEM CONFIGURATION AND OPERATION PRINCIPLE

Note:

When OPS operates, the power assistance of the steering wheel is lost because the pump motor is stopped.

(except for Mini-Lever Opt.)

Battery

N1

Key switch

Direction switch

Accelerator pedal switch

Motor driver

Drive motor

Motor driver

Pump motor

Seat switch

Display

Main controller

Oil pump

Oil control valve

Oil tank

Lift cylinder

Tilt cylinder

Item

Travel OPS

Material handling

OPS

Operation explanation

When the controller detects the seat switch turned off for two seconds, the drive motor control is stopped.

Travel OPS is released by returning the direction lever and accelerator pedal to the neutral position and turning on the seat switch.

Standard:

When the controller detects the seat switch turned off for two seconds, the movement of lift down and tilt forward is stopped by controlling the lift lock valve, tilt controlling valve. The movement of tilt backward, lift up and attachment is stopped by stopping the pump motor. Material handling OPS is released by passing one second after turning on the seat switch.

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

0-4

Item

Material handling OPS

Operation explanation

Note:

• Tilt backward

When the tilt lever is operated in the state of OPS operation, the mast might move by the selfweight in the state of backward tilting.

• Attachment

When the attachment lever is operated in the state of OPS operation, the attachment might move by the self-weight.

Mini lever (OPT):

When the controller detects the seat switch turned off for two seconds, the movement of lift, tilt and attachment is stopped by stopping the pump motor control and controlling the proportional solenoid valve.

Load handling material handling OPS is released by returning the all hydraulic control levers to the neutral position and turning on the seat switch.

(In case of mini lever, it is additional to the condition of releasing material handling OPS to return the all hydraulic control levers to the neutral position. Because the mini lever is small and physical operation force is light, it is considered that the luggage etc. put on the armrest move the mini lever by mistake.)

OPS operation information

(*)

Return to neutral warning

When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding the buzzer (pi-) for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turning off the seat switch.

When the accelerator pedal is operated with turning on the seat switch without returning the direction lever to the neutral position, it informs the operator that the travel OPS is not released by sounding the buzzer (pipipipi).

Abnormality warning

When the controller detects malfunction, the display indicates the diagnosis error code.

(*) The buzzer sounds only export model.

SEAT

STD equipped seat is the same one equipped on previous model. It has been equipped with non-suspension seat with seat belt manufactured by Michigan seat.

Compared to previous model, variety of optional seat is increased. Optional seats are shown below. (Equipped seats vary with the specification of option.)

All seats equip switches for operator presence sensing system.

When replacing seat, always use a genuine TOYOTA seat.

Otherwise, the OPS may fail to operate.

0-5

DISPLAY

GENERAL

The multiple display is provided in two types: standard easy model and optional all-round model.

Function list (only added or modified items)

{

:Provided — :Not provided

Status display function

Function

S P H

1 OPS indicator

Easy model (standard) All-round model (optional)

{ {

1.

Return-to-neutral warning

(1) When the operator turns the key switch on while depressing the accelerator pedal or turning the direction switch on to start the vehicle.

(2) After sat up, the operator depresses the accelerator pedal while turning the direction switch on and sitting down.

2.

OPS indicator

OPS indicator is displayed and the buzzer sounds for half seconds when the operator leaves the seat.

Note:

The buzzer sounds only export model.

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

1-1

OPS & IMPROVEMENTS

Page

GENERAL .......................................................... 1-2

MULTI-DISPLAY FUNCTIONS .......................... 1-3

MULTI-SCREEN DISPLAY.........................................

1-3

DIAGNOSIS ................................................................

1-5

MASK FUNCTIONS ....................................................

1-5

TROUBLESHOOTING ....................................... 1-9

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

1-2

GENERAL

Battery

Key switch

Direction switch

N1

Accelerator pedal switch

Motor driver

Drive motor

Motor driver

Pump motor

Oil pump

Seat switch

Display

Main controller

Oil control valve

Oil tank

Lift cylinder

Tilt cylinder

MULTI-DISPLAY FUNCTIONS

MULTI-SCREEN DISPLAY

GENERAL

Display and Buttons

Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-2.

Change:

Initial screen upon key switch on When OPS is operated

S A S

T O Y O T A

E Q U I P P E D

S P H

S P H S P H

(1) (2) (3) (4) (8) (9)

S E P / 3 0

A M

1 0 0

S P H

S P H

During traveling

1 0 m p h

1 1 : 0 0

S

P H

S P H

(5) (7) (6) (10) (11)

Upon error occurrence

A 1 1 A 1 2 A 1

1 2 3 4 5

.

3

O h

S

P H

S P H

(1) Parking brake ON indicator

(2) 2-speed travel speed set indicator

(3) Diagnosis ON indicator

(4) Overheat warning indicator

(5) Battery charge indicator

(6) Power select indicator

(7) Multiple display area

(8) DOWN button

(9) UP button

(10) Power select button

(11) Hour meter selector button

1-3

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

1-4

GENERAL FUNCTIONS


Change:

{

: General function z: Manager’s function

Function

Model USA model

(standard model)

Export model

Status display function OPS indicator

{ {

DISPLAY INDICATION LIST

Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-8, 9.

Add:

GENERAL Screen

MASK FUNCTION Screen

To be set by dealer or serviceman

OPTION SET SEAT BUZZER The buzzer sound before OPS operation.*

*: The buzzer sound only export model.

1-5

DIAGNOSIS

DIAGNOSIS CODE LIST


Add:

Display code

Diag memory code

Faulty Phenomenon on vehicle

A5 A5 Seat switch Seat switch abnormality

Detection controller

C/R

MASK FUNCTIONS

ANALYZER

Vehicle Abnormalities Not Stored in Diag Memory


Change:

Warning method Warning indicators

4

Return to neutral warning:

Warning buzzer sounds when starting is attempted by turning the key switch or seat switch ON with the direction switch ON or the accelerator pedal depressed.

• Beep

Short beeps

OPTION SET

OPTION SET Menu List


Add:

No.

Indication Description

Indication Meaning

Selection indication

OPT-23 SEAT BUZZER

Enable/disable

The buzzer sound only export model.

Y Enable N

Displayed code

No display

Meaning

Disable

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

1-6

Operation Procedure for OPTION SET Screen

Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-65, 66, 67.

New:

1.

Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen.

2.

Press button (2) twice to display “3. OPTION SET” and press button (3) (enter) to display the OPTION SET screen.

3.

Press button (3) to display the desired option item to be set on the screen.

4.

Functions of buttons on the OPTION SET screen are as follows:

• Button (1): N

→ Y

• Button (2): Y

→ N

• Button (3): Enter (to the next item screen)

*: Press button (3) on OPT-23 OPTION SET screen to display the MASK MENU screen.

MASK MENU screen

Button (1)

Button (2)

OPT-4 screen

Press button (3)

=

3

M E N U =

.

O P T I O N S E T

S P H

S P H

Button (3)

Press button (3)

< O P T 3 >

P / C L O C K Y / N

S P H

S P H

Press button (3)

<

O P T 1

>

D E M O M O D E Y / N

S P H

S P H

<

O P T 2

>

H / M S T A R T Y / N

S P H

S P H

Press button (3)

OPT-2 (H/M START) hour meter starting method:

Press button (2) while keeping button (1) pressed for 2 seconds or more.

OPT-3 screen

Button (1) Button (2)

<

O P T

D E S T I

4

>

J / I

S P H

S P H

Not used

Button (3)

Press button (3)

<

O P T 5

B L E V E L

>

Y / N

S P H

S P H

Press button (3)

< O P T

M P H

6 >

Y / N

S P H

S P H

Press button (3)

Not used

< O P T 7 >

C / C N T R E S

Y / N

S P H

S P H

Press button (3)

OPT-16 screen

Press button (3)

< O P T 1

B T Y P E

5 >

1 / 2

S P H

S P H

Press button (3)

< O P T

T I L T

1 4 >

F L I M Y / N

S P H

S P H

Press button (3)

< O P T 1 3 >

K N O B C O N T

Y / N

S P H

S P H

Press button (3)

<

O P T

T I L T

1 2

>

C O N T Y / N

S

P H

S P H

Press button (3)

< O P T 8

B A T T E R Y

>

A / B

S P H

S P H

Press button (3)

Not used

< O P T

S H O U T

9 >

O K U

Y / N

S P H

S P H

Press button (3)

<

O P T

P A R K I

1 1

N G

>

E R R Y / N

S P H

S P H

Press button (3)

<

O P T

S E A T

1

P

0

>

O F F Y / N

S P H

S P H

1-7

1-8

OPT-15 screen

Button (1)

Button (2)

<

O P T

3 6 V

1 6

>

Y / N

S P H

S P H

Button (3)

Press button (3)

< O P T 1 7 >

2 W A Y V A L V E Y / N

S P H

S P H

Press button (3)

<

4

O P T 1 8

>

W A Y V A L V E Y / N

S P H

S P H

Press button (3)

<

O P T

U S A

1 9

>

Y / N

S P H

S P H

Press button (3)

Not used

<

O P T 2 0

>

W H E E L I N D

Y / N

S P H

S P H

Press button (3)

Not used

<

O P T

S A S

2 1

>

Y / N

S

P H

S P H

Press button (3)

ADD:

MASK MENU screen

Press button (3)

<

O P T

S E A T

2 3

>

B U Z Z E R Y / N

S P H

S P H

MENU

Press button (3)

Not used

<

O P T 2 2

>

F I S H E R M A N Y / N

S P H

S P H

TROUBLESHOOTING

DIAGNOSIS CODE LIST

OPS relation

WHEN AN ERROR CODE IS DISPLAYED

Display code

A5

Diag memory code

A5 Seat switch abnormality

Error mode

WHEN NO ERROR CODE IS DISPLAYED

Display code Vehicle condition

Traveling and material handling fail with OPS operation display even after sitting on the seat.

Harness change relation

WHEN AN ERROR CODE IS DISPLAYED

Display code Diag memory code

61-1, 2

62-1, 2

61-1, 2

62-1, 2

63-1, 2, 3

67-1

72-1, 2, 3, 4

73-1, 2, 3

63-1, 2, 3

67-1

72-1, 2, 3, 4

73-1, 2, 3

Load sensor abnormality

Error mode

Tilt angle sensor abnormality

Tilt switch abnormality

Lifting height switch abnormality

Steering angle sensor abnormality

Steering knob synchronizer solenoid abnormality

A4

A6-1, 3, 5

C4-1, 2, 3, 4

C7

EE-1, 2, 3

A4

A6-1, 3, 5

C4-1, 2, 3, 4

C7

EE-1, 2, 3

Acceleration switch abnormality

Material handling switch abnormality

Accelerator potentiometer abnormality

Direction switch abnormality

F1-1, 2 F1-1, 2

Abnormal communication from multi-display

Main controller

→ multi-display communication abnormality

D15 overcurrent FF

H5-1, 2, 3, 4, 5

H6-1, 2, 3, 4, 5

H7-1, 2, 3, 4, 5

—

—

—

FF

H5-1, 2, 3, 4, 5

H6-1, 2, 3, 4, 5

H7-1, 2, 3, 4, 5

H8-1, 2, 3, 4, 5

H9-1, 2, 3

H8-1, 2, 3, 4, 5

H9-1, 2, 3

WHEN NO ERROR CODE IS DISPLAYED

Display code

Lift solenoid abnormality

Tilt solenoid abnormality

Attachment 1 solenoid abnormality

Attachment 2 solenoid abnormality

Unload valve solenoid abnormality

Vehicle condition

No display on multi-display

Only traveling disabled (no motor revolution)

Constant automatic fork leveling

Page

1-10

Page

1-12

1-51

1-30

1-31

1-34

1-37

1-40

1-43

Page

1-45

1-47

1-14

1-49

1-15

1-20

1-22

1-23

1-25

1-27

1-29

Page

1-52

1-53

1-55

1-9

1-10

OPS Relation

WHEN AN ERROR CODE IS DISPLAYED

A5 Seat switch abnormality (STD)

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

5

12

CN22

1

2

Seat switch

Condition for Error Detection

Output when the seat switch is kept ON.

Has the operator been sitting on the seat before key switch ON?

NO

Disconnect the seat SW harness CN22 and check the LSD.

ANL.: I/O MONITOR 2 I/O 2-3

LSD ON/OFF check

LSD: 1

• CPU-CN22 harness abnormality (potential 67 grounded) or

• CPU board abnormality

YES

LSD: 0

Normal

Seat switch abnormality

A5 Seat switch abnormality (Mini Lever)

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

5

12

CN42

7

8

CN43

1

2

Seat switch

1-11


Output when the seat switch is kept ON.

Has the operator been sitting on the seat before key switch ON?

NO

Disconnect the seat SW harness CN43 and check the LSD.


LSD ON/OFF check

LSD: 1

• CPU-CN43 harness abnormality (potential 67 grounded) or


YES

LSD: 0

Normal


1-12

WHEN NO ERROR CODE IS DISPLAYED

Traveling and material handling fail with OPS operation display even after sitting on the seat. (STD)

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

5

12

CN22

1

2

Seat switch


Seat switch OFF or discontinuity.

Disconnect CN22, connect SST2 to CN22 and check the LSD.


LSD ON/OFF check

LSD: 0

• CPU-CN22 harness abnormality (potential 67 line discontinuity) or


LSD: 1


1-13

Traveling and material handling fail with OPS operation display even after sitting on the seat. (Mini Lever)

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

5

12

CN42

7

8

CN43

1

2

Seat switch


Output when seat switch OFF or discontinuity.

Disconnect CN43, connect SST2 to CN43 and check the LSD.


LSD ON/OFF check

LSD: 0

• CPU-CN43 harness abnormality (potential 67 line discontinuity) or


LSD: 1


1-14

WHEN AN ERROR CODE IS DISPLAYED

CPU Board

63-1, 2, 3 Tilt switch abnormality

Related Portion

CPU board

CN101-23 (61, LSTF+)

CN102-8 (61, LSTF)

CN101-17 (62, LSTR+)

CN102-9 (62, LSTR)

CN101-16 (51, LS–)

J21

CN161 CN122

17 11

13

12

10

1 J2

CN87

1

3

4

2

Tilt switch


Output when open or short circuit of the tilt switch line from the CPU board to the tilt switch is detected.

63-1 Forward and backward tilt switch abnormality

63-2 Forward tilt switch abnormality

63-3 Backward tilt switch abnormality

Disconnect battery plug.

Connect battery plug again and turn key switch ON.

No error

A6-3 error is indicated

Check if an error is detected when the tilt lever is operated in either direction.

No error

63-1 error is indicated

Perform troubleshooting for A6-3.

• Tilt switch installation defect

• Tilt switch abnormality

ANL : I/O MONITOR 3 I/O3-3

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

1 is displayed on either switch.

0 is displayed on either switch after operating the tilt lever several times.

Memory 63-2, 63-3

Check the diagnosis memory

Memory 63-1

The tilt lever has been turned ON for two minutes or more in the past.

The forward and backward tilt switches were turned ON at the same time in the past.

(Check adjustment of each switch installation)

72-1, 2, 3, 4 Steering angle sensor abnormality

Related Portion

CN103-10 (16, D15V)

CPU board

CN101-24 (312, STS1)

CN101-30 (313, STS2)

CN101-21 (314, STSC)

CN101-16 (51, LS–)

CN162

13

CN161

9

11

8

12

J21

CN124

1

CN120

10

J4

11

12

1

J1

CN19

1

3

4

5

2

Steering angle sensor

1-15


Output when open or short circuit of the sensor line from the CPU board to the steering angle sensor is detected.

72-1 Steering angle sensor STS1 abnormality

72-2 Steering angle sensor STS2 abnormality

72-3 Steering angle sensor STSC abnormality

72-4 Steering angle sensor open

• 72-1

Connect battery plug and turn the key switch ON.

Turn the steering wheel.


72-1 error is not indicated


Check the STS1 input value turning the steering wheel.

Remain 0

Remain 1

Connector connection check.

B

A

1-16

A B


Disconnect CN32.

Short between CN19-3 and CN19-2 of main harness side with SST2.



Check the STS1 input value

Remain 0


Disconnect CN101.

(SST2 is connection state.)

CN101-24 (312)

b Continuity check

CN101-16 (51)

Continuity

CPU board defect

Change to 1

Steering angle sensor defect

No continuity

Main harness defect


Disconnect CN19.



Main harness defect

Change to 0



Remain 1

Continuity


Disconnect CN19, CN101.

CN101-24 (312)

b Continuity check

CN101-16 (51)

No continuity

CPU board defect

• 72-2





Connector connection check


Check the STS2 input value turning the steering wheel.

Remain 0

Remain 1


Disconnect CN32.





Remain 0


Disconnect CN101.


CN101-30 (313)

b Continuity check

CN101-16 (51)

Continuity

CPU board defect

Change to 1


No continuity

Main harness defect


Disconnect CN19.



Main harness defect

Change to 0



Remain 1

Continuity



CN101-30 (313)

b Continuity check

CN101-16 (51)

No continuity

CPU board defect

1-17

1-18

• 72-3


Turn the steering wheel to left or right for one round or more.





Check the STSC input value turning the steering wheel.

Remain 0

Remain 1


Disconnect CN32.




Check the STSC input value

Remain 0


Disconnect CN101.


CN101-21 (314)

b Continuity measurement

CN101-16 (51)

Continuity

CPU board defect

Change to 1

No continuity


Main harness defect


Disconnect CN19.



Main harness defect

Change to 0


Check the STSC input value

Remain 1

Continuity



CN101-21 (314)

b Continuity measurement

CN101-16 (51)

No continuity

CPU board defect

1-19

• 72-4







Disconnect CN19.

Connect battery plug.

Check voltage of power supply for steering angle sensor.

CN19-1 (16)

b Voltage measurement

CN19-2 (51)

Approx. 15 V


Connect CN19.


Approx. 0 V




Check voltage of power supply for steering angle sensor (at controller side connector).

CN103-10 (16)

b Continuity check

CN101-16 (51)

Approx. 15 V

Approx. 0 V

CPU board defect

Perform troubleshooting for 72-1 (STS1), 72-2 (STS2) Main harness defect

1-20

73-1, 2, 3 Steering knob synchronizer solenoid abnormality

Related Portion

CPU board

CN104-21 (329, SOLST+)

CN104-28 (330, SOLST–)

CN161

18

20

CN122

4

3

CN98

1

2

Steering knob synchronizer solenoid


Output when open or short circuit of the solenoid line from the CPU board to the steering knob synchronizer solenoid is detected.

73-1 Steering knob synchronizer solenoid open

73-2 Steering knob synchronizer solenoid short

73-3 Drive circuit MOS of steering knob synchronizer solenoid short

• 73-1

ACTIVE TEST : ACT-2 KSOL

Turn the steering knob synchronizer solenoid ON.

73-1 error is indicated.

73-1 error is not indicated.



Disconnect CN98.


Disconnect CN104.

CN104-21 (329)

b Resistance measurement

CN104-28 (330)

9.9 ± 1

Other than 9.9 ± 1 Ω (at 25°C)

Ω (at 25°C)

Disconnect CN98.

CN98-1 (329)


CN98-2 (330)

9.9 ± 1

Ω (at 25°C)

Other than 9.9 ± 1 Ω (at 25°C)

Steering knob synchronizer solenoid defect

CPU board defect

Main harness defect

• 73-2







Disconnect CN98.






Steering knob synchronizer solenoid defect


Disconnect CN104.

CN104-21 (329)

b Continuity check

CN104-28 (330)

No continuity

Continuity

Harness defect

CPU board defect

• 73-3







Disconnect CN152 and turn the key switch ON.

Check continuity

CN104-21 (329) to P1

CN104-21 (329) to P2

CN104-28 (330) to P1

CN104-28 (330) to P2

No continuity

CPU board defect

Continuity

Harness defect

1-21

1-22

A4 Acceleration switch abnormality

Related Portion

CPU board

CN102-1 (64, SWAC)

CN102-22 (51, POT–)

CN162

1

8

J22

CN121

10

4

J3

CN26

2

1

Accelerator potentiometer


Output when the acceleration ON signal is detected upon battery plug ON.

Was the accelerator pedal operated upon battery plug connection?

NO

YES

Disconnect CN26.

Normal

Reconnect battery plug.

NO

Is A4 error displayed?

YES

Disconnect battery plug and disconnect

CN102.

CN102-1 (64)

b Continuity check

CN102-22 (51)

Continuity

(Less than 20

Ω)

No continuity

CPU board defect

Adjust acceleration switch

Harness defect

A6-1, 3, 5 Material handling switch abnormality

Related Portion

CPU board

CN101-32 (60, LSL+)

CN102-6 (60, LSL)

CN101-11 (66, LSAT1+)

CN102-10 (63, LSAT1)

CN101-23 (61, LSTF+)

CN102-8 (61, LSTF)

CN101-17 (62, LSTR+)

CN102-9 (62, LSTR)

CN101-16 (51, LS–)

J21

CN161 CN122

12 12

7 9

17

13

12

11

10

1

J2

CN11

1

Lift switch

2

CN21

1

2

Attachment

No.1 switch

CN87

1

2

Forward tilt switch

3

4

Backward tilt switch


Output when the material handling switch ON signal is detected upon battery plug ON.

A6-1 Lift switch abnormality

A6-3 Forward and backward tilt switch abnormality

A6-5 Attachment No. 1 switch abnormality

Was the material handling lever operated upon battery plug connection?

YES

NO

Disconnect CN11 (A6-1), CN87 (A6-3) or CN21 (A6-5), and connect battery plug.

Normal

NO

Is A6 error displayed?

YES

A

Adjust limit switch or switch abnormality.

1-23

1-24

A



Continuity check

• A6-1

CN101-32 (60) to CN102-6 (60)

• A6-3

CN101-23 (61) to CN102-8 (61)

CN101-17 (62) to CN102-9 (62)

• A6-5

CN101-11 (63) to CN102-10 (63)

OK (short circuit)

NG (open circuit)

Continuity check

• A6-1

CN102-6 (60) to CN101-16 (51)

• A6-3

CN102-8 (61) to CN101-16 (51)

CN102-9 (62) to CN101-16 (51)

• A6-5

CN102-10 (63) to CN101-16 (51)

OK (open circuit)

NG (short circuit)

CPU board defect

Harness defect

Harness defect

C4-1, 2, 3, 4 Accelerator potentiometer abnormality

Related Portion

CPU board

CN102-1 (64, SWAC)

CN102-2 (52, POTA)

CN102-14 (53, POTA+)

CN102-22 (51, POT–)

J22

CN162

1

2

5

8

CN121

10

1

7

4

J3

CN26

2

3

4

1

Accelerator potentiometer

1-25


C4-1 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is on.

C4-2 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is on.

C4-3 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is off.

C4-4 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is being operated.

• C4-1

ANL : I/O MONITOR 2 I/O 2-1

Check the POTA value when the accelerator switch SWAC is turned from 0 to 1.

Less than 0.3V

0.3 V or more

CPU board defect

ANL : I/O MONITOR 2 I/O 2-1

Check the POTA value as the accelerator is depressed further.

The POTA value does not change.

The POTA value changes.

Disconnect CN26, and short between

POTA and POTA+ with SST8.

Error is indicated

Error is not indicated

Potentiometer adjustment defect

CN102-2 (52)


N1

4.8 V or more Less than 4.8 V

Potentiometer defect CPU board defect Main harness defect

1-26

• C4-2

Does C4-2 go out after disconnecting

CN26?

NO

YES

CN102-2 (52)


N1

Less than 4.5 V

4.5 V or more

CPU board defect

• C4-3


Check if the SWAC value changes from 0 to 1 as the accelerator pedal is depressed.

Changes to 1.

0 remains

Accelerator potentiometer check

Main harness defect

Accelerator switch defect


Check maximum POTA value when

SWAC is 0.

2.5 V or more

Less than 2.5 V

Does C4-3 go out after disconnecting

CN26?

NO

YES

Is C4-3 error displayed?

NO

Accelerator potentiometer check

YES

CPU board defect

CN102-2 (52)


N1

Less than 2.5 V

2.5 V or more

Main harness defect

CPU board defect

• C4-4

If C4-2, 3 occurs at the same time, perform troubleshooting for C4-2, 3 first.


Check the POTA value when the

SWAC display is turned from 0 to 1 or from 1 to 0.

Less than 1.4 V

1.4 V or more

Potentiometer adjustment defect

CPU board defect

C7 Direction switch abnormality (STD)

Related Portion

CPU board

CN101-1 (45, DSF)

CN101-2 (46, DSR)

CN101-16 (51, LS–)

J21

CN161

1

2

12

CN120

2

3

1 J1

CN9

5

4

6

Direction switch

1-27


Output when both forward and reverse direction switches are ON.


CN9.


Check the value of DSF, DSR.

Becomes 0.

DSF or DSR display will be 1.

CN101-1 (45)

CN101-2 (46)


N1

OK (Approx. 5 V)

NG (Other than OK)

CPU board defect

Direction switch inspection

Harness short circuit

1-28

C7 Direction switch abnormality (EZ Pedal)

Related Portion

CPU board

CN101-1 (45, DSF)

CN101-2 (46, DSR)

CN101-16 (51, LS–)

J21

CN161

1

2

12

CN120

2

3

1 J1

CN9

5

4

1

Direction switch


Output when both forward and reverse direction switches are ON.


CN9.


Check the value of DSF, DSR.

Becomes 0.

DSF or DSR display will be 1.

CN101-1 (45)

CN101-2 (46)


N1

OK (Approx. 5 V)

NG (Other than OK)

CPU board defect

Direction switch inspection

Harness short circuit

EE-1, 2, 3 Abnormal communication from multi-display

Related Portion

CPU board

CN103-13 (144, SMTDK)

CN103-14 (143, SDTMK)

CN103-15 (142, SDTMA)

CN103-16 (141, SMTDA)

CN162

17

18

14

15

CN124

2

3

9

8

CN1

7

4

8

3

CN103-10 (16, D15V)

CN103-12 (14, GNDD)

13

16

1

7

2

1

CN70-23

CN70-24

CN70-21

CN70-22

Display

CN-14

CN-30


Output upon detection of communication data abnormality from display.

• EE-1

Is F1 error displayed?

NO

Was the battery plug connected when the display is removed?

NO

Does the display turn on upon key switch ON?

YES

• EE-2

YES

YES

NO

See F1 error

Connect the display

Disconnect CN1

CN103-10 (16)


CN103-12 (14)

14 V or more

• Sub harness defect

• Display defect

Less than 14 V

• CPU board defect

• Harness defect


CN103 and CN70.

Check the continuity.

CN103-15 (142) to CN70-21 (142)

CN103-14 (143) to CN70-24 (143)

OK (Approx. 0

Ω)

• Display defect


NG

(Other than 0 Ω)

• Connector connection defect

• Harness defect

• EE-3

• Reset the tuning value.

• If EE-3 is displayed frequently, either the CPU board or the display may be defective.

1-29

1-30

FF D15 overcurrent

Related Portion

CN103-10 (16, D15V)

CN103-12 (14, GNDD)

CN162

13

16

CN124

1

7

J4

CPU board

CN1

2

1

Multi-display board


Output when overcurrent of D15V power source is detected.

Disconnect CN70, connect battery plug, and turn key switch ON.

No error

FF error is indicated.

Disconnect battery plug, disconnect

CN103, and measure the resistance between 10 pin and 12 pin of harness side.

CN103-10 pin (Tester probe )


CN103-12 pin (Tester probe )

Approx. 1 k

Ω or more

Approx.

1 k

Ω or less

CPU board defect

Display defect

Harness defect

H5-1, 2, 3, 4, 5 Lift solenoid abnormality

Related Portion

CN104-3 (3, SOL1+)

CPU board

CN104-5 (5, SOLa1)

CN104-4 (4, SOLb1)

CN163

4

CN164

10

CN163

5

CN122

12

J45

CN75

4

11 8

CN74

4

CN121

5

8

Lift a1 (DOWN) solenoid

Lift b1 (UP) solenoid

1-31


Output when open or short circuit is detected in the lift solenoid line from CPU board to the lift solenoid (raise and/ or lower).

• Error indication (reference)

H5-1 Lift b1 (UP) solenoid open-circuit abnormality

H5-2 Lift b1 (UP) solenoid load short-circuit abnormality

H5-1 Lift a1 (DOWN) solenoid open-circuit abnormality

H5-2 Lift a1 (DOWN) solenoid load short-circuit abnormality

H5-5 Lift solenoid drive circuit MOS short-circuit

• H5-1


Turn key switch ON.

Lift raising operation.

H5-1 error is indicated.

H5-1 error is not indicated.

Check connector connection

ANL : I/O MONITOR3 I/O3-2

Check lift solenoid current (during lift raising operation).

0.1 A or less

0.1 A or more


Replace CN74 with CN75.

(Use SST 20)

CPU board defect

Connect battery plug and turn key switch ON.

Lift raising operation. (note that lift on the vehicle is lowered.)



Harness defect

Lift b1 (UP) solenoid defect

1-32

• H5-2


Turn key switch ON.





Disconnect CN74.


Turn key switch ON.





Disconnect CN104.

CN104-3 (3)

b Continuity check

CN104-4 (4)

No continuity

CPU board defect

Continuity

• H5-3


Turn key switch ON.

Lift lowering operation.




Check lift solenoid current (during lift lowering operation).

0.1 A or less

0.1 A or more



(Use SST 20)


Lift lowering operation. (note that lift on the vehicle is raised.)



Harness defect


Lift b1 (UP) solenoid defect

Harness defect


CPU board defect

Lift a1 (DOWN) solenoid defect

• H5-4


Turn key switch ON.





Disconnect CN75.


Turn key switch ON.





Disconnect CN104.

CN104-3 (3)

b Continuity check

CN104-5 (5)

No continuity

CPU board defect

Continuity

• H5-5


Turn key switch ON.

Lift raising/lowering operation.




Disconnect CN104.


Lift lever at neutral position.

Check the voltage between

CN104-3 (3) and CN104-23 (N2),

CN104-5 (5) and CN104-23 (N2),

CN104-4 (4) and CN104-23 (N2).

10 V or less

CPU board defect

10 V or more


Lift a1 (DOWN) solenoid defect

Harness defect


Harness defect

1-33

1-34

H6-1, 2, 3, 4, 5 Tilt solenoid abnormality

Related Portion

CN104-6 (6, SOL2+)

CN104-7 (7, SOLa2)

CPU board

CN104-8 (8, SOLb2)

CN163

6

CN122

10

7 9

J46

11 6

CN75

3

7

CN74

3

7

Tilt a2 (FRONT) solenoid

Tilt b2 (REAR) solenoid


Output when open or short circuit is detected in the tilt solenoid line from CPU board to the tilt solenoid (forward and/or backward).


H6-1 Tilt a2 (FRONT) solenoid open-circuit abnormality

H6-2 Tilt a2 (FRONT) solenoid load short-circuit abnormality

H6-3 Tilt b2 (REAR) solenoid open-circuit abnormality

H6-4 Tilt b2 (REAR) solenoid load short-circuit abnormality

H6-5 Tilt solenoid drive circuit MOS short-circuit

• H6-1


Turn key switch ON.

Forward tilt operation.





Check tilt solenoid current (during forward tilt operation).

0.1 A or less



(Use SST 20)

0.1 A or more

CPU board defect


Forward tilt operation. (note that mast is tilted backward on the vehicle.)



Harness defect

Tilt a2 (FRONT) solenoid defect

• H6-2


Turn key switch ON.





Disconnect CN75.


Turn key switch ON.





Disconnect CN104.

CN104-6 (6)

b Continuity check

CN104-7 (7)

No continuity

CPU board defect

Continuity

• H6-3


Turn key switch ON.

Backward tilt operation.




Check tilt solenoid current (during backward tilt operation).

0.1 A or less



(Use SST 20)

0.1 A or more


Backward tilt operation. (note that mast is tilted forward on the vehicle.)



Harness defect


Tilt a2 (FRONT) solenoid defect

Harness defect


CPU board defect

Tilt b2 (REAR) solenoid defect

1-35

1-36

• H6-4


Turn key switch ON.

Backward tilt operation.




Disconnect CN74.


Turn key switch ON.





Disconnect CN104.

CN104-6 (6)

b Continuity check

CN104-8 (8)

No continuity

CPU board defect

Continuity

• H6-5


Turn key switch ON.

Forward/backward tilt operation.




Disconnect CN104.


Tilt lever at neutral position.


CN104-6 (6) and CN104-23 (N2),

CN104-7 (7) and CN104-23 (N2),

CN104-8 (8) and CN104-23 (N2).

10 V or less

CPU board defect

10 V or more


Tilt b2 (REAR) solenoid defect

Harness defect


Harness defect

H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality

Related Portion

CN104-11 (9, SOL3+)

CN104-13 (11, SOLb3)

CPU board

CN104-12 (10, SOLa3)

CN164 CN122

12 8

J47

14

13

11

CN121

CN122

7

CN74

2

6

CN75

2

6

Attachment 1 b3 solenoid

Attachment 1 a3 solenoid

1-37


Output when open or short circuit is detected in the attachment 1 solenoid line from the CPU board to the attachment 1 solenoid (raise and/or lower).


H7-1 Attachment 1 a3 solenoid open-circuit abnormality

H7-2 Attachment 1 a3 solenoid load short-circuit abnormality

H7-3 Attachment 1 b3 solenoid open-circuit abnormality

H7-4 Attachment 1 b3 solenoid load short-circuit abnormality

H7-5 Attachment 1 solenoid drive circuit MOS short-circuit

• H7-1


Turn key switch ON.

Attachment 1 raising operation.





Check attachment 1 solenoid current

(during attachment 1 raising operation).

0.1 A or less



(Use SST 20)

0.1 A or more

CPU board defect



(note that the attachment 1 is lowered on the vehicle.)



Harness defect

Attachment 1 a3 solenoid defect

1-38

• H7-2


Turn key switch ON.





Disconnect CN75.


Turn key switch ON.





Disconnect CN104.

CN104-11 (9)

b Continuity check

CN104-12 (10)

No continuity

CPU board defect

Continuity

• H7-3


Turn key switch ON.

Attachment 1 lowering operation.





(during attachment 1 lowering operation).

0.1 A or less



(Use SST 20)

0.1 A or more



(note that the attachment 1 is raised on the vehicle.)



Harness defect



Harness defect


CPU board defect

Attachment 1 b3 solenoid defect

• H7-4


Turn key switch ON.





Disconnect CN74.


Turn key switch ON.





Disconnect CN104.

CN104-11 (9)

b Continuity check

CN104-13 (11)

No continuity

CPU board defect

Continuity

• H7-5


Turn key switch ON.

Attachment 1 raising/lowering operation.




Disconnect CN104.


Attachment 1 lever at neutral position.


CN104-11 (9) and CN104-23 (N2),

CN104-12 (10) and CN104-23 (N2),

CN104-13 (11) and CN104-23 (N2).

10 V or less

CPU board defect

10 V or more



Harness defect


Harness defect

1-39

1-40

H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality

Related Portion

CN104-16 (34, SOL4+)

CN104-17 (35, SOLa4)

CPU board

CN104-18 (36, SOLb4)

CN164 CN122

15 6

J48

16 5

17

CN121

12

CN75

1

5

CN74

1

5

Attachment 2 a4 solenoid

Attachment 2 b4 solenoid


Output when open or short circuit is detected in the attachment 2 solenoid line from the CPU board to the attachment 2 solenoid (forward and/or backward).


H8-1 Attachment 2 a4 solenoid open-circuit abnormality

H8-2 Attachment 2 a4 solenoid load short-circuit abnormality

H8-3 Attachment 2 b4 solenoid open-circuit abnormality

H8-4 Attachment 2 b4 solenoid load short-circuit abnormality

H8-5 Attachment 2 solenoid drive circuit MOS short-circuit

• H8-1


Turn key switch ON.

Attachment 2 forward tilt operation.





(during attachment 2 forward tilt operation).

0.1 A or less



(Use SST 20)

0.1 A or more


CPU board defect



(note that the attachment 2 is tilted backward on the vehicle.)



Harness defect


• H8-2


Turn key switch ON.





Disconnect CN75.


Turn key switch ON.





Disconnect CN104.

CN104-16 (34)

b Continuity check

CN104-17 (35)

No continuity

CPU board defect

Continuity

• H8-3


Turn key switch ON.

Attachment 2 backward tilt operation.





(during attachment 2 backward tilt operation).

0.1 A or less



(Use SST 20)

0.1 A or more



(note that the attachment 2 is tilted forward on the vehicle.)



Harness defect



Harness defect


CPU board defect


1-41

1-42

• H8-4


Turn key switch ON.





Disconnect CN74.


Turn key switch ON.





Disconnect CN104.

CN104-16 (34)

b Continuity check

CN104-18 (36)

No continuity

CPU board defect

Continuity

• H8-5


Turn key switch ON.

Attachment 2 forward/backward operation.




Disconnect CN104.


Attachment 2 lever at neutral position.


CN104-16 (34) and CN104-23 (N2),

CN104-17 (35) and CN104-23 (N2),

CN104-18 (36) and CN104-23 (N2).

10 V or less

CPU board defect

10 V or more



Harness defect


Harness defect

H9-1, 2, 3 Unload valve solenoid abnormality

Related Portion

CPU board

CN104-26 (12, SOLP+)

CN104-27 (13, SOLP–)

CN164

18

19

CN122

2

1

CN76

1

2

Unload valve solenoid

1-43


Output when open or short circuit is detected in the unload valve solenoid line from the CPU board to the unload valve solenoid.


H9-1 Unload valve solenoid open-circuit abnormality

H9-2 Unload valve solenoid load short-circuit abnormality

H9-3 Unload valve solenoid drive circuit MOS short-circuit

• H9-1

ACTIVE TEST : ACT-3 PSOL

Set the unload valve solenoid to ON in the ACTIVE TEST.

(Connect battery plug and turn key switch ON.)





Disconnect CN104.

CN104-26 (12)

b Harness continuity check

CN104-27 (13)

Other than 9.9 ± 1 Ω

(at 25°C)

9.9 ± 1

Ω (at 25°C)

Disconnect CN76.

CN76-1 (12)

b Solenoid resistance check

CN76-2 (13)

Other than 9.9 ± 1

Ω

(at 25°C)

9.9 ± 1

Ω (at 25°C)

Unload valve solenoid defect

CPU board defect

Harness defect

1-44

• H9-2







Disconnect CN76.







Disconnect CN104.

CN104-26 (12)

b Harness continuity check

CN104-27 (13)

No continuity

CPU board defect

Continuity exists

• H9-3







Disconnect CN104.


Voltage check (short circuit in the harness) between

CN104-26 (12) and CN104-23 (N2),

CN104-27 (13) and CN104-23 (N2).

10 V or less

CPU board defect

10 V or more


Unload valve solenoid defect

Harness defect


Harness defect

61-1, 2 Load sensor abnormality

Related Portion

CPU board

CN102-17 (58, SPL+)

CN102-5 (59, SPL)

CN102-22 (51, POT–)

J22

CN162 CN121

7 9

4 3

8 4

J3

CN90

4

3

8

CN91

1

2

3

Load sensor


Output when the voltage of the load sensor is outside the specified range (open or short).

61-1 Load sensor open

61-2 Load sensor short

• 61-1


Disconnect CN90.





• Load sensor defect



Disconnect CN102.


CN102-17 (58)

b Continuity check

CN102-5 (59)

Continuity

CN102-5 (59)

b Continuity check

CN102-22 (51)

Continuity

Main harness defect

No continuity

No continuity

Main harness defect

CPU board defect

1-45

1-46

• 61-2


CN90, connect battery plug, and turn the key switch ON.

61-2 error remains.

Change to 61-1 error.


Disconnect CN102.

CN102-17 (58)

b Continuity check

CN102-5 (59)

Continuity

• Main harness defect

No continuity

CPU board defect


Disconnect CN102.


CN102-5 (59)

b Continuity check

CN102-22 (51)

Continuity No continuity

• Load sensor defect


Main harness defect

62-1, 2 Tilt angle sensor abnormality

Related Portion

CPU board

CN102-16 (57, POTTA+)

CN102-4 (56, POTTA)

CN102-22 (51, POT–)

J22

CN162

6

3

8

CN121

8

2

9

J3

CN8

1

2

Tilt angle sensor

3

1-47


Output when the voltage of the tilt angle sensor is outside the specified range (open or short).

62-1 Tilt angle sensor open

62-2 Tilt angle sensor short

• 62-1


Disconnect CN86.





Tilt angle sensor defect


Disconnect CN102.


CN102-16 (57)

b Continuity check

CN102-4 (56)

Continuity


CN102-4 (56)

b Continuity check

CN102-22 (51)

Continuity

Main harness defect

No continuity

No continuity

Main harness defect

CPU board defect

1-48

• 62-2


CN86, connect battery plug, and turn the key switch ON.

62-2 error remains.

Change to 62-1 error.


Disconnect CN102.

CN102-16 (57)

b Continuity check

CN102-4 (56)

Continuity

Main harness defect

No continuity

CPU board defect


Disconnect CN102.


CN102-4 (56)

b Continuity check

CN102-22 (51)

Continuity No continuity

Tilt angle sensor defect Main harness defect

67-1 Lifting height switch abnormality

Related Portion

CPU board

CN101-20 (91, MH2-1)

CN101-19 (90, MH1)

CN101-16 (51, LS–)

J21

CN161 CN120

16 6

15 7

12 1

J1

CN90

1

CN92

3

Lifting height switch

6 2

2 1

1-49


Output when open or short circuit of the lifting height switch line from the CPU board to the lifting height switch is detected.

ANL : I/O MONITOR 3-11

Check the lifting height switch input value.

Other than MH: 00–

MH: 00–

A


CN90.

ANL : I/O MONITOR 3-11

Check the lifting height switch input value. (with battery plug connected)

Other than MH: 00–

MH: 00–


CN101, and check the continuity.

CN101-20 (91) to CN101-16 (51)

CN101-19 (90) to CN101-16 (51)

CN101-20 (91) to CN101-19 (90)

No continuity

Continuity

Main harness defect


• Lifting height switch defect

CPU board defect

1-50

A

Check the lifting height upon error indicating.

Less than H2000

H2000 or more

Disconnect battery plug and CN90, and check continuity.

CN90-6 (90) to CN90-2 (51)

[OK] Continuity, [NG] No continuity

CN90-1 (91) to CN90-2 (51)

[OK] No continuity, [NG] Continuity

OK

NG


CN101 and CN103, and check the continuity.

• Short between CN90-6 and CN90-2 of main harness side with SST2.

CN101-19 (90)

b Continuity check

CN101-16 (51)

• Short between CN90-1 and CN90-2 of main harness side with SST2.

CN101-20 (91)

b Continuity check

CN101-16 (51)

Continuity

No continuity

CPU board defect

Disconnect battery plug and CN90, and check continuity.

CN90-6 (90) to CN90-2 (51)

[OK] No continuity, [NG] Continuity

CN90-1 (91) to CN90-2 (51)

[OK] Continuity, [NG] No continuity

NG OK


• Lifting height switch defect

Main harness defect

F1-1, 2 Main controller

→multi-display communication abnormality

Related Portion

CPU board

CN103-16 (141, SMTDA)

CN103-13 (144, SMTDK)

CN162

15

CN124

8

17 2

CN1

3

7

CN70-22 (141, SMTDA)

CN70-23 (144, SMTDK)

Multi-display

1-51


Output upon detection of communication data abnormality from CPU board.

NG

CN103, CN124, CN70 and CN1 connection condition check

OK

Correct the defect


CN103 and CN70.

CN103-16 (141)

b Continuity check

CN70-22 (141)

CN103-13 (144)

b Continuity check

CN70-23 (144)

No continuity

Continuity

Harness defect

(Between CN103 and CN70)


• Multi-display defect

Note:

Other error codes, if any, are not indicated because of no communication from the CPU board when F1-1 occurs. F1-1 is kept indicated on the multi-display screen regardless of key switch ON or OFF.

1-52

WHEN NO ERROR CODE IS DISPLAYED

No display on multi-display

Related Portion

CPU board

CN103-10 (16, D15V)

CN103-12 (14, GNDD)

CN162

13

CN124

1

16 7

CN1

2

1

CN70-14 (16, D15V)

CN70-30 (14, GNDD)

Muli-display


• No power supply to multi-display

• Multi-display defect

It is possible to perform traveling and material handling operation.

OK

NG

See page 4-145. (Vehicle does not move.)


CN1, and connect battery plug.

CN1-2 (16)


CN1-1 (14)

NG (0 V)

OK (Approx. 15 V)

Disconnect battery plug, connect CN1, disconnect CN70, and connect battery plug.

CN70-14 (16)


CN70-30 (14)

OK (Approx. 15 V)

NG (0 V)


CN1 and CN103.

1. CN1-2 (16)

b Continuity check

CN103-10 (16)

CN1-1 (14)

b Continuity check

CN103-12 (14)

2. CN1-2 (16)

b Short-circuit check

CN1-1 (14)

OK ( 1. Approx. 0 Ω

2.

∞ Ω)

NG ( 1. ∞ Ω

2. Approx. 0

Ω)

CPU board defect

Multi-display defect

Harness defect

(Between CN1 and CN103)

Harness defect

(Between CN1 and

CN70)

Only traveling disabled (no motor revolution)

Related Portion

CN101-1 (45, DSF)

CN161

1

CN101-2 (46, DSR)

2

CN101-16 (51, LS–)

12

CN120

2

3

1

CPU board

CN102-1 (64, SWAC)

CN102-2 (52, POTA)

CN102-14 (53, POTA+)

CN102-22 (51, POT–)

J1

CN162

1

2

5

8

CN121

16

1

7

4

CN9

5

4

6

J3

YES

Has beep sound been output?

NO


SWAC and POTA value check with accelerator pedal depressing.

Both change.

Both have no change.


DSF and DSR value check with direction switch operation.

Changes

No change

Voltage measures with direction switch

ON and accelerator ON.


N1

Other than OK


N1

OK (All approx. 24 V)

A

Direction switch

CN26

2

3

4

1

Accelerator portentiometer

Accelerator OFF, direction switch OFF, and parking OFF (It returns.)

Accelerator check

Direction switch check

Traveling AC driver defect

1-53

1-54

A

NO

Is there sound from the motor?

YES


Does front wheels rotate when jack up the vehicle to cause the front wheels to float?

Does not rotate

Rotates

Perform troubleshooting for C8

Motor cable and motor check

Brake check

Constant automatic fork leveling

Related Portion

CPU board

CN101-18 (70, SWTK)

CN101-16 (51, LS–)

CN161

4

12

CN122

2

1

CN84

1

2

Knob switch

1-55


Check the valve of automatic fork leveling switch.

OFF (display 0)

ON (display 1) Operate normally

Tilt knob switch OFF.

Automatic fork leveling is remained ON

Use it as it is.

OFF (display 0)


Check the valve of automatic fork leveling switch.

ON (display 1)

CN101-18


CN101-16

Approx. 5 V

• Harness defect

• Switch defect

Lift down the fork and operate the tilt lever to the forward position.

Not leaned forward from leveling position

Leaned forward from leveling position

Perform matching No.1, No.2

Does pump motor stop without a turning steering wheel when direction switch is neutral position and the fork is at leveling position?

Does not stop

Stop

CPU board defect

Tilt cylinder check

Approx. 0 V

CPU board defect

2-1

BODY

Page

SEAT SWITCH ................................................... 2-2

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

2-2

SEAT SWITCH

CN43

Inspection:

Push the seat cushion to check seat switch continuity.

Measuring position : between seat switch CN22-1 and

CN22-2

Standard : When not pushed :

∞ Ω

When pushed : 0

Ω

Note:

If the standard is not satisfied, replace the cushion ASSY.

3-1

APPENDIX

Page

SST LIST ............................................................ 3-2

CONNECTOR DRAWING .................................. 3-3

CONNECTING DIAGRAM................................ 3-13

ELECTRIC WIRING DIAGRAM ....................... 3-14

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

3-2

SST LIST

Illust.

Part number

09230-13130-71

Part name

AC controller diagnosis kit

1

Section

2

{

CONNECTOR DRAWING

CN1

DISPLAY

4

8

3

7

2

6

1

5

1 2

5 6

3

7

4

8

4

5

6

NO

1

2

3

P

14

16

141

143

7

8

144

142

C

W

TAB

J

CN70-30

R CN70-14

V CN70-22

SL CN70-24

O CN70-23

B CN70-21

CN3

HORN SW.

4

5

6

NO

1

2

3

P

14

16

141

143

7

8

144

142

REC

C

W

J

CN124-7

R J4

V CN124-8

SL CN124-3

O CN124-2

B CN124-9

1

2

NO

1

2

P

48

41

TAB

C

-

-

CN4

KEY SW.

J

HO+

HO-

( ):OPT

2

3

4

NO

1

P

41(-)

(41)

43

2

4

1

3

TAB

C J

AM(-)

(AM)

-

CN5

STOP LAMP SW.

IG

2

3

4

NO

1

P

41(-)

(41)

43

NO

1

2

P

48

41

1

2

REC

C

P

GR

J

HORN

J6

1

3

2

4

REC

C

GR(-)

(GR)

( ):OPT

J

CN29-1(-)

(CN29-1)

Y CN29-2

2 1 1 2

NO

1

2

P

101

111

TAB

C

R

SL

CN6

BRAKE SW.

NO

1

2

P

51

65

J

LS

ST

LS

ST

2

TAB

C

R

BR

1

J

LS

B

LS

B

NO

1

2

P

101

111

REC

C

Y

R

J

J9

CN123-1

NO

1

2

P

51

65

1 2

REC

C

B

Y

J

J1

CN120-4

3-3

6

7

8

9

10

11

12

13

14

NO

1

2

3

4

5

CN8

TURN & LIGHT SW.

6 5 4

14 13 12 11 10

3

9

2 1

8 7

P

TAB

C J

115

116

N2

108

109

110

-

-

-

-

-

-

LH

LT

EL

TR

TL

TB

11

12

13

14

8

9

6

7

10

3

4

5

NO

1

2

CN9

DIRECTIONAL SW.

115

116

N2

108

109

110

P

1 2

7 8

3 4 5 6

9 10 11 12 13 14

REC

C J

P

LG

L

SL

G

GR

CN45-3

CN46-3

J8

J14

J13

CN12-1

9 8 7 6 5 4 3 2 1

18 17 16 15 14 13 12 11 10

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18

P

TAB

C

13

14

15

16

10

11

8

9

12

17

18

5

6

3

4

7

NO

1

2 103

120

46

45

51

43

43

-

-

-

-

-

-

-

J

DSBU

DSFO

DSR

DSF

LS-

VBKY

VBKY

7

10

11

8

9

12

13

14

5

6

15

16

17

18

NO

1

2

3

4

NO P

1

2

60

51

P

103

120

46

45

51

43

43

C

CN9 <OPT>

3

6

2

5

1

4

4

5

6

NO

1

2

3

P

TAB

51

120

103

C

-

-

-

46

45

43

-

-

-

DIRECTIONAL PEDAL

J

LS-

DSFO

DSBU

DSR

DSF

VBKY

4

5

6

NO

1

2

3

P

51

120

103

46

45

43

1 2 3

4 5 6

REC

C

B

J

J1

Y

P

CN123-5

CN123-6

G CN120-3

W CN120-2

Y J5

CN11

LIFT SW.

2 1

NO P

1

2

60

51

TAB

C

R

BR

J

LS

L

LS

L

Y

Y

W

B

P

Y

G

1 2

REC

C J

R CN122-12

LG J2

REC

J

CN123-6

CN123-5

CN120-3

CN120-2

J1

J5

J5

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

3-4

CN12

FLASHER RILAY

1

2

NO

1

P

110

2 43

TAB

C

-

-

J

FRY

FRY

CN13

FR COMBI RH

3

6

2

5

1

4

3

4

5

6

NO

1

2

P

N2

104

TAB

C J

W J51

G CN14-4

102 Y CN16-1

108 G-Y CN14-1

N2 L CN14-2

101 R CN96-7

CN14

FR COMBI RH

2 1

4 3

P

TAB

NO

1

2

3

4

108

N2

N2

104

C

-

-

-

-

J

LF-R

LF-R

LC-R

LC-R

1

2

NO

1

P

110

2 43

REC

C

GR

Y

J

CN8-14

J5

3

4

5

6

NO

1

2

P

N2

104

102

108

N2

101

1

4

2

5

REC

C

L

O

G

SL

L

Y

3

6

J

J8

J10

J11

J14

J8

J9

1

3

2

4

REC

NO

1

2

P C J

108 G-Y CN13-4

N2 L CN13-5

3

4

N2

104

W J51

G CN13-2

CN15

PARKING SW.

NO

1

2

P

51

66

2 1

TAB

C

-

-

J

LS

PB

LS

PB

CN16

HEAD LAMP RH

2 1

NO

1

P

102

2 N2

TAB

C

-

-

J

LH-R

LH-R

CN17

FR COMBI LH

5

6

3

4

NO

1

2

P

N2

104

102

109

N2

3 2 1

6 5 4

TAB

C

W

G

J

J51

CN18-4

Y

G-Y

L

CN20-1

CN18-1

CN18-2

NO

1

2

P

51

66

1 2

REC

C

B

J

J1

R CN120-8

1 2

NO

1

P

102

2 N2

REC

C

Y

J

CN13-3

W J51

5

6

3

4

NO

1

2

P

N2

104

102

109

N2

1 2 3

4 5 6

REC

C

L

O

G

G

L

J

J8

J10

J11

J13

J8

CN18

FR COMBI LH

2

4

1

3

NO

1

2

3

4

P

TAB

109

N2

N2

104

C

-

-

-

-

J

LF-L

LF-L

LC-L

LC-L

CN19

STEERING SENSOR

1 2

3 4

REC

NO

1

2

3

4

P

N2

104

C

109 G-Y CN17-4

N2 L CN17-5

W

J

J51

G CN17-2

2 1

6 5 4 3

1

3 4 5

2

6

2

3

4

5

6

NO

1

P

16

51

312

313

314

TAB

-

-

-

C

-

-

J

IG

ESS

SS1

SS2

SSC

CN20

HEAD LAMP LH

2

3

4

5

6

NO

1

P

16

51

312

313

314

REC

B

Y

V

C

R

L

J

J4

J1

CN120-10

CN120-11

CN120-12

2 1

NO

1

P

102

2 N2

TAB

C

-

-

J

LH-L

LH-L

CN21

ATT SW.

1 2

NO

1

P

102

2 N2

REC

C

Y

W

J

CN17-3

J51

NO P

1 63

2 51

2 1

TAB

C

R

BR

J

LS

ATT

LS

ATT

CN22

SEAT SW.

NO P

1 63

2 51

1 2

REC

C

V

LG

J

CN122-9

J2

NO P

1 67

2 51

2 1

TAB

C

-

-

J

LS

D

LS

D

CN23

BACK CHIME

NO P

1 67

2 51

1 2

REC

C

L

B

J

CN161-5

J21

1

2

NO

1

2

P

198

N2

TAB

C

-

-

CN23-2

J

CHI

CHI

SMART ALARM

1

2

NO

1

2

P

103

N2

TAB

C

-

-

J

BZ

BZ

NO

1

2

P

198

N2

1

2

REC

C

GR

L

J

J12

J31

NO

1

2

P

103

N2

1

2

REC

C

O

W

J

J56

J54

CN24

FORWARD CHIME

NO

1

2

P

1

2

TAB

C J

CN26

ACCEL

4 3 2 1

NO

1

2

3

4

P

51

64

52

53

TAB

C

-

-

-

-

J

E2

IDL

VTA

VC

CN27

F4,F5,F6 FUSE

3

6

2

5

1

4

NO

1

2

3

P

P2

P1

4 44

5 41

6

P1

101

TAB

C

-

-

-

-

-

-

J

F6

F5

F4

F6

F5

F4

CN29

KEY SW.

2 1

NO P

1 41

2 43

TAB

C J

GR CN4-1

Y CN4-2

NO

1

P

120

2 N2

1

2

REC

C J

Y CN123-5

L J31

NO

1

2

3

4

P

51

64

52

53

1 2 3 4

REC

C J

W J3

SL CN121-10

GR CN121-1

O CN121-7

1

4

2

5

3

6

NO

1

2

3

4

5

6

P

P2

P1

P1

44

41

101

REC

C J

P CN136-6

W CN136-4

B CN136-3

BR

GR

J30

J29

Y CN123-4

1 2

NO P

1 41

2 43

REC

C

GR

Y

J

J6

J5

CN31

RR COMBI LH

2 1

4 3

1

3

2

4

NO

1

2

P

104

111

3

4

109

N2

TAB

L

L

C

L

L

J

TL

STP

TRN

E

NO

1

2

P

104

111

3

4

109

N2

C

G

SL

G-Y

W

REC

J

J55

J53

CN38-6

J54

CN32

TIRE ANGLE SENSOR

3 2 1

1 2 3

NO

1

P

51

2 317

3 316

TAB

C

-

-

-

J

GND

OUT

VCC

NO

1

P

51

C

W

2 317 Y

3 316 SL

REC

J

J22

CN163-13

CN163-14

CN34

RR COMBI RH

2

4

6

1

3

5

NO

1

P

104

2

3

4

111

103

5

6

108

N2

TAB

C

R

R

R

R

R

J

TL

STP

B/U

TRN

E

CN36

RR WORKING LAMP

1 2

3 4

5 6

2

3

4

NO

1

P

104

111

5

6

108

N2

REC

C

G

SL

O

J

J55

J53

J56

BR CN38-5

W J54

2 1

NO

1

P

107

2 N2

TAB

C

-

-

J

LW

LW

1 2

NO

1

P

107

2 N2

REC

C

V

W

J

CN38-7

J54

CN38

RR UPR

3 2 1

8 7 6 5 4

4

5

6

7

8

NO

1

2

3

P

43

111

198

104

108

109

107

N2

TAB

C

Y

J

J39

R CN123-1

GR CN165-5

O CN123-3

SL CN123-7

G CN123-8

B CN123-2

L J31

1

4

2

5 6 7

3

8

NO

1

2

3

P

43

111

198

4 104

5 108

6 109

7 107

8 N2

REC

C

L

SL

O

G

J

FB

J53

J56

J55

BR CN34-5

G-Y CN31-3

V

W

CN36-1

J54

CN41 <OPT>

MINI LEVER

8

9

10

5

6

7

NO P

1

2

3

4

20

21

28

22

23

29

24

25

30

51

5

10

4

9

3 2 1

8 7 6

TAB

G

O

LG

C

R

B

Y

V

L

GR

W

J

CN77-2

CN77-3

CN77-1

CN78-2

CN78-3

CN78-1

CN79-2

CN79-3

CN79-1

J49

8

9

6

7

10

3

4

5

NO P

1

2

20

21

28

22

23

29

24

25

30

51

1

6

2

7

3

8

4

9

5

10

REC

C J

R CN161-19

B CN164-2

G CN164-6

O CN161-17

LG CN161-13

Y

V

CN164-7

CN161-7

L CN164-3

GR CN164-8

W CN164-1

3-5

12

13

14

15

8

9

10

11

16

17

18

6

7

4

5

2

3

0

1

3-6

CN42 <OPT>

MINI LEVER

NO

1

2

3

4

5

6

7

8

P

26

27

31

70

67

51

4

8

3

7

2

6

1

5

TAB

C

V

SL

LG

J

CN80-2

CN80-3

CN80-1

BR

L

B

CN85-2

CN43-1

CN43-2

CN43 <OPT>

SEAT SW

NO

1

2

3

4

5

6

7

8

P

26

27

31

70

67

51

1 2 3

5 6 7

4

8

REC

C

V

J

CN164-4

SL CN164-5

LG CN164-9

BR CN161-14

L

B

CN161-5

J21

2 1

NO

1

2

TAB

P

67

51

C

-

-

CN45

HEAD LAMP RELAY

J

SOL

P

SOL

P

NO

1

2

P

67

51

1 2

C

L

B

REC

J

CN42-7

CN42-8

NO

1

2

P

101

101

3

4

115

102

2

4

1

3

-

-

C

-

-

TAB

J

COIL+

SW+

COIL-

SW-

CN46

TAIL LAMP RELAY

NO

1

2

3

4

P

101

101

116

104

CN50

FAN(EX)

2

4

1

3

-

-

C

-

-

TAB

J

COIL+

SW+

COIL-

SW-

NO

1

2

P

101

101

3

4

115

102

C

Y

Y

P

G

1

3

2

4

REC

J

J9

J9

CN8-8

J11

NO

1

2

3

4

P

101

101

116

104

C

Y

Y

LG

O

1

3

2

4

REC

J

J9

J9

CN8-9

J10

2 1

NO

1

2

P

44

39

TAB

C

R

B

J

FAN

EX

(+)

FAN

EX

(-)

1 2

NO

1

2

P

44

39

REC

C

BR

B

J

J30

J23

CN52

DM TEMP RH

NO

1

2

P

82

88

2 1

TAB

C

B

R

J

TD2-

TD2+

NO

1

2

P

82

88

1 2

REC

C

P

R

J

J28

CN109-13

CN53

DM SPEED RH

1

3

2

4

NO

1

2

3

4

P

79

80

82

81

TAB

C

B

L

R

W

J

SSD2+

SSD21

SSD2-

SSD22

CN55

PM TEMP

2 1

NO

1

2

P

86

89

TAB

C

B

R

J

TP-

TP+

CN56

PM SPEED

1 2

3 4

NO

1

2

3

4

P

83

84

86

85

TAB

C

R

W

B

L

J

SSP+

SSP1

SSP-

SSP2

CN58

DM TEMP LH

NO

1

2

P

78

87

2 1

TAB

C

B

R

J

TD1-

TD1+

CN59

DM SPEED LH

1 2

3 4

NO

1

2

3

4

P

75

76

78

77

TAB

C

B

L

R

W

J

SSD1+

SSD11

SSD1-

SSD12

1 2

3 4

NO

1

2

3

4

P

79

80

82

81

REC

C

O

BR

J

CN109-9

CN109-11

P

SL

J28

CN109-12

1 2

NO

1

2

P

86

89

REC

C

P

BR

J

J26

CN111-13

1

3

2

4

NO

1

2

3

4

P

83

84

86

85

C

LG

W

P

R

REC

J

CN111-9

CN111-11

J26

CN111-12

NO

1

2

P

78

87

1 2

REC

C

P

W

J

J27

CN110-13

1

3

2

4

NO

1

2

3

4

P

75

76

78

77

REC

C

O

BR

J

CN110-9

CN110-11

P

SL

J27

CN110-12

CN70

DISPLAY

REC

1 2

15

TAB

16

3

17

4 5

18

6 7 8 9 10 11

19 20 21 22 23 24 25 26 27

12 13

28 29

14

30

14

30

13 12

29 28

11 10 9 8 7 6 5

27 26 25 24 23 22 21 20 19

4

18

3

17

2

16

1

15

-

C

TAB

J

48V

NO P

1 43

2

5

6

3

4 137

138

7 180

8 124

9 125

10 126

11

12

127

182

13 181

14

15

16

N2

16

17

18

19

20

21

22

23

139

140

142

24

25

26

27

141

144

143

123

122

121

28

29

183

184

30 14

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

SL/L+

SL/L-

AVD(+)

CHG LED1

CHG LED2

CHG LED3

CHG LED4

AVD2

AVD1

D15V

N1

STT

SLL

SDTMA

SMTDA

SMTDK

SDTMK

CHG SW3

CHG SW2

CHG SW1

AVD3

AVD4

GNDD

9

10

7

8

11

12

13

14

15

3

4

5

6

NO

1

2

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

P

16

142

141

144

143

14

REC

C

R

B

V

O

SL

W

J

CN1-2

CN1-8

CN1-3

CN1-7

CN1-4

CN1-1

CN74 <OPT>

C/V SOL.(UPR)

6

7

8

NO P

1 34

2

3

4

5

9

6

3

36

11

8

4

4

8

3 2 1

7 6 5

TAB

-

-

-

-

-

-

-

C

-

J

SOL

ATa4

(+)

SOL

ATa3

(+)

SOL

Ta2

(+)

SOL

Lb1

(+)

SOL

ATb4

(-)

SOL

ATb3

(-)

SOL

Tb2

(-)

SOL

Lb1

(-)

CN75 <OPT>

C/V SOL.(LWR)

6

7

8

NO P

1 34

2

3

4

5

3

36

9

6

11

8

4

1

5

2

6

3

7

4

8

REC

C

G

L

LG

J

J48

J47

J46

R J45

W CN121-12

GR CN121-11

P CN121-6

B CN121-5

5

6

7

8

NO P

1

2

3

4

34

9

6

3

35

10

7

5

4

8

3 2 1

7 6 5

TAB

-

-

-

-

C

-

-

-

-

J

SOL

ATa4

(+)

SOL

ATa3

(+)

SOL

Ta2

(+)

SOL

Lb1

(+)

SOL

ATa4

(-)

SOL

ATa3

(-)

SOL

Ta2

(-)

SOL

La1

(-)

5

6

7

8

NO P

1

2

3

4

34

9

6

3

35

10

7

5

1

5

2

6

3

7

4

8

REC

C

G

L

J

J48

J47

LG

R

J46

J45

P CN122-5

BR CN122-7

V CN122-9

O CN122-11

CN76 <OPT>

C/V PRESSURE SOL.

NO

1

2

P

12

13

2 1

TAB

C

-

-

J

SOL

P

SOL

P

CN77 <OPT>

LIFT LEVER

NO

1

2

P

12

13

1 2

REC

C

BR

LG

J

CN122-2

CN122-1

4 3 2 1

NO

1

2

3

4

P

28

20

21

51

TAB

C

-

-

-

-

J

VC

VTA1

VTA2

E2

CN78 <OPT>

TILT LEVER

4 3 2 1

NO

1

2

3

4

P

29

22

23

51

TAB

-

-

-

C

-

J

VC

VTA1

VTA2

E2

1 2 3 4

NO

1

2

3

4

P

28

20

21

51

REC

C

G

R

B

W

J

CN41-3

CN41-1

CN41-2

J49

1 2 3 4

NO

1

2

3

4

P

29

22

23

51

REC

C

Y

O

LG

W

J

CN41-6

CN41-4

CN41-5

J49

CN79 <OPT>

ATT1 LEVER

4 3 2 1

NO

1

2

3

4

P

30

24

25

51

TAB

-

-

-

C

-

J

VC

VTA1

VTA2

E2

CN80 <OPT>

ATT2 LEVER

1 2 3 4

NO

1

2

3

4

P

30

24

25

51

REC

C

GR

V

L

W

J

CN41-9

CN41-7

CN41-8

J49

4 3 2 1

NO

1

2

3

4

P

31

26

27

51

TAB

C

-

-

-

-

J

VC

VTA1

VTA2

E2

CN84

TILT KNOB SW.

2 1

1 2 3 4

NO

1

2

3

4

P

31

26

27

51

REC

C

LG

J

CN42-3

V

SL

W

CN42-1

CN42-2

J49

1 2

NO

1

2

P

70

51

TAB

C

-

-

J

SOLD(+)

SOLD(-)

NO

1

2

P

70

51

REC

C

BR

B

J

CN122-2

J1

CN85 <OPT>

TILT KNOB SW.

2 1

NO

1

2

P

51

70

TAB

C

-

-

J

SWTK(-)

SWTK(+)

1 2

NO

1

2

P

51

70

REC

C

W

BR

J

J49

CN42-5

3-7

3-8

CN86

TILT SENSOR

3 2 1

NO

1

P

57

2 56

3 51

TAB

C

-

-

-

J

VRAT

VRAT

VRAT

CN87

TILT SW.

2

4

1

3

NO

1

2

3

4

P

61

51

62

51

CN88

LIFT SOL.

-

-

-

C

-

TAB

J

LSTF

LS-

LSTR

LS-

2 1

NO P

1 3

2 4

TAB

C

-

-

J

SOL

L

+

SOL

L

-

CN89

TILT SOL.

2 1

NO

1

2

P

6

7

TAB

C

-

-

J

SOL

T

+

SOL

T

-

CN90

MAST HARNESS

4 3 2 1

8 7 6 5

NO

1

2

3

4

5

6

7

8

P

91

51

59

58

90

51

TAB

C

B

R

Y

BR

J

CN92-3

CN92-1

CN91-2

CN91-1

O

R

CN92-2

CN91-3

CN91

PRESSURE SENSOR

1

3

2

NO

1

2

3

P

58

59

51

TAB

C

-

-

-

J

SP

L

SP

L

SP

L

1 2 3

NO

1

P

57

2 56

3 51

REC

C

L

J

CN121-8

G CN121-2

W J3

1

3

2

4

NO

1

2

3

4

P

61

51

62

51

REC

C

O

J

CN122-11

LG J2

LG CN122-10

LG J2

1 2

NO P

1 3

2 4

REC

C J

P CN163-4

LG CN163-5

1 2

NO

1

2

P

6

7

REC

C J

G CN163-6

B CN163-7

1

5

2

6

3

7

4

8

NO

1

2

3

4

5

6 90

7

8 51

P

91

51

59

58

REC

C

GR

B

Y

BR

J

CN120-6

J1

CN121-3

CN121-9

O

W

CN120-7

J3

NO

1

2

3

P

58

59

51

1

2

3

REC

C

BR

Y

R

J

CN90-4

CN90-3

CN90-8

CN92

HEIGHT SW.

3 2 1 1 2 3

NO

1

2

3

P

51

90

91

TAB

C

R

O

B

J

CN90-2

CN90-6

CN90-1

CN98

STEERING SOL.

2 1

NO

1

2

P

TAB

C J

329 B CN122-4

330 GR CN122-3

CN96 <OPT>

CMP LAMP SW

NO

1

2

3

P

51

90

91

REC

-

-

C

-

J

SWMH1

SWMH1

SWMH1

1 2

NO

1

2

P

329

330

REC

C

-

-

J

SOL

ST

SOL

ST

1

NO

1

P

117

2

3

4

5

6

7 101

8

7

TAB

C

-

-

J

STPOT-

SPL

CN109

DRIVE CONT.RH

8

9

10

11

12

13

6

7

4

5

NO

1

2

3

P

82

145

146

147

42

79

82

80

81

88

6

13

5

12

4

11 10

3

9

2

8

1

7

-

-

-

-

-

-

-

-

-

-

-

-

C

-

TAB

J

CUDID0

CUDID1

CANH

CANL

CANTRD

CANGND

KEYSTART

CUDON

SSD2+

SSD2-,TD2-

SSD21

SSD22

TD2+

NO

1

P

117

2

3

4

5

6

7 101

8

1

7

C

SL

REC

J

LCMP

R CN13-6

10

11

12

13

8

9

6

7

NO P

1 82

2

3

4

5

145

146

147

42

79

82

80

81

88

1 2 3 4 5 6

7 8 9 10 11 12 13

REC

C

P

J

J28

B

V

G

L

O

P

BR

SL

R

J64

J65

J66

J25

CN53-1

J28

CN53-2

CN53-4

CN52-2

CN110

DRIVE CONT.LH

6

7

8

9

10

11

12

13

NO

1

4

5

2

3

P

145

146

147

42

75

78

76

77

87

6 5 4 3 2 1

13 12 11 10 9 8 7

-

-

C

-

-

-

-

-

-

-

-

-

-

-

TAB

J

CUDID0

CUDID1

CANH

CANL

CANTRD

CANGND

KEYSTART

CUDON

SSD1+

SSD1-,TD1-

SSD11

SSD12

TD1+

11

12

13

6

7

4

5

8

9

10

NO

1

2

3

P

145

146

147

42

75

78

76

77

87

1

7

2

8

3

9 10

4

11

5 6

12 13

REC

C

B

V

G

L

O

P

BR

SL

W

J

J64

J65

J66

J25

CN59-1

J27

CN59-2

CN59-4

CN58-2

CN111

PUMP CONT.

7

10

11

8

9

12

13

4

5

6

NO

1

2

3

P

86

145

146

147

42

83

86

84

85

89

6

13

5

12

4

11 10

3

9

2

8

1

7

-

-

-

-

-

-

-

-

-

-

-

C

-

-

TAB

J

CUPID0

CUPID1

CANH

CANL

CANTRD

CANGND

KEYSTART

CUPON

SSP+

SSP-,TP-

SSP1

SSP2

TP+

CN112

RESISTOR

3 2 1

NO

1

P

145

2

3

146

147

TAB

C

B

V

G

J

J64

J65

J66

CN113

FAN(EX)

8

9

10

11

12

13

5

6

7

NO P

1

2

3

4

86

145

146

147

42

83

86

84

85

89

1 2 3 4 5 6

7 8 9 10 11 12 13

REC

C

G

L

LG

P

W

R

BR

P

B

V

J

J26

J64

J65

J66

J25

CN56-1

J26

CN56-2

CN56-4

CN55-2

1 2 3

NO

1

P

145

2

3

146

REC

C

-

-

J

R

R

2 1

NO

1

2

P

44

39

TAB

C

R

B

J

FAN

EX

(+)

FAN

EX

(-)

CN114

FAN(EX)

1 2

NO

1

2

P

44

39

REC

C

BR

B

J

J30

J23

2 1

NO

1

2

P

44

39

TAB

C

R

B

J

FAN

EX

(+)

FAN

EX

(-)

CN126

RESISTOR

NO

1

2

3

P

55

P2

3

1

2

TAB

C

W

W

J

CPR

P2

1 2

NO

1

2

P

44

39

REC

C

BR

B

J

J30

J23

NO

1

2

3

P

55

P2

1

2 3

REC

C

L

G

J

CN163-8

CN136-5

CN120

JOINT

4 3 2 1

8

12

7 6

11 10

5

9

9

10

7

8

11

12

4

5

6

NO

1

2

3

91

90

66

312

313

314

P

51

45

46

65

TAB

C

B

W

G

Y

J

J21

CN161-1

CN161-2

CN161-3

Y

V

L

GR

O

R

CN161-16

CN161-15

CN161-4

CN161-9

CN161-11

CN161-8

7

8

9

10

4

5

6

11

12

NO

1

2

3

91

90

66

312

313

314

P

51

45

46

65

GR

O

R

Y

V

L

C

B

W

G

Y

1 2 3 4

5 6 7 8

9 10 11 12

REC

J

J1

CN9-5

CN9-4

CN6-2

CN90-1

CN90-6

CN15-2

CN19-3

CN19-4

CN19-5

CN121

JOINT

6

12

5

11

4

10

3

9

2

8

1

7

( ):OPT

TAB

NO

1

P

52

C

GR

J

CN162-2

7

8

9

2

3

4

5

6

56

59

51

(4)

(8)

53

57

58

G

Y

W

O

L

BR

CN162-3

CN162-4

J22

(B) (CN163-5)

(P) (CN164-11)

CN162-5

CN162-6

CN162-7

10

11

12

64 SL CN162-1

(11) (GR) (CN164-14)

(36) (W) (CN164-17)

1

7

2 3 4 5 6

8 9 10 11 12

REC

( ):OPT

10

11

12

NO

1

2

3

4

5

6

7

8

9

P

52

56

59

51

(4)

(8)

C

GR

G

Y

W

(B)

(P)

J

CN26-3

CN86-2

CN90-3

J3

(CN74-8)

(CN74-7)

53

57

58

64

O

L

BR

SL

CN26-4

CN86-1

CN90-4

CN26-2

(11) (GR) (CN74-6)

(36) (W) (CN74-5)

CN122

JOINT

4

8

3 2 1

7 6 5

12 11 10 9

( ):OPT

8

9

6

7

10

11

12

3

4

5

NO

1

2

P

51(13)

70(12)

330

329

(35)

(34)

(10)

(9)

63(7)

62(6)

61(5)

60(3)

TAB

C J

LG J2(CN76-2)

BR CN84-1(CN76-1)

GR

B

(P)

CN98-2

CN98-1

(CN75-5)

(G)

(BR)

(J48)

(CN75-6)

(L) (J47)

V CN21-1(CN75-7)

LG CN87-3(J46)

O CN87-1(CN75-8)

R CN11-1(J45)

1 2 3

5 6 7

4

8

9 10 11 12

8

9

6

7

10

11

12

3

4

5

NO

1

2

P

51(13)

70(12)

330

329

(35)

(34)

(10)

(9)

63(7)

62(6)

61(5)

60(3)

REC

( ):OPT

(G)

(BR)

(L)

V

LG

O

R

C

LG

BR

GR

B

(P)

J

J21(CN164-19)

CN161-14(CN164-18)

CN161-20

CN161-18

(CN164-16)

(CN164-15)

(CN164-13)

(CN164-12)

CN161-7(CN163-7)

CN161-13(CN163-6)

CN161-17(CN164-10)

CN161-19(CN163-4)

3-9

3-10

CN123

JOINT

4 3

8 7

2

6

1

5

( ):OPT

TAB

3

4

5

6

7

NO

1

2

8

P

111

107

104

101

C

R

B

O

Y

J

CN5-2

SWR

J10

J9

120 Y CN9-3(CN9-2)

103 P

108 SL

CN9-2(CN9-3)

J14

109 G J13

CN124

JOINT

6 5 4 3 2

12 11 10 9 8

1

7

6

7

8

4

5

9

10

11

12

1

2

3

NO P

16

144

143

43

41

N2

14

141

142

GR

L

W

V

B

C

R

O

SL

TAB

J

J4

CN1-7

CN1-4

Y

CN136

CONTACTOR

J6

J8

CN1-1

CN1-3

CN1-8

J5

NO

1

2

3

4

5

6

P

2

1

P1

P1

P2

P2

3 2 1

6 5 4

TAB

C J

R CN163-11

V CN163-10

B CN27-3

W CN27-2

G

P

CN126-3

CN27-1

1

5

2

6

3

7

4

8

5

6

7

8

NO P

1

2

111

107

3

4

104

101

120

103

108

109

REC

O

Y

Y

P

SL

G

C

R

B

J

CN38-2

CN38-7

CN38-4

CN27-6

CN24-1

J32

CN38-5

CN38-6

1

7

2 3

8 9

4

10

5

11

6

12

6

7

8

4

5

9

10

11

12

1

2

3

NO P

16

144

143

43

41

N2

14

141

142

REC

C

R

O

SL

J

CN162-13

CN162-17

CN162-18

GR

L

W

V

B

J29

J31

CN162-16

CN162-15

CN162-14

Y J39

NO

1

2

3

4

5

6

P

2

1

P1

P1

P2

P2

1 2 3

4 5 6

REC

-

-

-

-

-

C

-

J

MB-

MB+

P1 TERM

P1 TERM

P2 TERM

P2 TERM

CN162

6

7

8

4

5

9

10

11

12

13

14

15

16

17

18

NO

1

2

3

145

146

147

199

16

142

141

14

144

143

P

64

52

56

59

53

57

58

51

8 7 6 5 4 3 2 1

18 17 16 15 14 13 12 11 10 9

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

C

-

TAB

J

SWAC

POTA

POTTA

SPL

POTA+

POTTA+

SPL+

POT-

CANH

CANL

CANGND

OPT0

D15V

SDTMA

SMTDA

GNDD

SMTDK

SDTMK

CN163

MAIN CONT.

MAIN CONT.

( ):OPT

NO

1

2

3

4

5

6

7

8

9 44

10 1

11 2

3

4

6

7

55

P

43

41

18

12 N2

13 317

14 316

-

-

-

-

-

-

-

-

-

-

C

-

-

-

-

6 5

14 13

4

12 11 10

3 2

9 8

1

7

TAB

J

VBKY

VBBT

B48V

SOLL+(SOL1+)

SOLL-(SOLb1)

SOLT+(SOL2+)

SOLT-(SOLa2)

CPR

VBMB

MB+

MB-

N2

POTH

POTH+

13

14

15

16

17

18

6

7

8

4

5

9

10

11

NO

1

2

3

145

146

147

199

16

142

141

14

144

143

P

64

52

56

59

53

57

58

51

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

REC

C

SL

GR

G

Y

O

L

BR

W

B

V

G

BR

R

B

V

W

O

SL

J

CN121-10

CN121-1

CN121-2

CN121-3

CN121-7

CN121-8

CN121-9

J22

J64

J65

J66

CN165-6

CN124-1

CN124-9

CN124-8

CN124-7

CN124-2

CN124-3

1 2 3 4

7 8 9 10 11 12

5 6

13 14

7

8

9

10

11

12

13

14

4

5

6

NO

1

2

3

7

55

44

1

2

N2

317

316

P

43

41

18

3

4

6

REC

C

Y

GR

O

P(R)

LG(B)

G(LG)

B(V)

L

BR

V

R

W

Y

SL

( ):OPT

J

J39

J29

J29

CN88-1(CN122-12)

CN88-2(CN121-5)

CN89-1(CN122-10)

CN89-2(CN122-9)

CN126-2

J30

CN136-2

CN136-1

N2 TERM

CN32-2

CN32-3

CN161

MAIN CONT.

( ):OPT

8

9

10

11

12

13

14

5

6

7

3

4

NO

1

2

P

45

46

65

66

67

39

63(24)

314

312

42

313

51

62(23)

70

15

16

17

90

91

61(22)

18

19

20

329

60(20)

330

9

20

8

19

7

18

6

17 16 15

5

14

4

13

3

12

2

11

1

10

C

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

TAB

J

DSF

DSR

LSB

LSPB

LSD

FAN-

LSAT1(POTAT11)

STSC

STS1

KEYSTART

STS2

LS-(POT-)

LSTR(POTT2)

SWTK

MH1

MH2-1

LSTF(POTT1)

SOLST+

LSL(POTL1)

SOLST-

8

9

10

11

12

13

14

5

6

7

3

4

NO

1

2

P

45

46

65

66

67

39

63(24)

314

312

42

313

51

62(23)

70

15

16

17

90

91

61(22)

18

19

20

329

60(20)

330

1

10

2

11

3

12

4

13

5

14 15 16

6

17

7

18

8

19

9

20

REC

( ):OPT

L

B

V

Y

R

L

V

B

L

Y

LG

BR

C

W

G

J

CN120-2

CN120-3

CN120-4

CN120-8

CN22-1(CN42-7)

J23

CN122-9(CN41-7)

CN120-12

CN120-10

J25

CN120-11

J21

CN122-10(CN41-5)

CN122-2(CN42-5)

O

GR

CN120-7

CN120-6

O CN122-11(CN41-4)

B

R

GR

CN122-4

CN122-12(CN41-1)

CN122-3

CN164 <OPT>

MAIN CONT.

27

28

29

30

31

P

51

21

25

26

10

11

34

35

36

5

8

9

12

13

5

6

7

3

4

10

11

12

8

9

NO

1

2

13

14

15

16

17

18

19

20

9 8 7 6

20 19

5 4 3 2 1

18 17 16 15 14 13 12 11 10

-

-

-

-

-

-

-

-

-

-

-

-

-

-

C

TAB

SOLa1

SOLb2

SOL3+

SOLa3

SOLb3

SOL4+

SOLa4

SOLb4

SOLP+

SOLP-

J

POT-

POTL2

POTAT12

POTAT21

POTAT22

POTL+

POTT+

POTAT1+

POTAT2+

1 2 3 4

10

5 6 7 8 9

11 12 13 14 15 16 17 18 19 20

27

28

29

30

31

P

51

21

25

26

10

11

34

35

36

12

13

5

8

9

5

6

7

3

4

10

11

12

8

9

NO

1

2

13

14

15

16

17

18

19

20

REC

O

P

L

SL

G

Y

GR

LG

L

V

C

W

B

J

CN41-10

CN41-2

CN41-8

CN42-1

CN42-2

CN41-3

CN41-6

CN41-9

CN42-3

CN122-11

CN121-6

CN122-8

BR

GR

G

P

W

CN122-7

CN121-11

CN122-6

CN122-5

CN121-12

BR CN122-2

LG CN122-1

CN165

EXCEPT

EZ PEDAL

BACK RELAY

3 2 1

6 5 4

5

6

3

4

NO

1

2

P

103

103

TAB

C J

G CN165-5

G CN165-4

1

4

2

5

3

6

REC

5

6

3

4

NO

1

2

P

16

N1

43

103

C

R

L

Y

O

J

J70

J11

J19

CN9-3

198 GR CN38-3

199 BR CN161-10

CN165

EZ PEDAL

BACK RELAY

3

6

2

5

1

4

4

5

6

NO

1

2

3

198

199

P

16

N1

43

TAB

C

W

B

R

W

W

J

IN+

GND

OUT+

OUT-

IN-

1 2 3

4 5 6

4

5

6

NO

1

2

3

P

16

N1

43

103

198

199

O

GR

BR

L

Y

C

R

REC

J

J70

J11

J19

CN9-3

CN38-3

CN161-10

3-11

3-12

JOINT

( ):OPT

CN6-1

CN84-2

J1

CN19-2

CN9-6(CN9-1)

CN120-1

CN90-2

CN15-1

(51,B)

CN123-3

J10

CN46-4

(104,O)

CN87-4

CN13-3

CN11-2

CN87-2

J2

CN21-2

CN122-1

(51,LG)

CN165-2

J11

CN17-3

(102,G)

CN121-4

J3

CN90-8

CN8-13

J13

CN17-2

CN13-2

CN45-4

CN111-2

CN55-1

J26

CN111-10

(86,P)

CN58-1

J27

CN56-3

CN59-3

CN17-4

CN109-1

CN110-10

(78,P)

CN52-1

J28 CN53-3

CN86-3

CN123-8

CN26-1

(51,W)

(109,G)

CN109-10

(82,P)

CN75-4

J45

CN122-12

(3,R)

CN75-3

J46

CN122-10

(6,LG)

CN75-2

J47

CN122-8

(9,L)

CN74-4

CN74-3

CN74-2

CN38-4

J55

CN34-1

(104,G)

CN31-1

CN162-9

J64

CN110-3

CN109-3

CN111-3

CN112-1

(145,B)

CN162-10

J65

CN110-4

CN109-4

CN111-4

CN112-2

(146,V)

CN1-2

J4

CN124-1

(16,R)

CN19-1

CN8-12

J14

CN123-7

(108,SL)

CN13-4

CN163-3

CN27-5

J29

CN124-5

(41,GR)

CN163-2

CN75-1

J48

CN122-6

(34,G)

CN74-1

CN162-11

J66

CN110-6

CN109-6

CN111-6

CN112-3

(147,G)

CN9-7(CN9-6)

CN12-2

J5

CN29-2 CN124-12

CN9-8

(43,Y)

CN122-1

CN22-2(CN42-8)

J21 CN161-12

CN114-1

CN50-1

CN27-4

J30

CN120-1

CN163-9

CN113-1

CN85-1

CN77-4

J49

CN41-10

CN78-4

CN79-4

CN80-4

(51,B)

(44,BR)

(51,W)

CN3-2

CN32-1

CN16-2,CN20-2

J6

CN124-5

CN29-1

J22

CN121-4

CN124-6

CN23-2

J31

CN24-2 CN38-8

N2 TERMINAL

(41,GR)

CN162-8

(51,W)

(N2,L)

J51

CN13-1,CN17-1

CN14-3,CN18-3

(N2,W)

CN38-3

J70

CN165-5

(198,GR)

CN23-1

CN13-1

CN17-5

CN13-5

CN8-10

J8 CN17-1

H

CN124-6

CN50-2

CN161-6

J23

CN114-2

CN23-1

J32 CN123-6

CN31-2

J53

CN38-2

(N2,L)

CN5-1

CN45-1

CN13-6

J9

CN46-2

SWR

CN123-4

CN45-2

CN46-1

(101,Y)

CN113-2

(39,B)

CN38-3

(103,P)

CN34-2

(111,SL)

CN111-7

J25

CN161-10

CN165-3

CN109-7

CN110-7

(42,L)

CN163-1

J39

CN124-12

(43,Y)

FB

CN38-1

CN36-2

CN31-4

J54

CN34-6

(N2,W)

CN23-2-2

CN38-8

CN38

-RR L

F

CN34

-R

-R

ST

T

L

L

-R

BU

L

REC

TAB

-L

-L

ST

T

L

L

CN31

REC

TAB

LF-LL

CN114

EX

FAN

CN32

REC

TAB

VRAH

CN113

EX

FAN

CN165

ONLY EZ PEDAL

REC

TAB

(R)

CN23

REC

TAB

RELAY

BACK

CHI

REC

(F)

CN24

CN23-2

REC

TAB

BZ

FB

LW

REC

TAB

CN36

REC

TAB

CN42

REC

TAB

CN41

CN22

REC

TAB

LS

D

CN136

REC

TAB

P1

F6

F5

F4

P3

PANEL

CONTACTOR

REC

TAB

CN27

CN96

TAB

REC

SW

CMP

+

(N1,L)

-

(117,SL)

CN126

REC

TAB

L

CMP

MAIN CONTROL

<COMPARTMENT LAMP OPT>

-LEVER OPT)

(EXCEPT MINI

<STD>

BATT

CN85

REC

TAB

CN43

REC

TAB

LS

D

(4)

CN80

REC

TAB

LEVER

ATT2

TK

SW

<MINI-LEVER OPT>

LEVER

ATT1

(3)

CN79

REC

TAB

(2)

CN78

REC

TAB

(1)

CN77

REC

TAB

LEVER

TILT

LEVER

LIFT

U

+

V

W

-

CN56

CN55

PANEL

CN161

CN162

CN163

CN164

<MINI-LEVER OPT>

W

-

V

U

+

CN109

REC

TAB

UNIT RH

U

V

+

-

W

CN110

REC

TAB

UNIT LH

N2 TERMINAL

DRIVE CONTROL DRIVE CONTROL

CN111

REC

TAB

CN112

REC

TAB

R

CN50

EX

FAN

PUMP CONTROL

LH-R

CN16

REC

TAB

CN13

REC

TAB

REC

TAB

CN14

LC-R

LF-R

UNIT

SSP

P

STM

P

AM

V

U

W

TAB

REC

CN124

TAB

REC

CN123

TAB

REC

CN122

REC

TAB

CN121

REC

TAB

CN120

CN89

CN88

CN75

SOL

LD

SOL

TF

SOL

AT1U

SOL

AT2U

SOL

CN76

CN59

CN58

D

STM

SSD

U

V

W

D

LH

AM

CN53

CN52

D

STM

SSD

U

V

W

D

RH

AM

CONTROL PEDAL OPT>

REC

TAB

DISPLAY

CN70

CN9

REC

TAB

REC

TAB

VRAT

CN86

TILT

CN26

REC

TAB

VRAD

REC

TAB

CN1

ACCEL

SW

TK

<DIRECTIONAL

CN74

H

(48,P)CN3-1

(N2,L)J8

CN84

REC

TAB

CN123-2

(107,B)

SWR

REC

TAB

R

BR

ATT

NO

NC

COM

LS

CN21

SW

L

J9

(101,Y)

D

L

H

SW

SW

SW

SST

D

SW

SW

H

CN3

CN19

CN9

<LEVER CONT. UNIT>

CN8

T

SOL

L

SOL

ST

SOL

LU

SOL

TR

SOL

AT1L

SOL

<MINI-LEVER OPT>

AT2L

SOL

REC

TAB

CN98

CN5

REC

TAB

CN87

LS

LS

TR

TF

REC

TAB

REC

TAB

CN11

R

BR

NO

NC

COM

L

LS

SL

R

ST

LS

NC

NO

COM

B

LS

BR

R

NC

NO

COM

REC

TAB CN6

CN4

K

TAB

REC

SW

<KEY-LESS-KEY OPT>

CN92

CN90

CN91

TAB

REC

LC-L

LF-L

CN18

REC

TAB

CN17

REC

TAB

REC

TAB

CN20

LH-L

L

SP

NC

NO

COM

MH1

SW

CN29

REC

TAB

CN4

K

TAB

REC

SW

CN15

REC

TAB

Y

HR

REC

TAB

CN45

PB

LS

Y

TR

REC

TAB

CN46

REC

TAB

Y

FR

CN12

7FBEU15-20 OPS Repair Manual CU341

FOREWORD

Service Information Bulletin

Technical News Brief

Hotline Tech Tips

SECTION INDEX

GENERAL

OPS & IMPROVEMENTS

BODY

APPENDIX

GENERAL

Page

INSPECTION METHOD

SEAT

Function list (only added or modified items)

OPS & IMPROVEMENTS

Page

GENERAL

Display and Buttons

GENERAL FUNCTIONS

DISPLAY INDICATION LIST

DIAGNOSIS CODE LIST

ANALYZER

Vehicle Abnormalities Not Stored in Diag Memory

OPTION SET

OPTION SET Menu List

Operation Procedure for OPTION SET Screen

DIAGNOSIS CODE LIST

WHEN AN ERROR CODE IS DISPLAYED

A5 Seat switch abnormality (STD)

A5 Seat switch abnormality (Mini Lever)

WHEN NO ERROR CODE IS DISPLAYED

Traveling and material handling fail with OPS operation display even after sitting on the seat. (STD)

Traveling and material handling fail with OPS operation display even after sitting on the seat. (Mini Lever)

WHEN AN ERROR CODE IS DISPLAYED

CPU Board

63-1, 2, 3 Tilt switch abnormality

72-1, 2, 3, 4 Steering angle sensor abnormality

73-1, 2, 3 Steering knob synchronizer solenoid abnormality

A4 Acceleration switch abnormality

A6-1, 3, 5 Material handling switch abnormality

C4-1, 2, 3, 4 Accelerator potentiometer abnormality

C7 Direction switch abnormality (STD)

C7 Direction switch abnormality (EZ Pedal)

EE-1, 2, 3 Abnormal communication from multi-display

FF D15 overcurrent

H5-1, 2, 3, 4, 5 Lift solenoid abnormality

H6-1, 2, 3, 4, 5 Tilt solenoid abnormality

H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality

H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality

H9-1, 2, 3 Unload valve solenoid abnormality

61-1, 2 Load sensor abnormality

62-1, 2 Tilt angle sensor abnormality

67-1 Lifting height switch abnormality

F1-1, 2 Main controller

WHEN NO ERROR CODE IS DISPLAYED

No display on multi-display

Only traveling disabled (no motor revolution)

Constant automatic fork leveling

BODY

Page

APPENDIX

Page

JOINT

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