FOREWORD This Manual contains specifications, maintenance, repair, diagnostic and service procedures for the chassis, body, electrical controller and material handling system of the TOYOTA ELECTRIC POWERED FORKLIFT 7FBEU15 to 20 series and 7FBEHU18. Please use this manual for providing quick, correct servicing of the corre- sponding forklift models. This manual deals with the above models as of April 2003. Please under- stand that disagreement can take place between the descriptions in the man- ual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. TOYOTA Material Handling Company [ADivison of TOYOTA INDUSTRIES CORPORATIONSECTION INDEX NAME : SECTION [paTTeRY CO [CONTROLLER [MULTI-DISPLAY FUNCTIONS ———s§- FE [TROUBLESHOOTING [moroR sc — t—“‘éz [DRIVEUNIT&FRONTAXLE «iC REAR AXLE na [STEERING SSS Ea BODY&FRAME ( MATERIAL HANDLING SYSTEM iI [mast CS [CYLINDER © (—EM Lorpump [OL CONTROL VALVE EE “SASFUNCTIONS zw APPENDIX EaGENERAL Page VEHICLE EXTERIOR VIEW. VEHICLE MODELS... 0-3 FRAME NUMBER..... 0-3 HOW TO USE THIS MANUAL......0-4 EXPLANATION METHOD 04 TERMINOLOGY. ABBREVIATIONS.. OPERATING TIPS... GENERAL INSTRUCTIONS JACK-UP POINT ... HOISTING THE VEHICLE... WIRE ROPE SUSPENSION ANGLE LIST MEMBER WEIGHTS.. TOWING THE VEHICLE. ELECTRICAL PARTS INSPECTION .. NOTES ON SAS... STANDARD BOLT & NUT TIGHTENING TORQUE.. BOLT STRENGTH CLASS IDENTIFICATION METHOD .. TIGHTENING TORQUE TABLE PRECOATED BOLTS..... HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .. 15, 0-2. RECOMMENDED LUBRICANT QUANTITY AND TYPES... LUBRICATION CHART... PERIODIC MAINTENANCE. PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS0-2 VEHICLE EXTERIOR VIEWVEHICLE MODELS Vehicle model code | Load Capacity | Vehicle Model Control method Voltage (V) 15 3000Ibs 7FBEUIS ‘AC microcomputer controller |” 36 (48) 8 3500Ibs 7FBEUI8 T T 18 3600Ibs | 7FBEHU18 T T 20 -40001bs | 7FBEU20 T T FRAME NUMBER Vehicle model Punching format Punching position 7FBEUIS 7FBEU15-10011 TFBEU18 7FBEHU18 7FBEU20-10011 7FBEU200-4 HOW TO USE THIS MANUAL. EXPLANATION METHOD 1. Operating procedure (1) Operating procedures are described using either pattem A or pattern B. Pattern A: Each step of the operation is explained with its own illustration. Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations. Example of pattern B DISASSEMBLY - INSPECTION - REASSEMBLY Tightening torque unit + Some step numbers may be &y omitted in some illustrations, ‘ j + When a part requiring H d tightening torque instruction is 3 not indicated in the illustration, GB the part name is described in SR the illustration frame T=48.11048.1 (47010 490) (3401035: Disassembly Procedure 1 Remove the cover. [Point 1] Ge Operation to be explained 2 Remove the bushing, [Point 2] 3 Remove the gear. Point Operations [POINT 1] Disassembly: Make match marks before removing the pump cover [POINT 2} Inspection Measure the bushing inside diameter. 19.12 mm (0.7528in) Explanation of operation point with illustration2. How to read component figures (©ample) (1) The component figures use the illustration in the parts catalog for the vehicle model. Please refer to the catalog to check the part name. 3207 Parts catalog FIG number 3. Matters omitted from this manual (1) This manual omits descriptions of the following jobs, but perform them in actual operation: (a) Cleaning and washing of removed parts as required (b) Visual inspection (partially described) TERMINOLOGY Caution: Important matters, negligence of which may cause accidents. Be sure to observe them. Note: Important items, negligence of which may cause accidents, or matters in operating procedure which require special attention. Standard: Value showing the allowable range in inspection or adjustment Limit: The maximum or minimum value allowed in inspection or adjustment. ABBREVIATIONS ‘Abbreviation Meaning ‘Abbreviation Meaning ‘ASSY ‘Assembly RH Right hand Society of Automotive Engineers ATT Attachment, SAE (USA) Electronically controlled fully EHPS hydraulic power steering SAS System of active stability FHPS Fully hydraulic power steering ‘ssT ‘Special service tool LH Left hand STD ‘Standard u Less T= Tightening torque OPT ‘Option ‘ooT Number of teeth (OOT) os Oversize us Undersize PS Power steering w with06 OPERATING TIPS GENERAL INSTRUCTIONS 1. Safe operation (1) After jacking up, always support with wooden blocks or rigid stands, (2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity. (3) Always disconnect the battery plug before the inspection or servicing of electrical parts. 2. Skillful operation (1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation (2) Check the cable color and wiring state before disconnecting any wiring. (3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting a precision part such as the control valve, use clean tools and operate in a clean location, (6) Follow the specified procedures for disassembly, inspection and reassembly. (6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the “standard tightening torque table’. 3. Protection of functional parts (battery operated vehicles) (1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection. Failure or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers, 4. Defect status check Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect. 5. Waste fluid disposal Always use a proper container when draining waste fluid from the vehicle. Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies, for appropriate disposal.0-7 JACK-UP POINT Always observe the following instructions when jacking up the vehicle: + When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface. + Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous. + Always support the load of jacked-up vehicle with wooden blocks at specified points. ‘Supporting the vehicle with the jack only is very dangerous. + Never, under any circumstances, put any part of the body (including hands and feet) under the Jacked-up vehicle. BD vack-up point Wooden block or stand setting pointsHOISTING THE VEHICLEWIRE ROPE SUSPENSION ANGLE LIST 0-9 [Suspension | Tension] Compression | Suspension [Suspension] tension] Compression | Suspension Angle method | Angle method o tee | otime e so | [41 | 1.00time ov “ wo 2 | 104 ® - | 2.00 30 tine | 027time |g 120° | 500 | 4.73time too + z . | 1.6 oo 60 tne, | 0-58 time "fz SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (th fl Rope | Cutting | Single-rope ‘Two-rope suspension four-rope suspension diameter] load | S¥Spension’ o o | 30 | 6 | oo | oO | 30° | 60 | 00 5 21380 | 3040 | 6080 | 5880 | 5200 | 4310 | 12160 | 1170 | 10400 | 8630 aay | 218) | (31) | 0.62) | (06) | (0.53) | (0.44) | (7.24) | (12) | (4.06) | (0.88) (©.24in) | Fago7] | 1683.6) | [1367] | 11323] | [1169] | [970] | [2734] | [2646] | 2337 | [1940] 3 31480 | 4410 | 6830 | 8530 | 7650 | 6260 | 17650 | 17060 | 16300 | 12550 32m | 221) | (045) | (0.9) | (0.87) | (0.78) | (0.64) | (1.8) | (1.74) | (1.56) | (1.28) (0.32in) | 7078) | (992.3) | (1985) | (1918) | [1720] | [1411] | 13969) | (3937) | [3440] | [2322] to mm | 49280 | 6960 | 14020 | 13440 | 11770 | 9810 | 27460 | 26480 | 23540 | 19610 arm | (6.02) | (0.74) | (4.43) | (4.37) | (1.2) | (1.0) | 28) | 7) | 24) | (20) (04m) | rr1¢90)] 1565.6] | [3153] | [3021] | (2646) | (2205) | (6174) | (5954) | (5292) | [4410] 12.5 mm| 76880 | 10980 | 21570 | 21280 | 18630 | 44710 | 43150 | 41790 | 37270 | 20420 osm | 784) | (1.12) | 22) | 2) | (4.9 | 5) | (4.4) | (42) | 8) | (30) 117387) (2469.5) | [4851] | (4631) | 14190) | (3308) | 19702) | (9261) | (8379) | 16615] 14mm | 26400 | 13730 | 27460 | 26480 | 23540 | 718630 | 64020 | 52860 | 47070 | 37270 som | 283] G4 | @a | 27) | 24 | 9 | 6) | 64) | 49) | 3.8) 21675]| (3087) | (6174) | ¢5e54) | (5292) | (4190) | (12348]| (116071 | (10584) [8379]0. MEMBER WEIGHTS Unit: kg (Ibs) Member Vehicle model Weight BATTERY ASSY See page 1-2. Drive motor ASSY All Models Approx. 37 (82) Pump motor ASSY All Models Approx. 31 (68) Front axle ASSY Wi drive motor ASSY All Models Approx. 122 (269) Rear axle ASSY WI rear axle cylinder ASSY All Models ‘Approx. 44 (97) 7FBEU15 Approx. 637 (1405) ee 7FBEUIB “Approx. 608 (1762) 7FBEHU18 ‘Approx. 637 (1405) 7FBEU20 Approx. 882 (1945) Mast ASSY W/ lift bracket (VW/ lift cylinder, L/ fork, Lifting height 3000mm (118 in), V mast) Al Models aa 7FBEU15 2095 (4620) Vehicle weight (without battery) TFBEUIE 2265 (4995) 7FBEHUTE 2040 (4500) 7FBEU20 2325 (5125) TOWING THE VEHICLE Note the cautions below when towing the vehicle. @ Lift the rear wheels for towing The traveling speed when towing must not exceed the maximum traveling speed of the forklift Before starting towing, always set the key switch to OFF and the direction switch to the neutral position. Before towing, either remove the fork or take action to prevent the fork from coming into contact with the ground due to bouncing.ELECTRICAL PARTS INSPECTION 1. Always disconnect the battery plug before inspecting or servicing electrical parts. 2. Pay sufficient attention when handling electronic parts. (1) Never subject electronic parts, such as computers and relays, to impact. (2) Never expose electronic parts to high temperature or moisture. (3) Do not touch connector terminals, as they may be deformed or damaged due to static electricity. 3” Use a circuit tester that matches the object and purpose of measurement. Analog type: This type is convenient for observing movement during operation and the operating condition. Measured value is only a reference Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or movement. (1) Difference between results of measurement with analog and digital types * The results of measurements using the analog type and the digital type may be different. Differences between the polarities of the analog type and the digital type are described below. 1) Analog circuit tester Example of measurement result ae Reverse Tester range: kO range a ‘Analog type | ‘Continuity Forward Fi 11k | 5 No continuity Reverse 2) Digital circuit tester Example of measurement result Fonward Reverse Tester range: 2 MQ range * Digital type SI S 'No continuity Forward 7 29 = Continuity Reverse 2MQ12 NOTES ON SAS A For the explanations of SAS functions and operation, also see "New Model Feature 7FBEU15 to 20 and 7FBEHU18 Pub. No.PU315", See page 16-6 FOR REPAIR WORK of this repair manual before servicing. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform necessary matching to ensure proper SAS function (see page 3-68). always be sure to operate the vehicle carefully. Be aware of the difference in control features between with and without SAS. Many precision valves are used in the SAS oil control valves. When disassembling or replacing hydraulic parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of the hydraulic oil is also very important. As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may cause vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the electrical parts (auxiliary equipment, optional parts, etc.)0-13 STANDARD BOLT & NUT TIGHTENING TORQUE Tightening torque of standard bolts and nuts are not indicated throughout the manual Use the charts and table below to judge the standard tightening torque. 1. Find the class of the bolt strength on the table below and then find the bolt tightening torque on the tightening torque table. 2. The nut tightening torque can be judged from its corresponding bolt type. BOLT STRENGTH CLASS IDENTIFICATION METHOD Identification by bolt shape Identification by part No. ‘Shape and class Hexagon head bolt edge(s) Hexagon Reealt Bolt with raised Part No. or etched — 91611-40625 numeral on hea TC — Length (mm) Hexagon bot _ Nominal diameter (mmm) Class (standard) No mark aT Hexagon flange bolt ou aT Hexagon Bolt with two head bolt raised lines on ST (standard) head Nominal diameter Hexagon Bolt with two or flange bolt Heer lines on an Hexagon Bolt with three head bolt raised lines on 7 (standard) head Stud bolt Hexagon Bolt with four head bolt raised lines on eT ee acanate (standard) head 4 Length (mm) Nominal diameter (mm) Welded bolt = 4 Class % No mark ar [mina ater Stud bott Length 2 mm groove(s) on one/both erota TIGHTENING TORQUE TABLE Standard tightening torque Nominal Hexagon Hexagon Glass | diameter | Pfc | head bot ps flange bolt es mm Nm] kofem | ftlb? | Nm | kgfom | ftibf é 10 54 35 | 48inibf | 59 6 | S2inibt 8 1.25 13 130 9 14 “5 10 fn 10 1.25 25 260 19 28 290 21 12 1.25 47 480 35 53 540 39 14 15 75 760 55 83 850 61 16 15 113 | 1150 | 83 = = = 6 4.0 64 5 | seiner | 75 75 | SSinibf 8 1.25 16 160 12 18 175 13 st 10 125 2 330 24 36 360 26 12 4.25 59 600 43 65 670 48 14 15 91 930 67 too | 1050 | 76 16 15 137 | 1400 | 101 187 | 1600 | 116 6 10 78 30 | 69inbf | 88 90 | 7einibf 8 1.25 19 195 14 21 215 18 er 10 125 38 400 29 43 440 2 12 4.25 2 730 53 79 810 59 14 15 110 | 1100 | 80 123 | 1250 | 90 16 15 170 | 1750 | 127 | 191 | 1950 | 141 6 70 11 110 3 72 720 ° 8 1.25 25 260 19 28 200 21 Pn 10 1.25 52 530 38 58 520 2 12 125 95 970 70 103 | 1050 | 76 14 15 147 | 1600 | 108 167 | 1700 | 123 16 15 226 | 2300 | 166 = = = 6 1.0 2 125 ° 14 145 @ 8 1.25 29 300 2 32 330 24 a 10 1.25 é1 620 45 68 6c0 50 12 1.25 tos | 1100 | 80 123 | 1250 | 90 14 15 172 | 1750 | 127 196 | 2000 | 145 16 15 265 | 2700 | 195 | 299 | 3050 | 221PRECOATED BOLTS (Bolts with seal lock agent coating on threads) 1. Do not replace or restore a precoated bolt as it isin the following cases (1) After it has been removed. (2) When it has been moved by tightness check, etc. (loosened or tightened) NOTE: For torque check, tighten the bolt at the lower limit of the allowable tightening torque range; if the bolt moves, ‘Seal tock agent retighten it according to the steps below. 2. How to reuse precoated bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even when replacing the bolt with a new one) (2) Completely dry the washed parts by blowing with air. (3) Apply a specified seal lock agent to the threaded Portion of the bolt. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1, When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or other damage on the contact surfaces before installation. 2. When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten 3. pedir tightening torque must not exceed twice the standard tightening torque. Nominal diameter Tightening torque standard Nm (kgfom) (1B inside diameter of screw Standard Tightening range of hose (in) 7/16-20UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5) 6 (0.24) 9/16-18UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35) (3/4-16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47) 7I8-14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6) 12 (0.47) 7/8-14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8) 15 (0.59) 1AM6-12UNF | 118 (1200) [86.8] | 112 to 123 (1140 to 1250) [82.5t0 90.4] | 19 (0.75) 1-5/16-12UNF | 137 (1400)[101.3] | 130 to 144 (1330 to 1470) [96.2 to 106.4] | 25 (0.98) PFI4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24) PF3IB 49 (500) [36.2] 4T to 52 (480 to 530) [34.7 to 38.3] 9 (0.35) PFI2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47) PF3I4 118 (1200) [86.8] | 112 to 123 (1140 to 1250) [82.5 to 90.4] | 19 (0.75) PFI 137 (1400) [101.3] | 130 to 144 (1330 to 1470) [96.2 to 106.4] | __ 25 (0.98)0-16 RECOMMENDED LUBRICANT QUANTITY AND TYPES ‘Application Type ‘Capacity — Hypoid gear oll ‘Approx. 0.4 (0.11 US gal) (API GL-4, SAE 75W-80) (Until purring out from the filer port) eT ‘STD: Hydraulic oil (ISO VG32) ‘See "Hydraulic oil level by lifting 2 Cold storage vehicle: Mobil Aero HFE height” below | MP grease Chassis parts | Molybdenum disulfide grease Appropriate amount Esso beacon 325 Battery Distilled water ‘Appropriate amount Hydraulic oil level by lifting height Unit:¢ (US gal) Lifting height Vmast FV Mast FSV Mast To 3000mm Capacity 14 (3.70) 17 (4.49) = (118 in) |” Hydraulic oil level in the tank 12.4 (3.27) To 4000mm Capacity 15 (3.98) 19 (6.01) 16 (4.22) (187.5 in) |” Hydraulic oil level in the tank 14.2 (3.75) To 6000mm Capacity 18 (4.75) 19 (5.01) (236 in) |" Hydraulic oil level in the tank 17.2 (4.54)LUBRICATION CHART 0-17 (©: Inspection and addition ©: Replacement A: MP grease B: Motor oil C: Gear oil (SAE 75W-80) D: Hydraulic oil (ISO VG32) E: Molybdenum disulfide grease 1. Mast strip 2. Tilt oylinder front pin 3. Mast support bushing 4, Lift chain 5. Drive unit 6. Brake link 7. Oil control valve lever pin |. Inspection every 8 hours (daily) II. Inspection every 40 hours (weekly) Ill Inspection every 250 hours (6 weekly) IV. Inspection every 1000 hours (6 monthly) V. Inspection 2000 hours (annual) 8. Steering rack and pinion gear 9. Accelerator link 10. Oil tank 11. Tilt steering lock device 12, Rear wheel bearing 13, Rear axle bearing8 PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection-Repair or Replacement if required M: Measurement Repair or Adjustment if required T: Retightening C: Cleaning L Lubrication *: For new vehicle *1: Flaw detector Every 6 | Every 3 | Every6 | Every 12 Inspection timing | ‘Weeks | months | months | months item Every | Every | Every | Every 250 hours | 500 hours | 1000 hours | 2000 hours ELECTRICAL SYSTEM Rotation sound abnormality ' - - e Motor Looseness in the connecting parts T a - e Insulation resistance M e e Charging level (Display) 7 = < = Electrolyte level 1 - eo e Electrolyte specific gravity M ra ra Looseness in the connecting parts 1 - - eo Battery ‘Abnormality in the upper portion of the 1 . . ~ battery and/or the case Insulation resistance e e Voltage measurement of each battery cell M after charging Contact looseness, damage, abrasion 1 va - Operating condition, contamination and 1 - . . abrasion of the auxiliary contact Mounting condition of the are shooter j Magnet switch (Operating condition and timing 1 Looseness of the coil installation locations 7 Mounting condition and looseness of the 1 main circuit lead wire ‘Operating condition and timing 1 va va - Micro switch Damage and looseness of installation Hi . . - locations Direction switch | Operating condition, damage 1 o - eo Operating condition 1 va ra © Controller Interior contamination, damage Cc e eo eo Motor input voltage M Fuses Looseness of the installation locations 1 eo oeinspection timing ] Every | Every | Every 6 | Every 12 weeks | months | months | months item Every | Every | Every | Every 250 hours | 500 hours | 1000 hours | 2000 hours Hamess deterioration, damage and i Oe looseness of the clamp < - < {incl charging | Looseness of the connections, taping 1 = = = cable) condition | Connecting condition and damage ofthe | } . . | battery connector | POWER TRANSMISSION SYSTEM Oilleak T = < < Drive unit Oil level 1 « + - Bolt or nut looseness T DRIVE SYSTEM Front axe Damage and deformation T Damage and deformation i Rear axle Looseness of rear axle bearing ' ‘Abnormal noise of rear axle bearing ' Tire pressure (OPT) M < - o Tire crack, damage and abnormal wear \ © - © Tire tread depth M « © © Metal piece, stone and other foreign matter | « « « ontire eaneels Loosening of wheel nut and bolt T e e « Rim, side ring and disc wheel damage \ © © « Looseness and abnormal noise of front 1 < < wheel bearing Looseness and abnormal noise of rear 1 } « « wheel bearing STEERING SYSTEM Play, loosening, looseness T = < o Steering wheel Function 1 e e = Oil leak i = < a Steering valve | Looseness of the installation locations T + « « ‘Wheels for | Tuming angle to left and right, 1 steering ane z Oileak 1 a - ra Power steering | Looseness of the installation locations 1 © © . Damage of power steering hose \Item. Inspection timing Every 6 weeks Every 3 months Every 6 months Every 12 months Every 250 hours Every 500 hours Every 1000 hours Every’ 2000 hours BRAKING SYSTEM Brake pedal Reserve Braking performance Parking brake Operating force and pull margin Braking performance Rod and cable Looseness and damage Operating condition Disc brake Clearance between disc and pad Wear of sliding portion and pad Disc wear and damage Looseness of the disc installation locations Operating condition Retum spring fatigue Tit T1t Tht tT TTT T1t TPT MATERIAL HANI IDLING SYSTEM Fork ‘Damage or wear of fork or stopper pin Fork deformation and wear Cracks at fork root and welded part of tooth tT a Mast and lift bracket Deformation and damage of each part and crack at welded part Wear and damage of roller Mast and lift bracket looseness Wear and damage of mast support bushing ‘Wear and damage of roller pin ‘Wear and damage of mast strip t , t TT T Chain and chain wheel Chain lubrication Deformation, damage and slackness of chain ‘Abnormality of chain anchor bolt Wear, damage and revolution of chain wheel + TT T TT T T/T THT TT T Various attachments ‘Abnormality and installation condition of each part t t t0-21 Every 6 | Every 3 | Every 6 | Every 12 Inspection ti Inspection timing | weeks | months | months | months item Every | Every | Every | Every 250 hours | 500 hours | 1000 hours | 2000 hours HYDRAULIC SYSTEM Looseness, deformation and damage ofrod | ~ < and rod end Cylinder operation \ e « e Natural drop and natural forward tt M « + « il leak and damage 1 e « « Cylinder Wear and damage of pin and cylinder i e e < bearing Loosening and damage of cylinder TT < . . mounting Lifting speed M | e e Uneven movement \ « « « ‘Oil pump Oil leak and abnormal sound i < < S Gil level and contamination H o < ra Hydraulic il fa il leak 1 e + + Tank and oll strainer cleaning c « Hydraulic oi re Filter clogging c Loose linkage 7 = = = Control lever Operation \ « « « Oilleak T < < - Gil control os Safety valve function 1 © © © Relief pressure measurement M Hydraulic hose | Oil leakage, deformation and damage T - < = and piping Looseness T e © « SAFETY DEVICES, ETC. Looseness of the installation locations T © = = Head guard ee eee, | Deformation, crack and damage 1 « « + Crack at welded portion 1 e e e Lighting system || Function and installation condition T = = < Piecion Function and installation condition 1 e « e indicator Hom Function and installation condition 7 = = = Backup buzzer | Function and installation condition T - = Rearview | Rear reflection status T = = - mirror Dirt, damage \ « « eEvery 6 | Every 3 | Every 6 ] Every 12 Inspection timin a "9 | weeks | months | months | months oy Every | Every | Every | Every 250 hours | 500 hours | 1000 hours | 2000 hours instruments | Operation 1 < © © Loosening and damage of mounting T < = Seat Seat belt damage and function ! e e e Deadman seat operation \ « ‘ ‘ Damage and cracks in frame, oross mem- i Body bers, etc. Bolts and nuts looseness T Functions 7 e = = Loosening and damage at sensor mounting | e e e portion SAS Damage, deformation, oil leakage and|oos-| } . e ened installation of functional parts Loosening and damage of wirehhamesses | | « « « Rusting and corrosion of load sensor \ Others Grease up v © = =0-23 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS. : Replacement Every Every Every Every Replacement cycle |g weeks | 3months | 6months | 12 months ro Every Every Every Every 250 hours 500 hours: 1000 hours | 2000 hours Drive unit gear oil ° e Hydraulic oll . S @ New Hydraulic oil filter vehicle initial e oe replacement Rear wheel bearing grease e = ‘@Every Power steering hose pyaar ‘@Every Power steering rubber parts 2 years ‘@Every Hydrat hose 2 years Every Lift chain 3 yearsBATTERY Page BATTERY COMPARTMENT AND REQUIRED WEIGHT. . SERVICE STANDARDS. DISPLAY TROUBLESHOOTING BATTERY ASSY REMOVAL - INSTALLATION .. INSPECTION .. REPLACING BATTERY PLUG TERMINAL. «1-2BATTERY COMPARTMENT AND REQUIRED WEIGHT ‘When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required weight as shown in the table below. Width Compartment dimensions mm (in) Minimum required battery Vehicle model weight (with case) Kg (Ib) Remarks Depth X Width Y Height Z fare 551 (21.7) | 997 (39.2)| 613 (24.1) 700 (1543) a Z 638 (25.1) t t ‘955 (2105) & 2 y4:3 SERVICE STANDARDS [Specific gravity 7.280 [20°C (68°F) [Specific gravity 1.150 [20°C (68°F)] 36V 32V Discharge end voltage Ey a8V Electrolyte Refined dilute sulfuric acid Fluid to be added Distilled water insulation resistance Battery discharged state % © @ x o a Oto 10 (exclusive) Oto 20 (exclusive) 20t0 30 (exclusive) 30 to 40 (exclusive) v oO oO oO; ololo 40 to 50 (exclusive) 50 to 60 (exclusive) 601070 (exclusive) 7010 80 (exclusive) ofololololo|olo 80 t0 90 (exclusive) ofolfololololololo ‘90 to 100 (exclusive) oLolololrolololofoloim= 700 or more |—|-|-|-|-|= ‘TMQ or more “| EZ DISPLAY Battery Charge Indicator The battery charge indicator indicates 10 levels of battery charge on the LCD. Low Remaining Battery Charge Warning ‘When the battery charge becomes below the set level, the battery charge indicator blinks and the alarm will sound for five seconds after the key switch is set to the ON position. Battery Overdischarge Warning ‘When the battery charge decreases further below the set level after the remaining battery charge warming, any attempt at traveling or material handling operation will cause all charge indicator segments to blink and the alarm to sound to warn the operator.14 TROUBLESHOOTING [Pate corosion | [[Satiaion—] (Pate warpage and ave substance feoing Improper charging —x\ Long storage Repeated overdischarge/ without operation = overcharge End of life —x\ Short circuit between cells \+— Detect ofelecroyte [+ — Exeassve charging Insufficient \ erent Defective electrolyte — \ \ \ Overaacharge —x\ Excessive ambient ___) 4 4 = {t+ | / Crack or electrolyte Battery defect | Damaged Improper chipping of cel separator water supply Imperfect Overcharge /— terminal connection Per pagel Fouled terminal or active substance connecting pit at bottom of cell pTon) (oF corroded connection Ghortoreut] [Eeciojte leakage andreducion] [LooseBATTERY ASSY REMOVAL - INSTALLATION Removal Procedure 1 Disconnect the battery plug, 2 Open the seat stand. 3. Release the steering release lever. 4 Remove the battery ASSY.[Point 1] Installation Procedure The installation procedure is the reverse of the removal procedure. Point Operations [POINT 1] Removal « Installation SST 25009-13201-7116 INSPECTION 1. Electrolyte inspection THe battery electrolyte is normal when it is transparent. Check turbidity when inspecting the specific gravity.{f it cannot be checked clearly, put the electrolyte in a beaker for inspection. 2. Battery electrolyte specific gravity inspection Use a hydrometer to measure the specific gravity of the electrolyte. Specific gravity upon complete charging .... 1,280[20°C(68°F)] Specific gravity upon end of discharge .... 4.180[20°C(68°F)] The specific gravity of the electrolyte at 20°C (68°F) is Pe "see used.68 1309 1.300 Equation for converting specific gravity 1,250) — 1.250 ‘Sqq=St+0.0007 (t-20) + eel ‘Sao: Specific gravity at 20°C 3.200, +200 ‘St: Specific gravity at t?C 3,150f ———___} 1.150 t: Electrolyte temperature upon measurement (°C) La * How to use the hydrometer (1) _ Insert the nozzle of the hydrometer into the electrolyte port and allow the electrolyte to be sucked into its outer tube. (2) Let the hydrometer float correctly without contact with the outer tube, top or bottom, and read the scale at the highest point of the electrolyte surface as illustrated at left when the bubbles in the electrolyte disappear. (3) After the measurement, wash the inside and outside of the hydrometer well with clear water and store it after wiping water off with clean cloth.* Battery control table 17 3, _ Insulation resistance inspection Measure the resistance between the battery and battery ease with an insulation resistance meter (megohmmeter). Insulation resistance .... 1 MQ or more Note: When the insulation resistance is less than 1 MQ, wash the battery with water after removing it from the vehicle. Fully dry the washed battery and measure the insulation resistance again. Install the battery on the vehicle after confirming that the insulation resistance is 1 MQ or more. Prepare a control table for each battery to record and maintain the inspection results. inspection date ‘ng time Inspected cell No Specie | Elearoyte | Added water ‘gravy | temperature |“ quantiy | Renarks | InspectorTerminal Screw driver LB (Crimping method Crimping tool es a (To prevent the contact, piece from bending) YJ Case Terminal REPLACING BATTERY PLUG TERMINAL 1, Disconnect battery plug cable one by one. Caution: Never disconnect more than one cable at the same time.Fatal accident may result by short circuit. 2. Insert a screwdriver from the terminal side, push down the spring at the bottom of the terminal and pull the cable to draw out the terminal. 3. Peel off the tip of the cable for Approx. 30mm, solder sufficiently and insert it to the contact portion of the new terminal Note: Be sure to prevent solder from pouring out and adhere to the contact surface of the terminal. 4, When crimping cables, never bend the terminal with a crimping tool 5. Insert the terminal to the battery plug. Check that the tip of the terminal goes over the tip of the spring and securely set in the position.CONTROLLER GENERAL............ cee eceee eee ee se eeenenee 2-2 SPECIFICATIONS COMPONENTS BEFORE REPAIR 246 CONNECTOR INSPECTION .............-----+ 27 CONTROLLER............-: ee eee eee eee eee 2-26 MAIN CONTROLLER ASSY . » 2-26 TRAVELING AC DRIVER. . 2-27 MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL ASSY. 2-28 CHECK MOTOR INPUT VOLTAGE ..............-- 2-30 REASSEMBLY ...........-- 0000 eeceee cece eee e ee 2-32 DISPLAY DIRECTION SWITCH. REMOVAL « INSTALLATION . DISASSEMBLY + INSPECTION * REASSEMBLY ..... 2-36 ACCELERATOR POTENTIOMETER ADJUSTMENT .............00eee creer eee 2-37 BRAKE SWITCH ADJUSTMENT ............... 2-38 MATERIAL HANDLING LEVER SWITCH ADJUSTMENT ............00 eee eee eee eee 2-39 24GENERAL 7FBEU series models are equipped with traveling/material handling controllers that control traveling and material handling system. They are multi-functional controller that utilize micro computer. The traveling/material handling controller provides high performance in a wide range by means of inverter control of the AC motor drive system. The main controller has a self-diagnosis function that automatically detects any abnormality of the main drive/pump circuits, accelerator, SAS function or any other sensor and displays the corresponding error code together with a warning beep. At the same time, an action such as disabling traveling, disabling material handling or restriction of traveling speed is automatically taken to ensure safety. Identification of faulty portion and functional inspection of the main drive/pump circuits, each operating system and sensors are also possible by setting the display to the analyzer (fault analysis) mode. ‘See page 3-24 in the "MULTI-DISPLAY FUNCTIONS" section for the diagnosis. ‘See page 3-34 in the “MULTI-DISPLAY FUNCTIONS: section for the analyzer. S, Control panel Material handling AC driver Contactor panel23 SPECIFICATIONS Contactor MB (for power supply) All Models. F1 (for drive and pump circuits) 500A F4 (for lights) 10A FUSES FS (for control circuit) 10A F6 (SAS, for solenoid) 10A ME251COMPONENTS25 2402 veorzore ro26 BEFORE REPAIR INSPECTION 1. Insulation resistance measurement handling controller. (1) Disconnect the battery plug and measure the resistance between battery plug and body. ‘Measurement terminals | Controller side of battery plug-body Resistance value depends greatly on the vehicle operating state, place and Standard: weather. (Approx. 1MQ or more) ‘Some components can be inspected after they are removed from the vehicle, while others can only be inspected as installed on the vehicle. The CPU board must be inspected as installed on the vehicle since the battery voltage must be applied. The explanation here is mainly for inspection of the controller ASSY as removed from the vehicle. Disassembly Procedure + Overhauling the control panel is rarely necessary. In most cases, failed parts is replaced after findi the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to the figures of configuration and ASSY + Do not disassemble traveling/material handling controller, as it should be replaced in a form of ASSY. out Caution for part replacement + Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of tightening may cause other failure. + When disconnecting the bars and harness, record the connecting location and place tags. When ‘connecting them again, be sure to confirm with the record and tags to prevent incorrect connection. Incorrect connection may cause other failure. + Always apply new silicon grease when reassembling parts originally coated with silicon grease. Otherwise, overheating may occur. * After installation, check that there is no interference of the bar and harness connection with other portion.CONNECTOR INSPECTION ‘When inspecting each board and the cause of the trouble is found, do not immediately replace the board but check the following items. + Abnormality in related harnesses + Looseness of the related connectors + Bending or damage of connector pin and defective contact of any related connector pin. If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be damaged. Always replace the board after careful inspection. When the cause of trouble is determined to be in the CPU board or other board, connect SST 09240- 23400-71 or to the corresponding connector pin and measure the applied voltage and resistance. Always disconnect the battery plug before measuring the resistance. Caution: Disconnect the battery plug before connecting or disconnecting CPU board. Not When the CPU or DC/MD board is determined to be the cause of trouble as the result of troubleshooting, always measure the applied voltage and resistance of each related portion when replacing. (1) SST Setting Method (a) Key switch OFF and battery plug disconnected. (b) Connect the SST to the corresponding connector pin. Caution: As connection of the wrong connector pin may damage normal portions, make sure to confirm the connector pin number before connecting it to the SST. Connectors to which SST 09240-24300-71 is applicable SST09240-23400-71 CPU board: CN101 to CN104 ‘$ST09230-13700-7 1Applicable connector oes CPU board: CN100,CN1058 (2) Measurement method and standard list How to read the list Teer pate Tester porbeQ [ Comer sino ‘Connector No. =~ Connector, Conditions ‘Standard Remarks ONt01-1 CNt01-26 poorox.ov Ae ‘eiis)_ | KeY switch OFF, DSF ON. 0 L Part name Level No. Conditions for measurement Main controller CPU board CN101 connector basic conditions (battery plug connected, key switch ON) [Standard vehicle] ‘Connector No.-2Connector No. Conditions ‘Standard: | Remarks CNI01-1 CN101-16 | Key switch OFF, DSF ON ‘Approx. OV (45, DSF) (61, LS) _| key switch OFF, DSF OFF Approx. 5V CN101-2 CN101-16 _ | Key switch OFF, DSR ON ‘Approx. OV (48, DSR) (61,LS-)__| Key switch OFF, DSR OFF Approx. 5V CNt01-3 ‘CN101-16 | Key switch OFF, LSB ON ‘Approx. 5V (65, LSB) (61, LS) _| Key switch OFF, LSB OFF Approx. OV CN101-4 ‘CN101-16 | Key switch OFF, LSPB ON ‘Approx. 5V (68, LSPB) (61,LS-) __| Key switch OFF, LSPB OFF Approx. OV CN101-5 CN101-16 | Key switch OFF, LSD ON ‘Approx. OV (67, LSD) (61,LS-)__| Key switch OFF, LSD OFF Approx. 5V eNnt01-6 = Unused = CNt01-7 CN101-16 (.0PTO) (1.us) | Unused ~ N101-8 CN101-16 (.LEDTK) (1,Ls) | Unused _ cNt01-9 entor-te | FANOFF sta oy (39, FAN-) (1S) | FANON ‘Approx. OV CN101-10 cnioi-16 | FAN OFF pe Bae Se (1.LS) | FANON ‘Approx. OV CNi01-11 CN101-16 | LSATI OFF ‘Approx. 5V) (63, LSAT1+) (61,.LS-) | LSAT1 ON Approx. OV N107-12 (309, SSTMA) _ Unused _2-9 Connector No.<>Connector No. Conditions ‘Standard: Remarks (CN101-13, (310, SSTMK) ~ Unused ~ CN101-14, (307, SMTSA) ~ Unused ~ CN101-15 (308, SMTSK) - Unused ~ (CN101-16 _ _ _ (51, LS-) CN101-17 (CN101-16 LSTR OFF Approx. 5V (62, LSTR#) (51, LS-) LSTRON ‘Approx. OV (CN101-18 CN101-16 Key switch OFF, SWTK ON Approx. OV (70, SWTK) (51, LS-) Key switch OFF, SWTK OFF Approx. 5V CN101-19 CN101-16 Lift cylinder at the bottom posi- (90, MH1) (1.LS-) | tion eS) N101-20 CN101-16 | Lift cylinder at the bottom posi- (91, MH2-1) (61,LS-) | tion Ee CN101-21 CN101-16 | Only vehicle with steering syn- | _ Approx. OV or (314, STSC) (51, LS-) chronizer Approx. 5V CN101-22 eN101-16 (68, LSAT2+) @1,Ls) | Unused — (CN101-23, (CN101-16 LSTF OFF Approx. 5V (61, LSTF+) (51, LS-) LSTF ON Approx. OV CN101-24 EN101-16 | Steering operation (only vehi- | Approx. OV to (312, STS1) (51, LS-) _| cle with steering synchronizer) ‘Approx. 5V (CN101-25, _ _— _ (CN101-26 _ _ _ (61, LS-) (CN101-27 (CN101-16 Unused _ (71, SWLE) (51, LS-) (CN101-28 _— _- _- (CN101-29 _ _ — CN101-30 CN101-16 _| Steering operation (only vehi- ‘Approx. OV to (313, STS2) (61,LS-) _| cle with steering synchronizer) Approx. 5V (CN101-31 — _ _— CN101-32, CN101-16 LSL OFF Approx. 5V (60, LSL+) (61, LS-) LSLON ‘Approx. OV GN101-33 = = = ‘CNt01-34 CN101-16 (61, POT) (61, LS+) acne0. CN101 connector basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle] Connector No.->Connector No. Conditions Standard Remarks CNI01-1 CNi01-16 | Key ewitch OFF, DSF ON ‘Approx. OV (45, DSF) (61,LS-) _| key switch OFF, DSF OFF ‘Approx. 5V ‘CNt01-2 CN101-16 | Key switch OFF, DSR ON ‘Approx. OV. (48, DSR) (61,LS-)_| Key switch OFF, DSR OFF ‘Approx. 5V ‘CNt01-3 CN101-16 | Key switch OFF, LSB ON ‘Approx. 5V) (65, LSB) (61.LS-)__| Key switch OFF, LSB OFF Approx. OV CNt01-4 CN101-16 | Key switch OFF, LSPB ON ‘Approx. 6V (66, LSPB) (61, LS) _| Key switch OFF, LSPB OFF Approx. OV CNt01-5 ‘CN101-16 | Key switch OFF, LSD ON ‘Approx. OV (67, LSD) (61,LS-) | Key switch OFF, LSD OFF ‘Approx. SV ent01-6 = Unused = Ni01-7 CNi01-16 (OPO) (61,Ls) | Unused _ CN101-8 CN101-16 (—, LEDTK) 1,Ls) | Unused ~ cN101-9 cntot-16 | FAN OFF fee oy (39, FAN) (1.L8) | pan on ‘Approx. OV CNt01-10 cnto116 | FAN OFF ee x (39, FAN) (1.LS) | FANON ‘Approx. OV CNi07-11 cntorie | _ (63, LSAT1+) (61, LS.) CN101-12 (309, SSTMA) _ Unused _ CN101-13 (310, SSTMK) ~ Unused ~ ONT01-14 (307, SMTSA) _ te _ CN101-15 (308, SMTSK) _ eit _ eNt01-16 _ _ _ (61, LS) CN101-17 CNi01-16 | _ (62, LSTR#) (61, LS-) CN101-18 CN101-16 | Key switch OFF, SWTK ON ‘Approx. OV (70, SWTK) (61, LS) _| Key switch OFF, SWTK OFF ‘Approx. 5V CN101-19 EN101-16 | Liftcylinder at the bottom posi- (90, MH1) (51, LS) | tion Approx. OVConnector No.<>Connector No. Conditions: Standard: CN101-20 CNi01-16 | Liftcylinder at the bottom pos- (91, MH2-1) (61,LS-) | tion ‘Approx. 5V eNt01-21 ‘CNI01-16 | Only vehicle with steering syn- | Approx OV or (314, STSC) (61, LS) _| chronizer ‘Approx. SV CNI01-22 CNi01-16 (68, LSAT2+) (61,Ls) | Unused _ CN101-23 cNtO1-16 | _ (61, LSTF+) (51, LS) CN01-24 EN101-16 | Steering operation (only vehi-_| Approx. OV to (312, STS1) (61,LS-) | cle with steering synchronizer) | Approx. 5V CNi01-25 = = = N101-26 _ _ _ (51, LS-) ‘CNi01-27 ON101-16 (71, SWLE) (61,Ls-) | Unused _ (CN101-28 = = = EN101-29 = = = CNt01-30 ENi01-18 | Steering operation (only vehi-_ | Approx. OVto (313, sTS2) (61, LS:) | cle with steering synchronizer) | Approx. 5V CNt01-31 = = = CN101-32 ento-1e | _ (60, LSL+) (51, LS-) CN101-33 = = = CN101-34 CN101-16 (61, POT) (61, LS) ‘Approx. OV CN102 connector basic conditions (battery plug connected, key switch ON)[Standard vehicle] ‘Connector No.-»Gonnector No. Conditions Standard | Remarks CN102-1 ‘CN102-22 _| Key switch OFF, SWAC ON ‘Approx. OV (64, SWAC) (61,POT-) _| Key switch OFF, SWAC OFF ‘Approx. 5V CN102-2 CN102-22 | Key switch OFF, accelerator anne (62, POTA) (61, POT-) _| pedal fully depressed eNn1023 eNt02-22 | _ _ (317,poTH) | 61, POT) ‘cN102-4 ‘CN102-22 | Variation upon changeover nar ear (68,POTTA) | (51, POT-) _| from forward to backward titing CN102-5 (CN102-22 (59, SPL) (51, POT) |— Oo212 (61, POT) Connector No.<»Connector No. Conditions ‘Standard: Remarks CN102-6 (CN102-22 LSL OFF Approx. 5V (60, LSL) (61,POT) | LSLON Approx. OV ‘CN102-7 CN102-22 | _ _ (21, POTL2) (51, POT-) ‘When the tilt lever is in the neu- cN102-8 CN102-22 __| tral position Approx. SV (61, LSTF) (61, POT) | When the tit lever is in the for- ward tilt position ‘Approx. OV When the tit lever is in the neu- cNt102-9 cn102-22 | tral position Approx. BV (62, LSTR) (51, POT-) When the tilt lever is in the A ov backward tilt position ‘PPrOX. coin N102-22 | LSAT1 OFF Approx. 5V LSAT LSAT2) (51,POT-) | LSAT1 ON ‘Approx. OV CN102-11 cN102-22 | _ (25, POTAT12) (51, POT-) _ CN102-12 cnt0222 | _ _ (26, POTAT21) | (51, POT) (CN102-13, CN102-22 _ (27, POTAT22) (61, POT) _ CN102-14 CN102-22 (63, POTA+) (61, POT) |— ‘Approx. 4.6V (CN102-15, (CN102-22, (316, POTH+) (61, POT) |— ‘Approx. 4.7V CN102-16 (CN102-22 (67, POTTA+) @1,PoT) | ea (CN102-17 (CN102-22 (68, SPL+) (1,PoT) | — ‘Approx. 5V ON102-18 CN102-22 (28, POTL+) (51,POT-) | 7 CN102-19 (CN102-22 (29, POTT+) (51,POT-) | — CN102-20 (CN102-22 _ _ (30, PoTaTi+) | (61, POT.) CN102-21 cNnto2-22 | _ _ (31, PoTaT24) | (61, POT) (CN102-222:13 CN102 connector basic conditions (battery plug connected, key switch ON) IMini-lever specification vehicle] Connector No.<=Connector No. Conditions Standard: | Remarks CNi02-1 CN102-22 | Key switch OFF, SWAC ON ‘Approx. OV (64, swacy (61,POT-) _| Key switch OFF, SWAC OFF ‘Approx. 5V ON102-2 CN102:22 _| Key switch OFF, accelerator av to av (62, POTA) (61, POT) _ | pedal fully depressed CNi02-3 cNi10222 | _ (317,POTH) | (61, POT) ‘CNT02-4 (GN102-22 | Variation upon changeover osvio3v (66, POTTA) | (61,POT-) _| from forward to backward titing CN102-5 GN102-22 (69, SPL) (1,PoT) | Ne Lever is in the neutral position cn102-6 N102-22 1.3V (20, POLT1) (SrPOT) | Chango when helitleveris | Civ aay , , tited forward and backward ; Lever isin the neutral position cN102-7 cn102-22 Approx. 3.3V Change when the lift lever is ere (51,POT) | tited forward and backward eae Lever is in the neutral position fearon et feorl Change when the tif lever is Reve , , tited forward and backward | Lever is in the neutral position qsrvortz, | rpoT) |Changewhen thetitieveris | APR SOY , , tited forward and backward Lever isin the neutral position (CN102-10 (CN102-22 ‘Change when the attachment 1 Approx. 1.3V. (24, POTAT11) (51, POT-) | lever is tilted forward and back-| 0.5V to 2.2V ward Lever in neutral position cN102-11 N102-22 | Change when attachment 1 Approx. 3.3V (25, POTAT12) | (51, POT) _| leveristited forward and back} 2.3V to 4V ward Lever in neutral position eNn102-12 cN102-22 | Change when attachment2 Approx. 1.3 (26, POTAT21) | (61, POT.) | Ieveris tited forward and back- | 0.8V to 2.2V ward Lever in neutral position cN102-13 CN102-22 | Change when attachment2 Approx. 3.3V (27, POTAT22) | (61, POT.) _| levers tited forward and back-|2.3V to 4V ward oN102-14 (GN102-22 (63, poTat) | (61,POT-) | ood14, Connector No.=-Connector No. Conditions ‘Standard: | Remarks N102-15 (CN102-22 (316, PoTH) | (61,PoT) | ‘Approx. 4.7V CN102-16 CN102-22 (67,PoTTAH) | (61, POT.) | So CN102-17 (CN102-22 (68, SPL+) 61,PoT) | eo CN102-18 (GN 102-22 (28, POTL+) (81, POT-) | eee N102-19 (CN 102-22 (29, POTT+) (1,PoT) | ‘Approx. 4.5V N102-20 (GN102-22 (@0,PoraTix | 61,POT) | — oo Lo N102-21 (CN102-22 (1, PoTat24 | 61,POT) | Approx. 4.5V ON102-22 _ _ _ (61, POT-) GN103 connector basic conditions (battery plug connected, key switch ON)[Standard vehicle] Connector No.<> Connector No. Conditions ‘Standard: Remarks CN103-1 aetCa = immeasurable = CN103-2 (198 CANL) = Immeasurable = N103-3 ‘CN103-12 (147, CANGND) | (14,GNDD) | — ‘Approx. OV cN103-4 CN103-12 | Key switch OFF acca aan (43, vBKY) | (14, GNDD) | Key switch ON eae ‘CN1035 CN103-12 324, sso+) | (14,GNDD) | Unused _ CN103-6 N103-12 (325, ss0-) | (14, 6NDD) | Unused ~ CN103-7 cNn103-12 | _ "Approx. 48V (41, VBBT) | (14, GNDD) ‘Approx. 36V 6N103-8 eN103-12 (cHkisy) | (14, GND) | Unused _ N103-9 CN103-12 (.CHKSV) (14,GNDD) | Unused _ ‘CNt03-10 CN103-12 (16,D15v) | (14,GNDD) | oY215 (14, GNDD) Connector No. Connector No. Conditions ‘Standard: Remarks GN103-11 (CN103-12 “CHK3.3v) | (14, GNDD) | Unused ~ ‘CN103-12 _ _ _ (14, GNDD) CN103-13 Aa = immeasurable = (CN103-14 (143, SoTMK) — immeasurable — CN103-15 (142, SDTMA) _— immeasurable _— CN103-16 (141, SMTDA) _- immeasurable — CN103 connector basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle] Connector No.= Connector No. Conditions Standard: | Remarks MastGAN} = Immeasurable = ios - immeasurable - (146, CANL) N103-3 CN103-12 (147, CANGND) | (14,GNDD) | ‘Approx. OV cN103-4 CN103-12 _| Key switch OFF era (43, VBKY) (14, GNDD) | Key switch ON Approx ey (CN103-5 (CN103-12 (324, SSO+) (14, GNDD) | Unused _ CN103-6 CN103-12 (325, SSO-) (14, GND) _ | Unused — (CN103-7 (CN103-12, _ Approx. 48V_ (41, VBBT) (14, GNDD) ‘Approx. 36V (CN103-8 (CN103-12, {CHK1sv) | (14,GNDD)_| Unused _ 6N103-8 CN103-12 (—. CHKSV) (14, GNDD) | Unused _ CN103-10 CN103-12 (16, D15v) (14,6NDD) | — ‘Approx. 15V (CN103-11 (CN103-12 (CHK3.3v) | (14, GNDD) | Unused _ (CN103-122-16 Connector No.<> Connector No. Conditions Standard: | Remarks ON103-13 Rutan = immeasurable = CN103-14 Ratecaan = immeasurable = CN103-15 mataciun = immeasurable = enoee = immeasurable = (141, SMTDA) CN104 Connector basic conditions (battery plug connected, key switch ON)[Standard vehicle} Connector No.<=Connector No. Conditions Standard: | Remarks CNt04-1 ‘CN104-22 ‘Approx. 48V (18, B48V) (N2,N2) | Key switch OFF Approx. 36V CN104-2 (CN104-22 ; ‘Approx. 48V (18, B48v) (N2,N2)_| Key switch OFF ‘Approx. 36V CN104-3 CN104-4 (3, SOLL#) (4, SOLL-) eel CN104-4 GN104-3 | Resistance measurement with | oy ao (4, SOLL-) (3, SOLL+) _| battery plug disconnected PPFOX. CN104-5 CN1043, (6, SOL a1) (3,SOLL+) | ~ CN104-6 ent04.7 | _ _ (sous) | (7,soLa2) CN104-6 cNi048 | _ (6. SoL2+) (8. SOL b2) Tit lever in the neutral position joni CN104-22 | Tit lever in the forward or back-| Approx. 11V (6. SOLT+) (SOLT) | ee ton ‘CN104-7 CN10422 | Resistance measurement with (7, SOLT-) (6. SOLT+) _ | battery plug disconnected ‘Approx. 102 CN104-6 cn104.6 | _ (8, SOL b2) (6. Sol2+) CN104-9 (CN104-22 ‘Approx. 48V (65, CPR) (N2, N2) ‘Approx. 36V CN104-10 CN104-22 ‘Approx. 48V (65, CPR) (N2, N2) Approx. 36V CN104-11 CN104-12 | _ _ @,80L3+) | (10, SoL23) CN104-11 N104-13 | _ _ @,So13+) | (11, SOLb3)Connector No. Unused - CNt05-11 crite = Unused =2-21 CN107 connector basic conditions (battery plug connected, key switch ON, connector disconnected) (P2, P2) Connector No. CN100 connector basic conditions (battery plug connected, key switch ON) Connector No.<>Connector No. Conditions ‘Standard: Remarks eatoay = Unused = ane) = Unused = Fx) - Unused — owtoos eee oe - anon = Unused = ey = Unused = Srna = Unused = pa = Unused = (CN26 connector basic conditions (battery plug connected, key switch ON) Connector No.<»Connector No. Conditions ‘Standard: Remarks (sa cPR) (P2.P2) [battery pug deconnected | APPFOX. 200 (CN26-22:22 Traveling AC driver 2 CN109 connector basic conditions (battery plug connected, key switch ON) Connector No.-2Connector No. Conditions Standard: | Remarks ‘CN109-10 (CN109-1 (82, SSD2-, Approx. OV (—, CUDIDO) 12) (CN109-2 (cupID1) - ed _ (CN109-3 (145, CANH) _- immeasurable _- CN109-4 (146, CANL) - immeasurable — (CN109-5 (.CANTRD) _ Unused _ CN109-6 CN109-6 (147, CANGND) | (147, GNDD) Ei ‘CN109-7, N2 ‘Approx. 48V (55, KEYSTART) (N2, N2) Approx. 36V CN108-8 (—, CUDON) Unused — (CN109-10 (CN109-9 (78, ss02-, |— ‘Approx. 12V (75, SSD2+) TD) (CN109-10 (CN109-10 (78, SSD2-, (78, SSD2-, | — ‘Approx. OV ‘TD2-) ‘TD2-) CN109-10 CN109-11 (78, sso2-, |— Oto 1av (76, SSD21) 12) (CN109-10 (CN109-12 (78, ssp2-,_ |— Oto 12v (77, S8D22) 12) (CN109-13 (78, TD2+) a immeasurable2:23 Traveling AC driver 4 CN110 connector basic conditions (battery plug connected, key switch ON) Connector No. 2) Operated: ON (0.2) 2. Operate the material handling lever and check that the limit switch is tumed on at dimension A beyond the no- play position. A= 5 to 15mm (0.39 to 0.79in) 3. Ifthe limit switch ON timing does not occur within dimension A, adjust the limit switch installation location. ‘As for the tlt lever operation, adjustment is not necessary, as the micro switch is built in the control valve ASSY.2-4034 MULTI-DISPLAY FUNCTIONS Page MULTIPLE DISPLAY ..............00-00000000 3-2 GENERAL. 0.2.0. ee ceeeeceeeceeeereeeeeeeenes 3-2 SPECIFICATIONS. .......0...00c00eeeeeeeeee ee 36 GENERAL FUNCTION AND MANAGER'S FUNCTION 3-7 DISPLAY INDICATION LIST.........02.00200ee0 ee 38 El ABBREVIATIONS DISPLAYED ON THE SCREEN... 3-10 GENERAL FUNCTIONS ..............-00--.0665 31 OPERATING PROCEDURE OF FUNCTION SETTING. 3-13 MANAGER'S FUNCTIONS..............2..0005 3-18 PASSWORD FOR MANAGER'S FUNCTION ........ 3.48 OPERATING PROCEDURE OF FUNCTION SETTING. 3-19 DIAGNOSIS . = 3-24 DIAGNOSIS CODE LIST = 3-24 MASK FUNCTIONS ..............-002002c0 eee 3.30 GENERAL... 0.0... 00eecseeeeeeeeeeeenerenees 3-30 PASSWORD FOR MASK FUNCTION .............+ 3-32 OPERATION ON MASK MENU SCREEN ........... 3-33 ANALYZER. . 3-34 TUNING. . = 3-64 OPTION SET. - 3-64 MATCHING ...... 002.0020 ecc eee eee eee eeeeeee 3-68 TIRE CONSTANT SET ....... 2... e eee eee eee ee 3-713.2 MULTIPLE DISPLAY GENERAL The multiple display indicates various types of vehicle information by switching the screen according to need. Display and Buttons (1) (2) (3) (4) Initial screen upon key switch on SERTSS AW TT” OO During traveling (40) (11) Upon error occurrence (1) | Parking brake ON indicator (7) | Multiple display area (2) | Travel speed limit indicator (8) | DOWN button (3) | Diagnosis ON indicator (9) | UP button (4) | Overheat warming indicator (10) | Power select button (6) | Battery charge indicator (11) | Hour meter selector button (6) | Power select indicator3:3 (1) Parking brake ON indicator This indicator comes on when the parking brake is activated. If the accelerator pedal is depressed with the direction lever in the forward or reverse position, beeps sound to warn the operator. (2) Travel speed limit This indicator comes on when the level is set to 7 or less on the TRAVEL SPEED LIMITTER LEVEL SETTING screen. (The setting in USA models can be changed only by the Manager's functions.) (3) Diagnosis ON indicator Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same time, the corresponding error code is displayed and buzzer sounds to warn the operator. Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to six error codes are displayed with alternation at intervals of 2 seconds. On a vehicle without matching performed for the SAS function, this indicator comes on to warn the service person. This indicator also comes on to warn the service person on a mini lever model vehicle without matching performed for the mini lever function. Perform matching by referring to the MATCHING section (4) Overheat warning indicator Ifthe temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or pump motor rises beyond the specified level, the overheat warning indicator blinks. At the same time, a buzzer sounds to warn the operator. When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks. Overheat warning indicator Description Indication ‘Overheat section CIR Main controlier DCR Traveling AC driver PCR Material handling AC driver DM Drive motor Overheat section PM Pump motor Vehicle Operation Restriction when Overheated Overheat ] Specitica- [yy Description of control lode ‘section tion Primary control ‘Secondary control Tertiary control ro sTD 41. Character indication and indicator blink UL-EE spec 2. Buzzer for 5 seconds controller |" opty 3. Change to half throttle i sTD- 1. Character indication and indicator blink reins |UL-EEspec 2. Buzzer for 5 seconds (PT) 3. Change to half throttle Material | STD- 1. Character indication and indicator blink 2. Buzzer for 5 seconds 3. Restrict material handling output handling |UL-EEspec. AC driver | (OPT) o| 2] x] ov] | «| 0] x34 : Description of control Overheat | Specifica- | 444 pti section tion Primary control ‘Secondary control ‘Tertiary control 1. Character indication | 1. Character indication and indicator blink | and indicator blink H | 2. Buzzer for 5 2. Buzzer continues seconds 3. Change to half 3. Change to mode | throttle STD) 1. Character indication P| and indicator blink blink 2. Buzzer continues 'S_|3. Change to half A throttle Prive motor 1. Character indicat 1. Character indicati waracter indication ; Character indication and indicator blink | "Character indication | ang indicator blink H |2. Buzzer for 5 pyres 2. Buzzer continues seconds F Rectict ative output {3 Change to half 3. Change to S mode i throttle UL-EE spec —m (OPT) Character indication i P| "and indicator bink | * Character indication peers and indicator blink Sseoee 2. Buzzer continues $ |3. Restrict drive oe ee output H 1. Character indication and indicator blink std | -P |2. Buzzer continues S13: Restrict material handling output 1. Character indication i 1. Character indication and indicator link | *- Character indication |” and indicator blink H | 2. Buzzer for 5 Pane besser 2. Buzzer continues seconds 5 Chanas to S mode |: Restrict material 3. Change to P mode | * Chang: handling output Pump motor| 1. Character indication | 1. Character indication and indicator blink | and indicator blink heapesecs P | 2. Buzzer for 5 2. Buzzer continues seconds 3. Restrict material 3. Change to S mode | _ handling output 1. Character indication ‘and indicator blink S | 2. Buzzer continues 3. Restrict material handling output35 (6) Battery charge indicator This indicator indicates the remaining battery charge in 10 stages. ‘A: Low remaining battery charge warning The battery charge indicator blinks when the remaining battery charge drops to the set level or below. When the key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to wam the operator. B: Battery overdischarge warning (lift interrupt function) ‘When the battery charge decreases further below the set level after the remaining battery charge warning, any Number of segments corresponding to attempt at traveling or material handling operation will the remaining battery charge. cause all charge indicator segments to blink and the alarm to sound to warn the operator. At this time, the ‘material handling operation is disabled in USA and Battery overdischarge warnin, Canada models. However, when the key switch is tumed —————7 from OFF to ON, the operation can be performed only once for 30 seconds. In export models, the material handling operation during traveling is disabled. Note: The level can be set using TUNING function of the mask function. (See page 3-54.) All segments blink. (6) Power select indicator (traveling and material handling) box enclosing S, P or H indicates the mode selected at present. The setting can be changed by pressing the power select button on the GENERAL screen. Ifall symbols are enclosed, control is performed in the original mode (level set on the POWER CONTROL LEVEL SETTING screen). (7) Multiple display area The date and time are normally displayed in this area. This area is also used for various function settings and error code displays of the diagnosis function. (8) DOWN button ‘The DOWN button is used for setting the clock on the GENERAL screen. The DOWN button is also used for setting the level of each function on the MANAGER'S FUNCTION screen’. *: Operation can be performed by inputting the manager's password, (9) UP button The UP button is used for setting the clock on the GENERAL screen. The UP button is also used for setting the level of each function on the MANAGER'S FUNCTION screen’. *: Operation can be performed by inputting the manager's password, (11) Power select button USA models: Press the button for 2 seconds or more on the GENERAL screen to set the clock Only when "YES" is selected on the MANAGER'S FUNCTION screen‘, the S, P or H modes can be changed by this button. ~A square indicating the selection moves to the right each time the power select button is pressed. Press the button for 2 seconds or more to set the level of each function. Export models: The button selects S, P or H mode. The selected mode can be changed each time the power select button is pressed on the GENERAL screen. Press the button for 2 seconds or more to set the level of each function. *: Operation can be performed by inputting the manager's password.36 (11) Hour meter selector button This button changes displayed items of multi-hour meter function (12) Low temperature warning indicator ‘Warn the low temperature of the traveling and material handling AC drivers. When the material handling AC driver temperature becomes low, a buzzer sounds to warn the operator for 5 seconds. At the same time, it restricts the material handling output. The low temperature section indication blinks. Description Indication Low temperature section COLD DCR Traveling AC driver COLD PCR ‘Material handling AC driver Maintenance timer indicator (13) Maintenance timer indicator This indicator blinks to notify the need of maintenance when the time set on the PLANNED MAINTENANCE HOUR ‘SETTING screen passes. When the key switch is turned from OFF to ON in this state, the buzzer sounds for 5 seconds to warn the operator. SPECIFICATIONS LCD Dot matrix + fixed display Buttons Four buttons Back light LED type that comes on when the key switch is tured to ON Heater ‘Temperature detection type (provided only on the cold-storage model)37 GENERAL FUNCTION AND MANAGER'S FUNCTION 1. General functions can generally been used or seen by the user. 2, The Manager's function is a function that the manager can use by inputting the password, 3. The functions included in the General function and the Manager's function differ in accordance with the specifications of the model as follows. O:General function @:Manager's function Model | USA mode! Export model Functions (standard model) | F*Port mode! Battery charge indicator o o ‘Speedometer Status display = Turion” | Travel speed limiter indicator Parking brake ON indicator Power select indicator Power select Traveling power control level setting Level setting - ‘function 2 | Material handling power control level setting Travel speed limiter level setting Maintenance hour meter setting Multi-hour meter function Key ON hour meter Traveling hour meter ‘Material handling hour meter Traveling or Material handling hour meter ‘Odometer Lap time meter Trip meter Maintenance hour meter Calendar - clock Warning function Battery overdischarge warning Low remaining battery charge warning ‘Overheat warning Low temperature war Parking brake ON warming Parking brake OFF warning ©} O} OJ Of Of Of Of O} Of Of Of O| Of C| O| Of e/ O} Of Of OJ CO} Of of O Retum to neutral warming ©} Of Of 0} Of Oo] Of 0} Of Of Of O| | Of O} Of 0} @| @) | ef of of oJ 0 Material handling operation lock OF ot ‘Overspeed alarm ° ° ‘Maintenance indicator ° ° Diagnosis display ° ° *4: Only for models with mini lever (OPT).38 DISPLAY INDICATION LIST USA models (standard models) GENERAL screen BF Te be selected by th user 2 ting ker Sa — ORS VV OAT PA TST PTT TATE 4 ‘Tobe set bythe user, ascot IE "Press batON OT Tae oF MANAGER'S FUNCTION screen] Fj ‘To be selected by the manz vfching to hour meter depla Traveling or materal handling system operation me Tower select Foner mode selection ‘To be set by the manager ravel speed imier level soling J Soting the wavel rater Tevel jeg alarm aveling speed setting for overspeed alam ne adjustment of each of vaveling and material Ranging Lnanefialitaeaal power control levels Tanned marnlanance hou sating| Selling the ime Tor planned matenancs Nour Meter set lustment of indicated ime ress Bunton (a) Tor 2 See OF Oe. MASK FUNCTION screen ‘To bo set by dealer or serviceman it Tagnoals G70" Codes OTSA A maT TO MONTTORT the temperature and vollage of each functional part anavzer [2 ‘ravelng-related sensors NITORS material handling and mast ConvOl Sensor, stearing knob synchronizer and other sensor rv ‘orced Test of each sw jad function adjusiment Tever adjustment TUNING itlever adjusiment Tever adjustment er adjustment nabling simultaneous Traveling and material handling BeToTe Siaring the hour meter count [ower contro fock selection ranging display or each destnaton ing he Wavaling speee ating he caToulaion constant Yor batory Charge matcator Ring he operation othe Avo OFF ToncTon in elaTon eee the mast forward tangle resinGTOn ie steering knob synchvonzer ing the mast forward tk speed cont FncTon the batter Teciing the fing the specication of ng the specication of -way miniTever models ie USA specification Ttching of he Weve angie i forward restieted aiching of te NL oat falching of tre re angie Sensor Toward GreCTON MATCHING ing ofthe I fever neutral postion aiching of fe It Tever neutal postion fatching of fe ATT 1 lever neival poston aiching of re neuital position ating the tre constantExport models GENERAL screen 5 Tobe selected ‘To be set by the user ravel alain Power contol select Enter password| Enter password| "Press ballon MANAGER'S FUNCTION screen] ‘ower select ‘To be set by the manager Travel speek alarm Power contol select Tanned maintenance Tock sot MASK FUNCTION screen “To be sot by dealer or serviceman v NITORT neck eck ‘orced itlever ANALYZER. ACT ur TUNING TONINGSTITV, ar ower Coriol Tock selection. at Tr ing alin tr OPTION SET ect i Tao atch Niatcing icing atching aching ing MATCHING the user ing to hour meter deDTa Tint vel SoM 7 “To be selected by the manager To hou meter dspla Timer Tavel sot Ts SSTETSTON CONSTETT TOE Tre the steering knob synchronizer the TSeRng TaVeTiag OF MATT] RANTING SySEM OGTATON TS ing the Wavel speed Tmter raveling speed setting for overspeed Samm Fine adusiment of each of reveling and material Randing re contol levels justment of ndicaTed UE woking Waveling or material handing system operation Tine made sevaction ating the Wavel speed Wer leva raveling speed selling or overspeed Sa ine adjustment of each of traveling and material hanging power contra levels. efing the ime for fanned rainerance Hour Meter iustment of indicated time al Gagnoals efor Sodes SIO the temperature and votage. TWavelng-rlated sensors material handling and mast COnMOl Sensors sigering knob synchronizer and other sensor Test of each switch ction adjustment adusimant ‘agjustment adjustment adjustment simultaneous Wave ie haur moter count ‘ach functional par ‘ara rateraT Rana splay for each destination Tavelng speed GSD Charge aeator ration othe Ao king brake OFF warnin mast forwar fe resion Tunson th elaion To The seat Sw ato The batiory voTage 12 specTication of [way Ai lever MOG icalion of d-way miniTever models fication ward Ut speed contol Tonto we UavaT a it Forwar Tire angle Sensor Tonwar Tt Tever neutal postion: TitTever neuial postion Tever neutral poston Tever neutral positon re constant om oft TesCeT SAGE i oft The3:10 ABBREVIATIONS DISPLAYED ON THE SCREEN [Abbreviation Meaning ‘Abbreviation Meaning Ai ‘Attachment switch 1 S802 Drive motor 2 rpm sensor 2 ‘Attachment switch 2 SSP Pump motor rpm sensor oR Controller sts Steering angle sensor DCR Traveling AG driver STS1 Steering angle sensor 1 DM Drive motor ‘STS2 Steering angle sensor 2 DSF Forward direction switch sTsc rer angle sensor for straight DSR Backward direction switch ‘SWAG | Accelerator switch FAN Cooling fan ‘SWTK | Tilt knob switch HIM Hour meter T Forward and backward tlt switch Kore [Deaton ofsterng angle knob pos rp Traralng NE ve corte Road K-POS _| Steering angle knob position TBP een Sa ese KSOL ‘Steering synchronizer solenoid 1D Drive motor temperature LOAD | Material handling hydraulic pressure [TEMP | CPU board surface temperature L Lift switch THCD | Main drive circuit temperature isB Brake switch THCP | Main pump circuit temperature isd Seat switch TILTF Forward tit restriction position MH Lifting height switch TTL Tilt level position PIC Power control TIRE Tire angle sensor voltage PCR Material handling AC driver 1P Pump motor temperature PM Pump motor VB48 Battery voltage POTA Accelerator potentiometer VBBD Wel) ier Dont ool POTT Tilt angle potentiometer BBP eee AC ihe power ‘SPD Main traveling speed VeKS Voltage after Key switch SPL Load sensor VBMB_| Main controller input voltage S801 Drive motor 1 rpm sensor VBSOL _| Solenoid power source voltage311 GENERAL FUNCTIONS Changing Display USA models (standard models) Button (1) Button (2) GENERAL screen > Hour meter display selection Button (3) Press button (3) for 2 seconds or more. CLOCK SET FUNCTION SELECTION screen Lb Press button (3) GENERAL screen2. Export models Baca enrel GENERAL screen (eas) Button (3) 1) Press button (3) for 2 seconds or more. TRAVEL SPEED LIMITTER, LEVEL SETTING screen OVERSPEED ALARM SETTING screen POWER CONTROL FUNCTION SELECTION CLOCK SET FUNCTION —) J SELECTION screen Press button (3) (To GENERAL screen)OPERATING PROCEDURE OF FUNCTION SETTING GENERAL SCREEN 1. Hour meter display selection Press button (4) to select the hour-meter display. 313, GENERAL screen rn q Button (3) Button (4) i SCY Press button (4) 4> Press button (4) A: Key ON hour meter H: Maintenance hour meter Press button (4) <> Press button (4) B:Traveling hour meter C:Material handling hour meter G:Trip meter <= et |(@t |e) SCE Press button (4) D:Traveling or material handling hour meter ana) > Press button (4) “The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more. Press button (3) on each screen to return to the GENERAL screen.Function Description A | Key ON hour meter Indicates the total key ON time B | Traveling hour meter Traveling operation time C | Material handling hour meter | Material handling operation time Traveling/material handling ‘Total time of traveling and material handling operation (when both D | hour meer operaons ‘occur at the same time, only operation time of either E | Odometer Total distance traveled F | Lap time meter Lap time upon key ON G | Trip meter Trip distance H | Maintenance hour meter ‘Accumulated time total in key on-state since last maintenance Button (3) Power select indicator Button (1) Button (2) aStalel Travel speed limiter level T Button (4) Button (3) Button (1) Button (2) Button (3) Traveling speed setting for overspeed alarm 2. Power select mode switching (S, P or H) (Export models only) Press button (3) on the GENERAL screen to change the travel/material handling power select mode. When all of S, P and H are highlighted by squares, the control is, performed in the mode set on the Power Control Level ‘Set Menu screen. S: Standard mode P: Power mode H: High power mode TRAVEL SPEED LIMITER LEVEL SETTING SCREEN (Export models only) The travel speed limiter level is set on this screen. Press button (3) on the GENERAL screen for 2 seconds or more to display the TRAVEL SPEED LIMITER LEVEL ‘SETTING screen. 1. Press button (1) to decrease the travel speed limiter level. 2. Press button (2) to increase the travel speed limiter level. 3. Press button (3) to display the next screen. OVERSPEED ALARM SETTING SCREEN (Export models only) ‘The traveling speed level for the overspeed alarm is set on this screen. Press button (3) on the TRAVEL SPEED LIMITER LEVEL SETTING screen to display the OVERSPEED ALARM ‘SETTING screen. 1. Press button (1) to decrease the traveling speed setting. 2. Press button (2) to increase the traveling speed setting. 3. Press button (3) to display the next screen.Button (1) Button (2) Button (3) Select "YES" press button TRAVELING POWER CONTROL LEVEL SETTING screen and 8) OF Press baton MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen SOX Press button PLANNED MAINTENANCE HOUR SETTING screen @) @) POWER CONTROL FUNCTION SELECTION SCREEN (Export models only) The travel and material handling power control levels can be set independently using this screen. Press button (3) on the OVERSPEED ALARM SETTING screen to display the POWER CONTROL FUNCTION SELECTION screen. 1. Press button (1) on the POWER CONTROL FUNCTION SELECTION screen, select "YES" and press button (3) to display the TRAVELING POWER CONTROL LEVEL SETTING screen (1) TRAVELING POWER CONTROL LEVEL SETTING screen 1) Press button (1) to select the lower level. 2) Press button (2) to select the higher level. 3) Press button (3) to display MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen. (2) MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen 1) Press button (1) to select the lower level. 2) Press button (1) to select the higher level. 3) Press button (3) to display the next screen. 2. To display the next screen, press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select “NO” and press button (3); alternatively, press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen3:16 CLOCK SET FUNCTION SELECTION SCREEN The year, month, day, day of week, time and 12/24-hour display can be set independently. USA models Press button (3) on the GENERAL screen for 2 seconds or more to display the CLOCK SET FUNCTION SELECTION screen. Button (1) Button (2) Button (3) Button (4) Press button (3) 7” for 2 seconds or more. Press button (3) 3. Press button (1) on the CLOCK SET FUNCTION SELECTION screen, select "YES" and press button (8) to display the CLOCK SET screen. (1) CLOCK SET screen 1) Press button (1) to decrease the selected (blinking) value. 2) Press button (2) to increase the selected (blinking) value. 3) Press button (3) to enter the selected (blinking) value and proceed to the next item. 4) Press button (3) when “MINUTES" is selected on the CLOCK SET FUNCTION SELECTION screen to display the next screen (GENERAL screen). 4. Press button (2) on the CLOCK SET FUNCTION SELECTION screen, select "NO" and press button (3) to display the GENERAL screen.3:18, MANAGER’S FUNCTIONS PASSWORD FOR MANAGER’S FUNCTION Note on password input 1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button may be damaged. 2. Ifa mistake is made part of the way through, turn the key switch to OFF and begin again. If the MANAGER'S FUNCTION screen does not appear after several attempts, the system may be faulty. Password Input Procedure Button (3) Button (4) 1. Press buttons (3) and (4) at the same time. GY Button (1) 8 J 2.Wi ithin 10 seconds, press button (1) MANAGERS FONCTION Seen Sed ca Button (2) Button (1) Button (2) 3, Within 10 seconds, press button (2) 4. Within 10 seconds, press buttons (1) and (2) at the same time for more than 2 seconds. Procedure ‘Operation Vehicle operation 1 Press buttons (3) and (4) at the same time. ‘A short beep sounds. 2 Press button (1). (in 10 seconds after pressing button (3) and (4)) [A short beep sounds. 3 Press button (2). (in 10 seconds after pressing button (1)) ‘A short beep sounds. Press buttons (1) and (2) at the same time and hold for 2 seconds. 10 seconds after pressing button (2), End of password | Short beeps sound, 5 ‘The MANAGER'S FUNCTION screen appears automatically.3:19 OPERATING PROCEDURE OF FUNCTION SETTING Changing Display Input the password on the GENERAL screen to display the MANAGER'S FUNCTION screen. MANAGER'S FUNCTION screen Button (3) TRAVEL SPEED LIMITER LEVEL SETTING screen OVER SPEED ALARM SETTING screen POWER CONTROL FUNCTION SELECTION screen SF Press ation 8) SUX Press button (3) Select "YES" press button ( TRAVELING POWER CONTROL LEVEL SETTING screen and (3). Button (1) Button (2) Press button (4) Select "YES" and press button (3) Select "NO" and press button (3) q Button (4) SCY Press button (3) for 2 seconds or more. Select "NO" and Press button (3). > Press button (3) Hour meter display selection Power control selection GENERAL screen % > Press button (3) CLOCK SET FUNCTION SELECTION screen PLANNED MAINTENANCE HOUR SETTING screen MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen3:20 MANAGER’S FUNCTION SCREEN 1. Hour meter display selection Press button (4) to select the hour-meter display. *: The displayed contents on each function screen is the same as that for the GENERAL function. Button (2) MANAGER'S FUNCTION screen AGS (=[e|| © Button (2) Button (4) i SCX Press button (4) 4} Press button (4) ‘AcKey ON hour meter H:Maintenance hour meter Oe Press button) B:Traveling hour meter C:Material handling hour meter G:Trip meter <> Press button (4) D:Traveling or material handling hour meter E:Odometer F:Lap time meter Press button (4) The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.Button (3) Power select indicator Button (1) Button (2) Travel speed limiterlevel | Button (4) Button (3) Button (1) Button (2) Button (3) Traveling speed setting for overspeed alarm 3-21 2. Power select mode switching (S, P or H) Press button (3) on the MANAGER'S FUNCTION screen to change the travel/material handling power select mode. When all of S, P and H are highlighted by squares, the control is performed in the mode set on the Power Control Level Set Menu screen S: Standard mode P: Power mode H: High power mode *: For Export models, the mode can be set by the GENERAL FUNCTION. TRAVEL SPEED LIMITER LEVEL SETTING SCREEN The travel speed limiter level is set on this screen. Press button (3) on the MANAGER'S FUNCTION screen for 2 seconds or more to display the TRAVEL SPEED LIMITER LEVEL SETTING screen, 1. Press button (1) to decrease the travel speed limiter level. 2. Press button (2) to increase the travel speed limiter level 3.__ Press button (3) to display the next screen. *: For Export models, the mode can be set by the GENERAL FUNCTION, OVERSPEED ALARM SETTING SCREEN The traveling speed level for the overspeed alarm is set on this screen. Press button (3) on the TRAVEL SPEED LIMITER LEVEL SETTING screen to display the OVERSPEED ALARM SETTING screen. 4. Press button (1) to decrease the traveling speed setting. 2. Press button (2) to increase the traveling speed setting 3.__ Press button (3) to display the next screen. *: For Export models, the mode can be set by the GENERAL FUNCTION.Button (1) Button (2) Button (3) Select "YES" and 5 press bution (3 TRAVELING POWER CONTROL LEVEL SETTING screen UY Press button (3) MATERIAL HANDLING POWER, CONTROL LEVEL SETTING screen > Press bution (3 PLANNED MAINTENANCE HOUR SETTING screen Button (1) Button (2) Button (4) Current time Button (3) POWER CONTROL FUNCTION SELECTION SCREEN The travel and material handling power control levels can be set independently using this screen. Press button (3) on the OVERSPEED ALARM SETTING screen to display the POWER CONTROL FUNCTION SELECTION screen. 1. _ Press button (1) on the POWER CONTROL FUNCTION SELECTION screen, select “YES” and press button (3) to display the TRAVELING POWER CONTROL LEVEL, SETTING screen. (1) TRAVELING POWER CONTROL LEVEL SETTING screen 1) Press button (1) to select the lower level 2) Press button (2) to select the higher level. 3) Press button (3) to display MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen. (2) MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen 1) Press button (1) to select the lower level. 2) Press button (1) to select the higher level. 3) Press button (3) to display the next screen. 2. To display the next screen, press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select "NO" and press button (3); alternatively, press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen. *: For Export models, the mode can be set by the GENERAL FUNCTION. PLANNED MAINTENANCE HOUR SETTING SCREEN Planned maintenance hour is set on this screen. The time setting can be set 10 to 2000 hours. Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select “NO” and press button (3); alternatively, press button (3) on the MATERIAL HANDLING. POWER CONTROL LEVEL SETTING screen to display the PLANNED MAINTENANCE HOUR SETTING screen. 1. Press button (1) to decrease the setting time. 2. Press button (2) to increase the setting time. 3. Press button (4) for 2 seconds or more to reset the current time. 4. Press button (3) to display the next screen.3.23 CLOCK SET FUNCTION SELECTION SCREEN The year, month, day, day of week, time and 12/24-hour display can be set independently. (They can also be set on the GENERAL screen) Press button (3) on the PLANNED MAINTENANCE HOUR SETTING screen to display the CLOCK SET FUNCTION SELECTION screen. Button (1) Button (2) Button (3) Button (4) Press button (3) 1. Press button (1) on the CLOCK SET FUNCTION SELECTION screen, select "YES" and press button (3) to display the CLOCK SET screen. 2. Press button (2) on the CLOCK SET FUNCTION SELECTION screen, select “NO” and press button (3), o press button (3) when “MINUTES is selected on the CLOCK SET FUNCTION SELECTION screen to display the MANAGERS FUNCTION screen. *: As for the setting method for CLOCK SET FUNCTION SELECTION screen, refer to CLOCK SET FUNCTION SELECTION screen in GENERAL functions. (See page 3-16.)3:24 DIAGNOSIS Wrench symbol Diagnosis codes ‘When diagnosis is activated, the diagnosis ON indicator ‘comes on and blinks on the screen and a beep sounds to warn the operator that some abnormality has ‘occurred on the vehicle. ‘Also, up to three diagnosis error codes are displayed on the screen. When the number of error codes exceeds three, up to six are displayed on screens. In order to enable battery level checking, battery charge indicator is displayed during diagnosis error codes. ‘Abnormality detection time (Key ON hour meter) display. DIAGNOSIS CODE LIST Displayed code: Code indicated on the display when an abnormality occurs in the vehicle Diag memory code: Code indicated on the display when mask function DIAG MEMORY is in use P3-39 CIR: Main controller, DCR_LH: Traveling AC driver 1, DCR_RH: Traveling AC driver 2, PCR: Material handling AC driver Diag Displayed | Detection $PY°4 | memory Faulty Phenomenon on vehicle | Detection code cow | DOR_LA, Boa DCR: Low temperature lay only DOR-RY coLD | _ Restricted material cor PCR: Low temperature econea ou PCR 30-1 | 30-1 |DCR_LH: Low voltage Traveling disabled DCR_LA 302 | 30-2 |DCR_RH: Low voltage a DCR_RH ’ Material handling and 30-3 30-3 | PCR: Low voltage pe steering stop PCR 31-1 | 31-1 | DCR_LH: Low starting voltage “Traveling disabled DCR_LA ing i 31-2 31-2 | DCR_RH: Low starting voltage. ae DCR_RH . Material handling and 31-3 31-3 | PCR: Low starting voltage F steering stop PCR 32-1 32-1 | DCR_LH: EEPROM abnormality DCR_LH 32-2 | 322 |DCR_RH: EEPROM abnormality Operate under the default [DCR_RH 32:3 | 323 | PCR: EEPROM abnormality PCR aaa | oa |Sammaniston sbnomaiy fom Cito DCR LH = Traveling disabled 332 | a2 | Communication abnormality from GIR to a Scale DoR_RH I ‘Communication abnormality from C7R to | Material handling and 333 | 333 [por power steering stop oe 61-1 61-1 | Load sensor: Open “No NL control and forward AG 61-2 | 61-2 |Load sensor: Short circuit NS Saran eee3-25 Diag Displayed Detection spayed | memory Faulty Phenomenon on vehicie | Detection code 62-1 | 62-1 _|Tilkangle sensor. Open No forward tit retition | Gx 622 | 622 | Titangle sensor: Short circuit ‘No automatic leveling Forward and backward tit SWE 65-1 | 834 | simultaneously on Wo forward - lo forward tit restriction es2 | esa [forward SWE Shor crcutormorethan | N° mate tveing (CIR en (Forward tt disabled) ackward tl ort cruit for more 833 | 833 | than 2 minutes 64-1 | 64-1 _|Lift solenoid: Open 642 | 642 _|Liftsolenoid: Shor circuit ea of it solenoid | cy, 643 | 643 _| Lift solenoid: Drive circuit abnormality 5-1 | 65-1_| Tilt solenoid: Open - 52 | 652 | Tilt solenoid: Shor circuit aan of tit solenoid | cr 5:3 _| 65:3 _| Tilt solenoid: Drive circuit abnormality No forward tit restriction 66-1 | 66-1 | Tit matching abnormality No auomaticieeeinge” [CR No low lift restriction and 67-1 | 67-1 | Lifing height switch abnormality forward tit restriction | CIR No automatic leveling 71-1 | 71-41 _| Tire angle sensor: Open Traveling stop, no steering | op 742] 712 | Tire angle sensor: Short Grout knob synchronizer 72-1°1 | 72-1 _| Steering angle sensor. STS1 abnormality 7221 | 722 _| Steering angle sensor. STS2 abnormally | No steering knob or 72-3°1 | 72-3 | Steering angle sensor: STSC abnormality | Synchronizer 72-471 | 72-4 | Steering angle sensor: Open 73-1°1_| 73-1 _| Steering knob synchronizer solenoid: Open : ‘Steering knob synchronizer solenoid: Shor | Steering knob T3241 | 732 | Circuit synchronizer solenoid | C/R . ‘Steering knob synchronizer solenoid: output stop 733° | 733 | Drive circuit abnormality | Traveling restriction, 74-4 | 74-1. |Tire angle sensor matching abnormality | Nevelng resvicton. | cin DCR_LH, m| A0-1 | DCR main drive circuit overheat Restricted traveling output) CR RH eR! in drive ck Restricted material m| A0-2 | PCR main drive circuit overheat handling output PCR POR ‘Traveling disabled ‘Att | Att | CIR: High voltage ‘Material handling and | cir power steering disabled (solenoid off)3:26 CIR (1) power steering disabled Diag Displayed Detection splayed | memory Faulty Phenomenon on vehicle | Detection code ‘At2_|_At2 |DCR_LH: High voltage DCR_LA Traveling disabled AT3__|_AT-3_|DCR_RH' High voltage DOR_RH ; Material handing and at-4 | at-4 |PCR: High voltage seer caren aeatieg [PCR 2-1 | CPU board overheat Restricted traveling output | C/R 2-2 |DCR_LH or DCR_RH board overheat _| Restricted traveling output | Doty Restricted material han- | 2-3. | PCR board overheat ea cas PCR PCR “Traveling disabled Material handling and 3 | A3__| Incorrect battery connection Meter aoonn cated [CR “MB not turned on Aa__| Ad _ | Accelerator switch abnormality Traveling disabled oR 6-1 | _AG-1 [Lift switch abnormality A6-3__| AGS [Tit ewitch abnormality Material handling disabled | C/R ‘6-5 __| AGS [Attachment switch 1 abnormality ‘AAT | AA‘ | CPU board thermo-sensor abnormality oR ARZ_| AA |DGR_L board thermo-sensor abnormality | Restricted traveling output | DCR_LH ‘AAS _| AA-3_|DCR_R board thermo-sensor abnormality DCR_RH wy | Restricted material han- Aas | Aad |PCRboard thermo-sensor abnormality | Resvicted 7 PCR Traveling disabled i “Material handling and AC | AC. | Semiconductor switch abnormality Maer atone mented {OR MB not turned on : ‘Communication abnormality from DCR_L - ap+ | apa [pour Traveling disabled oR Traveling disabled Communication abnormality from DCR_L_ | (when AD-4 and AD-6 AD2 |) AD2 | ci (2) occur atthe same time, |CR MB not turned on) ‘aps | aps | Communication abnormality fom DCRR | reveling aisabied oR to. CIR (1) Traveling disabled Communication abnormality from DCR_R | (when AD-2 and AD-6 AD4 | AD Hoc (2) occur atthe same time, | /R MB not turned on) aps | aps | Communication abnormality fom POR to [Material handing and | op3.27 Diag Displayed i Detection Sede. | memory Faulty Phenomenon on vehicle | Controller code Material handling and P power steering disabled ADS ADS Comminication abnormality from PCR to (when AD-2 and AD-4 oR (2) occur at the same time, MB not turned on) AF-1 ‘AF-1_| CPU abnormality (1) AF-2_| AF-2 |CPU abnormality (2) ‘Traveling disabled -Material handling disabled) C/R AF-3__| AF-3 | CPU abnormality (3) ~_|-Power steering disabled AF-4 | AF-4 | CPU abnormality (4) C1-1 C1-1 | DCR_LH current sensor offset abnormality = zi DCR_LH C12 1-2 | DCR_LH: Overcurrent Traveling disabled veling disat C13 | C13 | DCR_RH current sensor offset abnormality a DOR RH C1-4 1-4 | DCR_RH: Overcurrent 7 r DCR_LH m| C2-1. | Drive motor overheat DCR-RH om Drive motor 1 thermo-sensor Restricted traveling output 2-2 2-2 abnormality DCR_LH Drive motor 2 thermo-sensor C23 C23 abnormality DCR_RH esc eat bor TA m in drive circuit thermo-sensor DCR_LH ea 3.2 |DCR_RH main drive circuit thermo-sensor ested Taveling CL DCR RH abnormality I Cat ‘4-1 _| Accelerator potentiometer abnormality (1) C42__| C42 [Accelerator potentiometer abnormality (2) | Traveling disabled or C43 C4-3_| Accelerator potentiometer abnormality (6) C44 4-4 _| Accelerator potentiometer abnormality (4) | Display only c7 c7 Direction switch abnormality Traveling disabled CR Cet C8-1_| Drive motor 1 rpm sensor abnormality i DCR_LH Restricted traveling output 8-2 | C82 | Drive motor 2 rpm sensor abnormality DCR_RH ‘Traveling disabled 7 ‘Material handling and CB4 | CB-+1 |MB-contactor abnormality powersteering abled [OR (solenoid off) CB-2 | CB-2 |MB contactor fused Display only oR Ett E1-1_| PCR current sensor offset abnormality Material handling and PCR E12 1-2 | PCR: Overcurrent power steering disabled m| 2-1 | Pump motor overheat Restricted material Por PM. handling output E2-2 2-2 | Pump motor thermo-sensor abnormalityDiag Displayed ‘cle | Detection Played | memory Faulty Phenomenon on vehicle | Detection code PCR main drive circuit thermo-sensor | Restricted material ES E3 | abnormality handling output Boe e8 EB_| Pump motor rpm sensor abnormality ___| Material handling disabled | POR ce-+ | cea | Cemmuntaton abnormality om Display ‘Communication abnormality from Display | DSP! n'y Cis ui i ce2 | ce2 [POR ‘Communication abnormally from Displa EE-3 EES |i CIR (3) i ity splay | Operate under the default | C/R EFA | _EF-1_| EEPROM abnormality (1) ‘Operate under the default EF2 | EF-2 | EEPROM abnormality (2) Operate under the default | EFS | EFS | CPU abnormality Display only EF4_|_EF-1_|EEPROM abnormality () Operate under the default fia | ria | Communication abnormality from GIR to Desplay (1) Display ont Disp Fi2 | F12_| Communication abnormality from C7R to vy only aed Display (2) FF FF _|Di6V overcurrent Display off oR Hi-1°2_| H1-1°2 | Lift potentiometer abnormality (1) H1-2°2 | H1-2 2 | Lif potentiometer abnormality 2) H1-3°2 | Hi-3°2 | Lift potentiometer abnormality (3) Lif operation stop cm Hi-4°2_| Hi-4°2 | Lit potentiometer neutral abnormality Hi-5°2 | H1-5 2 | Lift potentiometer matching abnormality H2-1°2_| H2-1 2 | Tit potentiometer abnormality (1) H2-2°2_| H2-272 | Tilt potentiometer abnormality (2) H2-3°2 | H2-3°2 | Till potentiometer abnormality (3) Tilt operation stop oR H2-4°2_| H2-4°2 | Tilt potentiometer neutral abnormality H2-5°2 | H2-5 2 | Til potentiometer matching abnormality wa-1-2 | ta | AtaehmentT potentometer anomaly waa [Hea-2 [AtaehmeneT poeniometer somal 133-2 | a3 2 | Alachment t potentiometer abnormality | Attachment 1 operation | cp ® stop : 7p | Attachment 1 potentiometer neutral abnor- 9-42 | Hoa 2 | A 135-2 | Has 2 | Attachment 1 potentiometer matching abnormality a1 2 | Hana *2 [Attachment 2 potentiometer abnormality [Attachment 2 operation | Gp. (1) stop3-29 abnormality Diag 5 Displayed Detection splayed) memory Faulty Phenomenon on vehicle | Detection code niea-2 [naa 2 [Alechment 2 polenfoneter abnormally tia3 "2 | wag 2 [Attachment 2 potentiometer abnormality (3) Attachment 2 operation | og yaa? | Maca tp |Altachment 2 potentiometer neutral stop abnormality 4-52 | Ha.5 2 | Altachment 2 potentiometer matching abnormality H5-1°2_| H6-1 °2 | Litbt (UP) solenoid abnormality (1) Lift operation stop H5-2°2_| H5-2°2 [Liftb1 (UP) solenoid abnormality (2) Material handling disabled H5-3°2 | H6-3°2 [Liat (DOWN) solenoid abnormality (1) _ [Lif operation stop oR H5-4°2 | H5-4°2 [Liftat (DOWN) solenoid abnormality (2) _|Material handling disabled H5-5°2 | H5-5°2 | Lif solenoid drive circuit abnormality | Material handling disabled | H6-1°2 | H6-172 | Tilt a2 (FRONT) solenoid abnormality (1) _| Tit operation stop H6-2°2 | H6-2 “2 | Til a2 (FRONT) solenoid abnormality (2) _| Material handling disabled H6-3°2 | H6-3°2 | Titb2 (REAR) solenoid abnormality (1) _| Tit operation stop oR H6-4*2_| H6-4*2 | Tit b2 (REAR) solenoid abnormality (2) | Material handling disabled H6-5°2 | H65°2 | Til solenoid drive circuit abnormality | Material handling disabled 7-12 | H7-1 "2 | Attachment 1 3 solenoid abnormaity (1) | Avtachment 1 operation H7-2°2 | H7-2°2 | Attachment 1 a3 solenoid abnormality (2) _| Material handling disabled H7-3 2 | H7-3"2 | Attachment 1 b3 solenoid abnormality (1) | Steehment 1 operation | ci H7-4°2_ | H7-4°2 [Attachment 1 b3 solenoid abnormality (2) | Material handling disabled co | npg p [Attachment 1 solenoid drive circuit 7-52 | Hr-s-2 |Afechment Material handiing disabled He-1 *2 | H6-1 *2 | Attachment 2 a solenoid abnormality (1) | Atechment 2 operation H8-2°2 | H6-22 |Atachment 2 a4 solenoid abnormality (2) | Material handing disabled He-3*2 | H6-32 | Attachment 2 ba solenoid abnormality (1) | Atachment2 operation | cj H8-4*2_| H8-4 2 |Altachment 2 b4 solenoid abnormality (2) [Material handling disabled He-5°2 | He-5*2 ae a Material handling disabled H9-1°2 | H-1*2 | Unload valve solenoid open HE2"2 | HZ? | Unload valve solenoid shor Mena eae ee | coe 0-3-2 | Hog 72 | Unload valve solenoid drive circuit “1: Only on the vehicle with the steering knob synchronizer (OPT). *2: Only on the vehicle with the mini lever (OPT).MASK FUNCTIONS GENERAL In addition to the functions described in the instruction manual for use by general users, the multiple display provides the following mask functions for use by the service staff for vehicle maintenance and specification setting, ‘The mask functions are protected by password to prevent damage of the data by unintentional operation by users. Mask Function List When used Funetion Description i Board ae replace- | Others "Y | ment Displays the vehicle's electrical ‘Analyzer system operating status and reads | __ ____ | Uponvehicte Le the error information detected by Peer ion controllers, — Makes fine adjustment of taveling | _ © [Asrequested J and material handling functions. 2 by customer Specification | Sets each vehicle option and other | _ o _ setting specifications. “1 2 Each control function enabl/| En@Bl8 oF disables each contol — | %s _ disable Option set 3 Hour meter start] Starts the hour meter count. ° 3 - Enables or disables the demo Upon new Demo mode —_| mode. (Material handling prohibition | — - vehicle during traveling for vehicle delivery) |demonstration Updates voltage values of sensor 5 Matching signals under the standard vehicle | — a - condition, Makes the speedometer reading _ ° _ Tire constant set oppropriate. 2 “1: This matches the controller and screen control according to the installed options and control functions equipped on the vehicle; note that this function does not enable or disable the option or control function itself, *2: Board main controller *3: Board ~ Multiple display control board3:31 Preparation for the MASK MENU screen Caution: ‘When going to the MASK MENU screen from the general screen, always jack up the vehicle until the drive wheels (front tires) leave the ground, and support the vehicle with wooden blocks under the front frames. Be sure to fully lower the fork. 4. Check that the battery plug is connected securely and turn the key switch to ON. 2. Operate mask functions according to Password Input Procedure. (See page 3-32.)3:32 PASSWORD FOR MASK FUNCTION Note on password input 1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button may be damaged. 2. Ifa mistake is made part of the way through, tun the key switch to OFF and begin again. If the MASK MENU screen does not appear after several attempts, the system may be faulty. Password Input Procedure Button (1) Button (2) mois 1. Press buttons (1) and (2) at the same time. MASK MENU screen Button (1) E i=] 2) ithin 10 seconds, press button (1) 5. The VERSION screen is displayed for about 3 seconds, O <> auton 2) Button (2) Button (3) 2.Wi it fo » 3. Within 10 seconds, press button (2) 4. Within 10 seconds, press buttons (2) and (3) al the same time for more than 2 seconds. Procedure Operation Vehicle operation Press buttons (1) and (2) at the same time. ‘A short beep sounds: Press button (1). (in 10 seconds affer pressing button (1) and (2)) [A short beep sounds. Press button (2). (in 10 seconds after pressing button (1)) ‘A short beep sounds. Press buttons (2) and (3) at the same time and hold for 2 4 | seconds or more. (in 10 seconds after pressing button (2), End of | Short beeps sound. password input) 5 __| The version screen is displayed automatically. @ [After displaying the version screen for 3 seconds, the MASK MENU screen appears automatically.VERSION screen OPERATION ON MASK MENU SCREEN Button (2) Button (1) couion “ Unlike the analyzer function selection on of previous models, display of test screen does not prohibit the KS vehicle's ordinary operation. ala 1. _ Input the password on the general screen (see page 3-32) to display the MASK MENU screen. 2. Press button (1) or (2) to select the desired menu item, Button (3) and press button (3) (enter) to display the menu or Press button (1) or setting screen for each function. (2)1o switch screen. (1) ANALYZER screen This screen displays the vehicle's electrical system operating status and the error code detected by the controller. (2) TUNING screen Performs fine adjustment of traveling and material handling control Press button (1) or (3) OPTION SET screen (2) to switch screen, Matches the controller or display control according to the set option or control (4) MATCHING screen This screen is for updating the sensor output voltage x ale stored in the controller (output voltage values from the [amma ce SAS function sensors in the standard vehicle condition) Press button (1) or (5) WHEEL DIA screen (2) to switch screen Updates the tire information in the controller to correct the speed and trip meter display. (©) END screen GENERAL screen can displayed from this screen. Press button (3) on this screen to display the GENERAL screen. ‘As an alternative method, tum the key switch to OFF when any screen is displayed to display the general screen. Press button (1) or (2) to switch screen. Press button (1) or (2) to switch screen. IN (=) Ob Press buton (3) GENERAL screen W3.34 ANALYZER GENERAL 4, The analyzer supports inspection and troubleshooting of the control system using the communication function between the traveling/material handling controller and the display. 2. Setting the display into the ANALYZER screen makes it possible to inspect and detect abnormal functions of the operating system and sensors, such as main traveling, material handling, EHPS, SAS circuits and the accelerator. 3. Utilization of the analyzer functions enables quick, easy servicing. 4, The analyzer has the following functions: (1) Diagnosis memory function (DIAG MEMORY) The controller stores up to 10 error codes detected in the electrical system in the past. The diagnosis memory function displays these error codes. Each error code is displayed with its detection time as the key ON hour meter reading. (2) In/out monitor function (/O MONITOR) This function displays the analog input values from individual sensors in the traveling, material handling, EHPS and SAS systems. The circuit or sensor quality can be judged by monitoring the displayed value. (a) VOMONITOR1 Displays the temperature of each electrical functional part and the analog input voltage detected by each controller. (b) VO MONITOR2 Displays the ON/OFF states of traveling-related switches and the analog input voltage from related sensors. (©) VOMONITORS Displays ON/OFF of switches related to traveling and mast control and the analog input voltage values from related sensors. (4) VOMONITOR4 Displays the ON/OFF states of steering knob synchronizer-related and other switches and the analog input voltage values from related sensors. (3) Active test function (ACTIVE TEST) The controller outputs an operation signal (ON or OFF signal) to the selected item in order to permit ‘operation check of that function. (4) One error code at the time is displayed in the upper righthand portion on both the /O MONITOR and ACTIVE TEST screens.ANALYZER MENU SCREEN * Values shown in the 2nd column are display examples and not the standard values. ‘ANALYZER MENU screen Display ‘1st column | 2nd column Meaning 1. DIAG MEMORY DIAG-1 to | Error codes and DIAG-10 _| detection time Error display Main drive circuit 1 temperature (heat sink): °C system and mast control) L:0.90 3.50 10 Wort THCD:#25/+25 | tain drive circuit 2 temperature (heat sink): °C O12 | THOP:#25 Main pump circuit temperature (heat sink): °C ” Drive motor 1 temperature: °C O13 |TD:#26/+25 | Drive motor 2 temperature: °C O14 | TP#25 Pump motor temperature: °C ” Traveling AC driver 1 board temperature: °C Wo16 TBD:+25/#25 | traveling AC driver 2 board temperature: °C 2. /O MONITOR1 . Material handling AC driver board temperature: (voltage, wo18 — | TBP:+25 Pe temperature) v0 1-7 TEMP:+25.0 | CPU board temperature: °C 018 | VB48:38.0 Battery voltage: V 01-9 | VBKS:38.0 Key start voltage: V 101-10 | VBSOL;38 Solenoid voltage: V 101-11 | VBMB:38 Main battery input voltage: V Traveling AC driver 1 DC_BUS voltage: V HWo12 — |VBBD:38/38 | Traveling AC driver 2 DC_BUS voltage: V 101-13 | VBBP:38 Material handling AC driver DC_BUS voltage: V| oon POTAO.71 ‘Accelerator potentiometer voltage: V SWAC:0 Acceleration switch: 0 (OFF), 1 (ON) vo22 [0SFO Forward switch: 0 (OFF), 1 (ON) DSR:0 Reverse switch: 0 (OFF), 1 (ON) vos (tset Brake switch: 0 (OFF), 1(ON) 3, JO MONITOR2 LsD:1 Seat switch: 0 (OFF), 1 (ON) (traveling system) Yo2s | SSD1:3000 | Drove motor 1 ppm: rpm [3000] | [Main controller instruction rpm: rpm] vo2s | 38023000 | Drove motor 2 rpm: rpm [3000] | [Main controller instruction rpm: rpm] 7026 | SPD:100 Main traveling speed: kh L=—=— 1 _ | Lift switch: 0 (OFF), 1 (ON) 4,1 MONITORS (material handling Lift lever angle 1 sensor voltage: V V0 3-1 4 Lift lever angle 2 sensor voltage: V Lift raise switch: 0 (OFF), 1 (ON) Lift lower switch: 0 (OFF), 1 (ON)3:36 Display ANALYZER MENU play Meaning screen ist column | 2nd column L(SOly=— | Unused W032 7 ft van A soty0.a5 | if proportional valve current 49 _| Forward tit switch: 0 (OFF), 1 (ON) Backward tilt switch: 0 (OFF), 1 (ON) 10 3-3 Tilt lever angle 1 sensor voltage: V “ Tilt lever angle 2 sensor voltage: V 7.0.90 3.50 10 _| Forward tlt switch: 0 (OFF), 1 (ON) Backward tlt switch: 0 (OFF), 1 (ON) T(SOL):—— [Unused VO3-4 4 A T(S01):0.35 | THtProportional valve current: At — ‘Attachment 1 switch: 0 (OFF), 1 (ON) ‘Attachment 1 lever angle 1 sensor voltage: V VO 3-5 2 Attachment 1 lever angle 2 sensor voltage: V A1:0.90 3.50 01 | Attachment 1 raise switch: 0 (OFF), 1 (ON) 4,10 MONITOR3 Attachment 1 lower switch: 0 (OFF), 1 (ON) (material handling system and mast | 5 SOE ce | Une control) A (s01).0.35 _|Atachment 1 proportional valve current: A Aa — Unused Attachment 2 lever angle 1 sensor voltage: V V0 3-7 3 Attachment 2 lever angle 2 sensor voltage: V ‘A2:0.90 3.50 01 | Attachment 2 raise switch: 0 (OFF), 1 (ON) Attachment 2 lower switch: 0 (OFF), 1 (ON) ‘A2(SOL):—— | Unused v0 38 3 ‘A2(S01y0.35 | Attachment 2 proportional valve current: A 1039 ‘SWTK.O Tilt knob switch: 0 (OFF), 1 (ON) yo310 | SSP:2000 Pump motor rpm: rpm [2000] [Main controller instruction rpm: rpm] vO3-11 | MH:10- Lifting height switch: 0 (OFF), 1 (ON) v0 342 |POTT2.50 Tilt angle sensor voltage: V VO343 —_ |SPL:0.84(1.7) [Load sensor voltage: V (MPa display)3.37 ANALYZER MENU Display hier screen ist column | 2nd column ° STs: Unused vO 4-1 ea eo Steering angle sensor pulse: 0 (OFF), 1 (ON) K-POS:—(-) [Unused 0 4-2 4 s nob ek SILO MONITOR’ K-POS:159 (150) | S¥8ering angle knob position: Actual (target) (steering control) Unused ON/OFF (0) WO 4-3 4 Deviation of steering angle knob position K-DIFF:100 Steering knob synchronizer solenoid SOL:0 0 (OFF), 1 (ON) 1044 TIRE:2.40 Tire angle sensor voltage: V nor ROROFT [roe KSOL:—/— © | Unused sore ae 6. ACTIVE TEST KSOL: signal ae eee (operation test) ONJOFF (0) | 5 normal) 4 (error) PSOL—/— (©) | Unused AcT3 oo Unload valve output Unload valve check signal: 0 (normal), 1 (error) “1: Mini lever models (OPT) *2: 3-way and 4-way mini lever models (OPT) *3: 4-way mini lever models (OPT) *4: Steering knob synchronizer models (OPT)3:38, Operating Procedure 1. Input the password on the general screen (see page 3-32) to display the MASK MENU screen. 2. Check that “1. ANALYZER" is selected on the MASK MENU screen and press button (3) (enter) to display the ANALYZER MENU screen. 3. Select the menu item using buttons (1) and (2) and then press button (3) (enter) to display the set screen. Button (1): To the previous menu item screen Button (2): To the next menu item screen Button (3): Enter (to the selected menu item screen) If you select *7. END" on the MENU screen of the analyzer and press button (3), the MASK MENU screen is displayed Button (1) Button (2) 4 Press button (3) ZLEND screen MASK MENU screen Bulton (3) CY Press button (3) IAG MEMORYscreen " 1.01 Press button (1) or (2) to switch screen. 6. ACTIVE TEST screen Press button (1) or (2) to switch screen. Co Press button (1) or (2) to switch screen. (2.10 MONITOR? screen Prete bt Bd (=[5) (2) to switch screen. oS n (1) oF (2) to switch screen. 3.1 MONITOR2 screen 5.l/] MONITORS screen EKG a Press button (1) or ~ Q ee i 4, MONITORS screen Press button (1) or (2) to switch screen. Eg3-39 Diagnosis Memory Function (DIAG MEMORY) The controller stores up to 10 of the most recent errors. The DIAG MEMORY screen displays these diagnosis error codes together with their detection time (as key ON hour meter reading), The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to DIAG-10. Button (1) Operating Procedure ANALYZER MENU screen _/Button(2)} 4. Display the ANALYZER MENU screen. 2. Check that “1. DIAG MEMORY” is displayed and press i<\>| button (3) (enter). Past diagnosis codes are displayed | sequentially starting with the newest one. eaG 3. Functions of buttons on the 1. DIAG MEMORY screen are as follows: Button (1): Unused Button (3) Button (2): Unused SCP Press button (3) Button (3): Displays past diagnosis codes + Press button (3) on the DIAG-10 screen to display the mos) ae | B + When no error codes are displayed on the screen and the hour meter time is “O.0h', it indicates that no error codes. are stored in the memory. Key ON hour meter * Other screen cannot be displayed from DIAG MEMORY > Press button (9) sereen. Display ANALYZER MENU screen to display other *: For the details of diagnosis error codes, see DIAGNOSIS. CODE LIST on P3-24. No ettor occurrencey” regs button (3) is indicated oy <> Press baton (3) ANALYZER MENU screen3-40 Vehicle Abnormalities Not Stored in Diag Memory ‘Some abnormalities are not stored in diag memory even when the controller detects it and warn the operator. ‘Warning indicators Warning method Displayed code + Indication Parking brake ON warning: Parking brake ON 1 Warns if the direction switch is turned to the warning indicator forward or reverse position and the vehicle blinks travels when the parking brake is on. * Beep ‘Short beeps Parking brake OFF warning: 2.| Wams ifthe operator vacates the seat without | + Beep eye pulling the parking brake lever. (Warns even Short beeps vod when the key switch is OFF) Overdischarge warning (lift interrupt): ‘Warns if the battery discharge exceeds the level set by the tuning function. (see page 3-54.) ee When the warning is activated, material handling | * poten charge indica- 43 | operation is disabled on USA models (Including | Patten) charge Canadian models). However, when the key one switch is turned from OFF to ON, the operation ame a can be performed only once for 30 seconds. As Ps for export models, the material handling ‘operation during traveling is disabled. Return to neutral warming: 4 Wamns if the key switch is turned to ON when the | + Beep No display direction switch is in the forward or reverse Short beeps position. Material handling lock (OPT): ‘When the operator leaves the seat while “Be 5 | operating the mini lever and then sits down et beeps No display again, a buzzer sounds to warn the operator and the material handling operation will be disabled. Incomplete matching warning: (1) Tit angle sensor at fork in the level position (2) Tilt angle sensor at the forward tlt restriction angle (3) Pressure sensor at no-load state (4) Tire angle sensor at straight travel position (5) Lift lever angle sensor in lift lever neutral + Indication position (OPT) ‘Wrench symbol (6) Tit lever angle sensor at tit lever neutral position (OPT) (7) Attachment 1 lever angle sensor at attachment 1 lever neutral position (OPT) (8) Attachment 2 lever angle sensor at attachment 2 lever neutral position (OPT)VO MONITOR Activated Detected error code function No _at present Description of activated function VO MONITOR1 terminal, Button (1) ANALYZER MENU screen_[ Button (2) Button (3) Press button (3) (1) VO 1-1 screen (2) VO 1-2 screen <> Press bution (3) VO 1-3 screen This function displays the analog input voltage from each of traveling, material handling and SAS sensors. Monitoring the displayed values enables the quality of each circuit/sensor to be judged, ‘When any abnormality is detected, itis displayed as an error code on the screen. This function displays the temperature of each electrical functional part and the voltage at the respective Operating Procedure 1. Display the ANALYZER MENU screen, 2. Press button (2). 3. Check that “2. / MONITOR1” is displayed and press button (3) (enter). I/O monitor function (1) is activated and 1/0 1-1 to /O 1-13 are displayed sequential every time button (3) is pressed. 4, Functions of buttons on the I/O MONITOR1 screen are as follows: Button (1): Unused Button (2): Unused Button (3): Displays 1/0 1-1 to /O 1-13 screens sequentially *: Press button (3) on the I/O 1-13 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from / MONITOR1 screen, Display ANALYZER MENU screen to display other screen. (1) VO 1-4 screen THCD: Main drive circuit (1) (2) temperature (°C) ‘Temperatures of the main drive circuit element (1) (2) are displayed * Checks if the temperature measurement function is functioning properly. + The temperatures at the time of measurement are displayed. (2) U0 1-2 screen THCP: Main pump circuit temperature (°C) ‘Temperature of the main pump circuit element is displayed, + Checks if the temperature measurement function is functioning property. + The temperatures at the time of measurement are displayed,342 (8) VO 1-3 screen “Button (1) WO 1-2 screen Button (2) (4) vO. Button (3) SCY Press button (3) ©) v0 (VO uo (8) v0 <> press button (3) 1-7 screen > Press button (8) VO 1-9 screen @) 4) (5) (8) ” (8) VO 1-3 screen TD: Drive motor (1) (2) temperature (°C) ‘Temperatures of the drive motor (1) (2) is displayed, + Checks if the temperature measurement function is, functioning properly. + The temperatures at the time of measurement are displayed. VO 1-4 screen TP: Pump motor temperature (°C) ‘Temperature of the pump motor is displayed + Checks if the temperature measurement function is, functioning properly. + The temperatures at the time of measurement are displayed, VO 1-8 screen TBD: Traveling AC driver 1/2 board surface temperature (°C) ‘Surface temperatures of the traveling AC driver 1/2 board are displayed + Checks if the temperature measurement function is functioning properly. + The temperatures at the time of measurement are displayed. VO 1-6 screen TBP: Material handling AC driver board surface temperature (°c) Surface temperature of the material handling AC driver board is displayed. + Checks if the temperature measurement function is, functioning properly. + The temperatures at the time of measurement are displayed. VO 1-7 screen TEMP: CPU board temperature (°C) ‘The surface temperature of the main controller CPU board is displayed. + Checks if the temperature measurement function is, functioning properly. + The temperatures at the time of measurement are displayed. VO 1-8 screen \VB48: Battery voltage (V) The battery voltage is displayed. Standard: 36 V (36V models) 48 V (48V models)(10) (ty (12) (13) (9) VO 1-9 screen VO 1-8 screen Button (2) Button (1) SCX Press button (3) ANALYZER MENU screen, (9) U0 1-9 screen VBKS: Key start voltage (V) Power source voltage of traveling and material handling AC drivers are displayed, Standard: 36 V (36V models) 48 V (48V models) (10) 10 1-10 screen VBSOL: Solenoid power source voltage (V) Solenoid power source voltage is displayed. ‘Standard: 36 V (36V models) 48 V (48V models) (11) V0 1-11 screen VBMB: Main battery voltage input (V) Main controller input voltage after the MB contactor is displayed, ‘Standard: 36 V (36V models) 48 V (48V models) (12) VO 4-12 screen VBBD: Traveling AC driver 1/2 main drive circuit voltage (V) Voltages of the traveling AC driver 1/2 main drive circuit are displayed. Standard: 36 V (36V models) 48 V (48V models) (13) UO 1-13 screen VBBP: Material handling AC driver main drive circuit voltage (V) Voltage of the material handling AC driver main drive circuit is displayed Standard: 36 V (36V models) 48 V (48V models)3-44 VO MONITOR2 Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control. Button (3) Press button (3) (1)0 2-4 screen <> Press but VO 2-2 screen Operating Procedure 1. Display the ANALYZER MENU screen. 2. Press button (2) twice. 3. Check that “3. I/O MONITOR2’ is displayed and press button (3) (enter). /O monitor function (2) is activated and 1/0 2-1 to /O 2-6 are displayed sequential every time button (3) is pressed 4. Functions of buttons on the /O MONITOR2 screen are as follows: Button (1): Unused Button (2): Unused Button (3): Displays 1/0 2-1 to 0 2-6 screens sequentially *: Press button (3) on the I/O 2-6 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from /O MONITOR2 screen. Display ANALYZER MENU screen to display other screen (1) VO 2-4 screen + POTA: Accelerator potentiometer voltage (V) ‘A: When the accelerator pedal is released (SWAC: OFF) Standard: 0.3 to 2.4V B: Standard voltage when the accelerator pedal is depressed to its stroke end Standard: 1.7 to 4.7V B-A=1.4V or above + SWAC: Accelerator switch ‘When the accelerator pedal is released ‘SWAG: 0 = OFF Standard voltage when the accelerator pedal is depressed to its stroke end ‘SWAC: 1 = ON Operate the accelerator pedal to judge switch ON/OFF quality.(2) VO 2-2 screen WO 2-1screen Direction switch inspection ea DSF: Forward traveling switch A Button (2) DSR: Reverse traveling switch utton (1) (2) MO 2-2 screen Tndication DSF DSR Operation Forward traveling 4 (=ON) FF) Neutral 0 (=OFF) FF) Reverse traveling | _0 (OFF) 1 (ON) Button (3) o> Press button (3) an ‘the direction lever to judge switch ON/OFF (3) VO 2-3 screen oe SCY Press button (3) <> Press button (8) <> Press button (3) ANALYZER MENU screen 8) (4) (5) 8) VO 2-3 screen + LSB: Brake switch inspection ‘When the brake pedal is released LSB: 1=ON ‘When the brake pedal is depressed LSB: 0 = OFF Operate the brake pedal to judge switch ON/OFF quality. + LSD: Deadman seat check ‘When the seat is occupied LSD: 1=ON When the seat is not occupied LSD: 0 = OFF Take or leave a seat to judge switch ON/OFF quality. WO 2-4 screen ‘SSD1: Drive motor 1 rpm [target rpm] Inspect the rpm sensor while the vehicle is traveling, The rpm of the drive motor increases according to the speed increase, WO 2-5 screen ‘SSD2: Drive motor 2 rpm [target rpm] Inspect the rpm sensor while the vehicle is traveling, The rpm of the drive motor increases according to the speed increase VO 2-6 screen SPD: Traveling speed (mph or km/h) Check the traveling speed while the vehicle is jacked up. Gradually depress the accelerator pedal. Check that the traveling speed increase is almost at the same rate of the depression of the accelerator pedal to judge the quality.3-46 VO MONITOR3 This function dis voltages from sensors. ANALYZER MENU screen Button (1) Button (2) (1) v0 tandard models 3-4 screen (2) v0 + Standard models Press button (3) 3-2 screen lays the ON/OFF status of material handling and mast control switches and analog input Operating Procedure 1. Display the ANALYZER MENU screen. 2. Press button (2) three times. 3. Check that "4. I/O MONITORS’ is displayed and press button (3) (enter). I/O monitor function (3) is activated and I/O 3-1 to I/O 3-13 are displayed sequential every time button (3) is pressed. 4, Functions of buttons on the /O MONITORS screen are as follows: Button (1): Unused Button (2): Unused Button (3): Displays V/O 3-1 to VO 3-13 screens sequentially *: Press button (3) on the I/O 3-13 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from I/O MONITOR3 screen. Display ANALYZER MENU screen to display other screen (1) VO3-1 screen Standard models LL: Lift switch inspection When the lift lever is in the UP position the neutral or DOWN position 5 0-=OFF Operate the lift lever to judge ON/OFF quality. Mini lever models (OPT) LL: Lift lever angle 1 sensor voltage (V) Lift lever angle 2 sensor voltage (V) Lift raise switch (0=OFF, 1=ON) Lift lower switch Judge the raise and lower input quality by lit lever ‘operation, NO 3-3 screen

Forward tilt 4 (=ON) | 0 (=OFF) ale Neutral (0 (OFF) | 0 (OFF) Backward tit (OFF) | 1(ON) lever models (OPT) Button (3) So Operate the tit lever to judge ON/OFF quality Mini lever models (OPT) T: Tilt lever angle 1 sensor voltage (V) Tilt lever angle 2 sensor voltage (V) Forward tilt switch (0=OFF, 1=ON) Backward tilt switch (0=OFF, 1=ON) Judge the forward and backward tit input quality by lift lever operation Press button (3) Tilt lever angle 1 | Tilt lever angle 2 (4) V0 3-4 screen ee sensor voltage | sensor voltage Forward tt Tito23Vv | 22t035V Backwardtit | O4to16V | 29t042V alate Press button (3) 0 + Seway and 4-way min lever models (OPT) a Press button (8) VO 3-6 screen (4) 03-4 screen Standard models T (SOL): Unused Mini lever models (OPT) T (SOL): Tilt proportional valve solenoid current (A) Judge the output quality to the tilt proportional valve solenoid by tlt lever operation. ‘Standard: 0.3 to 0.85 A (Lever operated) (8) U0 3-5 screen Standard models At: Attachment 1 lever inspection When the attachment 1 lever is ON At: -.— -.— 1-= ON When the attachment 1 lever is in the neutral position, At —0-= OFF Operate the attachment 1 lever to judge ON/OFF quality 3-way and 4-way mini lever models (OPT) A: Attachment 1 lever angle 1 sensor voltage (V) ‘Attachment 1 lever angle 2 sensor voltage (V) Attachment 1 Attachment 1 lower switch (0=OFF, Judge the input quality by attachment 1 lever operation, ‘Attachment 1 lever | Attachment 1 lever angle 1 sensor | angle 2 sensor voltage voltage Raising 1.11023V 22t035V Lowering 0.410 16V 29t042VUU (7) WO 3-7 sc VO 3-5 screen (6) V0 3-6 ean 6 screen + Standard models eee Press button reen + Standard models + 2-way and 3-way minilever models (OPT) Button (3) = Seay and 4-way mini lever models (OP a> @ (8) 10 38 scr reen + Standard models + 2.way and 3-way mini lever models (OPT — a) Press button @) (6) 03-6 screen Standard models At (SOL): Unused way and 4-way jet models (OPT) At (SOL): Attachment 1 proportional valve solenoid current (A) Judge the output quality to attachment (1) proportional valve solenoid by attachment 1 lever operation. Standard: 0.3 to 0.85 A (Lever operated) (7) 0 3-7 screen Standard models, 2-way and 3-way mit models (OPT) ‘A2: Unused 4-way mini lever models (OPT) A2: Attachment 2 lever angle 1 sensor voltage Attachment 2 lever angle 2 sensor voltage Attachment 2 raise switch (0=OFF, 1=ON) Attachment 2 lower switch (0=OFF, 1=ON) Judge the forward and backward titt input quality by tit lever operation. lever ‘Attachment 2 lever | Attachment 2 lever angle 2 sensor | angle 2 sensor voltage voltage Raising 1.1102.3V 221035V Lowering 0.410 1.6V 2.9t042V (8) 03-8 screen Standard models, 2-way and 3-way models (OPT) ‘A2 (SOL): Unused 4-way mini lever models (OPT) ‘A2 (SOL): Attachment 2 proportional valve solenoid current (A) Judge the output quality to attachment 2 proportional valve solenoid by attachment 2 lever operation. ‘Standard: 0.3 to 0.85 A (Lever operated)VO 3-8 screen Button (2) (9)0 3-9 screen __Button (1) Button (3) Press button (10) 10 3-10 screen 3) 3.49 (9) U0 3-9 screen ‘SWTK: Automatic fork leveling cancel switch inspection 0=OFF 1=0N Operate the tilt knob switch to judge ON/OFF quality. (10) 10 3-10 screen ‘SSP: Pump motor rpm [target rpm] Inspect the rpm sensor during the actual material handling operation. Check that the pump motor rpm. increases according to the material handling speed increase. (11) VO 3-11 screen ‘MH: Lifting height switch inspection ‘Combination of lifting height switch ON/OFF MHI] MH2-4 switch | switch li height _ | Indication Low lifting height | 10- | 1(=ON) | 0(=OFF) SU Press button (3) (11) VO 3-11 screen (12) WO 3-12 screen — <> Press bution (3) (13) VO 3-13 screen SC} Press button (3) ANALYZER MENU screen High lifting height | O1- | 0 (OFF) | 1 (ON) ‘Change the lifting height to judge ON/OFF quality. (12) VO 3-42 screen POTT: Tilt angle sensor voltage (V) Check the input voltage of tilt angle sensor controller Standard when the mast is in the vertical position: Approx. 1.3 V When operating the mast forward from the vertical position: Input voltage decrease When operating the mast backward from the vertical Position: Input voltage increase (13) VO 3-13 screen SPL: Load sensor voltage (V), (MPa display) Check the input voltage of load sensor controller. Standard without load: Approx. 0.8 V Input voltage increases according to the load increaseVO MONITOR4 ON/OFF state of knob steering synchronizer and other switches and the analog input value from each sensor are indicated. Button (1) ANALYZER MENU screen _| Button (2) Button (3) Press button (3) (1) VO 4-1 screen Press button (3) VO 4-2 screen Operating Procedure 4. Display the ANALYZER MENU screen. 2. Press button (2) four times. 3. Check that “5. I/O MONITORG’ is displayed and press button (3) (enter). /O monitor function (4) is activated and /0 4-1 to /0 4-4 are displayed sequential every time button (3) is pressed. 4. Functions of buttons on the /O MONITORS screen are as follows: Button (1): Unused Button (2): Unused Button (3): Displays /O 4-1 to /O 4-4 screens sequentially, *: Press button (3) on the I/O 4-4 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from / MONITOR4 screen, Display ANALYZER MENU screen to display other screen. (1) V0 4-4 screen ‘Standard models ‘STS: Unused ‘Steering knob synchronizer model (OPT) STS: Steering angle sensor inspection 0=OFF 1=0N ‘Turning the steering wheel one round will turn STS1 and ‘STS2 ON, OFF and then ON. STSC turns on only when the steering wheel is in the standard position. ‘STSC sensor turns on when the actual value is 80 on the I/O 4-2 screen,3-51 VO 4-1 screen Sy Button (2) Button (1) (2) UO 4.2 screen Button (3) Press button (3) VO 4-3 screen NO 4-2 screen % eutton2 (3) VO 4-3 screen Button (1) Button (3) Press button (3) SU Press button (3) ANALYZER MENU screen (2) U0 4-2 screen Standard models K-POS: Unused Steering knob synchronizer models (OPT) K-POS: Actual value of knob position (target) Actual value: Knob position computed by the controller from the steering angle sensor signal. Target value: Knob position computed by the controller from the tire angle sensor signal. ‘Assuming the steering wheel is divided into 160 (0 to 159), the knob position of 80 is as indicated in the illustration to the left. This value increases when turning the steering wheel clockwise and decreases when turning it counterclockwise. (3) V0 4-3 screen Standard models K-DIFF: Unused SOL: Unused Steering knob synchronizer models (OPT) + K-DIFF: Deviation of steering angle knob position Difference between target and actual values at /O 4-2. + SOL: Steering synchronizer solenoid 0=OFF 1=0N Operate the steering wheel to check that the steering synchronizer solenoid turns on when there is deviation of steering angle knob position. (4) V0 4-4 screen TIRE: Tire angle sensor voltage (V) Operate the steering wheel to check the variation in voltage. Standard at tire straight travel position: Approx. 2.40 V3-52, ACTIVE TEST This function outputs ON/OFF signals to each switch related to the electrical system and compares controller input signals with those signals. Button (1) ANALYZER MENU screen _| Button (2) Button (3) Press button (3) > Press button (3) ACT-3 screen Operating Procedure 1. Display the ANALYZER MENU screen. 2. Press button (2) five times. 3. Check that “6. ACTIVE TEST" is displayed and press button (3) (enter). ACTIVE TEST function is activated and ACT-1 to ACT-3 are displayed sequential every time button (3) is pressed, 4, Functions of buttons on the ACTIVE TEST screen are as follows: Button (1): Forced ON Button (2): Forced OFF Button (3): Displays ACT-1 and ACT-3 sequentially *: Press button (3) on ACT-3 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from ACTIVE TEST screen. Display ANALYZER MENU screen to display other screen, (1) ACTA screen FAN: Fan (fan voltage (V)) Forcibly output the ON/OFF signal to check the fan operation and display visually + Press button (1) to select ON. Fan rotates and fan voltage is displayed. + Press button (2) to select OFF. Fan stops rotating and fan voltage is displayed. Note: Be sure to open the battery hood and remove the side cover to check the fan operation. (2) ACT-2 screen Standard models KSOL: Unused Steering knob synchronizer models (OPT) KSOL: Steering knob synchronizer solenoid 1; Signal check line ON (error) 0: Signal check line OFF (normal) ‘Tum the steering wheel slowly to check the deviation in the rear tire movement. ON (bypass open) selected: Tires rarely move OFF (bypass close) selected: Tires normally move3-53, ‘ACT-2 screen auton 1 (3)ACT-3 screen Button (2) ‘Standard models <> Press btn (3) ANALYZER MENU screen (3) ACT-3 screen Standard models PSOL: Unused Mini lever models (OPT) PSOL: Unload valve solenoid 1; Signal check line ON (error) 0: Signal check line OFF (normal) + Tum the key switch to ON and operate the material handiing lever. —f the unload valve turns on normally, material handling operation is possible.|f the unload valve stays off, material handling operation is disabled. + Turn the key switch to OFF and operate the material handling lever. —f the unload valve tums off normally, material handling operation is disabled. If the unload valve stays on, material handling operation is possible.3.54 TUNING General This function performs fine adjustment of traveling and material handling controls. When the use requests to limit the maximum speed or weaken the regenerative braking force, each setting can be performed on the TUNING screen in the procedures same as power control level setting. ‘59 tuning items are prepared including spares. Tuning Item List Tuning 1 Level (@ = Initial seting position) No. tem T1[2[3]4[s]el7]a! [Switchback regenerative breaking torque: t : 1 [Changes the regenerative braking torque at Weak | ° 'switchback. i ‘Acceleration OFF regenerative breaking torque 2. | Changes regenerative breaking torque when Weak ° acceleration is OFF i Battery waming setting level 4 [Changes the activation timings of low remaining — | ay : battery charge warning and battery ! overdischarge warning. (See P3-59) : Battery charge indicator correction Siow rast 4 | Corrects decreasing rate of battery charge decrease! Oi | soniwase| indicator. } i ow Fi 5 _[Fevelng speed miter f FB None just the maximum traveling speed speed se" [Attachment power control No.1 7 6 | Changes the pump motor output for when, ee Hone attachment switch No.1 is ON. ' Tit power contro: : 7 _ | Changes the pump motor output for when Low ate! tion the till switch is ON. speed | speed (The SAS function mast control speed is not limited.) i [Attachment power control No.2: *1 ‘ 8 _|Changes the pump motor output for when ‘on te) en |attachment switch No.2 is ON. nae i [Auto-off function activation time: Lage | 8 [Sets the time for activating auto-off function. Cr sto] | None 10_|Spare e H 11_ [Spare e : 12__|Spare e : "1: 4-way mini lever models (OPT)3-55, Tuning Level (@ = Inilal setting position) No. a Ti ]2[3]4[s[6[7]e! Lift lowering adjustment (1): 1 ; 20. |Adjusts solenoid output current at the beginning | Sma | = ° =! Large of lift lowering operation. i ‘ Lif lowering adjustment (2) ; Hie 21 adjusts inching speed during lift lowering operation. | S* | — ace Lift owering adjustment (3) ' ' 22 | Adjusts the maximum solenoid output current during | Smatt | = eo =! Lage ltt lowering operation ! ! Lit towering adjustment (4. Ss » oon 23. | adjusts acceleration during it lowering operation. | Week | a j Stora Lit iowering agjustment (5): =) © on 24 | adjusts deceleration during lit lowering operation, | Wee" | © | Sing Lift raising adjustment (1) i i 25 | Adjusts solenoid output current at the beginning of | Small | = =! Lege lift raising operation ' ' Litrasing adjustment 2): a i 26 | adjusts inching speed during lit raising operation. | S°” |—* bd | Fast Lift raising adjustment (2): ; t 27, | Adjusts the maximum solenoid output current during | Small | = o =! Lage lift raising operation ! H Lift raising adjustment (4): i i 28 | adjusts acceleration during lift raising operation. Weak + oo Lit raising ajusment (5) i on 29 | gjusts deceleration during it raising operation. | We | —® Ms ae Forward tit adjustment (1): f 30 |gjusts solenoid output current at the beginning of | Small |= . Large forward tit operation ; Forward tit adjustment (2) ' i 31 adjusts inching speed during forward tit operation. | S@” !—* * mrt Fast Forward tilt adjustment (3): ' 1 32 | Adjusts the maximum solenoid output current during | Small | = ° =! Large forward tit operation, H i Forward tit adjustment (4) ' ' 3° | adjusts acceleration during forward tit operation. | Week | —* ho Forward ti adjustment (5): wn | ' 34” Tagjusts deceleration during forward tit operation. | We2k | ° | Song Backward tit adjustment (1): i j 35. | Adjusts solenoid output current at the beginning of | Small |= ° Large backward tilt operation, i3.56 Tuning Level (@ = Initial setting position) No. bod 1[2[3[4[s]6[7 Backward tit adjustment (2) ‘Adjusts inching speed during backward tilt operation, * Ss 36 Slow Backward tilt adjustment (3): 37 | Adjusts the maximum solenoid output current during | Small backward tilt operation. 4 e Backward tit adjustment (4) [Adjusts acceleration during backward tit operation 4 @ 38 Weak Backward tit adjustment (5): Weak ‘Adjusts deceleration during backward tilt operation, 4 @ 39 ‘Strong ‘Attachment 1 lowering adjustment (1): 40 | Adjusts solenoid output current at the beginning of || small lowering operation of attachment 1 A e Large ‘Attachment 1 lowering adjustment (2) 41 | Adjusts inching speed during lowering operation of | Slow attachment 1 4 @ Fast ‘Attachment 1 lowering adjustment (3): 42 | Adjusts the maximum solenoid output current during | Small lowering operation of attachment 1. 4 ¢ Large ‘Attachment 1 lowering adjustment (4): 43. | Adjusts acceleration during lowering operation of | Weak attachment 4 ~< * Strong [Attachment 1 lowering adjustment (5): 44 | Adjusts deceleration during lowering operation of || Weak attachment 1 ~ © ‘strong ‘Attachment 1 raising adjustment (1) 45. | Adjusts solenoid output current at the beginning of | Small raising operation of attachment 4 4 e Large ‘Attachment 1 raising adjustment (2): 46 | adjusts inching speed during raising operation of | Slow attachment 1 4 e Fast Attachment 1 raising adjustment (3) 47 | Adjusts the maximum solenoid output current during | Small raising operation of attachment 1. 4 e Large [Attachment 1 raising adjustment (4): 48 | Adjusts acceleration during raising operation of Weak attachment 1. 4 ¢ y ‘strong [Attachment 1 raising adjustment (5): 49. | Adjusts deceleration during raising operation of Weak attachment 1 4 2 y ‘Strong Attachment 2 lowering adjustment (1): 50 | Adjusts solenoid output current at the beginning of | Small raising operation of attachment 2, 4 @ Y Large [Attachment 2 lowering adjustment (2) 51 | Adjusts inching speed during lowering operation of | Siow attachment 2. 4 e Y FastTuning iu Level (@ = Intal setting position) ‘em 1]2[3]4[s|6[7 [Attachment 2 lowering adjustment (3) i 52 | Adjusts the maximum solenoid output current during | Small | lowering operation of attachment 2. H Attachment 2 lowering adjustment (4): : 53 | Adjusts acceleration during lowering operation of Weak | —t e ~ ° attachment 2, ‘Attachment 2 lowering adjustment (5): 54 | Adjusts deceleration during lowering operation of | Weak attachment 2. Attachment 2 raising adjustment (1) 55 _| Adjusts solenoid output current at the beginning of raising operation of attachment 2. [Attachment 2 raising adjustment (2) 56 | Adjusts inching speed during raising operation of | Slow attachment 2. [Attachment 2 raising adjustment (3): raising operation of attachment 2. [Attachment 2 raising adjustment (4): 58 |Adjusts acceleration during raising operation of Weak attachment 2 57 | Adjusts the maximum solenoid output current during | Small | = ° ‘Attachment 2 raising adjustment (5): 59. | Adjusts deceleration during raising operation of attachment 2.TUNING Screen Operating Procedure 1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen. 2. Press button (2) to display “2. TUNING” and press button (3) (enter) to display the TUNING MENU. screen, 3. Press button (1) or (2) to display the tuning item desired to be set. Press button (3) (enter) to the TUNING screen of the selected item. Button (1): Display the previous tuning item Button (2): Display the next tuning item Button (3): Enter (display the selected tuning item) *: Press button (3) on the TUNING MENU screen, select “6. END" and press (3) to display MASK MENU screen, "2. TUNING2 LIFTV" to "S. TUNINGS ATT2V" (tuning No.20 to 59) are not used on the standard models. They are only used on the mini lever models (OPT). lay Button (1) MASK MENU screen ye) Button (3) SCP Press button (3) a Press button (3) —— apa] | © Ey Press button (1) or (2) to switch screen! Press button (1) or Press button (1) or (2) to switch screen (2) to switch screen *: Mini lever models onl *: Mini lever models ont Press button (1) or Press button (1) or (2) to switch screen (2) to switch screen *: Mini lever models on! *: Mini lever models onl Press button (1) oF (2) to switch screenBaten) Baton] TUNING 1 TUNING MENU sereen This function sets the tuning level of the standard functions. C OPERATING PROCEDURE wn 1. Display the TUNING MENU screen. 2. Check that “1. TUNING1" is displayed and press button (3) (enter) to display TUNING level setting screen. 3. Press button (3) to display the tuning item desired to be set. 4. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen) UF Press button (3) *: Press button (3) on the TUNING No. 12 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING. Display TUNING MENU screen to display other screen. Y_ Press button (3) TB Pres baton (3) TUNING MENU screen Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels (TUNING No.3) *: The default is level 7. Discharge TUNING setting levels level 7 2 3 4 5 6 Z 8 50 to 59%. 60 to 69% 70 to 79% ‘Low remaining battery charge warning coe Battery charge indicator blinks 81 to 89% 920% Overdischarge warning 91 10 99% “Ten segments of battery ‘charge indicator blink NO 100% warning3-60, Button (1) Button (2)} TUNING MENU screen noo AML UY Press button (3) ¥_ Press button (3) Press button (3) TUNING MENU screen TUNING 2 LIFTV This function changes the tuning level of the lift lever. OPERATING PROCEDURE 4. Display the TUNING MENU screen. 2. Press button (1) or (2) to display "2. TUNING2 LIFTV" and press button (3) (enter) to display TUNING level setting screen. 3. Press button (3) to display the tuning item desired to be set. 4, Functions of buttons on the TUNING level setting screen are as follows Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen) *: Press button (3) on the TUNING No.29 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING2 LIFTV. Display TUNING MENU screen to display other screen.3.61 Button (1) Button (2) TUNING MENU screen Press baton (8) TUNING MENU screen TUNING 4 ATT1V This function changes the tuning level of the attachment 4 lever. OPERATING PROCEDURE 4. Display the TUNING MENU screen. 2. Press button (1) or (2) to display "4. TUNING4 ATT1V" and press button (3) (enter) to display TUNING level setting screen. 3. Press button (3) to display the tur set. 4, Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen) item desired to be *: Press button (3) on the TUNING No.49 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING4 ATT1V. Display TUNING MENU. screen to display other screenButton (1) Button (a]_ TUNING 6 ATT2V TUNING MENU screen This function changes the tuning level of the attachment 2 lever. OPERATING PROCEDURE. 1. Display the TUNING MENU screen. 2. Press button (1) or (2) to display "5. TUNINGS ATT2V" and press button (3) (enter) to display TUNING level Button (3) setting screen. <7 Press button (3) 3. Press button (3) to display the tuning item desired to be set 4. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen) *: Press button (3) on the TUNING No.59 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNINGS ATT2V. Display TUNING MENU screen to display other screen CY Press button (3) TUNING MENU screen3-64 OPTION SET OPTION SET Menu List Selection No. | Indication Description ind ind on | Meaning | I | Meaning Enables simullaneous operation of OPT-1 |DEMO MODE. traveling and material handing before | Y | Enable | N | disable starting the hour meter. opT-2 |HMSTART | Starts hour meter count. Y [counting] nN | NO counting Disables level seting of traveling/material copr-3 |Pic Lock —_| handling power control, 2-speed travel | Y | Lock | N | Unlock speed and overspeed alarm (OPT), ‘Other : Sets the data according to the Ona | DEST destination. Changes the display. | spec a | ees Japan OPTS |— Not used. Si Setiingto Setto opr-s | MPH Changes the traveling speed unt to mph.| y [Setingto/ yy | Seto OPT? |— Notused S——— + [Adjust the charge indicator calculation Feature Feature opts |parrery* | Adjust th a | Feature |g | Feat OPTS |_— Not used Si Enables/alsables operation ofthe auto OPT-10/ SEAT P-OFF | power-off function in relation to the seat | Y | Enable | N | disable switch OPT-11 | PARKING ERR nme ee Y | Enable | N | disable Enables/disabies the active mast front at opr-t2| mit cont |Ensolesi Y | Enable | N | disable Enables/disables the sieering knob oPT-13|KNoB cont _ | Enablesitisat Y | enable | N | disable Enables/disables the mast forward tt OP T14 [TILT FL Y | enable | N | disable OPT-15|B-TYPE* | Battery type 7 | TYPE? TYPED - ‘Switches the batiery voltage between oPT-16] 36v Suitehes the y | sv | n | aev Sets specification of 2-way mini ia OPT-17 | 2-WAY VALVE * nana Y | 2way | N | than models 2away Sets specification of 4-way mini lever other OPT-18 | 4-WAY VALVE * Y | 4way | N | than models away OPT-15/USA™ Seis specification of USA models Y_ |USA| _N_ | Others OPT-20|— Not used Sa OPT-2i|— Not used SS OPT-22|— Not used Si *: The specification of the vehicle is selected at the time of vehicle shipment.3.65 Caution: + These functions are used to adjust the controller and display control according to the options installed on the vehicle; they do not enable or disable the actual function of the options. + When the controller board is replaced, it is necessary to reset it according to the vehicle specifications. + When OPT-12 TILT CONT is disabled by option setting, Indication when disable the disabled status is indicated for 5 seconds on the display upon key switch ON. Meaning of indication T-OFF: TILT CONT (active mast front tilt angle control) is disabled Operating Procedure for OPTION SET Screen 1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen. Press button (2) twice to display “3. OPTION SET" and press button (3) (enter) to display the OPTION ‘SET MENU screen, 3. Press button (3) to display the desired option item to be set on the screen. 4. Functions of buttons on the OPTION SET screen are as follows: Button (1): NY Button (2): YN Button (3): Enter (to the next item screen) *: Press button (3) on OPT-22 OPTION SET screen to display the MASK MENU screen. OPT-4 screen Button (1) 4} Press button (3) MASK MENU screen Button (2) Button (3) CY Press button (3) 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.3-66 OPT-3 screen Button (1) Button (2) Press button (3) OPT-16 screen > rss ton fd o » a a @) » 7 3 BG3.67 OPT-15 screen Button (2) Button (1) Button (3) ) Press button (3) OF Press button (8 ed Press button (3) MASK MENU screen >> Press button (3) Not used > Press button (3)3-68 MATCHING General Of the sensors used for SAS, steering knob synchronizer (OPT) and mini lever (OPT), the signal voltage values of the tit angle, load and tire angle sensors in the mast vertical position, no load state, and tire straight travel position respectively are stored in the controller at the time of vehicle shipment to be used as the bases for control. Therefore, if maintenance or parts replacement related to these sensors is, performed, matching (updating sensor signal voltage values of the vehicle in the vehicle standard state) becomes necessary. Matching of the titt angle sensor is also necessary when the vehicle posture is remarkably changed. Matching of the load sensor is also necessary when the load in the no load state is changed including removal and addition of attachments. Each lever angle sensor for mini lever function is controlled based on the memory of signal voltage values in the neutral position stored in the controller at the time of shipment. Therefore, when maintenance or parts replacement related to these sensors is required, matching needs to be performed. ‘SAS Matching Items and Conditions No, [Indication Description Condition 1 [TILTL [Tit angle sensor output in the fork level position is stored in the controler|.7 "14° > © Tilt angle sensor output of forward tilt control in the mast vertical position |"1-*2-*3-*6 2 |TILTF [is stored in the controller. 7:8 3 [LOAD [Load sensor output in the no load state is stored in the controller. 1467 Steering knob synchronizer Matching Item and Condition (OPT) No, [Indication Description Condition Tire angle sensor oulput in the straight travel position is stored nthe |. 4 [TIRE | controler. 1s Mini lever Matching Items and Conditions (OPT) No. [Indication Desoription Condition 5 |uipt |Uifleverangje sensor outpatin the li lever neuiral positon s storedin |. ag the controller. Till lever angle sensor output in the il Iever neutral position i storedin |.» 6 [TILT _|the controtier. ae 7 lati [Attachment 1 lever angle sensor output in the affachment T lever neutral | _+, position is stored in the controller. 2 larr2 [Attachment 2 lever angle sensor output inthe atlachment 2 lever neutial |, 34 Position is stored in the controller. Meaning of Conditions “1: When the main controller is replaced ‘When the tilt angle sensor is replaced *3: When the tit angle sensor rod is replaced or its length is changed "4: When the load sensor is replaced *5: When the tire angle sensor and sensor cover *6: When an attachment is changed *7: When the mast is replaced "8: When the tilt cylinder is replaced "9: When the lift lever angle sensor is replaced 10: When the tilt lever angle sensor is replaced “11: When the attachment 1 lever angle sensor is replaced “12: When the attachment 2 lever angle sensor is replaced removed/installed/replaced3-69 Before Matching Vehicle should be in the “Standard state" for matching. “Standard state” means the vehicle satisfies the following conditions: 1. Surface levelness check Matching on the unleveled or inclined surface may cause deviation of the standard. Perform matching on a level surface (inclination below 0.5") 2. No-load vertical condition check Signal voltage of the load sensor in no-load state is stored. Make sure that the following conditions are met Raise the fork of the V mast to approx. 500 mm (19.7 in). Make sure that the mast is in the vertical position by checking with an angle gauge. FV-FSV mast ‘The rear cylinder rod extension of the FV and FSV mast should be approx. 100 mm (3.9 in). Make sure that the mast is in the vertical position by a checking with an angle gauge. 100mm Tilt the mast from backward tilt position to forward until (3:9in) it becomes vertical 3. Tire pressure check (for optional Pneumatic tire models only) ~ Make sure that the tire pressure is at the specified level. oO Low pressure and deviation of tire pressure among the tires may hinder accurate matching, Vmast 500 mm, (19.7 in) x Tire straight traveling position check Signal voltage of the tire angle sensor in tire straight gz travel position is stored. Tire straight travel position is af the condition in which driving the vehicle 5 meters (16 ft) 22 with the steering wheel fixed causes the center of the Efe vehicle to stay within 50 mm (2.0 in) to the left and right Be of the line, sme | 582 Operating Procedure for MATCHING screen 1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen. 2. Press button (2) three times to display "4. MATCHING" and press button (3) (enter) to display the MATCHING setting screen. 3. Press button (3) to display the desired matching item. 4. Functions of buttons on the MATCHING setting screen are as follows: Button (1): Unused Button (2): Starts matching for the selected item Button (3): Display the next item3:70 *: Press button (3) on the ATT2 matching set screen to display the MASK MENU screen, OK on the display is indicated only after matching (by pressing button (2)). The value in parentheses is the one stored at present. The value outside parentheses is the one under the present vehicle condition, Note: Matching is necessary when the two values, inside and outside the parentheses are different in the vehicle standard condition. Button (1) Button (2) IEMASK MENU screen Button (3) > Press buton (3) UX Press button (3) > Press button (3)3-71 TIRE CONSTANT SET General In order to optimize the speed meter, tire constant that matches the tire outside diameter needs to be input in the controller. Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire size is changed or the tires are worn excessively to a degree affecting the speedometer function. Button (1) Button (2) MASK MENU screen > an |a Button (3) <> Press button) Operating Procedure for Tire Constant Setting 1. Input the password on the general screen (see page 3-32) to display the MASK MENU screen 2. Press button (2) four times to display "S. WHEEL DIA" and press button (3) (enter) to display the tire constant setting screen. 3. Press button (1) or (2) to set the desired tire constant and press button (3) (enter) to display the MASK MENU screen. 4. Functions of buttons on the tire constant setting screen are as follows: Button (1): Decrease the tire constant Button (2): Increase the tire constant Button (3): Enter and display MASK MENU screen Tire constant Tire Constant List Tire type Tire size ‘Applicable model | Tire constant ‘Smooth Cushion Lug 187 x12.18 All models 25 ‘Smooth Cushion Non-Mark Lug Pneumatic Jiug 18x7-8-16 7FBEU15,18 20 Flatless Jiug 18x78 TFBEU15,18 24372TROUBLESHOOTING Page BEFORE TROUBLESHOOTING................ 42 TROUBLESHOOTING METHOD ............... 44 SST SETTING METHOD 45 DIAGNOSIS CODE LIST 4-11 WHEN AN ERROR CODE IS DISPLAYED. CPU BOARD. ...... 0. cece cece eee eee eee eee TRAVELING/MATERIAL HANDLING AC DRIVER SAS SYSTEM MULTI-DISPLAY .......6 6-6 e cece e eee eee eee 4-143 WHEN NO ERROR CODE IS DISPLAYED. ...... 4-144 44BEFORE TROUBLESHOOTING CONNECTOR HANDLING 1. Disconnect the battery plug before connecting or disconnecting each connector or terminal. 2. When disconnecting a connector, do not pull it at the harness but hold the connector itself and pull it after unlocking it. To connect, push the connector fully unti itis locked in position. 3. Bring a tester probe into contact with a connector terminal from the rear side of the coupler (harness side) 4. Ifinsertion from the rear side is impossible, as in the case of a waterproof connector, bring the tester probe carefully into contact with the terminal so as not to cause deformation of the connector terminal. 5. Do not touch connector terminals directly with your hand. 6. When bringing tester probes into contact with live terminals, prevent two tester probes from coming into contact with each other. WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the following procedure: Continuity check 1, Disconnect the connectors at both ends of the corresponding harness. 2. Measure the resistance between corresponding terminals of the connectors at both ends. Standard:10 W or less Note: Measure while lightly shaking the wire harness up and down and sideways. Reference: Open circuit at the wire hamess occurs rarely partway through a vehicle wiring but mostly at connectors. Inspect especially the sensor connectors with sufficient care.43 Short circuit check 1. Disconnect the connectors at both ends of the corresponding hamess. 2. Disconnect the connectors at both ends of the corresponding harness. Standard: 1MQ or more Note: Measure while lightly shaking the wire harness up and down and sideways. 3. Measure the resistance between a terminal corresponding to the connector terminal and N1.Always inspect the connectors at both ends. Standard: 1MO or more or defective clamping. Visual and contact pressure checks + Disconnect the connectors at both ends of the corresponding hamess. + Visually inspect that there is neither rust nor foreign matter trapped at connector terminals, * Inspect that there is no loosening or damage at the locked Portion. Also, lightly pull the wire harness from the ‘connector to check that it does not come off. + Insert a male terminal same as that of the terminal to a female connector and check the extracting force. Defective contact may exist at a terminal where the extracting force is less than that of other terminals. Note: Even if there is rust or foreign matter trapped at the terminal, or the contact pressure between male and female terminals is low, abnormal contact condition may be changed to normal by disconnecting and reconnecting the connector.In that cas connector connection and If defect is perceived even once, terminal contact may be defective.TROUBLESHOOTING METHOD Disconnect the battery plug, t Connect SST1 to CN111 and ' connect A and 1 | beter _-— Repair or replacement ‘ANL./O ACTIVE TEST ACT-1 ee x Turn cooling fan on, + CPU board | (ON) To the next step depending on the result. (CN100-9 (43) OK {Voltage measurement |» + Cooling fan replacement (CN111-4 (N1) NG YY Connector and hamess NG inspection between C100 | NC ___. . Repair or replace the defective portion. and CNT11 OK —_ Explanation of Frames Voltage No. -_Upper row. Tester positive (+) probe A single frame indicates measurement wth @ en 100-9 (43) << 2 tester or an ordinary step. ONttt-4 Nt) {Lower row: Tester negative (-) probe Connector and pin No. ANL.:/O ACTIVE TEST ACT-1- analyzer function. ‘Tum cooling fan on. ‘Test item j I am eee rs coor (test method ‘A dash-line frame indicates SST connection. ‘An oval frame indicates connector or wire harness inspection.45 SST SETTING METHOD Use SSTs for quick, accurate electrical troubleshooting on the 7FBE series. Correct check will fal ifthe connection method is wrong.Since boards may be damaged by incorrect connection, careful operation is necessary. SST No. Part No. ‘SST name Remarks ‘Shorting harness SST2_ | 09232-13130-71 | Gor GNt9, 32,52, 56, 58, 86 and 90) SST 09230-13130-71 oa Saar (Controller check har- , lerator potentiometer check harness ness for 7FB) sste | 09238-13130-71 | Ger GN26, 41 and 42) SST13 | 09234-13900-71 | Shorting harness (for CN101 and 102) Drive and pump motor rpm sensor check SST19 | 09231-21320-71 | harness (for CN109, 110 and 111) Lift, Tit, ATT1, ATT2 solenoid check harness S8T20 | 09232-21320-71 | (oy GN74 and 75) Cai is kept connected, various boards may be damaged. Always disconnect the battery plug before SST connection and disconnection. If the battery plug46 SST19 Setting Method ‘Set SST19 when the error codes C8-1 and E8 are displayed. (1) Disconnect the battery plug (2) Connect $ST19 and CN110 (CN109, CN111) and connect CN1 and CN3 of SST19. (3) Connect the battery plug (4) Turn key switch ON and check LED while traveling. CN3 ‘Two LEDs47 CPU BOARD CONNECTOR CN101 CN104 CN103 CN102 CN101 CN102 CN103 — EGEnE I T1sI Tifelst al Ne 1 1 4 26 ‘OSH z POTA 2] 6. Ss} 65 138 [air POTH [ar “4 ee. iss] [a se. POT a. =| ar ts =[ ‘SPL —_ e[— = elo Tt — 7[ =| “ere | “Port Ta 3 a[—— | teoK | [72 POT. — 6 o[ 30 FAN ett tSTF o} sl 10] 39, FAN Tz por | [0] 76 yh i] 03 [tsar] TST af | oes 7 —| 1s0t8z) 7 a SN 231 or —| [a2| a noo | [as —T sousa ia{ | sstwk—] [63 | sariesa—] [is] tae [aro] Po [ ss] cer ia| | ~suirsa. (eay_[—(porarn) —| [ra| vas [some] [70] 85 cr 15[— | sans] [25 Poraria—| [as] —ta2—[-somma] [ar 9 —]-souse 16| st is. 12 26 porarzi —| [ie[ tax [sma] [a2] 10 —]-sotas ir] ez | —tstee | [is —2r POTATZ af 1 | souss: 8] 10 ‘swik—| [ia[ ss POTAT te[ ae |v 50] 90 at —] [5[ 316 OTH 45] 44 [van 0] — at m7 —| [46] —s7 POTTAT Te] | sua 2] aia —[—srsc—] [ar] 5 ‘SPL a7] 35 | soto 2 —— | tsarzz—| [a] 28 POT 78[ 36 | “sour |e ists [19] 9 POT sof 1 Br ef 312 Stst_—] [20] —30 POTATIT zo] 2 Me sf —— — | [2if—3e POTATE 21] 320 | SoLsT 25[ tS: zal st POT. Za] Na Nz 27 —— [swe 2a Nz Nz af = GUREEEEIO 2a[ 39 [aN zap = 25[ a2 [REVSTART] ‘o[ 38 [See ‘CN100 2e[ 12] sour a — 7 i zr} 1s | so aa isc ee 2a} 380 | Sos = — — 2[—— [anne ular Por S| — | Frxo- 4[—— | ewe, ee 6] — | -Fres 7 Fa e} [sei48 MAIN CONTROLLER CONNECTOR + COMPONENTS CN101 CN102 N103. CN104TRAVELING AC DRIVER 1 CONNECTOR » COMPONENTS: 49 u TRAVELING AC DRIVER 2 CONNECTOR * COMPONENTS, ne N1094:10 MATERIAL HANDLING AC DRIVER CONNECTOR + COMPONENTS ceNt11 P3 © [© U + B+| ©DIAGNOSIS CODE LIST ‘When an Error Code Is Displayed Displayed code | Pea memory Error mode Page 30-7 30-4 Traveling AC driver 1 low voltage 4-105 302 302 Traveling AC driver 2 low voltage 4106 303 30-3 Material handling AC driver low voltage 4107 att ott Traveling AC driver 1 low starting voltage 4108 312 312 Traveling AC driver 2 low starting voltage #109 313 343 Material handling AC driver low starting voltage 4110 324 32-1 Traveling AC driver 1 EEPROM abnormality aati 322 322 Traveling AC driver 2 EEPROM abnormality ain 323 323 Material handling AC driver EEPROM abnormality ati2 as = oe = Traveling AC driver T communication | 4 445 = = ia ae = Traveling AC driver2 communication | 4 444 3 |More mayne tcaver Vans 62 Load sensor abnormality 4137 6242 Tilt angie sensor abnormality 4139 63-123 __| Tilt switch abnormality +15 64-1,2,3 __ | Lift solenoid abnormality +16 €5-1,2,3__| Titsolenoid abnormality a8 66-4 Tilt matching abnormality 4-140 67-4 Lifting height switch abnormality a4 TAZ Tire angie sensor abnormality 4-20 72-4,2,3,4 72-1,2,3,4 _ | Steering angle sensor abnormality 422 73423 73-1,2,3 | Steering knob synchronizer solenoid abnormality 427 Tat Tat Tire angle matching abnormality 429 im] A0-1 Main drive circuit overheat 4-116 per = J A0-2 Main pump circuit overheat 4n7 POR At At ‘Main controller high voltage 430 Ai2 Ate Traveling AC driver 1 high voltage aie ATS At Traveling AC driver 2 high voltage 4119 Ata AVA Material handling AC driver high voltage 41204-12 ‘When an Error Code Is Displayed Diag memory Displayed code a Error mode Page cl J AQ CPU board overheat 431 om m| A2-2 Traveling AC driver board overheat 4-121 Do’ m| A2-3 Material handling AC driver board overheat 4-122 POR’ AB 73 Battery connection incorrect (CHG) 432 AA 4 ‘Acceleration Switch abnormality 433 AGTSS ‘A6-1,3.5 | Material handling switch abnormality 434 AAA BAA CPU board thermo-sensor abnormality #36 RAZ AAD Traveling AC driver 1 board thermo-sensor abnormality] 4-122 RAS AAS Traveling AC driver 2 board thermo-sensor abnormality] 4-123 Waterial handling AC driver board thermo-sensor AAS AA aonormalty 4-123 AC AC ‘Semiconductor switch abnormality 437 on ron Traveling AC driver 1 main controller communication | 4 59 abnormality Traveling AC driver 1 main controller communication AD-2 AD-2 abnonmatty 4-40 : Traveling AC driver 2 — main controller communication ao) io) abnormality oo Traveling AC driver 2 main controller communication aoa aes abnormality “42 Material handling AC driver — main controller nd aD) communication abnormality +483 Material handling AC driver > main controller ao nd ‘communication abnormality 4 AF A234 AF-1234 | CPU abnormality +45 crt cr Traveling AC driver 1 current sensor offset abnormality | 4-124 C12 C12 Traveling AC driver 1 overcurrent 4124 cr3 C13 Traveling AC driver 2 current sensor offset abnormality | 4-125 Cra cr-4 Traveling AC driver 2 overcurrent #125 cat Drive motor overheat 4-126 C22 C22 Drive motor 1 thermo-sensor abnormality 27 C23 C23 Drive motor 2 thermo-sensor abnormality a8‘When an Error Code Is Displayed Diag memory Displayed code ‘code Error mode Page aa an Traveling ke driver 1 main drive circuit thermo-sensor | 4 159 ae a Trevoing AG driver 2 main drive circuit thermo-sensor | 4 159 C4234 C4-4,2,3.4 _ | Accelerator potentiometer abnormality +46 7 C7 Direction switch abnormality 448 cet ce Drive motor 1 rpm sensor abnormality 4-130 C82 C82 Drive motor 2 rpm sensor abnormality 4134 CBA CB MB contactor abnormality 449 CB2 CB2 MB contactor fusion 451 aa wae pending ‘AC driver current sensor offset a ET2 Material handling AC driver overcurrent 4132 E24 Pump motor overheat 4133 E22 Pump motor thermo-sensor abnormality 4134 = 5 Mele handing AC poo main drive circuit ree Es Pump motor rpm sensor abnormality 4136 E423 ‘Abnormal communication from multi-display 452 EFA24 EF-1,2,4 __ | Main controller EEP-ROM abnormality 453 EF-3 EFS Main controller CPU abnormality 453 Fiz Fia2 ns > multi-display communication ie FF FF Di6 overcurrent +54 AVA2 HiA2 Lift lever potentiometer abnormality 455 His Hi3 Lift lever potentiometer abnormality 4-60 Hi-4 Hi-4 Lift lever potentiometer abnormality 462 HIS HIS Lift lever potentiometer abnormality 463 2-42 2-42 Tilt ever potentiometer abnormality 464 23 2-3 Tilt lever potentiometer abnormality 469 2-4 H2-4 Tilt lever potentiometer abnormality a7 25 2-5 Tilt lever potentiometer abnormality 472 HB-12 3-12 ‘Attachment 7 lever potentiometer abnormality 473 3-3 13-3 ‘Attachment 1 lever potentiometer abnormality 478 3-4 13-4 ‘Attachment 7 lever potentiometer abnormality 4-80 35 13-5 ‘Attachment 1 lever potentiometer abnormality 481 HAA? Aaa ‘Attachment 2 lever potentiometer abnormality 4824 ‘When an Error Code Is Displayed Displayed code | P@amemory Error mode Page na3 ‘Attachment 2 lever potentiometer abnormality 487 naa ‘Attachment 2 lever potentiometer abnormality 489 H45 ‘Attachment 2 lever potentiometer abnormality +80 15-7,2,34,5 _| Liftsolenoid abnormality +o H6-1,2,3.45 _| Tilt solenoid abnormality 434 H7-4,2,3.45 _| Attachment 1 solenoid abnormality 497 18-1235 H8-1,2,3.4,5 | Atlachment 2 solenoid abnormality 4100 HO123 H9-7,2,3 ___| Unload valve solenoid abnormality 4-103 ‘When no Error Code Is Displayed Displayed code Vehicle condition Page = No display on multi-display aaa = The vehicle does not move at all (display off) 4145 = Only traveling disabled (no motor revolution) 4146 = ‘Wobbiing 4148 = Only material handling is disabled (standard models) 4449 = Only material handling is disabled (Mini lever models) 4150 = ‘Steering knob not in the right position aA51 = Constant automatic fork leveling 4152 RoRe Traveling AC driver 1, 2 low temperature warning 4-153 COLD Material handling AC driver low temperature warning 4-153 PCRWHEN AN ERROR CODE IS DISPLAYED CPU BOARD 63-1,2,3 Tilt switch abnormality Related portion — Tit switch (CN101-23(61, LSTF+) (18) enieD ener (CN102-8(61, LSTF) 15 1 cpu CN101-17(62, LSTR#) (G5) 7 si cert | [enronogaisra <7 tel eator 981,18) (sp GFE ‘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 tlt switch abnormality 63-3 Backward tilt switch abnormality Disconnect battery plug an Connect battery plug again andtum |!ndicated __y bertorm troubleshooting for A6-3. key switch ON. No error 63-1 errors Check if an error is detected when indicated + Tilt switch installation defect jindicated iy the tit lever is operated in either + Tilt switch abnormality direction, r ‘error ‘ANL : VO MONITOR 3 1/03-3 Operate the tilt lever in either 1 is displayed on either switch. direction and check the switch input valve when the tit lever is neutral position. [0's displayed on either switch after Joperating the tilt lever several times. y Memory 63-2, 63-3 The tilt lever has been turned ON for two. oe Check the diagnosis memory minutes or more in the past ‘Memory 63-7 y ‘The forward and backward tit switches were tumed ON at the same time in the past. (Check adjustment of each switch installation)4-16 64-1,2,3, Lift solenoid abnormality Related portion Nas CN104-3(3, SOLL+) 7 cpu Lit board | | CN104-4(4, SOLL-) a solenoid Condition for error detection ‘Output when open or short circuit of the lift solenoid line from the CPU board to the lift solenoid is detected. 64-1 Lift solenoid open 64-2 Lift solenoid load short 63-3 Lift solenoid drive circuit MOS short circuit + 644 Disconnect battery plug and disconnect CN88. y Connect battery plug, and turn the key switch to ON. ‘Check the voltage of solenoid drive |5 V or more. P i cN88-1(3) peer _ Lift solenoid defect, Voltage measurement CN88-2(4) Tess than 5V y Disconnect battery plug and disconnect CN104. (CN104-3(3) ones crea) check Continuity era CN104-4(4) 1 Continuity check CN88-2(4) No continuity Hamess defect,+ 64-2 Disconnect battery plug and disconnect CN88. y 64-2 error is Connect battery plug, and turn key switch ON. —— Lift solenoid defect 64-2 error is indicated y Disconnect battery plug and disconnect CN104 CN104-3(3) 1 ‘Continuity check CN104-4(4) Continuity - Hamess defect No continuity ' CPU board defect, + 64-3 Disconnect battery plug and disconnect CN104, and turn key ‘switch ON. ‘Check continuity of harness CN104-3(3)-P 1 CN104-3(3)-P2 CN104-4(4)~P1 CN104-4(4)-P2 No continuity CPU board defect [Continuity _» Hamess detect418 65-1,2,3, Tilt solenoid abnormality Related portion CNB CN104-6(6, SOLT+) cpu board | [CN104-7(7, SOLT-) rit solenoid Condition for error detection detected. 65-1 Tilt solenoid open 65-2 Tilt solenoid load short 65-3 Tilt solenoid drive circuit MOS short circuit ‘Output when open or short circuit of the tilt solenoid line from the CPU board to the tlt solenoid is + 65-4 Connect battery plug, and tum key the forward position, (65-1 error is indi Disconnect battery plug and disconnect CN89, t Connect battery plug, and turn key ‘switch ON. Operate the tt lever to the forward position Check the voltage of solenoid drive CNB9-1(6) 1 Voltage measurement CN88-2(7) ted te than 5V Disconnect battery plug and disconnect CN104. CN104-6(6) 1 Continuity check CN89-1(6) CN104-7(7) 1 Continuity check CN89-2(7) No continuity, Hamess defect, switch ON. Operate the tit lever to |NO@MOr __ Connector connection check 5V or more jContinuly __,. cpu board defect Tilt solenoid defect4-19 + 65-2 switch ON. Operate the tit lever to the forward position. Y Disconnect battery plug. Disconnect CN104, and turn key ‘switch ON. Continuity check (CN104-6(6)-P1 CN104-6(6)-P2 CN104-7(7)-P 1 CN104-7(7)-P2 Connect battery plug and turn key eel ‘switch ON. Operate the titt lever to the forward position, 65-2 error is indicated y Disconnect battery plug Disconnect CN88. ! 65.2 ‘Connect battery plug and tum key | 65-2 error is switch ON. Operate the tit lever to [Not indicated the forward position [65-2 error is indicated y Disconnect battery plug. oes Continty 1 _ Continuity measurement cNt04-7(7) No continuity v CPU board defect + 653 65-3 errors, Connect battery plug and turn key | Dor [65-3 error is indicated [Continuity No continuity v CPU board defect Connector connection check Tilt solenoid defect Harness defect Connector connection defect, Hamess defect,4-20 T1AA2, Tire angle sensor abnormality Related portion cns2 (CN102-15(316, POTH#) 1 cpu | |cnt02-3(317, PTH) Tire angle board e sensor CN102-22(51, POT-) 3 Condition for error detection Output when the voltage of the tire angle sensor is outside the specified range (open or short) 71-1 Tire angle sensor open 71-2 Tire angle sensor short ' Disconnect battery plug and : | disconnect CN32. Connect SST2 | 71-2 erroris ' between CN32-1 andCN322 | indicated. ' tindicated | (Main hamess side). Connect is ee sere ere * battery plug and turn key switch [71-2 error is not indicated. Y Disconnect battery plug, Disconnect CN102, (SST2 is the connection state.) _| No continuity (CN102-15(316) {Continuity check ©N102-3(317) Main harness defect [Continuity Y (SST2 is the connection state.) CN102-3(317) No continuity 1 Continuity check cNn102-22(51) CPU board defect, Continuity vy Main hamess defectm2 CN32, connect battery plug, and tum key switch ON Disconnect battery plug, disconnect 1 Continuity check (©N102-3(317) Continuity v Main harness defect Change to 71. [74-2 error is indicated, y Disconnect battery plug. Disconnect CN102. uit CN102-15(316) |Nocontinuty CPU board defect -1 error. ' Disconnect battery plug. | Disconnect N142. © €N102-3(317) ' Connect SST2 between CNS2-2 | | and CN32-3. (Main hamess side) | | T___ Continuity check " CN102-22(51) contin Tire angle sensor defect “|No continuity Harness defect22 detected. 72-3 Steering angle 72-1 Steering angle sensor STS1 abnormality 72-2 Steering angle sensor STS2 abnormality sensor STSC abnormality 724,234 | Steering angle sensor abnormality Related portion ont3t cto (CN103-10(16, D1SV) 2 La) 7 (CN101-24(312, STS1) 15 3 | Ste py | [cnt01-30013, sts2) . 7 Steering board eat CN101-21(314, STSC) aed 7 5 CN130, 2 CN101-16(51, LS) (24 7 n [-—— Condition for error detection Output when open or short circuit of the sensor line from the CPU board to the steering angle sensor is, © Remain 0 Connector connection check 72-4 Steering angle sensor open * 724 1241 eror's Connect battery plug and turn the ales rat necated Tum the steering wheel. TE erate inicates y “ANL : /O MONITOR 4 /04-1 Ghosk ne STS input vac turning the steering wheel.4-23 Disconnect battery plug Disconnect CN32 Short between CN19-3 and CN19-2 of main harness side with SST2, Connect battery plug and turn the key switch ON. ¥ — "ANL :VO MONITOR 41/041 ]|Change to 1 AML WONONTOR eS eer Check the STS1 input value Remain 0 y Disconnect batiery plug. Disconnect CN101. (SST2 is connection state.) No continuity ONt01-24(312) |" Main harness 1 Continuity check eNnt01-16(51) (Continuity y CPU board defect Steering angle sensor defect Change to 0 Continuity Main harness defect Steering angle sensor defect eet Disonnedt baler Bua Discomect ONTS Connect batery plug and tum the key switch ON. y ‘ANL :/] MONITOR 4 /04. Check the STS1 input value Remain 1 y Disconnect battery plug Disconnect CN19, CN101 cN101-24(312) 1 Continuity check CN101-16(51) No continuity y CPU board defect,24 +722 72-2 erroris ‘Connect battery plug and turn the — |not indicated Ce key switch ON. Turn the steering whee! TE errors indicated Y [NL : VO MONITOR 4 1/04 ; Check the STS2 input value Bemeli turing the steering wheel. Remain 0 — v , ‘ Disconnect battery plug i * Dysconnect CONSE ‘ | Short between CN19-2 and CN19-4 | | of main hamess side with SST2. | Connect battery plug and turn the | * key switch ON ' Y 'ANL :VO MONITOR 4104-1 ]|Change to 1 ‘Check the STS2 input value ee ee Remain 0 y Disconnect batiery plug. Disconnect CN101. (SST2 is connection state.) No continuity CNt01-30(813) em Main hamess defect 1 Continuity check y CN101-16(51) Disconnect battery plug. Disconnect CN19, Conti a Connect battery plug and turn the ’ key switch ON. CPU board defect y Change to0 [f ANL : 0 MONITOR 4 04-1 Steering angle sensor defect Check the STS2 input value Remain 1 Y Disconnect battery plug. Continuity | Disconnect CN19, GN101 Main harness defect | on101-30(313) 1 Continuity check oNni01-1661) No continuity v CPU board defect4-25 * 723 Connect battery plug and turn the | 72-3 erroris key switch ON. not indicated |netindicated Maas sca etear eee Connector connection check right for one round or more. TB errors indicated ¥ ‘ANL : 10 MONITOR 4 1/04: ; ‘Check the STSC input value pemein turning the steering wheel Remain 0 ' Disconnect battery plug \ | Disconnect CN32. ; | Short between CN19-2 and CN19-5 ! | of main hamess side with SST2. | " Connect battery plug and turn the! | key switch ON. t Y ANL : /O MONITOR 4 /04-1 Change to 1 ‘Check the STSC input value ‘Steering angle sensor defect Remain 0 y Disconnect battery plug Disconnect CN101 — (SST2is connection state.) lo continuit oe ENI01-21014) Main hamess defect, 1 Continuity measurement Toecomed bene pg =e iery plug CRTC) Disconnect CN19. Continuity Connect battery plug and turn the ’ key switch ON. CPU board defect y Change to 0 |! ANL = VO MONITOR 4 /04-1 ‘Steering angle sensor defect traveling except in an emergency.431 Az ‘CPU board overheat Related portion (CPU board ‘Thermo-sensor THTOT (Output when the thermo-sensor on the CPU board detects a voltage over the set level. ‘ANL : 1/0 MONITOR 4 /01-7 continuous overloaded operation? TEMP: CPU board temperature |} 80 “Cor more Allow vehicle to stand for a while check (approx. 30 min.) Tess than 60°C Y Has the vehicle been subjected to |YES ‘Stop vehicle and perform check test with [standard load after 30 minutes, NO vy CPU board defect4:32 A Battery connection incorrect (CHG) Related portion CN104-2(18, B48V) Ee ie cpu board Condition for error detection Output when the voltage of B48V line after F5 fuse exceeds the set level. Is A3 error being displayed? wo. Po ne connect charger plug to the controller side plug. YES Y OPTION SET: OPT-16 36V Check the setings of battery _—|| Te settings are wore, act the settings voltage (36 V/ 48 V) The seliings are correct. y Less than 48 V (STD) ANL : /O MONITOR 1/01. Less than 65 V (48 V) Voltage check > PU board defect [48 V oF more (STD) }65 V or more (48 V) Y Pie Less than 48 V (STD) Voltage measurement [Less than 6SV(4BV) coy para defect Ni 48 V or more (STD) 65.V or more (48 V) y Check the battery and replace it with the a correct battery.4-33 AS ‘Acceleration switch abnormality Related portion oN132 CN102-1(64, SWAC) 12 PU board ¥ -) ©N102-22(51, POT-) ey 9 () CNT. 1] Condition for error detection ‘Output when the acceleration ON signal is detected upon battery plug ON. Was the accelerator pedal operated |YES oi eS upon battery plug connection? NO y Disconnect CN26. y Reconnect battery plug ‘ NO 1s A4 error displayed? [adjust acceleration switch YES en Disconnect battery plug and disconnect CN102. eaertecony cN102-1(64) ee tm Hames defect Continuity check cn102-2251) No continuity vy CPU board defectMaterial handling switch abnormality oI ont CNt01-32(60,L8L4) pp A CN102-6(60, LSL) cNnt30 2inewten 4 CN2i (CN101-11(63, LSAT1+) oumasary Ce Jen cou . 2 |e. switch board rot CN87 (CN101-23(61, LSTF+) ot 335 tot 1 | Forward CN102-8(61, LSTF) is ' 2 | tit switch CN101-17(62, LSTR*) 36 16 3 | Backward cnroz-oez.istey 7 be a 7 | tit switeh CN101-16(51, LS-) ( } Condition for error detection 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 |yeg ‘operated upon battery plug WES Normal connection? NO Y Disconnect CN11 (A6-1), CN87 (A6-3) or CN21 (A6-5), and connect battery plug, Y No 1s A6 error displayed? JMC__ Adjust mit switch or switch abnormality. YES oODisconnect battery plug Disconnect CN101, CN102. Continuity check + AG (CN101-32(60)-CN102-6(60) + A6-3 (CN101-23(61)-CN102-8(61) CN101-17(62)~CN102-9(62) AGS (CN101-11(63)~CN102-10(63) (OK (short circuit) Continuity check + A6-1 (CN102-6(60)~CN101-16(51) +A63 CN102-8(61)~CN101-16(51) CN102-9(62)~CN101-16(51) + AS ‘CN102-10(63)~CN101-16(51) (OK (open circuit) CPU board defect NG (open circuit) NG (short circuit) Hamess defect, Harness defect 4.35AAA ‘CPU board thermo-sensor abnormality Related portion [CPU board ‘Thermo-sensor THiOT Condition for error detection Output upon CPU board thermo-sensor abnormality detection + To correct, replace the CPU board4-37 ‘AC ‘Semiconductor switch abnormality Related portion cN126 CPR CN104-9 (55, CPR) PA Po P3 CN104-2 (18, B48V)] FS Traveling AC|CN109-7, driver 2 Traveling AC|CN110-7/ CN104.25 “20 \%2: KEY START)| cpu board driver 1 Material ONt11-7 handling AC driver Output when overcurrent Condition for error detection the semiconductor switch of the CPU board is detected. (AC error is indicated. Disconnect CN110, connect battery plug and turn key switch ON. ‘AC error is indicated. Disconnect CN109, connect battery plug and turn key switch ON. [AC error is indicated. Disconnect CN111, connect battery plug and turn key switch ON. [AC error is indicated. + CPU Dard defect + Hamess defect Y ‘AC error is not indicated y AC error is not indicated. y AC errors not indicated If CB-1 occurs at the same time, perform troubleshooting for CB-1 first. Disconnect CN126, connect battery | AC error is not indicated. plug and turn key switch ON. Disconnect CN110, and measure resistance between 7 pins by the side of hamess, and N1. 7 pin [Tester probe -] N1 [Tester probe +] {Resistance measurement Approx. 202 or more ‘Approx. 20 9 or less Hamess check Traveling AC driver 1 defect Disconnect CN109, and measure resistance between 7 pins by the side of hamess, and N1 7 pin [Tester probe -] N1 [Tester probe +] 1 Resistance measurement Approx. 20 0 or more ‘Approx. 20 @orless Harness check Traveling AC driver 2 defect Disconnect CN111, and resistance measurement between 7 pins by the side of harness, and N1 7 pin [Tester probe] N1 [Tester probe +] 1 __ Resistance measurement Approx. 20 0 or more ‘Approx. 20 Q or less. Harness check ‘Material handling AC driver defect4:38 © y CPR resistance check [OK (Approx. 20 2) Y P2 [Tester probe -] 1 Resistance measurement N1 [Tester probe +] ‘Short circuit y Disconnect P3 and Ni cable or copper bar from the traveling controller 1. Resistance measurement between P3 of controller side and N1 3 [Tester probe -] 1 Resistance measurement N1 [Tester probe +] ‘ie ‘circuit Disconnect P3 and N1 cable or copper bar from the traveling controller 1. Resistance measurement between P3 of controller side and N1 P3 [Tester probe -] 1 Resistance measurement N1 [Tester probe +] [" circuit Disconnect P3 and N1 cable or ‘copper bar from the material handling controller defect. Resistance measurement between P3 of controller side and Nt P3 [Tester probe -] 1 Resistance measurement N1 [Tester probe +] ‘Open circuit Check P3 or N1 cable NG (Other than OK) It short-circuits for a moment and resistance Tises gradually ‘Short circuit [Short circuit Short circuit CPR defect CPU board defect, Traveling AC driver 1 defect Traveling AC driver 2 defect Material handling defect4:39 ADA Traveling AC driver 1 — main controller communication abnormality Related portion JoN103-1(145, CANH) CN110-3(145, CANH) [CNi03-2(746, CANL) (CNI10-4(146, CANL) cpu | [ent03-3(147, CANGND) ‘CN110-6(147, CANGND) | Traveling board AC driver 1 JeN104-25(42, KEY START) (ope EN110-7(42, KEY START) 425 7 enna 1 R 2-4 3 Condition for error detection (Output when the CPU board cann jot receive data from the traveling AC driver 1 within specified time. Is AD-2 error displayed? es — ‘Was traveling AC driver 1 just replaced? y ¥ PES __» see ap-2 error. + Check CN103, CN104, CN110 and CN112 connection condition. + Tum the key switch OFF and ON, and it checks that an error is not displayed. + Traveling AC driver 1 resets on the way. YES a TAL VONONTOR11072.3.5.7 Jncate sata (Tare penta fat veg AC ver ee anierane + Harness check (Especially No. 42 line) + Check CN103, CN104, CN110 and prey CN112 connection condition Disconnect CN110. 18Vor ON110-7(42) Less than 15V_ | CNt10-7(4 FL nen ee Ni 15 V or more v Y yess tan Traveling AC driver 1 Disconnect battery plug disconnect | 67 nan defect onti2 120+ 10 (CN104-25(42) ent12-4 Tavita eee Less than 15 V + Resistance measurement nA ont12.2 t TEV PRETOD Reiser tet on Harness defect ‘Check the continuity of ‘communication line harness [No continuity (= 2), Hames defect CN103-1(145) ~ CN110-3(145) CN103-1(145) ~ CN112-1(145) CN103-2(146) ~ CN110-4(146) [Continuity (0) Traveling AC driver 1 defect CN103-2(146) ~ CN112-2(148) (There is possibilty that CPU board is defect.) GN103-3(147) ~ CN110-6(147)440 AD-2 Traveling AC driver 1 — main controller communication abnormality Related portion }CN103-1(145, CANH) (CN110-3(145, CANH) [CN103-2(146, CANL) CNT10-4(146, CANL) cpu | [eNt03-3(147. CANGND) ‘GNTI0-6(747, CANGND)]| Traveling board AC driver 1 Jon 104-25(42, KEY START) Gp) EN10-7142, KEY START) CN112 1 R 2 3 Condition for error detection Output when the CPU board cannot receive ID code from the traveling AC driver 1 upon key switch on, ‘Was traveling AC driver 1 just YES * Check CN103, CN104, CN110 and => __» N12 connection condition + Harness check (Especially No. 42 line.) replaced? r 18 AD-2 error displayed even ifit repeats the key switch with OFF 7 and ON? = (CN103-1(145) ~ CN112-1(145) (CN103-2(146) ~ CN110-4(146) (CN103-2(146) ~ CN112-2(146) (CN103-3(147) ~ CN110-6(147) Disconnect CN110 15Vor ‘eN110-7(42) CE Woe menses besethan 18g | CNHOZA) ot more Ni 715 Vor more v Y Lessthan 15V traveling AC driver 1 Disconnect battery plug, disconnect | oer than at ont12. 120100 (CN104-25(42) cNt12-4 > Voltage measurement Less than 15 V 1 Resistance measurement na onti22 PRE IOT Resist detect \" ormore GPU board defect ‘Check the continuity of Hamess defect communication ine hamess, CN103-1(145)~ CN110-3(145) | No-continuity (2) os defect pooumeiv om Traveling AC driver 1 defect (There is possibility that CPU board is defect.)4-41 AD-3 Traveling AC driver 2 — main controller communication abnormality Related portion ICN103-1(145, CANH) (CN109-3(145, CANH) cpu [CN703-2(746, CANL) tT [EN703-3(147, CANGND) CN109-4(146, CANL) ‘CN108-6(747, CANGND) board JCN104-25(42, KEY START) 25) £N109-7142, KEY START) cNtt2 Traveling AC driver 2 1 2 3 Condition for error detection Output when the CPU board cannot receive data from the traveling AC driver 2 within specified time. Is AD-4 error displayed? YES ~° Was traveling AC driver 2 just YES replaced? ye [= See AD-4 error. * Check CN103, CN104, CN109 and CN112 | connection condition. + Turn the key switch OFF and ON, and it checks that an error is not displayed. + Traveling AC driver 2 resets on the way. ‘ANL. :/]O MONITOR 1/01-1,3,5,12 || ingicate data (There is possibilty that traveling AC driver 2 is ‘The data check from the traveling AC defect.) driver 2. + Harness check (Especially No. 42 line) + Check CN103, CN104, CN109 and CN112 re display connection condition. ‘cN109-7(42) Disconnect CN108. 15Vor 1. Voltage measurement ‘CN109-7(42) more Ni Less than 15 V a 1 Voltage measurement ¥ 5 V or more a y Less than Traveling AC driver Disconnect battery plug, disconnect other than 15V Dasa cNni2 1204 100 ont12-4 ‘GN104-25(42) Less nan ‘T_ Resistance measurement 1 Voltage measurement ont122 Ni i i 75V or more PROFIT Restor detect GPU bool! detect Hames defect Check the continuity of lames def ‘communication ine harness ‘CN103-1(145) ~ CN109-3(145) ‘CN 103-1(145) ~ CN112-1(145) ©N103-2(146) ~ CN109-4(146) N103-2(146) ~ CN112-2(146) (CN103-3(147) ~ CN109-6(147) Continuity (0.2) [No continuity (= 2) — Hamess defect Traveling AC driver 2 defect (There is possibilty that CPU board is defect.)4-42 AD-4 Traveling AC driver 2 — main controller communication abnormality Related portion (CN103-1(145, CANH) (CN109-3(145, CANH)| CN103-2(146, CANL) (CN109-4(146, CANL)| cey | | 6N1033(147, CANGND) ‘N109-6(147, CANGND)] Traveling AC board | | CN104-25(42, KEY START) (ras) _GN100-742, KEY START) S*vEr2 CN109-1(82, CUDIDO)| cni12 [GN09-10(82, SSD-, TD2.) 1 R 2 3 [| Condition for error detection Output when the CPU board cannot receive ID code from the traveling AC driver 2 upon key switch on. * Check CN103, CN104, CN109 and CN112 Y continuity (0.35 Traveling AC driver 2 defect (There is possibilty that CPU board is defect.) Was traveling AC driver 2 just [YES Chock N15, GNtG ? aes + Harness check (Especially No. 42 line.) xO + There is possiblity that AD-4 error willbe displayed upon key switch turing to ON at frst isAD-4 error displayed evenifitrepeats [NO eateraukreitoeceuon time afier replacing the traveling AC driver 2. es ‘CN109-7 (42) Less than 15 V | [ Disconnect CN109. 18Vor Rhee > ent09-7 (42) more 1 Voltage check 7 8 Vormore Ni Disconnect battery plug, disconnect Less than Traveling AC driver 2 eure ner han By Noe enti21 + Resistance measurement Less than (CN104-25 (42) ous T Voltage check no Ymz0A cH Check the continuity of Resister defect 15 Vor more Seat TVET crt es CNI081 (145) ~ CNT093 (145) | ty 0) Hamess defect (CN103-1 (145) ~ CN112-1 (145) = comes (I CN103-2 (146) ~ CN100-4 (148) Hamess defect CN103-2 (146) ~ CN112-2 (146) CN103-3 (147) ~ CN109-6 (147) Y continuity Oy ‘CNt09-1 (62) ity 1 Continuity check No confinuly (8) amess defect CN109-10 (@2)4-43 ‘ADS Material handling AG driver — main controller communication abnormality Related portion JCN103-1(145, CANH) CN111-3(148, CANH) [oN103-2(146, CANL) CNTHT=ACHA6, CAND] tra cpu | [GN103-3(147, CANGND) ONT11-6(147, CANGND) Fondling board |cN104.25(42, KEY START) fap oNtH-T142, KEY START, AC Over cNt12 1 R 2 3 (J Condition for error detection Output when the CPU board cannot receive data from the material handling AC driver within specified time. Is AD-6 error displayed? YES |e __» see AD-6 error. NO + Check CN103, CN104, CN111 and CN112 ‘Was material handling controller YES connection condition. «Tum the key switch OFF and ON, and it checks just replaced? re that an error is not displayed. + Material handling AC driver resets on the way. (CN103-2(146) ~ CN112-2(148) CN103-3(147) ~ CN111-6(147) VOMONITOR 11/01-2,4,6.13 || ingicate data __ (There is possibilty that material handling AC ‘The data check from the material driver is defect.) handling controler. + Hamess check (Especially No. 42 line) * Check CN103, CN104, CN111 and pe display CN112 connection condition ‘CNT11-7(42) Disconnect CN111 18Vor 1 Voltage measurement Less than 15V | CN111-7(42) more | Mt Voltage measurement yevernee Nt ’ Less than Material handling Disconnect battery plug, disconnect | Other than ov AC driver defect cNnt12 1204109 Less th cNt12-4 ‘CN104-25(42) icv ‘T_ Resistance measurement 1 Voltage measurement cNt12-2 M 7202 100 Resister defect Y j20 + 10 esist 15 Vor more Coy poard defect Check the continuity of Harness defect communication line harness No continuity (2). Hames defect (CN103-1(145) ~ CN111-3(145) (CN103-1(145) ~ CN112-1(145) CN103-2(146) ~ CN111-4(148) [Continuity (0.0) | Material handling AC driver defect ed (There is possibility that CPU board is defect.)444 ADS ‘Material handling AC driver —> main controller communication abnormality Related portion CN103-1(145, CANH) CN111-2(145, CANH) ‘CNT03-2(746, CANL) ‘CN111-4(148, CANL) cpu | [CNT03-3(147, CANGND) CNTT-6(147, CANGND)] Material board | [CN104-25(42, KEY START) CN111-7(42, KEY START)| handling 25) AC driver CNT11-2067, CUPIDI)| cnti2 [_ONTI1-10(67, SSP, TP.) 7 R 2 r— Condition for error detection (Output when the CPU board cannot receive ID code from the material handling AC driver upon key ¥ Continuity (0.3) Material handling AC driver defect (There is possibility that CPU board is defect.) switch on Wias material handing AG arver [YES Check oN108,CN104, CNITT and. cNtt2 2 oe + Harness check (Especially No. 42 line.) yo + There is possibilty that AD-6 error will be displayed upon key switch turing to ON at first 1s AD ‘error displayed even fitrepeats. [NO : patafsuastem Orr aniont tine ater repiacng the material handing AC pes ONT11-7(42) Less than 15 V | [ Disconnect CN111 18Vor ry same >] ennt-7(42) more 1 Voltage check YY 15V or more Nt Y Disconnect battery plug, disconnect | other than Tess than Material handling cNt12, famine 18V AC driver defect, enti21 1 Resistance measurement Less than yen ma Check the continuity of Resister defect, TS Vor more communication line harness. CPU board defect CN103-1(145) ~ CN111-3(145) Harness defect GNi03-1(145)~CNi12-1(145) _|Necontinuty (=O). nee GN103-2(146) ~ CN111-4(148) N103-2(146) ~ CN112-2(148) N103-9(147) ~ CN111-6(147) Y Continuity 0) ‘cni11-2(67) ee 1 Continuity check Ccontinuly (=) Hames defect cNnt11-107)4.45, AF-1,2,3,4 CPU abnormality Related portion ‘CPU board CPU Condition for error detection (Output when abnormality of CPU element is detected. + CPU board defectC4-1,2,3,4 | Accelerator potentiometer abnormality cNt32 cN26-——_— CN102-1(64, SWAC) re cn26-2, |CN102-2(52, POTA) a CN26-3 ‘Accelerator (CN102-14(53, POTA#) " cn26-4| | eentiometer cpu board ‘CNT30 ON102-22(51, POT.) ey CN26-1 T___] Condition for error detection 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. 4-3 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 operated. + Cat ‘ANL : 1 MONITOR 2 VO 2-1 Check the POTA value when the |/0.3 Vor more accelerator switch SWAC is turned |--_ CPU board defect from 0 to 1 Tess than 0.3 y The POTA value ‘ANL :/] MONITOR 2 /O 2-4 changes Check the POTA value asthe | PANGS. _ potentiometer adjustment defect accelerator is depressed further. The POTA value does yy not change, Disconnect CN26, and short "Error is not indicated | between ' POTA and POTA+ with SST8. ‘cN102-2(52) 1 Voltage measurement Potentomder defect mt 4.8 V or more Tess than 4.8.V CPU board defect Main hamess defect447 + 04-2 Does C4-2 go out after disconnecting CN267 [YES _y accelerator potentiometer check r (CN102-2(62) 1 Voltage measurement Nt Reais Main hamess defect Less than4.5V CPU board defect, + C43 ‘ANL : 1/0 MONITOR 2 102-1 ‘Check ifthe SWAC value changes from 0 to 1 as the accelerator pedal is depressed. soit ‘Accelerator switch defect Changes to 1 Y ‘ANL : VO MONITOR 2 V02- Check maximum POTA value when SWAG is 0. Less than 2.5V YES —_ee| 1s C4-3 error displayed? NO 2.5 V oF more Does C4-3 go out after disconnecting CN26? a CPU board defect [ES _ Accelerator potentiometer check NO y ‘N102-2(52) 7 Voltage measurement Ni ee Main harness defect Less than 25V PU baad defect + C44 If C4-2, 3 occurs at the same time, perform troubleshooting for C4-2, 3 first. ‘ANL : VO MONITOR 2 VO: Check the POTA value when the SWAC display is turned from 0 to or from 1 to 0. ms Niormers) Potentiometer adjustment defect Less than 1.4V CPU board defect,448 C7 Direction switch abnormality Related portion cN130 cng |CN101-1(45, DSF) 5 a |CN101-2(48, DSR) Direction cpu 3 4 board switch |CN101-16(51, LS-) (@) ji @) A Condition for error detection (Output when both forward and reverse direction switches are ON. Disconnect battery plug and disconnect CNS Y ‘ANL : VO MONITOR 2.02-2 Becomes 0 ‘Check the value of DSDSR. | | Check the value of DSF, DSR. Deeotion ween epetonl t Nt a (CN101-1(45) CN101-2(46) ING (Other than OK) DSF or DSR display will be 1 Voltage measurement +> Hamess short circuit [OK (approx. 5 V) v CPU board defect4.49 cB MB contactor abnormality Related portion Pt CN104-14,15(44, VBMB) — CN104-1,2(18, B48V) oe cpu MB contactor col cnta4 ont36 board > [EN 104-1911, MB 7 Lent04-2042, Me-) Condition for error detection Output when the voltage difference between B48V and VBMB lines exceeds the set level. If31-1, 2, 3, A1-1, 2, 3, 4, AD-2, 4, 6, C1-2, 4 and 1-2 occurs at the same time, perform troubleshooting for 31-1, 2, 3, A1-1, 2, 3, 4, AD-2, 4, 6, C1-2, 4 and E1-2 first. Is the contactor ON sound heard upon key switch ON? Wo O t= The votage diference check of 1 and 2. 4.0N104-14(44) 1 Voltage measurement Nt 2.CN104-1(18) T _ Voltage measurement Nt Check the deference of voltage value between CN104-1 and CN104-147. 30 V or more, ——> Less than Less than 32 V (STD) ANL VO MONITOR1 V01-8.11 |i 30y ‘ANL : 10 MONITOR 1/01-8 Less than 43 V (48 V) Check the deference of voltage || {7545-: Battery vohaye check value between VB48 and VBMB. ——__] [32Vormore (STD) Battery char ovr more /43 V or more (48 V) nyenarse NG (~ 2) F6 fuse check ‘OK (OR) Replace F6 fuse ‘Check the deference of voltage value between P1 and P2 Ey P41, P2 [20'V or ST MIB contactor defect 1) Voltage measurement Ni = than 30V Hamess check [Less than 30V CPU board defect4-50 Measure contactor signal voltage. | NG Signal voltage check of CPU board Disconnect connector of contactor, |(Less than @ v) | Eonrecter Less than 9 V and measure voltage between = |] Aa connector terminals on CPU board Gutoazoene® Measurement side CPU board defect Pr (9 V or more) (9 V or more MB contactor defect Check the harness between CN104 and MB contactor. ANL: VO MONITOR’ VO1-11 —_ ]] 36 Vor more (S7D) ‘Check the VME voltage al the ormore (48V) CPU board defect time of traveling/material handling operation. Less than 15 V (STD) Less than 20 V (48 V) en Tess than 1S V(STD) Less than 20 V (48 V) v MB contactor defect Check the P2 voltage at the time of | 15 v or more (STD) traveling/material handling 120 V or more (48 V) + F6 fuse check i operation + Hamess check t Voltage measurement Mt451 CB-2 MB contactor fu Related portion Pt CN104-14,15(44, VBMB)} P26 MB contactor coil cpu cN134 oNn136 board 2 [eN104-19(1, MB) 7 LeN104-20(2, MB.) —— Condition for error detection Output when the battery (VBMB line) voltage does not drop after key switch OFF key switch ON to OFF? 1s contactor OFF sound heard upon |YES p= _.! “Tur key switch OFF. CN104-19(1) 1 Voltage measurement CN104.20(2) NG (6~ 10) OK(OV) MB contactor defect je If 30-3, 31-3, 33-3, A0-2, A1-4, A2-3, AC, AD-5, 6, E1-1, 2 and E2-1 occurs at the same time, perform troubleshooting for 30-3, 31-3, 33-3, AO-2, A1-4, A2-3, AC, AD-5, 6, E1-1, 2 and E2-1 first. Check voltage change upon key switch OFF, P2 ae @}-— Voltage measurement Y Nt Disconnect battery plug, and Fusion Drop to 15Vorlessin_[Novoltage change inspect contactor contact. 5 seconds after key | upon key switch co] Y switch OFF, OFF. Replace y MB contactor.| CPU board defect + Material handling AC driver ‘abnormality Connect battery plug, turn key Although there was voltage , ‘switch ON, and check the error Error change for a moment after" Under Material handling aaa Sey ein OFF treaty Prohibion error generation a again by more than 15 V. y |________y cpu board defect Perform troubleshooting of the corresponding error. : ft ecerco2 | Is MB contactor tumed OFF with | YES Except CB-2 Tm key switch ON, and check the the key switch OFF? > error display. NO No error CB2 display y ‘Check CN104,CN134,CN136 connection condition. + CPU board defect + Hames leak4-52 EE-1,2,3 | Abnormal communication from multi-display Related portion cN131 GNI JCN103-13(144, SMTDK) -— i CN70-23) JCN103-14(143, SDTMK), 7] cN70-24| Jcn103-15(142, SOTMA) [= 5 cN70-24 cpu | [cNnt03-16(141, swTDA) | 5 CN70-22| Display board JcN103-10(16, D15V) a cn70-14] lont03-12(14, GNOD) _|—> fi CN70-39] Condition for error detection Output upon detection of communication data abnormality from display + BEA Is FI error displayed? YES | + see F 1 error y° ‘Was the battery plug connected when the display is removed? YES |-——— Connect the display Yr Disconnect CN1 Does the display turn on upon key | NO CN103-10 (16) switch ON? |] 1 Voltage measurement 5 CN103-12 (14) \" Vor more + EE-2—_» + Sub hamess defect - CPU board defect + Display defect + Hamess defect y Disconnect battery plug and ING di sct CN103 and CN70. Check the continu (other than 02). Connector connection defect (CN103-15 (142) ~ CN70-21 (142) (CN103-14 (143) ~ CN70-24 (143) + Hamess defect, ‘OK (Approx. 0.2) v + Display defect + CPU board defect + EES + Reset the tuning value. + If EE-3 is displayed frequently, either the CPU board or the display may be defective. {= than 14V453, EF-,2,4 M controller EEP-ROM abnormal Related portion CPU board Condi in for error detection (Output when abnormality of EEP-ROM element is detected. + CPU board defect EF-3 Main controller CPU abnormality Related portion CPU board Condition for error detection Output when abnormality of CPU element is detected, + CPU board defect4-54 FF (D15 overcurrent Related portion CN70-14(16, D15V) CN70-30(14, GNDD) ero CN103-10(16, D15V) board | | CN103-12(14, GNDD) Multi-display board Condition for error detection ‘Output when overcurrent of D15V power source is detected. Disconnect CN70, connect battery [No error freer plug, and turn key switch ON. Display defect FF error is indicated. Disconnect battery plug, disconnect ‘CN103, and measure the Approx. resistance between 10 pin and 12 | 1k Q or less a pin of hamess side. CN103-10 pin (Tester probe -) 1__ Resistance measurement (CN103-12 pin (Tester probe +) (Approx. 1k Q oF more CPU board defect455 HI Lift lever potentiometer abnormality Related portion Nat cnr? (CN102-18(28,POTL+) a A (CN102-6(20,POTL1) cpu 1 2 board | | CN102-7(21,POTL2) Lift lever 2 3 (CN101-34(51,POT-) 10 49 4 Condition for error detection Output when the voltage of the lift lever potentiometer is outside the specified range (open or short) | + Error indication (reference) H1-1 Lift lever potentiometer open abnormal H1-2 Lift lever potentiometer short abnormality . HI Do not operate the material handling lever during all checking. Connect battery plug Peery Tum key switch ON. ‘Check connector connection Lift lever at neutral position. Hit erroris indicated. y ‘ANL : /O MONITORS /03-1 Chek the lift lever potentiometer voltage. (Only voltage Only voltage | Both voltage 1 isles than |2islessthan |and 2 are less 0.3V. 03v. than 0.3 V.456 " Disconnect battery plug. | Disconnect CN41 " Short between CN41-3 (28) and | CN41-1 (20) (at main hamess side) ‘ with SSTB. ' Connect battery plug 1 Tur key switch ON. Hi-2 errors not indicated. 11-2 error is {indicated Disconnect battery plug. Disconnect CN101 and CN102. (SSTB is the connection state.) 1. CN102-18 (28) I Continuity check CN102-6 (20) 2. CN102-6 (20) L—_Continuity check CN101-34 (51) 2. Continuity 1. Continuity 12. No continuity CPU board defect, Disconnect battery plug, Connect CN41. Replace the connectors of lift lever (CN77) with ttt lever (CN78). Connect battery plug. Tum key switch ON. H1-1 remains. 1. No continuity Hi-1 changes to H2-1 Lift potentiometer defect, [> Main hamess defect Sub-harness defect457 * Disconnect batiery plug. ‘ | Disconnect CN41. 1‘ ' Short between CN41-3 (28) and F412 errors | CN41-2 (21) (at main hamess side) | * with SSTB. i ' Connect battery plug j tch ON. ' Disconnect battery plug. Connect CN41 Replace the connectors of lit lever (CN77) with tit ever (CN78) Connect battery plug Tur key switch ON. H1-1 remains, 1 Turn ke . “|H12 error is. not indicated. Disconnect battery plug Disconnect CN101 and CN102 (SST is the connection state.) 4, CN102-18 (28) 1 Continuity check (N102-7 (21) 2. CN102-7 (21) 41. No continuity 2. Continuity t_ Continuity check CN101-34 (51) 7. Continuity 2. No continuity CPU board defect, H1-1 changes toH2-1 Lift potentiometer defect Main harness defect, Sub-harness defect4-58, ' Disconnect battery plug. ' Disconnect CN41 " Short between CN41-3 (28) and CN41-1 (20) (at main hamese side) ‘POtnSeated._, | © ' with STB * Connect battery plug. | Turn key switch ON. - a Hi-2 error is indicated | Disconnect battery plug, | Disconnect CN41 5 Disconnect battery plug. i Dsconnect GNTON an CN102 or ; (SST8 is the connection state.) irzerocis | {Guioa-18 a) i Continuity check eni02s 20) 2. enioe.s 20) Pe Conny heck : entor-o4 1) 7. Continuity 2. No continuity CPU board defect, as Disconnect battery plug : Disconnect CN101 and CN102. Le (SST8 is the connection state.) ' Short between CN41-3(28) and | 1. CN102-18 (28) " CN41-2 (21) (at main hamess side) ‘2ctindicated._,/ “> Continuity check "with SST. ' cnt02-7 (21) ' Connect battery plug, ' 2. €N102-7 (21) | Turn key switch ON. ' 1 Continuity check Boats : CNt01-34 (61) 7 Continuity 2. No continuity Disconnect battery plug. CPU board defect Connect N41 Replace the connectors of lift lever |H1-1 remains (CN77) with tit lever (CN78) Connect battery plug. Turn key switch ON. Hi-i changes toHa-t Sub-hamess defect Lift potentiometer defect 4. No continuity 2. Continuity Main harness defect 1. No continuity 2. Continuity Main harness defect+ H1-2 Do not operate the material handling lever during all chec! Connect battery plug. ‘Turn key switch ON. Lift lever at neutral position, Hi-2 erroris indicated. y Disconnect battery plug. Disconnect CN41 Connect battery plug and turn the key switch to ON. 1-2 remains. y Disconnect battery plug, Disconnect CN102 1, CN102-18 (28) 1 Continuity check CN102-6 (20) 2. CN102-18 (28) 1 Continuity check eN102-7 (21) 7. No continuity 2. No continuity CPU board defect H1-2 errors not indicated. Check connector connection Disconnect battery plug wiacames | Ben ce es pone tol cnt01-34 (61) 1 Continuity check N41-10 (51) Continuity Main hamess detect Y Disconnect battery plug. 4. Continuity | Connect CN41 and CN101 2 Continuity | Replace the connectors of it lever | 1-2 remains (CN77) with tit lever (CN78). Connect battery plug. Tur key switch ON. Hi-2 changes Main hamess eta defect Sub-hamess defect y Lit potentiometer defect4-60 1-3 Lift lever potentiometer abnormality ——$ Related portion cNat N77 (CN102-18(28,POTL#) 3 : €N102-6(20,POTL1) cpu 1 2 board | | cN102-7(21,POTL2) Lift lever 2 3 CN101-34(51,POT-) 10 49 4 Condition for error detection the specified range. * Error indication (reference) H1-3 Lift lever potentiometer abnormality ‘Output when the voltage of the lift lever potentiometers 1, 2 with the lift lever at neutral position is outside H1-3 error is, Connect battery plug. ri Tum key switch ON. not indicated. Lift lever operation. Hi-3 erroris indicated. y ‘ANL : /]O MONITORS 03-4 Chek the lift lever potentiometer voltage (*1) y Disconnect battery plug. Replace the connectors of the lift lever (CN77) with the tt lever (CN78), Connect battery plug and turn the key switch to ON. y ‘ANL : VO MONITORS 03-3 Chek the tilt lever potentiometer voltage Within (*1) +0.2V [Below or above ("1) +0.2V. ‘Check connector connection Lift lever potentiometer defect4-61 @ y Disconnect battery plug, Disconnect CN102. Retum the lift lever connector (CN77) and the tit lever connector (CN78) to the original connection. Connect battery plug and turn key switch ON. y ‘ANL : 1 MONITOR3 /03-1 Chek the lift lever potentiometer voltage [03 Vorless i oo " Disconnect battery plug ' Short at the connectors below (CPU | board side) wath the aligator clip of | $8713 in connection ' Connect battery plug and turn key switch ON. CN101-11 (63) ~ CN102-6 (20) CN101-11 (63) ~ CN102-7 (21) ‘ANL : /] MONITOR3 /03-1 Chek the lift lever potentiometer voltage [4.5 Vor less CPU board defect 0.3 V or more 4.5 V or more CPU board defect, Hamess defect,4-62 Ht-4 Lift lever potentiometer abnormality Related portion Related portion Nat ead CN102-18(28,POTL+) 3 1 (CN102-6(20,POTL1) i cpu 1 2 board | | CN102-7(21,POTL2) 7 aes (CN101-34(51,POT>) o a r LD Condition for error detection Output when the lift lever voltage value is outside the specified neutral range (lever operated) upon key switch ON. + Error indication (reference) H1-4 Lift lever neutral abnormality ‘Check that the lift lever returned to neutral poston. Hi-A goes out Normal Tum key switch ON again Do not operate the ever upon key switch ON. Hid remains Y ‘Check the installation state of the lift | NG Readj lever potentiometer. eda ieaitintt OK y MATCHING. LIFT Perform matching of the lift lever || OK jx eee ealerne ial vehena Vehicle operation can be started again NG v Lift potentiometer defect