Toyota 7FBMF 16 50

TOYOTA 7FBMF 16-50
SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CONTROLLER 2
MULTI-DISPLAY FUNCTIONS 3
TROUBLESHOOTING 4
MOTOR 5
DRIVE UNIT 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
SAS FUNCTIONS 17
APPENDIX 18
0-1
GENERAL
Page Page
EXTERIOR VIEWS ........................... 0-2 SAFE LOAD FOR EACH WIRE 0
VEHICLE MODELS .......................... 0-4 ROPE SUSPENSION 1
ANGLE ............................................ 0-16
FRAME NUMBER............................. 0-4 2
COMPONENTS WEIGHT ............. 0-17
HOW TO USE THIS 3
MANUAL .......................................... 0-5 RECOMMENDED LUBRICANT
QUANTITY & TYPES .................. 0-18 4
EXPLANATION METHOD ................. 0-5
LUBRICATION CHART ................ 0-19 5
TERMINOLOGY................................. 0-6
PERIODIC MAINTENANCE ......... 0-21
ABBREVIATIONS.............................. 0-6 6
PERIODIC REPLACEMENT
OPERATIONAL TIPS ...................... 0-7 7
OF PARTS AND
JACK-UP POINT .............................. 0-8 LUBRICANTS ............................... 0-25 8
HOISTING THE VEHICLE .............. 0-9
Totaldokument, service...........0-26 9
CAUTION FOR TOWING ................ 0-9
10
PARKING BRAKE RELEASE
METHOD.......................................... 0-9 11
ATTENTIVE POINTS ON SAS .... 0-10 12
CIRCUIT TESTER .......................... 0-11
13
STANDARD BOLT & NUT
TIGHTENING TORQUE .............. 0-13 14
BOLT STRENGTH TYPE 15
IDENTIFICATION METHOD.......... 0-13
16
TIGHTENING TORQUE TABLE ...... 0-14
17
PRECOATED BOLTS ................... 0-15
HIGH PRESSURE HOSE 18
FITTING TIGHTENING 19
TORQUE......................................... 0-15
20
WIRE ROPE SUSPENSION
ANGLE LIST .................................. 0-16 21
22
0-2
EXTERIOR VIEWS
16 ~ 35 Model
0-3
40 ~ 50 Model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
0-4
VEHICLE MODELS
Model code Load capacity Vehicle model Voltage
16 1.6 ton 7FBMF16 80 V/72 V
18 1.8 ton 7FBMF18 ↑
20 2.0 ton 7FBMF20 ↑
25 2.5 ton 7FBMF25 ↑
30 3.0 ton 7FBMF30 ↑
35 3.5 ton 7FBMF35 ↑
40 4.0 ton 7FBMF40 ↑
45 4.5 ton 7FBMF45 ↑
50 5.0 ton 7FBMF50 ↑
FRAME NUMBER
Vehicle model Punching format Frame No. punching position
)%0) Punching position
)%0)
)%0)
)%0)
)%0)
)%0)
)%0)
)%0)
)%0)
)%0)
)%0) )%0)
)%0)
0-5
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, 0
followed by explanation of cautions and notes summarized as point operations.
1
Example of description in pattern B
2
DISASSEMBLY • INSPECTION • REASSEMBLY
Tightening torque unit T = N⋅m (kgf⋅cm) [ft⋅lbf] 3
• Step Nos. are sometimes partially
4
omitted in illustrations.
• When a part requiring tightening 5
torque instruction is not indicated
in the illustration, the part name is 6
described in the illustration frame.
7
T = 46.1 ~ 48.1
(470 ~ 490)
8
9
[34.0 ~ 35.5]
10
11
12
Disassembly Procedure 13
1 Remove the cover. [Point 1]
14
2 Remove the bushing [Point 2] Operation explained later
3 Remove the gear. 15
Point Operations Explanation of key point for operation with an illustration
16

[Point 1] 17
Disassembly:
Put a match mark when removing the pump cover. 18
[Point 2] 19
Inspection:
Measure the bushing inside diameter.
Limit: 19.12 mm (0.7528 in)
20
21
22
0-6
2. How to read components figures (Example)

(1) The components figure uses the illustration
in the parts catalog for the vehicle model. 3201
Please refer to the catalog to check the part
name. FIG number in parts catalog
The number at the top right of each

components figure indicates the Fig.
number in the parts catalog.
3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but they should be performed in the actual
operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters of which negligence may cause hazards to the human body. Be sure to observe
them.
Note:
Important items of which negligence may cause breakage or breakdown, or matters in operation
procedure requiring special attention.
Standard: Values showing the allowable range for inspections and adjustments.
Limit: Maximum or minimum allowable value for inspections or adjustments.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
Society of Automotive
ASSY Assembly SAE
Engineers (USA)
ATT Attachment SAS System of active stability
Central hydraulic
CHPS SST Special service tool
power steering
LH Left hand STD Standard
L/ Less T= Tightening torque
OPT Option T Number of teeth ()
O/S Oversize U/S Undersize
PS Power steering W/ With
RH Right hand
0-7
OPERATIONAL TIPS
1. Safe operation
(1) After jacking the vehicle, always support it with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy components, use wire rope(s) with a sufficient allowance in
load capacity.
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic's tools, necessary measuring instruments (circuit tester, megger, oil
pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and
operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace gaskets, packing and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use the bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.)
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Protection of functional parts
(1) Thoroughly check each connector for any failure in or imperfect connection before reconnecting the
battery plug after the end of vehicle inspection or maintenance.
Failure in or imperfect connection of connectors related to controllers in particular may
damage elements inside the controllers.
4. Confirming defect status
Do not start immediate disassembly or replacement, but first confirm if such disassembly or
replacement is actually needed.
5. Handling of waste fluid, etc.
When draining waste fluid from the vehicle, always catch it with an appropriate container.
Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other
harmful substance may cause adverse affect to people or environmental destruction, sort each waste
and always ask an authorized contractor for appropriate disposal.
6. Handling of electronic parts
(1) Never apply impacts to electronic parts such as a
microcomputer or relay.
(2) Never let electronic parts be exposed to a high
temperature or humidity.
(3) Do not touch connector pins since they may be
deformed or be damaged due to static electricity.
0-8
JACK-UP POINTS
Strictly observe the following instructions when jacking up the vehicle.
• When a load is on the fork, unload it and park the vehicle on a flat floor. Be sure to avoid an inclined or
uneven place.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up points. Jacking up at any
other point will be dangerous.
• Never operate while the vehicle is held with a jack. Always support the frame with a wooden block after
jacking it up.
• In any case, never let a part of the body (including hands and feet) be under the jacked-up vehicle.
:
Jack-up point
:
Wooden block or stand
setting point
0-9
HOISTING THE VEHICLE

When hoisting the vehicle, use the mast hook on the front of
the vehicle and a wire net on the rear wheel.
Caution:
• Use wire ropes having sufficient strength.
• Never hoist the forklift by the weight hook holes or
head guard.
CAUTION FOR TOWING

Note:
Before towing, be sure to release the parking brake. (See
the section below on Parking Brake Release Method.)
1. When towing the forklift, always lift the rear wheels away
from the ground.
2. The traveling speed when towing must not exceed the
maximum traveling speed of the forklift.
3. Always set the key switch to OFF and the direction

switch to the neutral position before starting towing.
In case of towing by connection with a wire rope with the
operator on the forklift, however, set the key switch to
ON (PS operation) and always set the direction switch to
the neutral position.
4. Before towing, either remove the fork or take action to
prevent the fork from contacting with the ground due to
bounding.
PARKING BRAKE RELEASE METHOD
1. Remove the toe board.

2. Remove the plug from the center of the parking brake
cover.
Plug
L 3. As shown in the figure, install the service bolt (or SST),

nut and plate washer to the plug hole.
Service bolt
Service bolt size:
M14 × 1.5, L = 40 mm (all screws)
Note:
• If you do not have a service bolt, use the SST.
SST 09460-21320-71
Nut Piston
Washer • Screw the service bolt securely into the parking brake
piston.
0-10
4. Fix the head of the service bolt, then tighten the nut
clockwise to fully pull in the parking brake piston. This
releases the parking brake.
Fix
ATTENTIVE POINTS ON SAS

1. Reference should be made to separate manual “New Model Feature 7FBMF16 to 50 Pub. No.PE313”
for the explanations of SAS functions and operations.
2. Read Section 17 “SAS Precautions for Repair” on Page 17-11 in this repair manual in advance.
3. Whenever the repair or replacement is performed on a place that relates to SAS function, match the
procedure by which the SAS regain proper function must be performed. (See Page 3-51)
4. Care should always be taken to always operate the truck safely.
Be aware of the difference between truck with and truck without SAS, because the control features are
different.
5. The SAS oil control valves have many precision valves. Since dirty or contaminated hydraulic oil will
adversely affect the function of these valves, always clean the parts at the time of installation after
disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replacement of the
hydraulic oil is very important.
6. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause
faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary
equipment, optional parts, etc.).
0-11
CIRCUIT TESTER
Circuit testers are available in both analog and digital types. They should be used selectively according to
the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured value
should only be used for reference or rough judgment.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.
1. Difference in measurement results between the digital type and analog type
* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester in accordance with its operation manual.
Cautions when the polarities are different between the analog type and digital type are described
below.
(1) Analog circuit tester
Forward direction Reverse direction Measurement result example
Tester range: kΩ range
Analog type
Continuity exists
Forward
11 kΩ
No continuity
Reverse
∞
(2) Digital circuit tester

Forward direction Reverse direction
Measurement result example
Tester range: MΩ range
Digital type
No continuity
Forward
1
Continuity exists
Reverse
2 MΩ
0-12
2. Difference in result of measurement with a circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor, such as a diode, varies with the circuit tester power supply voltage.
The diode characteristics are shown in the figure below.
(mA) The resistance values of the same semiconductor measured
6
with two types of circuit testers having different power supply
5
voltages are different.
Forward current
4 Germanium
diode
This manual describes the results of measurement with a
3
circuit tester whose power supply voltage is 3.0 V.
2 Silicon
diode
1
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)
3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement range switches over the internal circuit to
vary the circuit resistance. Even when the same diode is measured, the measurement result varies
with the measurement range.
Always use the range described in the repair manual for
measurement.
Resistor Meter
0Ω
Variable resistor
Current flow
Resistor
Range:×10 (SW1)
Resistor
Range:×1
Power source: 1.5V
Red Black
0-13
STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2. The nut tightening torque can be judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.
Shape and class Class Hexagon head bolt
4 = 4T
5 = 5T
Bolt head No. 6 = 6T Parts No.
Hexagon 7 = 7T 91611-40625
head bolt 8 = 8T
Length (mm)
No mark 4T Diameter (mm)
Class
Hexagon
No mark 4T
flange bolt Diameter
Hexagon Two protruding 5T

head bolt lines Length
Hexagon Two protruding 6T

flange bolt lines
Stud bolt
Hexagon Three protruding 7T
head bolt lines
Parts No.
92132-40614
Hexagon Four protruding 8T
head bolt lines Length (mm)
Diameter (mm)
Class
Welded bolt 4T
Diameter
No mark 4T Length
Stud bolt
Grooved 6T
0-14
TIGHTENING TORQUE TABLE

Specified torque
Diameter Pitch Hexagon Hexagon
Class
mm mm head bolt flange bolt
N⋅m kgf⋅cm ft⋅lbf N⋅m kgf⋅cm ft⋅lbf
6 1.0 5.4 55 48 in⋅lbf 5.9 60 52 in⋅lbf
8 1.25 13 130 9 14 145 10
10 1.25 25 260 19 28 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 75 760 55 83 850 61
16 1.5 113 1150 83   
6 1.0 6.4 65 56 in⋅lbf 7.5 75 65 in⋅lbf
8 1.25 16 160 12 18 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 137 1400 101 157 1600 116
6 1.0 7.8 80 69 in⋅lbf 8.8 90 78 in⋅lbf
8 1.25 19 195 14 21 215 16
10 1.25 38 400 29 43 440 32
6T
12 1.25 72 730 53 79 810 59
14 1.5 110 1100 80 123 1250 90
16 1.5 170 1750 127 191 1950 141
6 1.0 11 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 103 1050 76
14 1.5 147 1500 108 167 1700 123
16 1.5 226 2300 166   
6 1.0 12 125 9 14 145 9
8 1.25 29 300 22 32 330 24
10 1.25 61 620 45 68 690 50
8T
12 1.25 108 1100 80 123 1250 90
14 1.5 172 1750 127 196 2000 145
16 1.5 265 2700 195 299 3050 221
0-15
PRECOATED BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use a precoated bolt as it is in either of the
following cases:
(a) After it is removed.
(b) When the precoated bolt is moved (loosened or
Seal lock agent
tightened) during a check, etc.
Note:
For torque checks, use the lower limit of the
allowable tightening torque range. If the bolt moves,
retighten it in accordance with the steps below.
2. Method for reuse of precoated bolts

(1) Clean the bolt and threaded hole. (The threaded hole
must be cleaned even for replacement of the bolt.)
(2) Perfectly dry the cleaned parts by blowing them with
air.
(3) Coat the specified seal lock agent on the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with
clean cloth to remove foreign matter and dirt. Also make sure there are no dent or other damage on
the contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the
fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N⋅m (kgf⋅cm) [ft⋅lbf] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16  20UNF 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
9/16  18UNF 49 (500) [36.2] 47 ~ 52 (480 ~ 530) [34.7 ~ 38.3] 9 (0.35)
3/4  16UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8  14UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47), 15 (0.59)
1⋅1/16  12UNF 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
1⋅5/16  12UNF 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
PF3/8 49 (500) [36.2] 47 ~ 52 (480 ~ 530) [34.7 ~ 38.3] 9 (0.35)
PF1/2 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
0-16
WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension
Lifting angle Tension Compression Lifting angle Tension Compression
method method
1 tf
0° 1.00 time 0 time 90° 1.41 time 1.00 time
90°
tf
41
2t 1. 2t
30°
tf
30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
1.04 120°
t
2f
2t 2t
60° 1.16 time 0.58 time 60°

f
6t
1.1
2t
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Single-rope
Rope Cutting suspension Two-rope suspension Four-rope suspension
diameter load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
0-17
COMPONENTS WEIGHT
Member Model Weight kg (lbs)
Battery ASSY See page 1-2.
16⋅18 Approx. 62 (137)
Drive motor ASSY 20 ~ 35 Approx. 73 (161)
40 ~ 50 Approx. 96 (212)
16⋅18 Approx. 57 (126)
Pump motor ASSY 20 ~ 35 Approx. 60 (132)
40 ~ 50 Approx. 97 (214)
16 Approx. 430 (948)
18 Approx. 560 (1235)
20 Approx. 510 (1125)
25 Approx. 820 (1808)
Counterweight 30 Approx. 940 (2073)
35 Approx. 1470 (3241)
40 Approx. 950 (2095)
45 Approx. 1300 (2867)
50 Approx. 1790 (3947)
16⋅18 Approx. 440 (970)
20⋅25 Approx. 500 (1100)
V mast ASSY L/fork and backrest 30 Approx. 610 (1350)
(with lift cylinder, max. lifting
height: 3300 (130 in)) 35 Approx. 715 (1580)
40⋅45 Approx. 930 (2050)
50 Approx. 1100 (2430)
0-18
RECOMMENDED LUBRICANT QUANTITY & TYPES

Description Application Quantity (US gal) Classification Type
16 ~ 25 model 5.9 (1.56)
API SHELL DONAX
Drive unit 30 ~ 35 model 6.5 (1.72)
GL-4 TD *)
40 ~ 50 model 11.0 (2.90)
Hydraulic oil 16⋅18 model 15.0 (3.96)
(V⋅FV⋅FSV mast: 20 ~ 35 model 17.0 (4.49) ISO
Hydraulic oil
lifting height VG32
3300 mm (130 in)) 40 ~ 50 model 33.5 (8.84)
• MP grease
Chassis parts All model Proper quantity  • Molybdenum
disulfide grease
Battery All model Proper quantity  Distilled water
*) Shell Donax TD = OK/Q8 T2200
P/N: 755224-020 20 liter

0-19
LUBRICATION CHART
16 ~ 35 Model
1 2 2 1
3 1 3 3 2
4 5 1 3
5 4
1 5
10 4 4
11 5
13 5
6 1 1 6
7 1 1 7
8 1 1 8
9 1 1 9
12 5
I
II
III
IV
Inspection I. Inspect every 8 hours (daily)

Replacement II. Inspect every 40 hours (weekly)
MP Grease III. Inspect every 250 hours (monthly)
Engine oil IV. Inspect every 1000 hours (6 monthly)
Gear oil V. Inspect every 2000 hours (annual)
Hydraulic oil
Molybdenum disulfide grease
1 Chain 8 Tie rod end pin

2 Drive unit 9 Rear axle cylinder end pin
3 Tilt cylinder front pin 10 Oil tank
4 Mast support bushing 11 Rear axle beam front pin
5 Tilt steering lock mechanism 12 Rear axle beam rear pin
6 Steering knuckle king pin 13 Swing lock cylinder crank and rod pin
7 Rear wheel bearing
0-20
40 ~ 50 Model
1 2 2 1
3 1 3 3 2
4 5 1 3
5 4
1 5
10 4 4
11 5
13 5
6 1 1 6
7 1 1 7
8 1 1 8
9 1 1 9
12 5
I
II
III
IV
Inspection I. Inspect every 8 hours (daily)

Replacement II. Inspect every 40 hours (weekly)
MP Grease III. Inspect every 250 hours (monthly)
Engine oil IV. Inspect every 1000 hours (6 monthly)
Gear oil V. Inspect every 2000 hours (annual)
Hydraulic oil
Molybdenum disulfide grease
1 Chain 8 Tie rod end pin

2 Drive unit 9 Rear axle cylinder end pin
3 Tilt cylinder front pin 10 Oil tank
4 Mast support bushing 11 Rear axle beam front pin
5 Tilt steering lock mechanism 12 Rear axle beam rear pin
6 Steering knuckle king pin 13 Swing lock cylinder crank and rod pin
7 Rear wheel bearing
0-21
PERIODIC MAINTENANCE
Inspection Method
I : Inspection⋅Repair or Replacement if required.

M : Measurement⋅Repair or Adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector
Inspection Period Every Every Every Every
month 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound I ← ← ←
Looseness in the connecting parts T ← ← ←
Insulation resistance M ← ←
Brush wear and sliding condition
Motor I ←
(For PS motor only)
Commutator contamination, damage
I ←
(For PS motor only)
Brush, spring wear
M
(For PS motor only)
Charging level I ← ← ←
Electrolyte level I ← ← ←
Electrolyte specific gravity M ← ← ←
Terminal looseness I ← ← ←
Battery Abnormality in the upper portion of the
I ← ← ←
battery case
Insulation resistance M ← ←
Voltage measurement of each battery cell after
M
charging
Contact looseness, damage, abrasion I ← ← ←
Operating condition of the auxiliary contact,
I ← ← ←
contamination, abrasion
Magnet Mounting condition of the arc shooter I
contactor Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead wire,
I
looseness
Operating condition and timing I ← ← ←
Microswitch
Damage and looseness of installing parts I ← ← ←
Direction switch Operation condition, damage I ← ← ←
Operation condition I ← ← ←
Controller Interior contamination, damage C ← ← ←
Motor input voltage M
Fuse Looseness I ← ← ←
0-22

Harness deterioration, champ damage and
I ← ← ←
Wiring looseness
(including Looseness in connecting parts, taping condition I ← ← ←
charging cord) Connecting condition and damage of the
I ← ← ←
battery connector
POWER TRANSFER SYSTEM
Oil leakage I ← ← ←
Drive unit Oil level I ← ← ←
Bolt or nut looseness T
DRIVE SYSTEM
Tire inflation pressure M ← ← ←
Tire cuts, damage and uneven wearing I ← ← ←
Loose rim and hub nuts T ← ← ←
Tire groove depth M ← ← ←
Metal chips, pebbles and other foreign matter
Wheels I ← ← ←
trapped in tire grooves
Rim, side bearing and disc wheel damage I ← ← ←
Abnormal sound and looseness of front wheel
I ← ← ←
bearing
Abnormal sound and looseness of rear wheel
I ← ← ←
bearing
Front axle
Cracks, damage and deformation of housing I
Cracks, damage and deformation of beam I
Rear axle Looseness of axle beam in vehicle longitudinal
M* M
direction
STEERING SYSTEM
Play and looseness I ← ← ←
Steering wheel
Function I ← ← ←
Oil leak I ← ← ←
Steering valve
Looseness of mounting T ← ← ←
Power steering Mounting and linkage looseness I ← ← ←
Damage of power steering hose I
King pin looseness I ← ← ←
Knuckle
Cracks and deformation I
0-23

BRAKING SYSTEM
Play and allowance M ← ← ←
Brake pedal
Braking effect I ← ← ←
Function of switch I ← ← ←
Parking brake Braking effect I ← ← ←
Brake pipe Leak, damage and mounting condition I ← ← ←
Function, wear, damage, leak and mounting
Brake valve I
looseness
Brake disk (For Wear of disk I
foot brake) Damage of each part I
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I ← ← ←
Forks Misalignment between left and right fork fingers I ← ← ←
Cracks at fork root and welded part I*1
Deformation and damage of each part and
I ← ← ←
crack at welded part
Mast and lift bracket looseness I ← ← ←
Mast and lift Wear and damage of mast support bushing I
bracket
Wear, damage and rotating condition of rollers I ← ← ←
Wear and damage of roller pins I
Wear and damage of mast strip I ← ← ←
Tension, deformation and damage of chain I ← ← ←
Chain lubrication I ← ← ←
Chain and chain
wheel Abnormality of chain anchor bolt I ← ← ←
Wear, damage and rotating condition of chain
I ← ← ←
wheel
Various Abnormality and mounting condition of each
I ← ← ←
attachments part
HYDRAULIC SYSTEM
Loosening and damage of cylinder mounting T ← ← ←
Deformation and damage of rod, and rod end I ← ← ←
Cylinder operation I ← ← ←
Natural drop and natural forward tilt
M ← ← ←
Cylinder (hydraulic drift)
Oil leak and damage I ← ← ←
Wear and damage of pin and pin support I ← ← ←
Lifting speed M ← ← ←
Uneven movement I ← ← ←
Oil pump Oil leak and abnormal sound I ← ← ←
0-24

HYDRAULIC SYSTEM
Oil level and contamination I ← ← ←
Hydraulic oil
Tank and oil strainer C ←
tank
Loose lever I ← ← ←
Control lever
Operation I ← ← ←
Oil control valve Relief pressure measurement M
Relief valve functions I ← ← ←
Hydraulic piping Deformation and damage I ← ← ←
Loose joint T ← ← ←
SAFETY DEVICES, ETC.
Cracks at welded portion I ← ← ←
Head guard
Deformation and damage I ← ← ←
Loosening of mounting T ← ← ←
Back-rest
Deformation, crack and damage I ← ← ←
Lighting system Function and mounting condition I ← ← ←
Horn Function and mounting condition I ← ← ←
Direction
Function and mounting condition I ← ← ←
indicator
Instruments Functions I ← ← ←
Backup buzzer Function and mounting condition I ← ← ←
Rear-view Dirt, damage I ← ← ←
mirror Rear reflection status I ← ← ←
Loosening and damage of mounting I ← ← ←
Seat
Seatbelt damage and function I ← ← ←
Damage and cracks of frame, cross members,
I
Body etc.
Bolts and nuts looseness T
Functions I ← ← ←
Loosening and damage at sensor mounting
I ← ← ←
portion
Damage, deformation, oil leakage and loosen-
SAS I ← ← ←
ing of the mounting of functional parts
Loosening and damage of wire harnesses I ← ← ←
Lock cylinder accumulator performance I
Rusting and corrosion of load sensor I
Others Grease up L ← ← ←
0-25
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

: Replacement
Replacement timing Every Every Every Every
Drive unit oil
Hydraulic oil ←
New vehicle
Hydraulic oil filter ←
initial replacement
Rear wheel bearing grease
Brake valve rubber parts
Disk brake piston seals

(For foot brake)
Power steering hose Every 2 years
Power steering rubber parts Every 2 years
Hydraulic hose Every 2 years
Chain Every 3 years
Every 10,000
Swing lock cylinder
hours
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
0-26
Totaldokument
Toyota 7FBMF 16-50
Var 250:e timme
Pos Kontroll av: Pos Kontroll av: Pos Kontroll av:
0:0 Grupp 0 Hel maskin 3:0 Grupp 3 Bromsar/hjul 5:9 Fartreglage

0:1 Dörrar/luckor 3:1 Däck/hjul 5:10 Microbrytare
0:2 Motviktsinfästning 3:2 Lufttryck däck 5:11 Kontaktorer/kontakter
0:3 Förarskydd/hytt 3:3 Hjulbultar/hjullager 5:12 Säkringar
0:4 Batterilåsning 3:4 Färdbroms, funktion/läckage 5:13 Batterivätskenivå
0:5 Skyltar/dekaler 3:5 Parkeringsbroms 5:14 Batteri, smuts/läckage
0:6 Förarmiljö 3:7 Pedallänkage/pedalspel 5:15 Batterianslutningar
0:7 Stol/mattor 5:16 Batteripoler reng./infettning
0:8 Pedalgummin 4:0 Grupp 4 Styrning 5:17 Batterihandskar, kontroll
0:9 Torkare/spolare 4:1 Styrlänkar, kontroll
0:10 Provkörning test av 4:2 Slangar/rör, läckage 6:0 Grupp 6 Hydraulik
samtliga funktioner 4:3 Styraxel/upphängning 6:1 Slangar/rör, läckage
0:11 Smörjning enligt schema 6:2 Ventilreglage/länkage
0:12 SAS system, funktion 5:0 Grupp 5 Elsystem 6:3 Andningsfilter/ventilatorer
5:1 Belysning/körriktningsvisare 6:4 Oljenivå
1:0 Grupp 1 Motorer 5:2 Instrument/kontrollampor
1:1 Missljud 5:3 Signalhorn 7:0 Grupp 7 Arbetsfunktion
1:2 Fastsättning/infästning 5:4 P-broms-/Backalarm 7:1 Lyftstativ
5:5 Timmätare, avläsning 7:2 Gafflar
2:0 Grupp 2 Kraftöverföring 5:6 Färdväljare 7:3 Lyftkedjor
2:1 Oljenivå 5:7 Kablar/anslutningar 7:4 Laststöd
2:2 Fastsättning 5:8 Transistorpanel 7:5 Lyft-/tiltcylindrar
Var 500:e timme tillkommer: Var 1000:e timme tillkommer: Var 2000:e timme tillkommer:
1:0 Grupp 1 Motorer 1:0 Grupp 1 Motorer 0:0 Grupp 0 Hel maskin
1:3 Drivmotor, renblåsning 1:9 Styrp.motorkol, kontroll (*) 0:13 Ram, kontroll av sprickor
1:4 Pumpmotor, renblåsning 0:14 Bultar/Muttrar, fastsättning
1:5 Styrp. motor, renblåsning (*) 3:0 Grupp 3 Bromsar/hjul
1:6 Motorer, isolationsprov 3:10 Hjullager infettning 2:0 Grupp 2 Kraftöverföring
2:3 Drivaxel, oljebyte
5:0 Grupp 5 Elsystem 4:0 Grupp 4 Styrning 2:4 Drivaxel, fastsättn./sprickor
5:18 Batteri, isolationsprov 4:4 Slangar, kontroll
3:0 Grupp 3 Bromsar/hjul
6:0 Grupp 6 Hydraulik 3:11 Bromslameller, slitagekontroll
6:5 Hydraulolja, byte
6:6 Returfilter, byte 5:0 Grupp 5 Elsystem
6:7 Sugfilter, rengöring/byte 5:19 Batteribelastningsprov
6:8 Andningsfilter, reng./byte 5:20 Motorström, mätning
6:0 Grupp 6 Hydraulik

6:9 Hydraultryck, kontroll
7:0 Grupp 7 Arbetsfunktion

7:6 Gafflar, gaffeltest
(*) Endast 7FBMF 16-35
7FBMF 16-50
© BT Svenska AB 04/04
1-1
BATTERY
Page
BATTERY COMPARTMENT AND
0
REQUIRED WEIGHT .....................................................1-2
SERVICE STANDARD ....................................................1-3 1
DISPLAY .............................................................................1-3 2
TROUBLESHOOTING ....................................................1-4 3
BATTERY ASSY ...............................................................1-5 4
REMOVAL • INSTALLATION..............................................1-5
5
INSPECTION .....................................................................1-6
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1-2
BATTERY COMPARTMENT AND REQUIRED WEIGHT

1
When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
Battery case dimensions mm (in) Necessary minimum
Vehicle model Forward- battery weight Remarks
DIN No. Width Y Height Z (with case) kg (lb)
Rear X
1026
7FBMF16, 18 4PzS440L 708 (27.8) 627 (24.6) 1220 (2690)
(40.3)
7FBMF20, 25 5PzS550L 852 (33.5) ↑ ↑ 1530 (3374)

STD
7FBMF30, 35 6PzS660L 996 (39.1) ↑ ↑ 1780 (3925)
1140 1034
7FBMF40, 45, 50 7PzS770L ↑ 2030 (4476)
(44.9) (40.6)
1028
7FBMF16, 18 3PzS420L 567 (22.3) 784 (30.9) 1240 (2734)
(40.5)
7FBMF20.25 4PzS560L 711 (28.0) ↑ ↑ 1560 (3440)

OP
T
7FBMF30, 35 5PzS700L 855 (34.8) ↑ ↑ 1860 (4101)
7FBMF40, 45, 50 6PzS840L 999 (39.3) ↑ ↑ 2180 (4807)

ra
Re
X
d-
ar
rw
Fo
Z Height
Y
Width
1-3
SERVICE STANDARD
Specific gravity upon full charge* 1.280 [20°C (68°F)]
Specific gravity upon end of discharge* 1.150 [20°C (68°F)]
72 V 61 V
Discharge end voltage*
80 V 68 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled (deionized) water
0
Insulation resistance 1 MΩ or more 1
*: Referemce (Comply with the secifications given by the battery manufacturer.)
2
DISPLAY
Battery Charge Indicator 3
The battery charge indicator indicates 10 levels of battery 4
charge on the LCD.
5
6
Battery capacity indicator 7
Low Remaining Battery Charge Warning
8
Battery LCD
discharged
state %
10 9
F
8 7 6 5 4 3 2 1
E When the remaining battery charge drops below the set 9
level, the charge display blinks.
10
0 to 10

(exclusive)
10 to 20

When the key switch is turned to OFF and ON again in this
(exclusive)
20 to 30
state, the buzzer sounds for 5 seconds to warn the operator. 11
 
12
(exclusive)
30 to 40 Battery Overdischarge Warning Function
  
(exclusive)
40 to 50
(exclusive)
    When the battery charge decreases further below the set 13
level after the remaining battery charge warning, any attempt
50 to 60
(exclusive)
     at traveling/material handling operation will cause all charge 14
60 to 70 indicator segments to blink and the alarm to sound to warn
(exclusive)
     
the operator. 15
70 to 80
      
(exclusive)
80 to 90
16
       
(exclusive)
90 to 100
        
17
(exclusive)
100 or more          
18
19
20
21
22
1-4
TROUBLESHOOTING
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Long storage without Repeated overdischarge/
operation overcharge
Short circuit
End of life between cells Excessive charging
Defect of electrolyte current
Insufficient
electrolyte
Defective Excessive ambient
Battery defect
electrolyte temperature
Overdischarge
Damaged Crack or chipping of cell

separator Improper water
supply
Overcharge
Imperfect terminal
connection
Deposition of freed Fouled terminal or

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

1-5
BATTERY ASSY
REMOVAL • INSTALLATION
Always remove or install the battery in no-load state (without any load on the fork).
0
1 1
2
4
3
4
3
5
6
5
7
8
9
2 10
Removal Procedure
11
1 Open the seat stand and disconnect the battery plug. 12
2 Open the rear toe board.
3 Open the hood (RH). 13
4
5
Remove the battery stopper.
Remove the battery ASSY. [Point 1]
14
Installation Procedure 15
The installation procedure is the reverse of the removal procedure. 16
Point Operations
17
[Point 1]
18
SST
Removal Installation:
•
SST 25001-21320-71
19
20
21
22
1-6
INSPECTION
1. Electrolyte inspection
The battery electrolyte is colorless and transparent in
normal state. Inspect any turbidity at the time of specific
gravity inspection. If not checked clearly, put the
electrolyte in a breaker for inspection.
2. Battery electrolyte specific gravity inspection

Use a hydrometer and measure the specific gravity of
the electrolyte.
Specific gravity upon perfect charging:
1.280 [20°C (68°F)] (Reference)
Specific gravity upon end of discharge:
1.150 [20°C (68°F)] (Reference)
The specific gravity of the electrolyte is expressed with
that at 20°C (68°F) as the standard.
Equation for converting specific gravity

S20 = St+0.0007 (t-20)
1,300 1,300 S20 = Specific gravity at 20°C
1,250
1,250 St : Specific gravity at t°C
1,200 t : Electrolyte temperature (°C) at the time of
1,200
measurement
1,150 1,150
How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the electrolyte
Hydrometer port and let the electrolyte be sucked into its outer tube.
(2) Make the hydrometer in the outer tube float correctly
Rubber without contact with the outer tube, its top or bottom.
bulb Wait until the air bubbles in the sucked electrolyte
Outer tube
disappear. Read the scale at the top of the raised
portion of the surface as shown at left.
Nozzle
(3) After the measurement, wash the inside and outside
of the hydrometer with clear water, and wipe the
hydrometer thoroughly with clean cloth for storage.
1-7
3. Insulation resistance inspection

Measure the resistance between the battery and battery
case with an insulation resistance meter (megger).
Insulation resistance value: 1 MΩ or more
Note:
• When the insulation resistance is less than 1 MΩ ,
remove the battery from the vehicle and wash it with
water.
• After washing with water, make the battery dry
thoroughly. Measure the insulation resistance again
and install the battery on the vehicle after confirming
that it is 1 MΩ or more.
Battery control table

Prepare a control table for the battery to record and maintain the inspection results.
Inspection date Specific Electrolyte Added water Remarks
Inspected cell No. Inspector
and time gravity temperature quantity
2-1
CONTROLLERS
Page Page
GENERAL .......................................... 2-2 REMOVAL • INSTALLATION............ 2-34 0
SPECIFICATIONS ............................ 2-3 CONTACTOR PANEL ................... 2-35 1
COMPONENTS ................................. 2-4 REMOVAL • INSTALLATION............ 2-35 2
BEFORE STARTING REPAIR INSPECTION ................................... 2-37
3
WORK ............................................... 2-7 INSTALLATION ............................... 2-38
4
INSULATION RESISTANCE DISPLAY ........................................... 2-39
MEASUREMENT ............................. 2-7
DIRECTION SWITCH .................... 2-40
5
DISASSEMBLY ................................. 2-7
REMOVAL • INSTALLATION............ 2-40 6
PRECAUTIONS FOR PARTS
REPLACEMENT.............................. 2-7 DISASSEMBLY • INSPECTION • 7
REASSEMBLY .............................. 2-41
CONNECTOR 8
ACCELERATOR
INSPECTION LIST ......................... 2-8
POTENTIOMETER 9
BOARD INSPECTION ....................... 2-8 ADJUSTMENT .............................. 2-43
10
MAIN CONTROLLER .................... 2-22 BRAKE SWITCH
REMOVAL • INSTALLATION............ 2-22 ADJUSTMENT .............................. 2-44 11
TRAVELING/MATERIAL FOOT BRAKE.................................. 2-44 12
HANDLING CONTROLLER ...... 2-23
13
(16 • 18 MODEL) ............................. 2-23 14
REMOVAL • INSTALLATION 15
(20 ~ 50 MODEL)........................... 2-25
16
FAN INSPECTION ........................... 2-27
MOTOR INPUT VOLTAGE CHECK . 2-28 17
SAS (WITH PS) CONTROLLER 18
(16 ~ 35 MODEL) ......................... 2-30
19
REMOVAL • INSTALLATION............ 2-30
20
INSPECTION ................................... 2-32
SAS CONTROLLER 21
(40 ~ 50 MODEL) ......................... 2-34 22
2-2
GENERAL
2
The 7FBMF Series is equipped with a main controller, traveling/material handling controller, SAS
controller, and PS controller (16 ~ 35 model). Each of these is a multifunctional controller utilizing a
microcomputer.
The traveling/material handling controller provides high performance operations over a wide range with
the inverter control of the AC motor drive system.
The main controller has communication circuits that connect each controller and the display, and
automatically detects errors in the traveling/material handling main circuit, accelerator, SAS functions, PS
circuit (16 35 model), other sensors, etc., and also has a self diagnosis function that displays an “error
•
code” on the display with a buzzer sound (peep sound). At the same time, countermeasures to stop
traveling/material handling and traveling speed limitation are automatically taken simultaneously for safety
measures.
Troubleshooting and a function check for the traveling/material handling main circuit, each operation
system, sensors, etc., can be conducted by switching the display to the ANALYZER (fault analysis) mode.
For diagnosis function, see the “Multi-Display Function” section (page 3-58).
For the ANALYZER mode, see the “Multi-Display Function” section (page 3-19).
16 ~ 35 model
Material handling controller
Traveling controller
Main controller
SAS (with PS) controller
40 ~ 50 model
Main controller
SAS controller
2-3
SPECIFICATIONS
16 18 model
•
20 ~ 35 model 40 ~ 50 model
F1 (For traveling/material handling circuit) 500A 600A 700A
F3 (For PS circuit) 40A ← 
F4 (For lamps) 10A ← ←
Fuses
F5 (For control circuit) 10A ← ←
← ←
0
F6 (For SAS, solenoid) 10A
F7 (For DC-DC) 10A ← ←
← ←
1
Contactor MB (For power supply) ME251
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
2-4
COMPONENTS
Main controller
2401
2-5
SAS (with PS) Controller (16 ~ 35 model)

2401
0
1
2
3
4
5
6
7
8
SAS controller (40 ~ 50 model) 9
2401 10
11
12
13
14
15
16
17
18
19
20
21
22
2-6
Contactor panel
2402
2-7
BEFORE STARTING REPAIR WORK

INSULATION RESISTANCE MEASUREMENT
Note:
Be sure to measure the insulation resistance before inspecting the controller.
Disconnect the battery plug, and measure the resistance between the battery plug and the body.
Measurement terminals Between the battery plug controller side and the body
Larger resistance value is desirable, but the resistance changes greatly
Standard depending on the vehicle usage conditions, location, and weather.
(Approx. 1 MΩ or more)
DISASSEMBLY
• Control panel overhaul is rarely required. In most cases, defective parts should be replaced by
identifying the cause of trouble through inspections. Therefore, carry out correct repair work by referring
to the components drawings and assembly drawings.
• For the traveling/material handling controller, whole of assembly is replaced and do not disassemble it.
PRECAUTIONS FOR PARTS REPLACEMENT

• Tighten the bar and harness set nuts and screws to the specified torque. Loose or unfastened nuts and
screws will cause new problems.
• When disconnecting bars and harnesses, always record the mounting position or attach a tag. During
reassembly, check the record or tag to avoid incorrect assembly or wiring. Incorrect assembly or wiring
will cause new problems.
• Be sure to apply silicone grease on the parts that have been greased before. Failure to apply grease
could result in overheating.
• When reassembly is completed, check to see if the non-contact portions of bars and wirings are free
from undesirable contacts.
2-8
CONNECTOR INSPECTION LIST

BOARD INSPECTION
When the troubleshooting results judge that boards, such as a CPU board, must be replaced, avoid
immediately replacing the board and check the following items.
• Abnormal harnesses in the related circuit
• Loose connectors in the related circuit
• Bent or damaged connector pins, and contact failure in the related circuit
If the real cause of the trouble is one of the above items, a replaced new board may be damaged.
The board must be replaced with cautions.
When the cause of the trouble is found in the boards or CPU board, connect the SST 09240-23400-71 or
SST 09230-13700-71 to the corresponding connector and measure the applied voltage and resistance of
each connector. When measuring the resistance, be sure to disconnect the battery plug.
Caution:
When removing and installing the CPU board, etc., be sure to disconnect the battery plug.
Note:
• When troubleshooting determines that the problem lies in the CPU board, etc., and the board will
be replaced, be sure to measure the applied voltage and resistance of the related areas before
replacing the board.
(1) SST setup method
(a) Turn the key switch to OFF and disconnect the battery plug.
(b) Connect the SST to the corresponding connector pins.
Caution:
If the SST is set to a wrong connecter pin No., a properly functioning area could be damaged. Be
sufficiently careful when connecting the SST.
SST 09240-23400-71 SST 09240-23400-71

Applicable connectors
CPU board : CN101 to CN104
SCPU board : CN141, CN142
DC/SD board : CN148
SST 09230-13700-71
SST 09230-13700-71
Applicable connectors
CPU board : CN100, CN105, CN107
SCPU board : CN140, CN144 to CN146
DC/SD board : CN147
Traveling/material handling controller : CN110, CN111
2-9
(2) List of measurement methods and standard values

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

CN103-4 CN103-12 Key switch OFF Approx. 0V
(43, VBKY) (14, GNDD) Key switch ON Approx. 48V
Product name
Level No. Measurement conditions
Main Controller
CPU board
CN101 Basic conditions (Battery plug connected, key switch ON)
CN101-1 CN101-16 Key switch OFF, DSF Approx. 0 V
(45, DSF) (51, LS-) Key switch OFF, DS neutral Approx. 5 V
CN101-2 CN101-16 Key switch OFF, DSR Approx. 0 V
(46, DSR) (51, LS-) Key switch OFF, DS neutral Approx. 5 V
CN101-3 CN101-16 Key switch OFF, brake ON Approx. 5 V
(65, LSB) (51, LS-) Key switch OFF, brake OFF Approx. 0 V
Key switch OFF, parking brake ON Approx. 5 V
CN101-4 CN101-16
(66, LSPB) (51, LS-) Key switch OFF, parking brake OFF
Approx. 0 V
(With released)
CN101-5 CN101-16 Key switch OFF, person on seat Approx. 0 V
(67, LSD) (51, LS-) Key switch OFF, person not on seat Approx. 5 V
CN101-6  Not used 
CN101-7 CN101-16
Not used 
(, OPTO) (51, LS-)
CN101-8 CN101-16
Not used 
(, LEDTK) (51, LS-)
CN101-9 CN101-16 When fan OFF Approx. 80 V
(39, FAN-) (51, LS-) When fan ON Approx. 32 V
CN101-10 CN101-16 When fan OFF Approx. 80 V
(39, FAN-) (51, LS-) When fan ON Approx. 32 V
CN101-11 CN101-16
Not used 
(63, LSAT1+) (51, LS-)
CN101-12
 Immeasurable 
(309, SSTMA)
CN101-13
(310, SSTMK)
CN101-14
(307, SMTSA)
2-10

CN101-15
(308, SMTSK)
CN101-16
  
(51, LS-)
CN101-17 CN101-16
Not used 
(62, LSTR+) (51, LS-)
Key switch OFF, fork automatic lev-
Approx. 0 V
CN101-18 CN101-16 eling switch ON
(70, SWTK) (51, LS-) Key switch OFF, fork automatic lev-
Approx. 5 V
eling switch OFF
CN101-19 CN101-16
Lift lowest position Approx. 0 V
(90, MH1) (51, LS-)
CN101-20 CN101-16
(91, MH2-1) (51, LS-)
CN101-21 CN101-16
(92, MH2-2) (51, LS-)
CN101-22 CN101-16
Not used 
(68, LSAT2+) (51, LS-)
CN101-23 CN101-16
Not used 
(61, LSTF+) (51, LS-)
CN101-24 CN101-16
Not used 
(-, LSOPT) (51, LS-)
CN101-25   
CN101-26
  
(51, LS-)
CN101-27 CN101-16
Not used 
(71, SWLE) (51, LS-)
CN101-28   
CN101-29   
CN101-30 CN101-16
Not used 
(73, LSPA) (51, LS-)
CN101-31   
CN101-32 CN101-16
Not used 
(60, LSL+) (51, LS-)
CN101-33   
CN101-34 CN101-16
Approx. 0 V
(51, POT-) (51, LS-)
2-11

Key switch OFF, accelerator pedal
Approx. 0 V
CN102-1 CN102-22 depressed
(64, SWAC) (51, POT-) Key switch OFF, accelerator pedal
Approx. 5 V
not depressed
CN102-2 CN102-22 Key switch OFF, accelerator pedal
0.4 V ~ 3 V
(52, POTA) (51, POT-) fully depressed
CN102-3
 Not used 
(, AOPT)
CN102-4 CN102-22 Amount of change when tilt moved
0.5 V ~ 3 V
(56, POTTA) (51, POT-) from forward to backward
CN102-5 CN102-22
 0.5 V ~ 4.5 V
(59, SPL) (51, POT-)
When lever is neutral Approx. 1.3 V
CN102-6 CN102-22
(20, POTL1) (51, POT-) Amount of change when lift lever is
0.5 V ~ 2.2 V
moved forward or backward
CN102-7 CN102-22
(21, POTL2) (51, POT-) Amount of change when lift lever is
2.3 V ~ 4 V
CN102-8 CN102-22
(22, POTT1) (51, POT-) Amount of change when tilt lever is
0.5 V ~ 2.2 V
CN102-9 CN102-22
(23, POTT2) (51, POT-) Amount of change when tilt lever is
2.3 V ~ 4 V
CN102-10 CN102-22 Amount of change when attach- *1
(24, POTAT11) (51, POT-) ment 1 lever is moved forward or 0.5 V ~ 2.2 V
backward
(25, POTAT12) (51, POT-) ment 1 lever is moved forward or 2.3 V ~ 4 V
backward
(26, POTAT21) (51, POT-) ment 2 lever is moved forward or 0.5 V ~ 2.2 V
backward
(27, POTAT22) (51, POT-) ment 2 lever is moved forward or 2.3 V ~ 4 V
backward
CN102-14 CN102-22
Approx. 4.6 V
(53, POTA+) (51, POT-)
CN102-15 CN102-22
Not used 
(, AOPT+) (51, POT-)
CN102-16 CN102-22
Approx. 4.7 V
(57, POTTA+) (51, POT-)
CN102-17 CN102-22
Approx. 5 V
(58, SPL+) (51, POT-)
2-12

CN102-18 CN102-22
Approx. 4.5 V
(28, POTL+) (51, POT-)
CN102-19 CN102-22
Approx. 4.5 V
(29, POTT+) (51, POT-)
CN102-20 CN102-22
Approx. 4.5 V
(30, POTAT1+) (51, POT-)
CN102-21 CN102-22
Approx. 4.5 V
(31, POTAT2+) (51, POT-)
CN102-22
  
(51, POT-)
*1: 3-way oil control valve


CN103-1
(145, CANH)
CN103-2
(146, CANL)
CN103-3 CN103-12
Approx. 0 V
(147, CANGND) (14, GNDD)
CN103-4 CN103-12 Key switch OFF Approx. 0 V
(43, VBKY) (14, GNDD) Key switch ON Approx. 48 V
CN103-5 CN103-12
Approx. 1 V
(324, SSO+) (14, GNDD)
CN103-6 CN103-12
Approx. 0 V
(325, SSO-) (14, GNDD)
CN103-7 CN103-12
Approx. 48 V
(41, VBBT) (14, GNDD)
CN103-8 CN103-12
Not used 
(, CHK15V) (14, GNDD)
CN103-9 CN103-12
Not used 
(, CHK5V) (14, GNDD)
CN103-10 CN103-12
Approx. 15 V
(16, D15V) (14, GNDD)
CN103-11 CN103-12
Not used 
(, CHK3.3V) (14, GNDD)
CN103-12
  
(14, GNDD)
CN103-13
(144, SMTDK)
CN103-14
(143, SDTMK)
CN103-15
(142, SDTMA)
CN103-16
(141, SMTDA)
2-13

CN104-1 CN104-22
Key switch OFF Approx. 80 V
(18, B80V) (N2, N2)
CN104-2 CN104-22
(18, B80V) (N2, N2)
CN104-3 CN104-4 When lever is neutral Approx. 0 V
(3, SOLL+) (4, SOLLU) Amount of change when lift is raised 2V~8V
When lever is neutral Approx. 0 V
CN104-3 CN104-5
(3, SOLL+) (5, SOLLD) Amount of change when lift is low-
2V~8V
ered
CN104-4 CN104-3 Measure the resistance with the
Approx. 7 Ω
(4, SOLLU) (3, SOLL+) battery plug disconnected
Approx. 7 Ω
(5, SOLLD) (3, SOLL+) battery plug disconnected
CN104-6 CN104-7
(6, SOLT+) (7, SOLTF) Amount of change when tilt is
2V~8V
moved forward
CN104-6 CN104-8
(6, SOLT+) (8, SOLTR) Amount of change when tilt is
2V~8V
moved backward
Approx. 7 Ω
(7, SOLTF) (6, SOLT+) battery plug disconnected
Approx. 7 Ω
(8, SOLTR) (6, SOLT+) battery plug disconnected
CN104-9 CN104-22
Approx. 80 V
(55, CPR) (N2, N2)
CN104-10 CN104-22
Approx. 80 V
(55, CPR) (N2, N2)
CN104-11 CN104-12
Amount of change when attachment *1
(9, SOLAT1+) (10, SOLAT1U) 2V~8V
1 lever is moved backward
CN104-11 CN104-13
(9, SOLAT1+) (11, SOLAT1L) 2V~8V
1 lever is moved forward
Approx. 7 Ω *1
(10, SOLAT1U) (9, SOLAT1+) battery plug disconnected
Approx. 7 Ω *1
(11, SOLAT1L) (9, SOLAT1+) battery plug disconnected
CN104-14 CN104-22
Approx. 80 V
(44, VBMB) (N2, N2)
CN104-15 CN104-22
Approx. 80 V
(44, VBMB) (N2, N2)
CN104-16 CN104-17
(34, SOLAT2+) (35, SOLAT2U) 2V~8V
2 lever is moved forward
When lever is midway Approx. 0 V
CN104-16 CN104-18
(34, SOLAT2+) (36, SOLAT2L) 2V~8V
2 lever is moved backward
2-14

Approx. 7 Ω *2
(35, SOLAT2U) (34, SOLAT2+) battery plug disconnected
Approx. 7 Ω *2
(36, SOLAT2L) (34, SOLAT2+) battery plug disconnected
CN104-19 CN104-20 Set CN104-20 to (-) probe and
Approx. 11 V
(1, MB+) (2, MB-) measure
Approx. 20 Ω
(2, MB-) (1, MB+) battery plug disconnected
Approx. 11 V
(37, SOLD+) (38, SOLD-) measure
CN104-22
  
(N2, N2)
CN104-23
  
(N2, N2)
CN104-24 CN104-22 When fan stopped Approx. 80 V
(39, FAN-) (N2, N2) When fan ON Approx. 32 V
CN104-25 CN104-22 Key switch OFF Approx. 0 V
(42, KEYSTART) (N2, N2) Key switch ON Approx. 80 V
Approx. 11 V *3
(12, SOLP+) (13, SOLP-) measure
Approx. 10 Ω *3
(13, SOLP-) (12, SOLP+) battery plug disconnected
Approx. 10 Ω
(60, LSL+) (51, LS-) battery plug disconnected

*3: 40 ~ 50 model only
2-15

When fan stopped Approx. 80 V
CN105-4 CN104-22
(130, FAN1) (N2, N2) When fan ON (Depending on vehi- Approx. 1 V
cle conditions.) (Approx. 32 V)
CN105-5 CN104-22
CN105-6 CN104-22
CN105-7 CN104-22
CN105-8 CN104-22
CN105-9 CN104-22
CN105-10
 Not used 
(, FAN7)
CN105-11
 Not used 
(, CHKG)
CN107 Basic conditions (Battery plug connected, key switch ON, connector disconnected)
CN107-1 CN107-2 When circuit board cover fan ON
Approx. 24 V
(127, FANR+) (128, FANR-) (active test 1 execution)
CN107-2
  
(128, FANR-)
Traveling Controller

CN110-1
 Not used 
(, CUDID0)
CN110-2
 Not used 
(, CUDID1)
CN110-3
(145, CANH)
CN110-4
(146, CANL)
2-16

CN110-5
 Not used 
(, CANTRD)
CN110-6 CN110-6
Approx. 0 V
CN110-7 N2
Approx. 80 V
(55, KEYSTART) (N2, N2)
CN110-8
 Not used 
(, CUDON)
CN110-9 CN110-10
Approx. 12 V
(80, SSD+) (83, DDS-⋅TD-)
CN110-10 CN110-10
Approx. 0 V
(83, SSD-⋅TD-) (83, SSD-⋅TD-)
CN110-11 CN110-10
0 V ~ 12 V
(81, SSD1) (83, SSD-⋅TD-)
CN110-12 CN110-10
0 V ~ 12 V
(82, SSD2) (83, SSD-⋅TD-)
CN110-13
 Not used 
(88, TD+)
Material Handling Controller

CN111-1
 Not used 
(, CUPID0)
CN111-2 CN111-10
Approx. 0 V
(, CUPID1) (87, SSP-⋅TP-)
CN111-3
(145, CANH)
CN111-4
(146, CANL)
CN111-5
 Not used 
(, CANTRD)
CN111-6 CN111-6
Approx. 0 V
CN111-7 N2
Approx. 80 V
(55, KEYSTART) (N2, N2)
CN111-8
 Not used 
(, CUPON)
CN111-9 CN111-10
Approx. 12 V
(84, SSP+) (87, SSP-⋅TP-)
CN111-10 CN111-10
Approx. 0 V
(87, SSP-⋅TP-) (87, SSP-⋅TP-)
CN111-11 CN111-10
0 V ~ 12 V
(85, SSP1) (87, SSP-⋅TP-)
CN111-12 CN111-10
0 V ~ 12 V
(86, SSP2) (87, SSP-⋅TP-)
CN111-13
(89, TP+)
2-17
SAS Controller
SCPU board
CN140 for software write, not connected
CN140-1
 Not used 
(C5V)
CN140-2
 Not used 
(GNDC)
CN140-3
 Not used 
(FTXD)
CN140-4
 Not used 
(VPP)
CN140-5
 Not used 
(MD2)
CN140-6
 Not used 
(FRES)
CN140-7
 Not used 
(FRXD)
CN140-8
 Not used 
(SELR)

CN141-1
(, SSTXA)
CN141-2
(, SXTSA)
CN141-3
(309, SSTMA)
CN141-4
(307, SMTSA)
When traveling stopped 0V
CN141-5 CN141-15
Traveling stopped, battery plug dis-
(324, SS+) (325, SS-) 0 V, 620 Ω
connected
CN141-6
(312, STS1)
CN141-7
(313, STS2)
CN141-8
(314, STSC)
CN141-9
(, SSTXK)
CN141-10
(, SXTSK)
CN141-11
(310, SSTMK)
CN141-12
(308, SMTSK)
CN141-13 CN141-16
Approx. 5 V
(138, SL/L-) (315, STS-)
2-18

CN141-14 CN141-16
Approx. 5 V
(137, SL/L+) (315, STS-)
CN141-15 CN141-6
When traveling stopped Approx. 2.5 V
(325, SS-) (312, STS1)
CN141-16 CN141-6
0V
(315, STS-) (312, STS1)
CN141-17 CN141-16
Approx. 15 V
(311, STS+) (315, STS1)

Key switch OFF, accelerator pedal
Approx. 5 V
CN142-1 depressed
 *4
(65, SLSB) Key switch OFF, accelerator pedal
Approx. 0 V
not depressed
CN142-2 CN142-8
When vehicle is level Approx. 3.2 V *3
(319, POTS) (314, STSC)
CN142-3 CN142-8
When steering wheel is neutral Approx. 2.0 V
(317, POTH) (314, STSC)
CN142-7
 Not used 
(, POTOPT-)
CN142-8 CN146-6
Approx. 0 V
(320, SPOT-) (312, STS1)
CN142-9
 Not used 
(, POTOPT+)
CN142-10 CN142-8
Approx. 5 V *3
(318, POTS+) (314, STSC)
CN412-11 CN142-8
Approx. 5 V
(316, POTH+) (314, STSC)

2-19

CN144-1 CN144-2
Approx. 5 V
(321, SYR+) (323, SYR-)
CN144-2 CN146-6
0V
(323, SYR-) (353, GNDSC)
CN144-3 CN144-2
Approx. 2.5 V
(332, SYR) (323, SYR-)

CN145-1
 Immeasurable  *4
(340, TMPSG)
CN145-2
 Immeasurable  *4
(P24, SH+)
CN145-3 CN148-7
0V *4
(N1, SH-) (N1, N1)

CN146-1
(PS15V)
CN146-2 CN146-6
(44, VBMB) (353, GNDSC)
CN146-3 CN146-4
Approx. 21 V
(350, PS20V) (351, GNDPS)
CN146-4
(351, GNDPS)
CN146-5 CN146-6
Approx. 15 V
(352, SC15V) (353, GNDSC)
CN146-6 CN148-7
0V
(353, GNDSC) (N1, N1)
CN146-7
(331, DRSOL+)
CN146-8
(332, DRSOL-)
CN146-9
(333, CKSOLS)
CN146-10
(334, CKSOLST)
CN146-11 CN146-6
0V
(335, SGSOLS) (353, GNDSC)
CN146-12 CN146-6
Approx. 15 V
(336, SGSOLST) (353, GNDSC)
CN146-13 CN146-6
Approx. 15 V
(337, RESOL) (353, GNDSC)
2-20
DC/SD Board
CN147-1 Not used 
CN147-2 CN147-6
Key switch ON Approx. 80 V
(44, VBMB) (353, GNDSC)
CN147-3 CN147-4
Approx. 21 V
(350, PS20V) (351, GNDPS)
CN147-4
(351, GNDPS)
CN147-5 CN147-6
Approx. 15 V
(352, SC15V) (353, GNDSC)
CN147-6 CN148-7
0V
(353, GNDSC) (351, GNDPS)
CN147-7
(331, DRSOL+)
CN147-8
(332, DRSOL-)
CN147-9 CN147-6

(333, CKSOLS) (353, GNDSC)
CN147-10 CN147-6

(334, CKSOLST) (353, GNDSC)
CN147-11 CN147-6
0V
(335, SGSOLS) (353, GNDSC)
CN147-12 CN147-6
Approx. 15 V
(336, SGSOLST) (353, GNDSC)
CN147-13 CN147-6
Approx. 15 V
(337, RESOL) (353, GNDSC)
CN147-14
 Not used 
(CKT-G)

CN148-1 CN148-6 Key switch ON Approx. 12 V
(327, SOLS+) (328, SOLS-) Key switch OFF 0 V, Approx. 6 Ω
CN148-2 CN148-5
Key switch OFF 0 V, Approx. 10 V
(329, SOLST+) (330, SOLST-)
CN148-3 CN148-7 Key switch ON Approx. 80 V
(44, VBMB) (N1, N1) Key switch OFF 0V
CN148-4
(CK20V)
CN148-5 CN148-7
Approx. 12 V
(330, SOLST-) (N1, N1)
CN148-6 CN148-7
0V
(328, SOLS-) (N1, N1)
CN148-7
(N1, N1)
CN148-8
(CK15V)
2-21

CN149-1
(340, TMPSG)

CN51-1 CN51-4
Approx. 80 V
(P21, VBP21) (N1, TMPS)
CN51-2 CN51-4
Approx. 80 V
(P21, VBP21) (N1, TMPS)
CN51-3 CN51-4
When PS motor stopped Approx. 80 V
(P23, P23) (N1, TMPS)
CN51-4 CN148-7
0V
(N1, N1) (N1, TMPS)
2-22
MAIN CONTROLLER
Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Remove the controller cover.
3 Disconnect the connector and remove the main controller.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
2-23
TRAVELING/MATERIAL HANDLING CONTROLLER

REMOVAL • INSTALLATION (16 • 18 MODEL)
Caution:
Before starting the job, measure the voltage between P3 and N2. If there is any voltage, insert a
resistor at approx. 100 Ω between P3 and N2 to discharge the capacitor.
7
6
5
Removal Procedure
3 Remove the main controller. (See page 2-22)
4 Remove the controller cover bracket.
5 Disconnect the connectors and terminals from the traveling/material handling controller. [Point 1]
6 Remove the short bar No.1 and No.2.
7 Remove the traveling/material handling controller.
2-24
Point Operations
[Point 1]
P3
Installation:
P14 P7 1. Be sure to wire correctly and connect the terminal in
P15 P8 the prescribed orientation.
P16 P9 A = 45° C = 90° E = 0° ~ 90°
N2 N1 B = 45° D = 30°
2. Tighten to the specified torque.
T = 14 ~ 18 N⋅m (143 ~ 184 kgf⋅cm) [10.3 ~ 13.3 ft⋅lbf]
P3. P7. P14 P9. P16
A C
N1 P8. P15
D
B
N2
E
E
2-25
REMOVAL • INSTALLATION (20 ~ 50 MODEL)

Caution:
Before starting the job, measure the voltage between P3 and N2. If there is any voltage, insert a
8
3
6
Removal Procedure
3 Remove the main controller. (See page 2-22.)
4 Remove the contactor panel. (See page 2-35.)
5 Remove the controller cover bracket.
6 Disconnect the connectors and terminals from the traveling/material handling controller. [Point 1]
7 Remove copper bars No.1 and No.2.
8 Remove the traveling/material handling controller.
2-26
Point Operations
[Point 1]
P3
Installation:
P14 P7 1. Be sure to wire correctly and connect the terminal in
P15 P8 the prescribed orientation.
P16 P9 A = 45° C = 90° E = 0° ~ 90°
N2 N1 B = 45° D = 30°
T = 14 ~ 18 N⋅m (143 ~ 184 kgf⋅cm) [10.3 ~ 13.3 ft⋅lbf]
P3. P7. P14 P9. P16
A C
N1 P8. P15
D
B
N2
E
E
2-27
FAN INSPECTION
Inspection Method
Fan connector disconnection
Portion to be
Measurement terminals Standard Tester range
inspected
Traveling
CN132-1 (7) - CN132-2 (8)
controller fan
∞Ω Ω×1
Material handling
CN133-1 (9) - CN133-2 (10)
controller fan
2-28
MOTOR INPUT VOLTAGE CHECK

When the traveling/material handling operation is judged abnormal or when the controller is overhauled,
measure the motor input voltage and accurately determine whether or not the controller is functioning
normally.
Drive motor input voltage measurement method
Procedure
2 Jack up the front wheels.
4 Remove the main controller set bolt and slide the main controller over a little. (Connectors are
connected.)
5 Attach the analog voltmeter’s (-) probe to the N1 terminal.
6 Attach the voltmeter’s (+) probe to P7 (P8, P9).
7 Connect the battery plug.
8 Turn the key switch to ON.
9 Shift the direction switch forward/backward.
10 Completely depress the accelerator pedal and then read and record the voltage.
11 Also follow steps 6 to 10 for P8 and P9.
12 Compare the voltages measured for P7, P8, and P9. The error should be within the standard.
Standard: Within 4 V
P7
P8
P9
N1
2-29
Pump Motor Input Voltage Measurement Method
Procedure
3 Connect the analog voltmeter’s (-) probe to the N2 terminal.
4 Connect the voltmeter’s (+) probe to P14 (P15, P16).
5 Connect the battery plug.
6 Turn the key switch to ON.
7 Move the tilt lever backward, read the voltage while in the relief position, and record the voltage.
8 Also follow steps 4 to 7 for P15 and P16.
9 Compare the voltages measured for P14, P15, and P16. The error should be within the standard.
Standard: Within 4 V
P14
P15
P16
N2
2-30
SAS (WITH PS) CONTROLLER (16 ~ 35 MODEL)

Note:
• Do not give the shock because SAS (with PS) controller is weak to the shock.
• Do not use an impact wrench when removing or installing the SAS (with PS) controller set bolts
or cover set bolts.
Removal Procedure
3 Remove the hood ASSY (LH).
4 Disconnect the connector and remove the reverse buzzer.
5 Remove the seat stand damper. [Point 1]
6 Remove the SAS (with PS) controller set bolts. [Point 2]
7 Lift up the SAS (with PS) controller, disconnect the connector, and remove the SAS (with PS)
controller.
2-31
Point Operations
[Point 1]
•
Secure the seat stand with a string, etc., so that it does not
fall over.
[Point 2]
Collar
Removal:
When removing the SAS (with PS) controller, be careful not
to drop the rubber or collar.
Rubber
Installation:
When installing, make sure the rubber is correctly inserted
and then tighten the bolts.
2-32
INSPECTION
Similarly as the traveling and load handling controllers, some components can be inspected after removal
from the vehicle while others cannot unless they are installed on the vehicle.
The SCPU and DC/SD boards are to be inspected as installed on the vehicle because they must be
applied with the battery voltage. The inspection method for the SAS (with PS) control panel ASSY
explained here is mainly for the state after removal from the vehicle.
1. TMPS (transistor for PS)
Inspection method
Disconnect the TMPS wiring.
Portion to be
inspected
C2E1 (-) probe - E2 (+) probe ∞Ω
C2E1-E2
C2E1 (+) probe - E2 (-) probe Continuity shall exist.
G2 (-) probe - E2 (+) probe ∞Ω
TMPS G2-E2 Ω × 1k
G2 (+) probe - E2 (-) probe ∞Ω
C2E1 (-) - C1 (+) Continuity shall exist.
C2E1-C1
C2E1 (+) - C1 (-) ∞Ω
E2 C1 G2
E2
C2E1
TMPS
Caution:
• When shifting to check C2E1-E2 from G2-E2 short connect G2-E2 to avoid the possibility of
continuity on both directions.
• Never touch G2 terminal with bare hands because static electricity may damage the transistor.
2-33
2. SH (shunt)
Inspection method
Disconnect the SH wiring.
Portion to be inspected Measurement terminals Standard Tester range
SH Both terminals of SH Continuity exists. Ω×1
SH
2-34
SAS CONTROLLER (40 ~ 50 MODEL)

Note:
• The SAS controller contains components with low shock resistance. Do not jolt the controller.
• Do not use an impact wrench when removing or installing the SAS controller set bolts or cover
set bolts.
Removal Procedure
3 Remove the SAS controller cover.
4 Disconnect the connector and remove the SAS controller.
2-35
CONTACTOR PANEL
3
2
Removal Procedure
3 Disconnect the connectors and terminals from the contactor panel. [Point 1]
4 Remove the contactor panel.
2-36
Point Operations
P1
[Point 1]
Installation:
A
1. Install the terminal at the prescribed orientation.
A = 90°
P3
T = 11 ~ 15 N⋅m (112 ~ 153 kgf⋅cm) [8.10 ~ 11.1 ft⋅lbf]
2-37
INSPECTION
1. MB (Power supply contactor)
Inspection Method
Disconnect the CN134 connector and measure the MB coil resistance.
Portion to be
inspected
Approx. 20 Ω
MB Coil Both CN134 terminals Ω×1
(at 20 ºC (68 ºF))
CN134
2. Fuses
Inspection Method
Remove the fuse and measure the resistance.
Portion to be
inspected
Fuse Both fuse terminals 0Ω Ω×1
F7 F5 F4
F6
F1
2-38
INSTALLATION
Contactor panel installation diagram
T = N⋅m (kgf⋅cm) [ft⋅lbf]
T = 2.9 ~ 3.9 (29 ~ 39) T = 7.8 ~ 11.8 (80 ~ 120)

[2.1 ~ 2.9] [5.8 ~ 8.6]
F5
F4
T = 2.9 ~ 3.9
(30 ~ 40)
[2.2 ~ 2.9]
P1
T = 13 ~ 17
(130 ~ 170) F7 F6 T = 7.8 ~ 11.8
[8.8 ~ 11.6] (80 ~ 120)
[5.8 ~ 8.6]
F1
T = 11 ~ 15 T = 7.8 ~ 11.8
(112 ~ 153) (80 ~ 120) [5.8 ~ 8.6]
[8.10 ~ 11.1]
T = 2.0 ~ 3.0 P2
(20 ~ 30)
[1.4 ~ 2.2]
T = 7.8 ~ 11.8
(80 ~ 120)
[5.8 ~ 8.6]
T = 13 ~ 17
(130 ~ 170)
[8.8 ~ 11.6]
P3 T = 1.5 ~ 3.5
(1.5 ~ 3.5)
CN134 [1.1 ~ 2.5]
CN135
CN136
Caution:
Be sure not to forget to install the insulation sheet.
• Failure to install the insulation sheet beneath the MB contactor could result in a serious problem.
• After installing the contactor panel, inspect the insulation resistance between the bracket and
the P terminals.
Standard: 3 MΩ or more
MB contactor
Insulation
sheet
2-39
DISPLAY
If the trouble is found in the display, apply the battery voltage and measure the voltage to the connector.
CN70
CN70 connector basic conditions (Battery plug on)

Connector No.⇔Connector No. Standard
CN70 - 14 CN70 - 30
Approx. 10 ~ 18V
(16, D15V) (14, GNDD)
2-40
DIRECTION SWITCH
Removal Procedure
2 Remove the steering wheel column cover.
3 Disconnect the connector and remove the meter cover W/display.
4 Disconnect the connector and remove the direction switch.
2-41
Removal Procedure
1 Remove the connector cover and disconnect the connector.
2 Remove the plate W/base and micro switch.
3 Remove the base W/micro switch. [Point 1]
4 Remove the cam.
The reassembly procedure is the reverse of the disassembly procedure.
2-42
Point Operations
DSF0 DSBU [Point 1]
DSR
Installation:
1. Install the micro switch in the correct position.
DSF
2. When replacing the micro switch, perform the wiring

NC
DSF
C
following the line colors.
NO W-O R
45 51 W-BR
NC
46 NO
DSR 46 45 43
NC
DSBU 51 120 103
C
NO
43 103
NC
C O G
B
NO
120
DSFO
Inspection
DSF
When the direction switch has been assembled, inspect the

continuity before installing the switch.
DSR 46 45 43
DSBU Standard:
51 120 103
Lever Position
Inspection
DSFO Neutral Forward Reverse
Location
DSF ∞Ω 0Ω ∞Ω
DSR ∞Ω ∞Ω 0Ω
DSBU ∞Ω ∞Ω 0Ω
DSFO ∞Ω 0Ω ∞Ω
2-43
ACCELERATOR POTENTIOMETER
ADJUSTMENT
1. Inspect the operation to make sure the accelerator pedal
turns the switch to ON and OFF.
Measurement terminals 51-64
When pedal is not operated ∞Ω
Standard
When pedal is operated 0Ω
2. Accelerator potentiometer installation adjustment

(1) Insert a 1.5 mm (0.0059 in) thickness gauge between
the accelerator link stopper and the accelerator
bracket.
(2) Temporarily install the potentiometer so that the
accelerator switch (between 51 and 64) turns to ON
(0 Ω).
(3) Inspect the accelerator switch's (between 51 and 64)
ON/OFF switching point.
Switch status
T (Adjustment gap) mm (in)
(between 51 and 64)
T = 1.0 (0.039) OFF (∞ Ω)
Standard
T = 2.0 (0.079) ON (0 Ω)
(4) If the mesured value does not satisfy the standard,

adjust the timing while rotating the accelerator
potentiometer.
(5) After adjustment, apply screw lock agent (08833-
76002-71 (08833-00080)) to the set screw threads.
2-44
BRAKE SWITCH ADJUSTMENT

FOOT BRAKE
1. Inspect the brake pedal play.

Standard: 5 ~ 9 mm (0.20 ~ 0.35 in)
For brake
regeneration If the measured value does not satisfy the standard,
adjust the length of the brake pedal push rod. (See 10-
For stop lamp 29.)
5 ~ 9 mm 2. Operate the brake pedal and check that the stop lamp
(1.97 ~ 0.35 in)
A limit switch operates (ON) when the play range is 5 to 9
mm (0.20 to 0.35 in).
Standard: When not operating: OFF (∞ Ω)
When operating: ON (0 Ω)
3. When the brake pedal play disappears, depress the pedal
3 ~ 8 mm
deeper (3 to 8 mm (0.12 to 0.31 in)) and check to see if
(0.12 ~ 0.31 in) the brake regeneration limit switch actuates (OFF).
Standard: When not operating: ON (0 Ω)
When operating: OFF (∞ Ω)
A 4. If not within the standard value, adjust the switch by

bending the limit switch brackets.
B A: Brake regeneration limit switch

B: Stop lamp limit switch
Note:
The adjustment is all right as long as there is no problem
with the pedal play and stop lamp operation even if there
Limit switch bracket
is 0.1mm (0.004 in) gap between the pedal stopper bolt
and the pedal.
3-1
MULTI-DISPLAY FUNCTIONS
Page
MULTIPLE DISPLAY .......................................................3-2
0
GENERAL..........................................................................3-2
1
SPECIFICATIONS .............................................................3-7
GENERAL FUNCTIONS ....................................................3-7 2
DISPLAY INDICATION LIST .............................................3-8 3
ABBREVIATIONS DISPLAYED ON THE SCREEN..........3-9 4
NORMAL FUNCTION SCREEN .................................3-10
5
OPERATION PROCEDURE ............................................3-10
6
MASK FUNCTIONS .......................................................3-15
GENERAL........................................................................3-15 7
PASSWORD ....................................................................3-17 8
ANALYZER ......................................................................3-19 9
TUNING............................................................................3-37
10
OPTION SET....................................................................3-46
MATCHING ......................................................................3-51
11
WHEEL DIA .....................................................................3-56 12
DIAGNOSIS .....................................................................3-57 13
DIAGNOSIS CODE LIST .................................................3-57 14
FLÖDESSCHEMA, PROGRAMMERING ....................3-63

15
16
17
18
19
20
21
22
3-2
MULTIPLE DISPLAY
3
GENERAL
The multiple display is capable of indicating various types of vehicle information by switching the screen
according to the displayed contents.
Note:
Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button
may be damaged.
(1) (2) (3) (4) (5) (9) (10)
When the vehicle is in stopped state.
( (1) to (8) in the table vary with each
function activation state.)
(8)
(6) (7) (11)
Initial screen Upon error occurrence
(12)
During traveling Low temperature warning indicator
No. Description No. Description

(1) Swing lock indicator (7) Power select indicator
(2) Parking brake indicator (8) Multiple screen display area
(3) Travel 2nd speed setting indicator (9) Travel 2nd speed control set switch
(4) Diagnostic mode indicator (10) Hour meter select switch
(5) Overheat warning indicator (11) Power select switch
(6) Battery capacity indicator (12) Low temperature warning indicator
3-3
(1) Swing lock indicator

This indicator comes on when the rear wheel swing lock is activated. It automatically goes out
when the swing lock is released.
(2) Parking brake indicator
This indicator comes on when the parking brake is activated. If the operator fails to release the
parking brake during forward or reverse traveling, alarm sounds (beeps) to warn the operator.
(3) Travel 2nd speed setting indicator
0
This indicator comes on or goes off whenever the operator presses the travel 2nd speed control.
When this indicator is on, the travel 2nd speed control is activated to limit the maximum vehicle
speed to the set level. The speed control level can be set using the travel 2nd speed control level
1
SET UP screen.
(4) Diagnostic mode indicator
2
This indicator blinks when the diagnostic mode operates, the error code is displayed, and the 3
buzzer sounds.
Up to 3 abnormality codes are displayed at a time. When more than 3 abnormalities occur at a 4
time, up to 6 abnormality codes are displayed with switching at intervals of 2 seconds.
When the SAS function matching is not complete, this indicator comes on to warn the serviceman. 5
If it is on, carry out matching by referring to the Matching section.
(5) Overheat warning indicator 6
When the temperature of the main control controller, traveling controller, material-handling
controller, drive motor, or pump motor exceeds the specified temperature, the overheat warning 7
indicator flashes and a warning sound is generated to warn the operator. In addition, when the
overheat warning indicator is flashing, vehicle operation is restricted and the overheating area is 8
shown on the display.
9
Overheat warning indicator
Display information:
C/R : Main control controller
10
DCR: Traveling controller
PCR: Material-handling controller
11
DM : Drive motor (Traveling motor)
PM : Pump motor (Material-handling motor)
12
13
Overheat position
14
15
16
17
18
19
20
21
22
3-4
Vehicle Operation Restriction at Overheating
D/R: Main control controller overheat

Specifica-
Mode Content of control
tion
STD, H mode 1. Character display flashes, indicator flashes

Fisher-
P mode 2. “Peep peep peep” buzzer sounds continuously
man spec.
(OPT) S mode 3. Material-handling power restricted
DCR: Traveling controller overheat PCR: Material-handling controller overheat

Specifica- Specifica-
Mode Content of control Mode Content of control
tion tion
STD, H mode 1. Character display flashes, indicator flashes STD, H mode 1. Character display flashes, indicator flashes
Fisher- Fisher-
P mode 2. “Peep peep peep” buzzer sounds for 5 sec P mode 2. “Peep peep peep” buzzer sounds for 5 sec
man spec. man spec.
(OPT) S mode 3. Switches to half throttle (OPT) S mode 3. Material-handling power restricted
DM: Drive motor overheat

Specifica- Content of control
Mode
tion Primary control Secondary control The 3rd control
1. Character display flashes, indicator flashes 1. Character display flashes, indicator flashes
H mode 2. “Peep peep peep” buzzer sounds for 5 sec 2. Continuous buzzer sound “peep, peep”
3. Switches to S mode 3. Switches to half throttle
STD
1. Character display flashes, indicator flashes
P mode
2. “Peep peep peep” buzzer sounds for 5 sec
S mode
3. Switches to half throttle
1. Character display flashes, indicator flashes 1. Character display flashes, indicator flashes 1. Character display flashes, indicator flashes
H mode 2. “Peep peep peep” buzzer sounds for 5 sec 2. No buzzer sound 2. Continuous buzzer sound “peep. peep”
Fisher- 3. Switches to S mode 3. Traveling power restricted 3. Switches to half throttle
man spec.
(OPT) 1. Character display flashes, indicator flashes 1. Character display flashes, indicator flashes
P mode
2. “Peep peep peep” buzzer sounds for 5 sec 2. Continuous buzzer sound “peep. peep”
S mode
3. Traveling power restricted 3. Switches to half throttle
PM: Pump motor overheat

Specifica-
Mode Content of control
tion
STD, H mode 1. Character display flashes, indicator flashes

Fisher-
P mode 2. “Peep peep peep” buzzer sounds for 5 sec
man spec.
(OPT) S mode 3. Material-handling power restricted
3-5
(6) Battery capacity indicator

This indicator indicates the remaining battery capacity in 10 stages.
A: Low remaining battery capacity alarm
The battery capacity indicator blinks when the remaining battery capacity drops to the set level
or below. When the key switch is turned from OFF to ON in this state, the alarm sounds for 5
seconds to warn the operator of the low battery capacity.
B: Battery overdischarge alarm (lift interrupt function)
0
If traveling or material handling operation is attempted when the remaining battery capacity
drops below the setting level after the warning of “low remaining battery alarm”, all segments of
the battery capacity indicator will blink and alarm sound will notify the operator. In this case, the
1
material handling operation is prohibited. However, the operation is possible only once for 30
seconds by turning the key switch from OFF to ON. 2
Note: 3
The level can be set using TUNING FUNCTION of the MASK MENU. (See page 3-37)
4
Low remaining battery capacity alarm Battery over-discharge alarm
5
6
7
The battery capacity indicator segments
corresponding to the remaining capacity blink.
All battery capacity indicator segments blink. 8
(7) Power select indicator (traveling and material handling) 9
The currently selected mode is indicated by enclosing S, P or H with a square. Press the power
select switch on the NORMAL FUNCTION screen to change the mode setting. 10
When all of S, P and H are enclosed in squares, the control is performed in the mode set on the
POWER CONTROL SET UP SELECTION screen. 11
(8) Multiple-screen display area
The date and time are normally indicated in this area. This area is also used for various purposes
12
such as function setting and abnormality code display by the diagnosis function.
13
(9) Travel 2nd speed control set switch
Press this switch on the NORMAL FUNCTION screen to set or clear Travel 2nd speed control. 14
(10) Hour meter select switch
This switch changes the screen of multi-hour-meter function. 15
(11) Power select switch
This switch selects the operating mode from S, P and H. Press this switch on the NORMAL
16
FUNCTION screen to shift the position of the square indicating the currently selected mode
sequentially to the right. Press the switch continuously for 2 seconds to set the level of each 17
function.
18
19
20
21
22
3-6
(12) Low temperature warning indicator

When the traveling controller and material-handling
controller temperature becomes too low, a warning is
given, the power is restricted, and the area where the
temperature has become too low is shown on the
display.
Display information:
Low temperature position COLD DCR: Traveling controller
COLD PCR: Material-handling controller
3-7
SPECIFICATIONS
LCD Dot matrix + fixed display
Buttons Three buttons
Back light LED type that comes on when the key switch is turned to ON
GENERAL FUNCTIONS
1. General functions can generally been used or seen by the user.
2. Two types of multi-screen displays are available: the easy model (the standard specification), and the
all-round model (option).
Setting of the functions are listed in the table below.
: Provided : Not provided

All-round
Model Easy model
model
Functions (standard)
(optional)
Battery capacity indicator
Speedometer
Status Travel 2nd speed setting indicator
display Swing lock indicator
Parking brake indicator
Power select indicator
Power select function
Level Travel power control level setting
setting Material handling power control level setting
Travel 2nd speed control level setting
Key switch on hour meter
Drive (travel) or pump (material handling) motors service

hour meter
Drive (travel) motor service hour meter 
Integrating Pump (material handling) motor service hour meter 
meter
Lap time meter 
Odometer 
Trip meter 
Calendar/Clock
Battery over-discharge warning
Low battery capacity warning
Overheat warning
Parking brake ON warning
Warning
Parking brake OFF warning
Return to neutral warning
Over speed alarm 
Diagnostic code display
3-8
DISPLAY INDICATION LIST

NORMAL FUNCTION screen
Press switch (3) for 2 sec.
• For user setting
Travel 2nd speed ON/OFF ON or OFF setting of Travel 2nd speed control
Input of password
Switching over hour meter display Checking traveling or material handling system ON time
Power select Power mode selection
• For user setting
Traveling speed level Setting of Travel 2nd speed control level
Speed alarm Traveling speed setting for over-speed alarm
Power control select Fine adjustment of power control level
Clock set Adjustment of indicated time
MASK FUNCTION screen

• For setting by dealer or serviceman
ANALYZER DIAG MEMORY Checking past diagnosis codes stored in memory
I/O MONITOR1 Checking the temperature and voltage of each functional part
I/O MONITOR2 Checking traveling-related sensors
I/O MONITOR3 Checking material handling and mast control sensors
I/O MONITOR4 Knob position correction control and checking other sensors
ACTIVE TEST Forced ON/OFF test of each switch
TUNING TUNING1 Standard function adjustment
TUNING2 LIFTV Lift lever adjustment
TUNING3 TILTV Tilt lever adjustment
TUNING4 ATT1V ATT 1 lever adjustment
TUNING5 ATT2V ATT 2 lever adjustment
OPTION SET DEMO MODE Operation is possible during traveling/Material-handling before H/M start
H/M START Start the hour meter count
P/C LOCK Power control lock selection
DESTI Display information changes by delivery destination
B LEVEL Not specified
MPH Vehicle speed display setting
C/CNT RES Not specified
BATTERY Battery characteristics selection
SHOU-TOKU Not specified
AUTO P-OFF Auto power OFF setting selection
PARKING ERR Parking brake OFF alarm selection
TILT CONT Mast forward tilt angle restriction selection
SWG W-LOCK Not specified
TILT F-LIM Mast forward tilt/level function selection
B-TYPE Battery type selection
72V 72V/80V selection
2-WAY VALVE 2-way valve selection
FISHERMAN Fishing specifications selection
MATCHING TILTL Tilt/level angle
TILTF Tilt forward restricted angle
LOAD NL load
TIRE Tire angle sensor forward direction
SWG Not specified
LIFT Lift lever neutral
TILT Tilt lever neutral
ATT1 Attachment 1 lever neutral
ATT2 Attachment 2 lever neutral
WHEEL DIA WHEEL DIA Tire constant setting
3-9
ABBREVIATIONS DISPLAYED ON THE SCREEN

Abbreviation Meaning Abbreviation Meaning
A1 (SOL) Attachment 1 proportional valve SSD Drive motor rpm
A2 (SOL) Attachment 2 proportional valve SSOL Swing solenoid
APOT Analog input voltage SSP Pump motor rpm
ATT1 Attachment 1 STS Steering angle sensor
ATT2 Attachment 2 SWAC Accelerator switch
C/R Controller SWG Swing angle sensor (Unused)
DCR Traveling controller SWTK Tilt knob switch
DM Drive motor T (SOL) Tilt proportional valve
Traveling controller circuit board tempera-
DSF Forward direction switch TBD
ture
Material-handling controller circuit board
DSOL Brake change valve solenoid output TBP
temperature
DSR Reverse direction switch TD Drive motor temperature
FAN Fan output TEMP Control circuit board temperature
Traveling controller main circuit tempera-
H/M Hour meter THCD
ture
Material-handling controller main circuit
K-DIFF Steering angle knob position differential THCP
temperature
K-POS Steering angle knob position TILTF Tilt forward angle
KSOL Knob position correcting solenoid TILTL Tilt level
L (SOL) Lift proportional valve TIRE Tire angle sensor
LOAD Material-handling hydraulic pressure TP Pump motor temperature
LSB Brake switch VB80 Battery voltage
LSD Seat switch VBBD Traveling controller main circuit power
Material-handling controller main circuit
MH Lift height switch VBBP
power
P/C Power control VBKS Key start voltage
PCR Material-handling controller
VBMB (M) Voltage after MB contactor (main input)
PM Pump motor
POTA Accelerator potention
VBMB (S) Voltage after MB contactor (SAS input)
POTT Tilt angle sensor
PSOL Unload valve VBSOL Solenoid voltage
SPD Main vehicle speed YAW Yaw rate sensor voltage
SPL Pressure sensor
3-10
NORMAL FUNCTION SCREEN

OPERATION PROCEDURE
Switch (1) Switch (2)
NORMAL FUNCTION
Travel 2nd speed ON/OFF setting
Hour meter display selection
Power select mode

Press Switch (3)
for 2 seconds or more.
Switch (3)
TRAVEL 2ND SPEED CONTROL LEVEL SETTING screen
Press Switch (3)
OVERSPEED ALARM SETTING screen
*: This screen is displayed only on the all-

round model.
The easy model does not have this screen.
Press Switch (3)

POWER CONTROL SET UP SELECTION screen
Press Switch (3)
CLOCK SET UP SELECTION screen
Press
switch (3)
Upon returning to the NORMAL FUNCTION screen after moving to each function setting screen, the
power select mode is set to “S”. If necessary, select the desired mode.
3-11
Travel 2nd speed setting indicator Switch (1) NORMALLY INDICATED SCREEN
1. Selecting travel 2nd speed control ON/OFF.

Press switch (1) to enable or disable the travel 2nd
speed control indicator. When the indicator is displayed,
the travel 2nd speed control is enabled.
2. Selection of hour meter type to be displayed.

Press switch (2) to select the hour meter type to be
displayed.
The display information differs between the easy model
(standard setting) and the all-around model (optional
setting).
: Provided -: Not provided
Easy All-round
Function model model Description
(standard) (optional)
A (1) Key switch on hour meter Indicate the total key ON hours
(2) Drive motor service hour meter  Drive motor ON hours
B
(3) Pump motor service hour meter  Pump motor ON hours
(4) Drive or pump motors service hour Total of drive and pump motor ON

C meter hours
(5) Odometer  Total traveling distance
D (6) Lap time meter  Lap time at key ON
E (7) Trip meter  Trip traveling distance
Press
switch (2)
Press switch (2) Press switch (2)

Switch(3)
Press
A switch (2) D
(Easy
model)
Press switch (2)

Press switch (2)
Drive
Press
switch (2)
B C
Odometer
Material handling
The lap time meter and trip meter can be reset by pressing switch (1) for 2 seconds or more.
3-12
3. Selecting the power select mode ( S , P or H ) Press

switch (3) on the NORMAL FUNCTION screen to select
the desired power mode by shifting to the corresponding
indicator position.
H : The most active mode with the quickest cycle-
time
P : The highest efficiency mode with quick cycle
time and long operation hour
S : The longest operation hour mode
Power select indicator Switch (3)
• Pattern1: When nothing is set on the POWER CONTROL SET UP SELECTION screen
Each time switch (3) is pressed, the selected mode position shifts to the right in the order shown
below:
S → P → H → S and so on
• Pattern2: When setting is made on the POWER CONTROL SET UP SELECTION screen
Each time switch (3) is pressed, the selected mode shifts to the right as shown below:
S → P → H → S P H → S → P and so on
When all modes are enclosed in squares, the control is made by the mode selected on the POWER
CONTROL SET UP SELECTION screen.
4. Switching to travel 2nd speed control level, over speed alarm level, power control level or clock set
function.
• Press switch (3) on the NORMAL FUNCTION screen for 2 seconds or more to display the TRAVEL
2ND SPEED CONTROL LEVEL SETTING screen.
TRAVEL 2ND SPEED CONTROL LEVEL SETTING SCREEN
Use this screen to set the travel speed control level.
(1) Press switch (1) to decrease the travel speed control
level.
(2) Press switch (2) to increase the travel speed control
level.
(3) Press switch (3) to go to the next screen, (OVER
SPEED ALARM SETTING screen).
Switch (3)

OVER SPEED ALARM SETTING SCREEN
This screen sets the traveling speed level for overspeed
alarming. To call the OVER SPEED ALARM SETTING
screen from the TRAVEL 2ND SPEED CONTROL LEVEL
SETTING screen, press switch (3) once.
(1) Press switch (1) to decrease the set traveling speed.
(2) Press switch (2) to increase the set traveling speed.
(3) Press switch (3) to go to the next screen, POWER
Switch (3) CONTROL SET UP SELECTION screen.
Vehicle speed setting for speed alarm
3-13
POWER CONTROL SET UP SELECTION SCREEN

The travel and material handling power control levels can be
set independently using this screen.
Press switch (3) on the OVER SPEED ALARM SETTING
screen to display the POWER CONTROL SET UP
SELECTION screen.
1. Press switch (1) on the POWER CONTROL SET UP
Select “YES” and Switch (3) SELECTION screen, select “YES”, and then press
press switch (3) switch (3) to display the TRAVELING POWER
CONTROL LEVEL SETTING screen.
TRAVELING POWER CONTROL LEVEL
SETTING screen
(1) TRAVELING POWER CONTROL LEVEL SETTING
screen
Press switch (1) to select the lower level.
Press switch (2) to select the higher level.
Press switch (3) to display the next screen
(MATERIAL HANDLING POWER CONTROL SET
Press switch (3)
screen).
MATERIAL HANDLING POWER CONTROL

LEVEL SETTING screen
(2) MATERIAL HANDLING POWER CONTROL LEVEL
SETTING screen
Press switch (1) to select the lower level.
Press switch (2) to select the higher level.
Press switch (3) to display the next screen (CLOCK
SET UP SELECTION screen).
Press switch (3)
2. Press switch (2) on the POWER CONTROL SET UP
CLOCK SET UP SELECTION screen SELECTION screen, select “NO”, and then press switch
(3) to display the next screen (CLOCK SET UP
SELECTION screen).
3-14
CLOCK SET UP SELECTION SCREEN

The year, month, day, day of week, time and 12/24-hour system can be set independently.
Press switch (2) on the POWER CONTROL SETUP SELECTION screen, select “NO” and press switch (3)
to open the CLOCK SET UP SELECTION screen.
Switch (1) Switch (2) LIFTING POWER CONTROL Switch (1) Switch (2)
Select “NO” screen
Press switch (3)

Select “NO”
Select “YES”
Select “YES”, and

press switch (3)
Press switch (3)

:
:
NOMAL FUNCTION screen (End of clock setting)
1. Press switch (1) on the CLOCK SET UP SELECTION screen, select “YES” and press switch (3) to
open the CLOCK SET UP SELECTION screen.
(1) CLOCK SET UP SELECTION screen
• Press switch (1) to decrease the set value (blinking).
• Press switch (2) to increase the set value (blinking).
• Press switch (3) to set the currently selected item (blinking) and go to the next item.
• Press switch (3) when Minute is selected on the CLOCK SET UP SELECTION screen to return
to the NORMAL FUNCTION screen.
2. Press switch (2) on the CLOCK SET UP SELECTION screen, select “NO” and press switch (3) to
return to the NORMAL FUNCTION screen.
3-15
MASK FUNCTIONS
GENERAL
In addition to the functions described in the instruction manual for use by general users, the multiple-
screen 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 unintentional operation by users.
Mask Function List

When used
Functions Description Board

Delivery replace- Others
ment
Used for displaying the operation status
Upon vehicle
of electrical systems onboard or for
Analyzer   abnormality
accessing information on errors detected
detection
by the controller.
Used for fine-tuning the traveling and As requested
Tuning 
material handing control features. *2 by customer
Used for changing the setups according
Specifications  
to the availability of options. *1 *2⋅*4
Used for changing the setups according
Availability of con-
to the availability of various control fea-  
trols *2⋅*4⋅*3
tures.
Option
Multiple hour meter Used for starting up the multiple hour
setting 
startup meter. *4
Used for setting and canceling the dem-
Upon new
Demonstration onstration mode. (Function prohibiting
  vehicle dem-
mode material handing operation during travel-
onstration
ing which is set at the time of delivery.)
Used for readjusting the sensor signal

Matching voltage values associated with the stan-  
*2⋅*3
dard vehicle condition.
Used for improving the speedometer

Wheel dia. (tire constant) accuracy by updating the wheel diameter  
*2
information.
*1 : These functions are used to adjust the controller and display setups to the availability of optional or
control features. They do not enable or disable the actual functioning of the optional or control
features.
*2 : Board ................. Main controller
*3 : Board ................. SAS controller control board
*4 : Board ................. Multiple-screen display control board
3-16
Preparation for the MASK MENU screen
Caution:
Always jack up the frame until the drive wheels (front
tires) leave the ground and support the vehicle with
wooden block under both side frames in the front. Fully
lower the fork.
1. See that the battery plug is connected securely and turn

the key switch to ON.
2. Operate the MASK MENU according to the password

input procedure explained on page 3-17.
3-17
PASSWORD
Notes on password input:
1. Always operate switches displayed on the display with a finger tip. If a sharp edged tool is used, the
switch may be damaged.
2. If a wrong input is found midway, turn the key switch to OFF and restart from the beginning. If the
MASK MENU cannot be displayed after several attempts, the system may be faulty.
Password Input Procedure

Step Operation Vehicle operation
A short high-pitched electronic
1 Press switches (1) and (2) at a time.
sound is given off.
2 Press switch (1).
sound is given off.
3 Press switch (2).
sound is given off.
Simultaneously press switches (2) and (3) for 2 seconds or more. A longer high-pitched electronic
4
(End of password input) sound is given off.
5 The version screen appears automatically.
6 After displaying the version screen for 3 seconds, the MASK MENU screen appears automatically.
Switch (1) Switch (2) Switch (2)
Switch (3)
Press switch (1) and Within 10 seconds, press switch
(2) simultaneously (2) and (3) simultaneously for
Switch (1) more than 2 seconds.
VERSION screen
Within 10 seconds, Switch (2)

press switch (1) The version screen is displayed
for about 2 seconds.
To MASK MENU screen
Within 10
seconds, press
switch (2)
3-18
VERSION screen OPERATION ON MASK MENU SCREEN

Operation Procedure
ANALYZER screen 1. Input the password on the NORMAL FUNCTION screen
(as explained on the preceding page) to display the
MASK MENU screen.
2. Select a desired function using switches (1) and (2).

Then, press switch (3) (set) to display the function
Switch (3) screen or setting screen of the selected function.
Press (1) or (2) to (1) ANALYZER screen
switch screen. This screen indicates the electrical system status and
TUNING screen reads the error information detected by the controller.
(2) TUNING screen
Use this screen for fine adjustment of control of the
traveling and material handling.
Press (1) or (2) to

switch screen.
OPTION SET screen (3) OPTION SET screen

Use this screen to match the controller or display
control according to the set option or control.
Press (1) or (2) to

switch screen.
MATCHING screen (4) MATCHING screen

This screen updates the signal voltage values stored
in the controller (signal voltage values from the SAS
function and the mini lever function sensors under the
standard vehicle condition).
Press (1) or (2) to

switch screen.
WHEEL DIA screen

(5) WHEEL DIA screen
This screen rewrites the tire information in the
controller for correcting the speed indication and trip
meter.
Press (1) or (2) to

Press (1) or (2)
switch screen.
to switch
screen. (6) END screen
END screen
It is possible to go to the normal function screen from
this screen. Press switch (3) on this screen to go to
the NORMAL FUNCTION screen.
Press switch (2) to return to the (1) ANALYZER
MENU. As an alternative method, turn the key switch
Press switch (3) to OFF when any menu is displayed to return to the
NORMAL FUNCTION screen normal function screen.
3-19
ANALYZER
GENERAL
1. Switching the multi-display to the analyzer mode permits checks of traveling, material handling and
SAS main circuits, operation systems such as the accelerator and sensor functions as well as
detection of problem components.
2. Full utilization of the analyzer functions helps quick, easy servicing.
3. The analyzer supports inspection of the control system and troubleshooting through full
communication with the traveling/material handling controller.
4. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes (diagnosis codes) detected in the electrical system in the
past. The diagnosis function reads these error codes and indicates them on the display.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors in the traveling, material
handling and SAS systems. Monitoring the displayed values enables the quality of each circuit/
sensor to be judged.
1) I/O MONITOR1
Displays the temperature and analog input voltage at the respective terminal of each
electrical component detected by the controller.
2) I/O MONITOR2
Displays each switch ON/OFF state and analog input voltages from sensors for traveling
and swing control.
3) I/O MONITOR3
Displays the material handling and mast switch ON/OFF states and analog input voltages
from material handling and mast sensors.
4) I/O MONITOR4
Displays the ON/OFF states of knob position correction control and other switches and the
analog input voltages from respective sensors.
(3) Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activate signal (ON or OFF signal) to the
selected item in order to permit operation check of that function.
(4) One latest error code at the time of an error will be displayed on the upper right of the I/O
MONITOR screen or ACTIVE TEST screen.
3-20
ANALYZER MENU SCREEN LIST

Note:
Values displayed on the second row are examples and not the standard.
Indication
Analyzer menu screen Description
Line 1 Line 2*
DIAG MEMORY Display error
DIAG-1 ~ code together
Occurred error display
DIAG-10 with gener-
ated time
I/O MONITOR1 I/O 1-1 THCD: +25 Traveling controller main circuit (heat sink) temperature: °C
• Voltage
I/O 1-2 THCP: +25 Material-handling controller main circuit (heat sink) temperature: °C
• Temperature
I/O 1-3 TD: +25 Drive motor temperature: °C
I/O 1-4 TP: +25 Pump motor temperature: °C
I/O 1-5 TBD: +25 Traveling controller circuit board temperature: °C
I/O 1-6 TBP: +25 Material-handling controller circuit board temperature: °C
I/O 1-7 TEMP: +25.0 Control circuit board temperature: °C
I/O 1-8 VB80: 84.0 Battery voltage: V
I/O 1-9 VBKS: 84.0 Key star voltage: V
I/O 1-10 VBSOL: 84 Solenoid voltage: V
I/O 1-11 VBMB (M): 84 Voltage after MB contactor (main input): V
I/O 1-12 VBMB (S): 84 Voltage after MB contactor (SAS input): V
I/O 1-13 VBBD: 84 Traveling controller DC_BUS voltage: V
I/O 1-14 VBBP: 84 Material-handling controller DC_BUS voltage: V
I/O MONITOR2 POTA: 0.71 Accelerator potention voltage: V
I/O 2-1
• Traveling system SWAC: 0 Accelerator switch: 0 (OFF), 1 (ON)
• Swing control system
DSF: 0 Forward switch: 0 (OFF), 1 (ON)
I/O 2-2
DSR: 1 Reverse switch: 0 (OFF), 1 (ON)
LSB: 1 Brake switch: 0 (OFF), 1 (ON)
I/O 2-3
LSD:1 Sheet switch: 0 (OFF), 1 (ON)
I/O 2-4 SSD: 3000 Traveling motor speed: rpm
SPD: Main vehicle speed: km/h (or mph)
I/O 2-5
M10.0 S10.0 SAS vehicle speed: km/h (or mph)
I/O 2-6 YAW: 2.50 Yaw rate sensor voltage: V
I/O 2-7 SWG: 2.50 Swing angle sensor voltage: V
I/O MONITOR3 Lift lever angle 1 sensor voltage: V
• Material-handling system L: 0.75 Lift lever angle 2 sensor voltage: V
I/O 3-1
• Mast control system 3.80 01 Lift upward SW: 0 (OFF), 1 (ON)
Lift downward SW: 0 (OFF), 1 (ON)
I/O 3-2 L (SOL): 0.78 Lift proportional valve current: A
Tilt lever angle 1 sensor voltage: V
T: 1.75 Tilt lever angle 2 sensor voltage: V
I/O 3-3
2.80 10 Tilt forward tilt SW: 0 (OFF), 1 (ON)
Tilt backward tilt SW: 0 (OFF), 1 (ON)
I/O 3-4 T (SOL): 0.78 Tilt proportional valve current: A
Attachment 1 lever angle 1 sensor voltage: V
A1: 1.27 Attachment 1 lever angle 2 sensor voltage: V
I/O 3-5
3.28 00 *1 Attachment 1 upward SW: 0 (OFF), 1 (ON)
Attachment 1 downward SW: 0 (OFF), 1 (ON)
A1 (SOL):
I/O 3-6 Attachment 1 proportional valve current: A
0.00 *1
Attachment 2 lever angle 1 sensor voltage: V
A2: 1.27 Attachment 2 lever angle 2 sensor voltage: V
I/O 3-7
3.28 00 *2 Attachment 2 forward tilt SW: 0 (OFF), 1 (ON)
Attachment 2 backward tilt SW: 0 (OFF), 1 (ON)
A2 (SOL):
I/O 3-8 Attachment 2 proportional valve current: A
0.00 *2
I/O 3-9 SWTK: 0 Tile knob SW: 0 (OFF), 1 (ON)
I/O 3-10 SSP: 2000 Pump motor speed: rpm
I/O 3-11 MH: 100 Lift height SW: 0 (OFF), 1 (ON)
I/O 3-12 POTT: 2.50 Tilt angle sensor voltage: V
SPL: Pressure sensor voltage: V
I/O 3-13
0.84 (1.7) (MPa display)
*: The values written in line 2 are display example references and are not standard values.
*1: The mini lever 2-way specifications are shown using a bar display (-.-- -.-- --).
*2: The mini lever 2-way and 3-way specifications are shown using a bar display (-.-- -.-- --).
3-21
Indication
Analyzer menu screen Description
Line 1 Line 2*
I/O MONITOR4 I/O 4-1 STS: 001 Steering angle sensor pulse output: 0 (OFF), 1 (ON)
• Steering control
K-POS: Steering angle knob position: Actual value
• Others I/O 4-2
159 (150) (Target value)
K-DIFF: 100 Steering angle knob position deviation
I/O 4-3
SOL: 0 Knob position correcting solenoid: 0 (OFF), 1 (ON)
I/O 4-4 TIRE: 2.50 Tire angle sensor voltage: V
I/O 4-5 AOPT: 2.50 Spare
I/O 4-6 LSOPT1: 0 Spare
ACTIVE TEST FAN: Fan output
ACT-1
• Operation test ON/OFF (100) Fan voltage: V
DSOL: Brake change valve solenoid output
ACT-2
ON/OFF (0) Brake change valve solenoid check signal: 0 (Normal), 1 (Error)
SSOL: Swing solenoid output
ACT-3
ON/OFF (0) Swing solenoid check signal: 0 (Normal), 1 (Error)
KSOL: Knob position correcting solenoid output
ACT-4
ON/OFF (0) Knob position correcting solenoid check signal: 0 (Normal), 1 (Error)
PSOL: Unload valve output
ACT-5
ON/OFF (0) Unload valve check signal: 0 (Normal), 1 (Error)
*: The values written in line 2 are display example references and are not standard values.
*1: The mini lever 2-way specifications are shown using a bar display (-.-- -.-- --).
*2: The mini lever 2-way and 3-way specifications are shown using a bar display (-.-- -.-- --).
3-22
Operation Procedure
1. Input the password on the NORMAL FUNCTION screen (as instructed before) to display the MASK
MENU screen.
2. Check that “1. ANALYZER” is selected on the screen and press switch (3) (enter) to call the
ANALYZER MENU screen.
3. Select the menu for the desired test using switches (1) and (2) and then press switch (3) (enter) to
display the set screen.
•Switch (1):The cursor moves to the preceding item.
•Switch (2):The cursor moves to the next item.
•Switch (3):Enters (and changes to the test screen for the selected item).
Note:
If you select “7. END” on the ANALYZER MENU screen and press switch (3), the MASK MENU
screen appears again.
Press switch (3)

ANALYZER screen END screen
Switch (3) Press (1) or (2) to

Press switch (3) switch screen.
DIAG MEMORY screen ACTIVE TEST screen
Press (1) or (2) to

switch screen.
Press (1) or (2) to Press (1) or (2) to

switch screen. switch screen.
I/O MONITOR1 screen I/O MONITOR4 screen

I/O MONITOR3 screen
I/O MONITOR2 screen
Press (1) or (2) to

switch screen.
3-23
DIAG MEMORY
The controller stores up to 10 most recent errors. The DIAG MEMORY screen displays these diagnosis
codes together with their detection time information (in key ON hour meter reading).
The most recent diagnosis code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to DIAG-
10.
Switch (2) Operation Procedure

Switch (1)
ANALYZER MENU screen
1. Call the ANALYZER MENU screen.
2. Check that “1. DIAG MEMORY” is displayed and then
press switch (3) (enter) to activate the diag memory
function which displays diagnosis codes detected in the
past sequentially starting from the most recent one.
3. Functions of switches on the 1. DIAG MEMORY screen
Switch (3)
are as follows:
Press switch (3) • Switch (1): Not used
• Switch (2): Not used
DIAG-1 screen • Switch (3): Displays diagnosis code detected in the
past.
Note:
Press switch (3) on the DIAG-10 screen to return to the
ANALYZER MENU screen.
Hour meter
When no error codes are displayed on the screen and
the hour-meter time is “0.0h,” it indicates that no errors
occurred in the past after that row.
Press switch (3)
It is impossible to directly jump from the DIAG MEMORY
DIAG-2 screen screen to other test screen. Return to the ANALYZER
MENU screen once and then go to the desired test
screen.
Note:
As for diagnosis codes, problem components, error
modes and phenomena on the vehicle, see pages 3-57
through 3-62.
Press switch (3)
Indicate occurrence of no error.
DIAG-3 screen
Press switch (3)
DIAG-10 screen
Press
switch (3)
3-24
Vehicle Abnormalities Not Stored in Diag Memory

There are abnormalities that are not stored in the diagnosis memory even if the controller detects them.
Alarm item Alarm content Symbol displayed
1. Parking brake ON alarm: • Alarm indication: Blinking
This alarm is given when the direction lever is parking brake indicator
shifted into forward or reverse and the vehicle • A short high-pitched elec-
travels while the parking switch is in parking. tronic sound
2. Parking brake OFF alarm: • Alarm sound (short high-

This alarm is given when the operator gets off the pitched electronic sound)
driver's seat without setting the parking switch to No display
parking. (The warning is also given when the key
switch is turned to OFF.)
3. Overdischarge alarm (lift interrupt) • Alarm indication: Blinking
Overdischarged state of the battery is warned at battery charge indicator
the level set at the tuning (explained later) to pro- • Alarm sound (short high-
hibit material handling. pitched electronic sound)
4. Return to neutral alarm • Alarm sound (short high-
Alarm occurs when the key switch is turned to ON pitched electronic sound)
No display
while the direction switch is set at the forward or
reverse position.
5. Material-handling lock: • Alarm sound (short high-
When the operator leaves the seat during mini pitched electronic sound)
No display
lever operation and then sits down again, an alarm
sounds and the material-handling operation stops.
6. Mismatching alarm • Alarm indication
(1) Tilt angle sensor when the fork is horizontal (spanner symbol)
(2) Tilt angle sensor at forward tilt limit angle
(3) Pressure sensor in no-load state
(4) Tire angle sensor during forward motion
(5) Lift lever angle sensor when lift lever is in
neutral
(6) Tilt lever angle sensor when tilt lever is in
neutral
(7) Attachment 1 lever angle sensor when
attachment 1 lever is in neutral
(8) Attachment 2 lever angle sensor when
attachment 2 lever is in neutral
Activated function No. I/O MONITOR Function

Detected error code at present This function displays the analog input voltage from each of
traveling, material handling and SAS sensors. The circuit or
sensor quality can be judged by monitoring the displayed
value.
During activation of I/O MONITOR function
When any abnormality is detected, it is indicated as an error
code on the display.
Description of activated function
3-25
I/O MONITOR1
This function displays the temperature of each electrical component and the voltage at the respective
terminal.
Operation Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (2) once.
3. Check that the “2. I/O MONITOR1” is displayed and press switch (3) to activate the I/O MONITOR1
function and display I/O1-1 through I/O1 14 sequentially.
4. Functions of switches on this screen are as follows:
• Switch (1): Unused
• Switch (3): Sequentially changes the screen from I/O1-1 to I/O1-14 sequentially.
Note:
Press switch (3) on the I/O1-14 screen to return to the ANALYZER MENU screen.
It is impossible to directly jump from I/O MONITOR1 function screen to another test screen. Return
to the ANALYZER MENU screen once and then go to the desired test menu.

Switch (3)
Press switch (3)

I/O1-1 screen (1) I/O1-1 screen
THCD: Main drive circuit temperature (°C)
Temperature of the main traveling circuit
• Check the temperature measurement function to
see it is operating normally.
• The temperature during measurement is displayed.
Press switch (3)
I/O1-2 screen
(2) I/O1-2 screen
THPC: Main material handling circuit temperature
(°C)
Temperature of the main material handling circuit
Press switch (3)
I/O1-3 screen
(3) I/O1-3 screen

TD: Drive motor temperature (°C)
Temperature at the drive motor
Press switch (3)
3-26
I/O 1-3 screen (4) I/O1-4 screen

Press switch (3) TP: Pump motor temperature (°C)
Temperature at the pump motor.
I/O1-4 screen
Press switch (3)
I/O1-5 screen
(5) I/O1-5 screen
TBD: Traveling control circuit board temperature (°C)
Temperature of the traveling controller control circuit
board.
Press switch (3) • The temperature during measurement is displayed.
I/O1-6 screen
(6) I/O1-6 screen
TBP: Material-handling control circuit board temperature
(°C)
Temperature of the material-handling controller
control circuit board.
Press switch (3) see it is operating normally.
I/O1-7 screen • The temperature during measurement is displayed.
(7) I/O1-7 screen
TEMP: Temperature on the CPU board (°C)
Temperature on the CPU board of the main controller
Press switch (3)
I/O1-8 screen
(8) I/O1-8 screen
VB80: Battery voltage (V)
This is the battery voltage.
Standard: Battery voltage
Press switch (3)

I/O1-9 screen
(9) I/O1-9 screen
VBKS: Key start voltage (V)
Voltage for traveling controller and material-handling
controller control power supply.

Press switch (3)
3-27

Press switch (3) Switch (1) VBSOL: Solenoid power voltage (V)
Switch (2)
I/O1-10 screen Solenoid power voltage.
Press switch (3) Switch (3)
I/O1-11 screen
(11) I/O1-11 screen
VBMB(M): Voltage (V) after (main input) MB contactor
Input voltage to the main controller after the MB
contactor.
Press switch (3)

I/O1-12 screen
(12) I/O1-12 screen
VBMB(S): Voltage (V) after (SAS input) MB contactor
Input voltage to the SAS controller after the MB
contactor.
Press switch (3)

I/O1-13 screen
(13) I/O1-13 screen
VBBD: Traveling controller main circuit voltage (V)
Traveling controller main circuit power supply voltage
value.
Press switch (3) Standard: Battery voltage

I/O1-14 screen
(14) I/O1-14 screen

VBBP: Material-handling controller main circuit
Press voltage (V)
switch (3) The Material-handling controller main circuit power
supply value.

3-28
I/O MONITOR2
This function displays the ON/OFF status of traveling and swing switches and analog input voltages of
sensors.
Operation Procedure
2. Press switch (2) twice.
function and display I/O2-1 through I/O2-7 sequentially.
• Switch (3): Press switch (3) each time to sequentially change the screen from I/O2-1 to I/O2-7.
Note:
Press switch (3) on the I/O2-7 screen to return to the ANALYZER MENU screen.
It is impossible to directly jump from I/O MONITOR2 function screen to another test menu. Return
to the ANALYZER MENU screen once and then go to the desired test screen.
(1) I/O2-1 screen

Switch (1) Switch (2) • POTA: Accelerator potentiometer voltage (V)
a Standard voltage when the accelerator pedal is not
depressed (SWAC at OFF): 0.3 ~ 2.4 V
b Standard voltage when the accelerator pedal is
depressed to its stroke end: 1.7 ~ 4.7 V
c Normal if b - a = 1.4 V or more
Switch (3)
• SWAC: Accelerator switch check
Press switch (3) When accelerator pedal is not operated:
0→OFF
I/O2-1 screen
When accelerator pedal is depressed:
1→ON
Switch ON/OFF quality judgment by operating the
accelerator pedal
Full gas = ca 3,30 volt

Press switch (3)
I/O2-2 screen
(2) I/O2-2 screen
• Direction switch check
DSF: Forward switch, DSR: reverse switch
Indication
DSF DSR
Operation
Press switch (3) Forward traveling 1 0
I/O2-3 screen Neutral 0 0
Reverse traveling 0 1
1→ON 0→OFF

direction lever
3-29

Press switch (3) Switch (1) • LSB: Brake switch check
I/O2-3 screen Switch (2) When brake pedal is not operated: 1→ON
When brake pedal is depressed: 0→OFF
brake pedal
• LSD: Seat switch check
When the operator is on the seat: 1→ON
Switch (3) When the operator leaves the seat: 0→OFF
Press switch (3) Switch ON/OFF quality judgment by sitting on and
I/O2-4 screen leaving the operator’s seat.
(4) I/O2-4 screen
SSD: Drive motor rpm sensor (rpm)
Check the rpm sensors while actually traveling the
vehicle. The number of rpm increases with the
traveling speed.
Press switch (3)
I/O2-5 screen
(5) I/O2-5 screen
SPDM: Main traveling speed (km/h)
SPDS: SAS traveling speed (km/h)
Check the vehicle speed by actually depressing the
accelerator pedal to increase the speed. Check that the
measured value changes in proportion to the traveling
Press switch (3) speed. Also, check that the value detected by the main
I/O2-6 screen *Un used
controller equals the input value to the SAS controller.
(6) I/O2-6 screen
YAW: Yaw rate sensor voltage (V)
Check the input voltage to the yaw rate sensor
controller.
Standard when the vehicle is stopping: 2.50 V

Press switch (3)
I/O2-7 screen Note:
Yaw rate sensor is not set for the vehicle with
double-tire.
(7) I/O2-7 screen

SWG: Not used
3-30
I/O MONITOR3
This function displays the ON/OFF status of material handling and mast control switches and analog input
voltages from sensors.
Operation Procedure
2. Press switch (2) three times.
3. Check that the “4. I/O MONITOR3” is displayed and press switch (3) to activate the Input/Output
MONITOR3 function and display I/O3-1 through I/O3-13 sequentially.
• Switch (3): Sequentially changes the screen from I/O3-1 to I/O3-13.
Note:
Press switch (3) on the I/O3-13 screen to return to the ANALYZER MENU screen. It is impossible to
directly jump from I/O MONITOR3 function screen to another test screen. Return to the ANALYZER
MENU screen once and then go to the desired test screen.
Switch (1) (1) I/O3-1 screen

Switch (2)
ANALYZER MENU screen • L: Lift lever angle 1 sensor voltage (V), lift lever
angle 2 sensor voltage (V), lift upward input (0:
OFF, 1: ON), lift downward input (0: OFF, 1: ON)
The lift lever operation is used to determine
whether the upward/downward input is good or
bad.
Switch (3) 00: Neutral, 10: Upward direction, 01: Downward
Press switch (3) direction
I/O3-1 screen Lift Lever Angle 1 Lift Lever Angle 2
Sensor Voltage Sensor Voltage
During upward operation 1.1 V ~ 2.3 V 2.2 V ~ 3.5 V
During downward operation 0.4 V ~ 1.6 V 2.9 V ~ 4.2 V
(2) I/O 3-2 screen

Lever angle1 Lever angle2 Lever direction • L (SOL): Lift proportional valve solenoid current (A)
The lift lever operation is used to determine
Press switch (3)
whether the output to the lift proportional valve is
I/O3-2 screen good or bad.
Standard:Solenoid current (during lever opera-
tion) 0.3 A ~ 0.85A
(3) I/O3-3 screen
• T: Tilt lever angle 1 sensor voltage (V), tilt lever
angle 2 sensor voltage (V), tilt forward tilt input (0:
Press switch (3) OFF, 1: ON), tilt backward tilt input (0: OFF, 1: ON).
The tilt lever operation is used to determine whether
I/O3-3 screen
the forward tilt and backward tilt inputs are good or bad.
00: Neutral, 10: Forward direction, 01: Backward
direction
Tilt Lever Angle 1 Tilt Lever Angle 2
Sensor Voltage Sensor Voltage
Lever angle1 Lever angle2 Lever direction During backward tilt operation 1.1 V ~ 2.3 V 2.2 V ~ 3.5 V
During forward tilt operation 0.4 V ~ 1.6 V 2.9 V ~ 4.2 V
3-31
I/O3-3 screen
Press switch (3)

(4) I/O3-4 screen
I/O3-4 screen • T (SOL): Tilt proportional valve solenoid current (A)
The tilt lever operation is used to determine if the
output to the tilt proportional valve is good or bad.
Standard: Solenoid current (during lever
operations) 0.3 A ~ 0.85 A
Press switch (3) (5) I/O3-5 screen

I/O3-5 screen
• A1: Attachment 1 lever angle sensor voltage (V),
attachment 1 lever angle 2 sensor voltage (V),
attachment 1 upward input (0: OFF, 1: ON),
attachment 1 downward input (0: OFF, 1: ON)
Use the attachment 1 lever operation to determine
whether the input is good or bad.
Attachment 1 Lever Attachment 1 Lever
Angle 1 Sensor Voltage Angle 2 Sensor Voltage
Press switch (3)
I/O3-6 screen During downward operation 0.4 V ~ 1.6 V 2.9 V ~ 4.2 V
(6) I/O3-6 screen

• A1 (SOL): Attachment 1 proportional valve solenoid
current (A)
if the output to the attachment 1 proportional valve
Press switch (3)
solenoid is good or bad.
I/O3-7 screen operations) 0.3 A ~ 0.85 A
(7) I/O3-7 screen
• A2: Attachment 2 lever angle sensor voltage (V),
attachment 2 lever angle 2 sensor voltage (V),
attachment 2 upward input (0: OFF, 1: ON),
attachment 1 downward input (0: OFF, 1: ON)
whether the input is good or bad.
Press switch (3)
Attachment 2 Lever Attachment 2 Lever
I/O3-8 screen Angle 1 Sensor Voltage Angle 2 Sensor Voltage
During downward operation 0.4 V ~ 1.6 V 2.9 V ~ 4.2 V
(8) I/O3-8 screen

• A2 (SOL): Attachment 2 proportional valve solenoid
current (A)
Press switch (3) if the output to the attachment 2 proportional valve
solenoid is good or bad.
I/O3-9 screen
operations) 0.3 A ~ 0.85 A
(9) I/O3-9 screen
SWTK: Fork automatic leveling switch: 1→ON
0→OFF
Fork automatic leveling switch operation is used to
determine if ON/OFF is good or bad.
3-32

• SSP: Pump motor speed (rpm)
Press switch (3)
When checking the rotating sensor, first have the
I/O3-10 screen vehicle actually handle materials and then check
the sensor. The Material-handling motor speed
increases as the Material-handling speed
increases.
(11) I/O3-11 screen
• MH: Lift height switch: 1→ON
Press switch (3) 0→OFF
I/O3-11 screen 1 0 0
MH2-2
MH2-1
MH1
Material-handling is moved upward and downward to
Press switch (3) determine if ON/OFF is good or bad.
I/O3-12 screen Standard: Refer to the following table.
MH1 MH2-1 MH2-2
Low lifting height 1 0 0
High lifting height 0 1 0
Press switch (3) (12) I/O3-12 screen

• POTT: Tilt angle sensor voltage (V)
I/O3-13 screen
Check the tilt angle sensor controller input voltage
value.
Mast vertical state standard:
Press
switch (3)
16 ~ 30 model: approx. 1.3 V.
35 model: approx. 1.0 V
40 ~ 50 model: approx. 2.2 V
Vertical → Forward tilt: Reduces input voltage
Vertical → Backward tilt: Increases input voltage
(13) I/O3-13 screen

• SPL: Load sensor voltage (V), (MPa display)
Check the load sensor controller input voltage
value.
Standard when unloaded: Approx. 0.8V
The input voltage increases as the load increases.
3-33
I/O MONITOR4
This function displays ON/OFF status of the knob position correction and other switches and analog input
voltages from sensors.
Operation Procedure
1. Display the Analyzer Menu screen.
2. Press switch (2) four times.
function and display I/O4-1 through I/O4-6 sequentially.
• Switch (3): Press switch (3) to change the screen sequentially from I/O4-1 to I/O4-6.
Note:
Press switch (3) on the I/O4-6 screen to return to the ANALYZER MENU screen. It is impossible to
directly jump from I/O MONITOR4 function screen to another test screen. Return to the ANALYZER
MENU screen once and then go to the desired test screen.
(1) I/O4-1 screen
Switch (1)
Switch (2)
STS: Steering angle sensor: 1→ON
0→OFF
0 0 1
STSC
STS2
Press switch (3) Switch (3) STS1
I/O4-1 screen
When the steering wheel is rotated to the right or left,
STS1 and STS2 repeat ON and OFF.
The STS is set to upon one wheel rotation from the
straight traveling position as the reference.
Press switch (3)
I/O4-2 screen
Press
switch (3)
Press switch (3)
(2) I/O4-2 screen

K-POS: Steering angle knob position: Actual value
(target)
Operate the steering wheel and check variation of the
value.
Standard: 80 when the steering wheel is at the
neutral position
Left←Neutral→Right
0←80→160
3-34
I/O4-2 screen
(3) I/O4-3 screen
K-DIFF:Steering angle knob position deviation
Press switch (3)
Actual value (target)
I/O4-3 screen
SOL: Knob position correcting solenoid: 0→OFF
1→ON
Operate the steering wheel and check that the knob
position correcting solenoid turns ON when the
steering angle knob position is deviated.
Caution:
Press switch (3) The knob position is mainly corrected when
returning the steering wheel to the neutral
I/O4-4 screen
(straight traveling) position.
(4) I/O4-4 screen
TIRE: Tire angle sensor voltage (V)
Operate the steering wheel and check the voltage
changes.
Press switch (3) Standard when tire is traveling straight: 2.00 V
Turn to the left↔Straight traveling↔Turn to the right

Voltage decreases←Standard→Voltage increases
I/O4-5 screen
(5) I/O4-5 screen
AOPT: Spare
Press switch (3)
I/O4-6 screen
(6) I/O4-6 screen
LSOPT1: Spare
Press
switch (3)
3-35
ACTIVE TEST
This function outputs ON/OFF signals to switches in the electrical system and compare controller input
signals with those signals.
Operation Procedure
2. Press switch (2) five times.
3. Check that the “6. ACTIVE TEST” is displayed and press switch (3) to activate the ACTIVE TEST
function and display ACT-1 through ACT-5 screens sequentially.
• Switch (1): Forced ON
• Switch (2): Forced OFF
• Switch (3): Sequentially changes the screen from ACT-1 to ACT-5.
Note:
Press switch (3) on the ACT-5 screen to return to the ANALYZER MENU screen.
It is impossible to directly jump from the ACTIVE TEST FUNCTION screen to another test screen.
Return to the ANALYZER MENU screen once and then go to the desired test screen.
(1) ACT-1 screen
• FAN: Fan
Observe the fan operation and check the display indication by compulsorily outputting the ON/OFF
signal.
Open the seat stand to check the fan.
• Press switch (1) and select ON........ The fan rotates and fan voltage is displayed.
• Press switch (2) and select OFF...... The fan stops rotating and the fan voltage is displayed.
(2) ACT-2 screen
• DSOL: Brake change valve solenoid
(1) → Signal check line ON (error occurred)
(0) → Signal check line OFF (normal)
Check to make sure the machine platform does not move when DSOL is turned OFF and the
traveling operation is performed.
(3) ACT-3 screen
• SSOL: Swing solenoid
Jack up the rear axle and check that the rear axle swings properly.
(4) ACT-4 screen
• KSOL: Knob position correcting solenoid
(1) → Signal check line on (error occurred)
(0) → Signal check line off (normal)
Turn steering wheel slowly and check for a deviation in tire movement.
ON (bypass open) → Tire also does not move.
OFF (bypass closed) → Tire moves. (Normal operation)
3-36
(5) ACT-5 screen

• PSOL: Upload valve solenoid
• Turn the switch to ON and operate the material-handling lever.
…If the unload valve turns ON normally, material-handling can be performed. If it remains OFF,
Material-handling is not possible.
• Turn the switch to OFF and operate the material-handling lever.
…If the unload valve turns OFF normally, material-handling is not possible. If it remains ON,
Material-handling can be performed.

ACTIVE TEST screen ACT-5 screen
Press
switch (3)
Switch (3)
ACT-1 screen ACT-4 screen
ACT-2 screen ACT-3 screen
Press
switch (3)
3-37
TUNING
GENERAL
When the user requests to limit the maximum speed or weaken the regenerative braking force, each
setting can be performed on the TUNING screen.
Tuning Item List
Tun- Level (: Initial setting position)

Item
ing No. 1 2 3 4 5 6 7 8
Switch back regenerative breaking torque:
1 Sets the braking torque at switch back regen- Weak Strong
eration.
Acceleration OFF regenerative breaking
torque:
2
Sets the breaking torque at acceleration OFF
Weak Strong
regeneration.
Battery warning setting level:
Sets the operation timing of remaining bat- Slow
3
tery charge warning and over-discharge
Fast
Disabled
warning. (Refer to the explanation hereafter.)
4
Battery charge indicator correction: Slow
Sets the battery charge indicator calibration. decrease
Fast
decrease
Traveling speed limiter: Slow Fast None

5
Sets the maximum traveling speed limit. speed speed
Attachment power control No.1: Fast
Slow speed
6 Sets the material handling motor output for
when attachment switch No.1 is ON.
speed

Tilt power control:
Sets the material handling motor output for Fast
Slow speed
7 when the tilt switch is ON.
(The SAS function mast control speed is not
speed

limited.)
Attachment power control No.2: Fast
Slow speed
8 Sets the material handling motor output for
when attachment switch No.2 is ON.
speed

9 ~ 12 Spare
13 ~ 19 Not used (Not displayed)
Lift downward adjustment 1:

20 Adjusts the solenoid output current when the Small Large
lift begins moving downward.
21 Adjusts the inching for the lift downward Slow Fast
movement.
22 Adjusts the solenoid maximum output current Small Large
for the lift downward movement.
23 Adjusts the acceleration for the lift downward Weak Strong
movement.
3-38

Item
ing No. 1 2 3 4 5 6 7 8
24 Adjusts the deceleration for the lift downward Weak Strong
movement.
Lift upward adjustment 1:
lift begins moving upward.
26 Adjusts the inching for the lift upward move- Slow Fast
ment.
for the lift upward movement.
28 Adjusts the acceleration for the lift upward Weak Strong
movement.
29 Adjusts the deceleration for the lift upward Weak Strong
movement.
Tilt forward tilt adjustment 1:
tilt begins tilt forward.
31 Adjusts the inching for the tilt forward tilt Slow Fast
movement.
for the tilt forward tilt movement.
33 Adjusts the acceleration for the tilt forward tilt Weak Strong
movement.
34 Adjusts the deceleration for the tilt forward tilt Weak Strong
movement.
Tilt backward tilt adjustment 1:
tilt begins tilt backward.
36 Adjusts the inching for the tilt backward tilt Slow Fast
movement.
for the tilt backward tilt movement.
38 Adjusts the acceleration for the tilt backward Weak Strong
tilt movement.
39 Adjusts the deceleration for the tilt backward Weak Strong
tilt movement.
Attachment 1 downward adjustment 1:
40 Adjusts the solenoid output current when Small Large
attachment 1 begins moving downward.
41 Adjusts the inching for the attachment 1 Slow Fast
downward movement.
3-39

Item
ing No. 1 2 3 4 5 6 7 8
for the attachment 1 downward movement.
43 Adjusts the acceleration for the attachment 1 Weak Strong
downward movement.
44 Adjusts the deceleration for the attachment 1 Weak Strong
downward movement.
Attachment 1 upward adjustment 1:
attachment 1 begins moving upward.
upward movement.
for the attachment 1 upward movement.
upward movement.
upward movement.
attachment 2 begins moving downward.
downward movement.
52 Adjusts the solenoid maximum output voltage Small Large
for the attachment 2 downward movement.
downward movement.
downward movement.
attachment 2 begins moving upward.
upward movement.
for the attachment 2 upward movement.
58 Adjusts the acceleration for the attachment 2 Weak Large
upward movement.
59 Adjusts the deceleration for the attachment 2 Weak Large
upward movement.
3-39A
Tuning 1 Parametervärde = Standardvärde

Parameter Ämne 1 2 3 4 5 6 7 8
1 Reverseringsbroms Svag Stark
2 Rullbroms Svag Stark
Larmnivå för urladdat Tidigare Senare Ingen

3 batteri varning varning varning
Korrigering av Långsam Snabb

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

6 extrafunktion 1 varvtal varvtal
Lågt Högt
7 Hydraulvarv för tilt
varvtal varvtal
Hydraulvarv för Lågt Högt

8 extrafunktion 2 varvtal varvtal
9>11 Används ej
Justering av accele-
12* ration och rullbroms Svag Stark
under 5 km/h
12* - Justering av parameter 12 är endast möjlig på maskiner tillverkade senare

än Sept. 2003, samt på äldre maskiner med uppdaterad programvara!
3-39B
Tuning 2 - Parametrar för minispakar
Lyft & Sänk
Ström
1000 mA
3*
(8)
2*
500 mA
2* (1)
1*
Tid
4* 5*
1* Startström - Parameter 20-sänk, 25-lyft
2* Accelerationskurva - Parameter 21-sänk, 26-lyft
3* Slutström - Parameter 22-sänk, 27-lyft
4* Acceleration - Parameter 23-sänk, 28-lyft
5* Deceleration - Parameter 24-sänk, 29-lyft
(4* och 5* - Parametervärde 1=lång fördröjning, 8=kort fördröjning)

3-39C

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

3-39D

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

3-39E

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

3-40
TUNING Screen Operation Procedure

1. Input the password on the NORMAL FUNCTION screen (See page 3-17) to display the MASK MANU
screen.
2. Press switch (2) to display “2. TUNING.” Press switch (3) (enter) to display the TUNING MENU screen.
3. Functions of switches on the TUNING MENU screen are as follows.
• Switch (1): The cursor moves to the preceding item.
• Switch (2): The cursor moves to the next item.
• Switch (3): Enters (Changes to the tuning screen for the selected item.)
Note:
Press switch (3) on the End screen to return to the MASK MENU screen.

TUNING screen
Press switch (3)
Switch (3)
Press switch (3)
TUNING 1 screen END screen
Press (1) or (2) to

switch screen.

TUNING 2 LIFTV screen TUNING 5 ATT2V screen

TUNING 4 ATT1V screen
TUNING 3 TILTV screen
Press (1) or (2) to

switch screen.
3-41
Switch (1) Switch (2) TUNING 1 FUNCTION Screen Operation Procedure

1. Input the password on the NORMAL FUNCTION screen
(see page 3-17) to display the MASK MENU screen.
2. Press switch (2) to display “2. TUNING”. Press switch

(3) (enter) to display the TUNING MENU screen.
Switch (3)
Press switch (3) 3. With “1. TUNING 1” displayed, press switch (3) each
time to sequentially display No.1 through No.12.
4. Functions of switches on the TUNING screen are as

follows:
• Switch (1): Decreases the tuning level.
• Switch (2): Increases the tuning level.
Press switch (3) • Switch (3): Enters (and switches to the next screen).
Note:
• Press switch (3) on the TUNING NO.12 (spare) screen
to return to the TUNING MENU screen.
• It is impossible to directly jump from the TUNING 1
function screen to another TUNING screen. Return to
the TUNING MENU screen once and then go to the
Press switch (3) desired TUNING screen.
Press
switch (3)
Low Remaining Battery Charge Alarm and Overdischarge Alarm Setting Levels (Tuning No. 3)
Level 7 is the initial setting.

Discharge Tuning setting level
level 1 2 3 4 5 6 7 8
50% ~ 59%
60% ~ 69%
70% ~ 79%
Low remaining charge alarm
80% Battery charge meter blinking.
81% ~ 89%
90%
Overdischarge alarm
91% ~ 99% 10 segments of the battery charge
indicator blink.
100% No alarm
3-42
Switch (1) Switch (2) TUNING 2 LIFTV FUNCTION Screen Operation Procedure

Switch (3)
Press switch (3) 3. Press switch (2) to display “2. TUNING 2 LIFTV”. Press
switch (3) each time to sequentially display No.20
through No.29.

follows:
Press switch (3) • Switch (2): Increases the tuning level.
• Switch (3): Enters (and switches to the next screen).
Note:
• Press switch (3) on the TUNING NO.29 screen to the
TUNING MENU screen.
Press switch (3) the TUNING MENU screen once and then go to the
desired TUNING screen.
Press
switch (3)
3-43
Switch (1) Switch (2) TUNING 3 TILTV FUNCTION Screen Operation Procedure

Switch (3)
Press switch (3) 3. Press switch (2) twice to display “3. TUNING 3 TILTV”.
Press switch (3) each time to sequentially display No.30
through No.39.

follows:
Press switch (3) • Switch (2): Increases the tuning level.
Note:
• Press switch (3) on the Tuning No.39 screen to return
to the TUNING MENU screen.
Press switch (3) the TUNING MENU screen once and then go to the
Press
switch (3)
3-44
Switch (1) Switch (2) TUNING 4 ATT1V FUNCTION Screen Operation

Procedure

Switch (3) (3) (enter) to display the TUNING MENU screen.
Press switch (3)
3. Press switch (2) three times to display “4. TUNING ATT
1”. Press switch (3) each time to sequentially display
No.40 through No.49.

follows:
Press switch (3) • Switch (1): Decreases the tuning level.
Note:
• Press switch (3) on the TUNING NO.49 screen to return
Press switch (3) function screen to another TUNING screen. Return to
Press
switch (3)
3-45
Switch (1) Switch (2) TUNING 5 ATT2V FUNCTION Screen Operation

Procedure

Switch (3) (3) (enter) to display the TUNING MENU screen.
Press switch (3)
3. Press switch (2) four times to display “5. TUNING 5 ATT
2”. Press switch (3) each time to sequentially display
No.50 through No.59.

follows:
Press switch (3) • Switch (1): Decreases the tuning level.
Note:
• Press switch (3) on the TUNING NO.59 screen to return
Press switch (3) function screen to another TUNING screen. Return to
Press
switch (3)
3-46
OPTION SET
Option Set Menu List
Selection (display)
No. Indication Description
Y N
Enables simultaneous traveling and mate-
OPT-1 DEMO MODE rial handling before starting the hour Enable (Y) Disable (N)
meter.
No counting
OPT-2 H/M START Start counting by hour meter. Counting (Y)
(N)
Disables setting of levels for traveling/load
Lock release
OPT-3 P/C LOCK handling power control, travel 2nd speed Lock (Y)
(N)
control and overspeed alarm (option).
Sets the data according to the destination. For other
OPT-4 DESTI *1 For Japan (J)
Changes the display indication. than Japan (I)
OPT-5 B LEVEL Unused - (Y) - (N)
Setting to mph Setting to km/h
OPT-6 MPH *1 Displays the vehicle speed in mph.
(Y) (N)
OPT-7 C/CNT RES Unused - (Y) - (N)
Adjusts the charge indicator calculation Characteristic Characteristic
OPT-8 BATTERY *2
constant. (A) (B)
OPT-9 SHOU-TOKU Unused - (Y) - (N)
Enables/disables the auto power off func-
OPT-10 AUTO P-OFF Enable (Y) Disable (N)
tion.
Enables/disables the parking brake OFF
OPT-11 PARKING ERR Enable (Y) Disable (N)
alarm.
Enables/disables the mast forward tilt
OPT-12 TILT CONT Enable (Y) Disable (N)
automatic stopping function.
OPT-13 SWG W-LOCK Unused - (Y) - (N)
Enables/disables the mast forward tilt
OPT-14 TILT F-LIM Enable (Y) Disable (N)
speed limit control.
OPT-15 B-TYPE *3 Battery type TYPE1 (1) TYPE2 (2)
OPT-16 72V *1 72V/80V 72V (Y) 80V (N)
Other than
OPT-17 2-WAY VALVE *1 2way valve 2WAY (Y)
2WAY (N)
OPT-18 FISHERMAN *1 Fisherman specifications Enable (Y) Disable (N)
*1 : Matched to the specification of the vehicle at the time of vehicle shipment.
*2, *3 : Select according to the decreasing speed of the battery charge indicator reading (quick or slow).
The default value upon shipment is A2. (Select other type when the optimum value cannot be
obtained by tuning.)
Select according to the battery type. (Reference)
A1: USA Röd = Varning, problem
A2: EEC
B1: JAPAN type Gul = Standard, måste
B2: Maintenance-free battery
Grön = Standard, valmöjlighet
3-47
Note:
When the controller board is replaced, it is necessary to set again according to the vehicle
specification.
Caution:
• The Option Set function is used to adjust the
controller with the display control according to the
options equipped on the vehicle and does not enable
or disable the function itself.
• When the TILT CONT is disabled by option setting, the
disabled status is displayed for 5 seconds upon key
switch ON.
Indication contents:
T-OFF: TILT CONT (mast forward tilt automatic stopping
function is disabled)
3-48
Operation Procedure Screen

1. Input the password on the NORMAL FUNCTION screen (see page 3-17) to display the MASK MENU
screen.
2. Press switch (2) to display “3. OPTION SET.” Press switch (3) (enter) to display the OPTION SET
screen.
3. Select a desired option menu item using switch (3).
4. Functions of switches on the OPTION SET screens are as follows:
• Switch (1): Changes the setting from N to Y.
• Switch (2): Changes the setting from Y to N.
• Switch (3): Enters (and changes to the next item setting screen).
Note:
Press switch (3) on the OPT-18 OPTION SET screen to return to the MASK MENU screen.
Press switch (3)

Switch (1)
OPTION SET screen Switch (2) OPT-7 screen
Press switch (3) Switch (3) Press switch (3)

OPT-1 screen OPT-6 screen

*1
Press
switch (3)
*1. OPT-2 (H/M START) hour meter starting method:

While holding down switch (1) for at least 2 sec, press switch (2).
3-49
OPT-7 screen
Press switch (3)
Press switch (3)

Press switch (3)
Press switch (3)

Press switch (3)
Press switch (3)

Press switch (3)
Press switch (3)

Press switch (3)
Press
switch (3)
3-50
OPT-17 screen
OPT-18 screen
Press switch (3)
To MASK MENU screen

3-51
MATCHING
GENERAL
For the tilt angle, load sensor and tire angle sensor among sensors used for SAS functions, the signal
voltage values under the mast vertical and no load are stored, respectively, in the controller for the control
based on these values. When servicing or replacing these sensors, matching (updating the sensor signal
voltage to match the standard vehicle condition) is necessary. Also, matching is needed for the tilt angle
sensor when the vehicle posture has changed excessively, and for the load sensor when the load under no
load condition (no load on fork) is changed because of addition or removal of any attachment.
For the lever angle sensors used for the mini lever function, the lever neutral status signal voltage values
are stored in the controller memory at the factory before shipment, and these values are used as the basis
for control. Therefore, when equipment or parts related to these sensors are replaced, matching must be
performed (updating of the sensor signal voltage values while the vehicle is in the standard state).
SAS Matching Menu List

No. Indication Description Necessary condition
(1)⋅(3)⋅(4)⋅(7)
1 TILTL Stores the tilt angle sensor fork level position output value in the controller.
(8)⋅(9)
Stores the tilt angle sensor forward tilt control mast vertical standard position (1)⋅(3)⋅(4)⋅(7)
2 TILTF
output value in the controller. (8)⋅(9)
3 LOAD Stores the output value when the load sensor is unloaded in the controller. (1)⋅(5)⋅(7)⋅(8)
Stores the tire angle sensor vehicle forward motion status output value in the (2)⋅(6)
4 TIRE
controller.
5 SWG Not used.
MINI LEVER Matching Menu List

No. Indication Description Necessary condition
Stores the lift lever angle sensor's lift lever neutral status output value in the
6 LIFT (1)⋅(10)
controller.
Stores the tilt angle sensor's tilt lever neutral status output value in the con-
7 TILT (1)⋅(11)
troller.
Stores the attachment 1 lever angle sensor's attachment 1 lever neutral sta-
8 ATT1 (1)⋅(12)
tus output value in the controller.
Stores the attachment 2 lever angle sensor's attachment 2 lever neutral sta-
9 ATT2 (1)⋅(13)
tus output value in the controller.
Contents of necessary conditions:

(1) Main controller replacement
(2) SAS controller replacement
(3) Tilt angle sensor replacement
(4) Length change or replacement of tilt angle sensor rod
(5) Load sensor replacement
(6) Removal Installatio or replacement of tire angle sensor or sensor cover
•
(7) Change of attachment

(8) Mast replacement
(9) Tilt cylinder replacement
(10) Lift lever angle sensor replacement
(11) Tilt lever angle sensor replacement
(12) Attachment No.1 lever angle sensor replacement
(13) Attachment No.2 lever angle sensor replacement
3-52
Matching- Kalibrering av SAS systemet

V mast FV⋅FSV mast
TILTL - Kalibrering av tiltvinkelsensor med
horisontella gafflar.
TILTF - Kalibrering av tiltvinkelsensor med
100 mm (3.9 in)

vertikal mast.
LOAD - Kalibrering av lastsensor med grund-
last. Detta inkluderar vikten av stativbalkar och
aggregat. På en V mast (standardmast) lyfter
man upp gafflarna ca 500mm. 500 mm (19.7 in)
På FV och FSV (frilyftsmaster) lyfter man upp
gafflarna ca 100mm upp i huvudlyftsområdet.
Se fig.
Tabellen nedan visar max tillåten vikt för aggre-
gat, inklusive gaffelvagn. Överskrider den sam-
manlagda vikten av gaffelvagn och aggregat
värdena i tabellen, så skall aggregatets vikt
räknas som last. Man kalibrerar då grundlasten
utan aggregatet monterat.
Tillåten maxvikt för installation på mast.
Model
Lift height 16 18 20 25 30 35 40 45 50
mm (in.)
700 800 950 950 1200 1400 1500 1800 1800
3000 (118) or less
(1544) (1764) (2095) (2095) (2646) (3086) (3307) (3968) (3968)
700 700 950 950 1200 1400 1500 1600 1600
3300 (130) ~ 4000 (157.5)
(1544) (1544) (2095) (2095) (2646) (3086) (3307) (3527) (3527)
600 650 900 900 1000 1000 1500 1500 1500
4300 (169) ~ 5000 (197)
(1323) (1433) (1985) (1985) (2205) (2205) (3307) (3307) (3307)
450 550 650 800 800 1000 1200 1500 1500
5500 (216.5) ~ 6000 (236)
(992) (1213) (1433) (1764) (1764) (2205) (2646) (3307) (3307)
500 500
6500 (256) ~ 7000 (275.5) - - - - - - -
(1103) (1103)
3-53
Within 50 mm (2.0
TIRE - Kalibrering av raka styrhjul. Kör in) each on the left
fram och tillbaka, och ställ styrhjulen så and right sides
rakt som möjligt. På en sträcka av 5 meter

bör inte trucken avvika mer än 50mm från
centrumlinjen. Se fig.
5 m (16 ft)
SWG - Används inte.

LIFT - Kalibrering av lyftspaken i neutral-
läge.
TILT - Kalibrering av tiltspaken i neutral-
läge.
ATT 1 - Kalibrering av 3:e spaken i
neutralläge.
ATT 2 - Kalibrering av 4:e spaken i
neutralläge.
ATT2
ATT1
Tilt
Lilt
Fork automatic leveling switch

3-54
Operation Procedure
1. Input the password on the NORMAL FUNCTION screen (see page 3-17) to display the MASK MENU
screen.
2. Press switch (2) to display “4. MATCHING.” Press switch (3) (enter) to display the MATCHING set
screen.
3. select the desired matching item using switch (3).
4. Functions of switches on the MATCHING set screen are as follows:
• Switch (1): Unused.
• Switch (2): Performs matching of the selected item.
• Switch (3): Causes transition to the next item.
Note:
Press switch (3) on the ATT2 MATCHING set screen to return to the MASK MENU screen.
Press switch (3)

Switch (3)
Press switch (3)
Press switch (3)

Press switch (3)
Press switch (3)
If values in 1 and 2 below are different while the vehicle is in the standard state, the item needs
matching. Matching is also needed when the control panel or each sensor is replaced.
1. The value in parentheses is the stored value at present.
2. The value outside the parentheses is the one in the present vehicle state.
3. OK is displayed only when matching is performed (switch (2) is pressed).
3-55
MATCHING TIRE screen
MASK MENU screen
Press switch (3)

Press switch (3)
Press switch (3)

Press switch (3)
Press switch (3)

3-56
WHEEL DIA
It is necessary to input the tire constant to the controller according to the tire radius, for optimizing the
speedometer reading. 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 indication.
Operation Procedure
Tire constant Switch (1) Switch (2)
2. Press switch (2) to display “5. WHEEL DIA.” Press

switch (3) (set) to display the CONSTANT SETUP
screen.
Switch (3) 3. Select the desired tire constant value using switches (1)
and (2). Press switch (3) to enter the value and return to
the MASK MENU screen.
Functions of switches on this screen are as follows:
• Switch (1): Decreases the tire constant.
• Switch (2): Increases the tire constant.
• Switch (3): Enters the selected value and returns to
the MASK MENU screen.
Tire Constant List

Tire type Pneumatic Shaped Cushion Pneumatic
Model Single Over size Dual Single Over size Dual
21×8-9/6.00 6.50-10/5.00 21×8-9-14PR 6.50-10-14PR
7FBMF16-18  
41 54 39 52
21×8-9/6.00 23×9-10/6.50 21×8-9-14PR 23×9-10-18PR
7FBMF20  
41 58 39 51
23×9-10/6.50 23×9-10-18PR
7FBMF25    
58 51
23×10-12/8.00
7FBMF30-35     
62
250-15/7.00 7.00-15/5.50 250-15-18PR 7.00-15-12PR
7FBMF40  
95 99 91 98
7FBMF45 250-15/7.00 28×12.5-15/9.75 7.00-15/5.50 250-15-18PR 7.00-15-12PR

V, FV mast 95 98 99 91 98
7FBMF45 28×12.5-15/9.75 7.00-15/5.50 7.00-15-12PR
  
FSV mast 98 99 98
28×12.5-15/9.75 7.00-15/5.50 7.00-15-12PR
7FBMF50   
98 99 98
Note:
The non-marking white tire (OPT)'s tire constant is the same as for the cushion single.
3-57
Spanner symbol
DIAGNOSIS
1. When diagnosis is activated, a spanner symbol appears
on the display with alarm sounding to warn the operator
of an abnormal state of the vehicle.
2. Also, one or up to 3 diagnosis codes appear to indicate

the trouble locations. If 3 are exceeded, the screen
Diagnosis codes Abnormality detection time changes to indicate max. 6 codes.
3. The battery charge can be checked even while diagnosis

codes are displayed.
DIAGNOSIS CODE LIST

Display indication: Information can be checked on the display when vehicle trouble occurs.
Diagnosis memory: Use indication information that can be checked when the mask function DIAG
MEMORY function is used.
Display Diag
Defect mode Phenomenon on vehicle Detect controller
indication memory
Traveling controller low tempera-
- Traveling output restricted Traveling controller
ture
Material-handling controller low Material-handling control-

- Material-handling output restricted
temperature ler
30-1 30-1 Traveling controller low voltage Traveling stop Traveling controller
Material-handling controller low Material-handling control-
30-3 30-3 Material-handling stop
voltage ler
Traveling controller startup volt-
31-1 31-1 Traveling stop Traveling controller
age drop
Material-handling controller star- Material-handling control-
tup voltage drop ler
Traveling controller EEPROM
32-1 32-1 Traveling stop Traveling controller
error
Material-handling controller Material-handling control-
EEPROM error ler
Main controller → Traveling con-
33-1 33-1 Operate using the default value Traveling controller
troller communication error
Main controller → Material-han-
Material-handling control-
33-3 33-3 dling controller communication Operate using the default value
ler
error
Swing lock stop while rotating
51-1 51-1 Vehicle speed sensor open The PS operates normally (some func- SAS controller
tions are restricted).
52-1 52-1 Yaw rate sensor open
52-2 52-2 Yaw rate sensor VCC short-circuit
Swing lock stop while rotating SAS controller
Yaw rate sensor neutral voltage
52-3 52-3
error
53-1 53-1 Swing angle sensor open
Swing angle sensor VCC short- Material-handling lock stop SAS controller
53-2 53-2
circuit
3-58
Display Diag
indication memory
54-1 54-1 Swing solenoid error
Swing lock status hold SAS controller
54-2 54-2 Swing solenoid error
Swing angle sensor matching
55-1 55-1 Material-handling lock stop SAS controller
value error
61-1 61-1 Pressure sensor open NL control
No forward tilt regulations Main controller
61-2 61-2 Pressure sensor short-circuit No automatic leveling
62-1 62-1 Tilt angle sensor open No forward tilt regulations
Main controller
62-2 62-2 Tilt angle sensor short-circuit No automatic leveling
No forward tilt regulations
66-1 66-1 Tilt matching error Main controller
No automatic leveling
Low lift height control
67-1 67-1 Lift height switch error No forward tilt regulations Main controller
No automatic leveling
71-1 71-1 Tire angle sensor open
Knob offset occurs SAS controller
71-2 71-2 Tire angle senor VCC short-circuit
72-1 72-1 Steering angle sensor SS1 error Knob offset occurs
72-2 72-2 Steering angle sensor SS2 error Steering becomes stiff
72-3 72-3 Steering angle sensor SSC error Knob offset occurs SAS controller
Knob offset occurs
72-4 72-4 Steering angle sensor open
PS operation stops
73-1 73-1 Knob offset solenoid open
Knob offset occurs SAS controller
73-2 73-2 Knob offset solenoid short circuit
Tire angle sensor matching value
74-1 74-1 Knob offset occurs SAS controller
error
Traveling main circuit temperature

DCR A0-1 Traveling output restricted Traveling controller
erroneous increase
PCR Material-handling main circuit Material-handling control-

A0-2 Material-handling output restricted
temperature erroneous increase ler
A0-4 A0-4 Main controller fan error Fan stops

CPU circuit board internal air fan Fan stops Main controller
A0-5 A0-5
error Material-handling stops (solenoid off)
Traveling stop
A1-1 A1-1 Main controller high voltage Main controller
Material-handling stops (solenoid off)
A1-2 A1-2 Traveling controller high voltage Traveling stop Traveling controller
Material-handling controller high Material-handling control-
A1-4 A1-4 Material-handling stops
voltage ler
C/R CPU board temperature errone-

A2-1 Traveling output restricted Main controller
ous increase
DCR Traveling board temperature erro-

A2-2 Traveling output restricted Traveling controller
neous increase
PCR Material-handling board tempera- Material-handling control-

A2-3 Material-handling output restricted
ture erroneous increase ler
A4 A4 Accelerator switch error Traveling stop Main controller

3-59
Display Diag
indication memory
CPU board temperature sensor
AA-1 AA-1 Display only Main controller
error
Traveling controller board temper-
AA-2 AA-2 Display only Traveling controller
ature sensor error
Material-handling controller board Material-handling control-
AA-4 AA-4 Display only
temperature sensor error ler
Traveling stop
AC AC Semiconductor switch error Main controller
Material-handling stops
Traveling controller → Main con-
AD-1 AD-1 Traveling stop
troller communication error (1)
Traveling controller → Main con- Traveling stop
AD-2 AD-2
troller communication error (2) Material-handling stops
Material-handling controller → Main controller
AD-5 AD-5 Main controller communication Material-handling stops
error (1)
Material-handling controller →
Traveling stop
AD-6 AD-6 Main controller communication
Material-handling stops
error (2)
AF-1 AF-1 CPU error (1)
AF-2 AF-2 CPU error (2) Traveling stop
Main controller
AF-3 AF-3 CPU error (3) Material-handling stops
AF-6 AF-6 CPU error (2) Swing control and PS control opera-
SAS controller
AF-7 AF-7 CPU error (3) tion stops
C1-1 C1-1 Traveling current sensor error
Traveling stop Traveling controller
C1-2 C1-2 Traveling over current error
Traveling motor temperature erro-

DM C2-1
neous increase
Traveling output restricted Traveling controller
Traveling motor temperature sen-
C2-2 C2-2
sor error
Traveling main circuit temperature
C3-1 C3-1 Traveling output restricted Traveling controller
sensor error
C4-1 C4-1 Accelerator potention error (1)
C4-2 C4-2 Accelerator potention error (2) Traveling stop
Main controller
C4-3 C4-3 Accelerator potention error (3)
C4-4 C4-4 Accelerator potention error (4) Display only
C7 C7 Direction switch error Traveling stop Main controller
C8-1 C8-1 Traveling rotation sensor error Crawl traveling Traveling controller
Traveling stop
CB-1 CB-1 MB contactor error
Material-handling stops (solenoid off) Main controller
CB-2 CB-2 MB contactor fusion Display only
3-60
Display Diag
indication memory
Material-handling current sensor
E1-1 E1-1 Material-handling control-
error Material-handling stops
ler
E1-2 E1-2 Material-handling over current
Material-handling motor tempera-

PM E2-1
ture erroneous increase Material-handling control-
Material-handling output restricted
ler
Material-handling motor tempera-
E2-2 E2-2
ture sensor error
Material-handling main circuit Material-handling control-
E3 E3 Material-handling output restricted
temperature sensor error ler
Material-handling rotation sensor Material-handling control-
E8 E8 Material-handling stops
error ler
Display → Main control communi-
EE-1 EE-1 Display only
cation error (1)
EE-2 EE-2 Display only Main controller
cation error (2)
EE-3 EE-3 Operate using the default value
cation error (3)
EF-1 EF-1 EEPROM error (1)
Operate using the default value
Main controller
EF-3 EF-3 CPU error Display only
EF-4 EF-4 EEPROM error (3) Operate using the default value
Swing control and PS control opera-
tion stopped SAS controller
EF-6 EF-6 EEPROM error (2) Display only
F0 F0 PS main circuit error PS operation stops SAS controller
Main controller → Display com-
F1-1 F1-1
munication error (1)
Display only Display
Main controller → Display com-
F1-2 F1-2
munication error (2)
SAS controller → Main control
FE-1 FE-1
communication error (1)
Display only Main controller
SAS controller → Main control
FE-2 FE-2
Material-handling lock stop
Main controller → SAS controller
FE-4 FE-4 PS normal control (restrictions on
some functions) SAS controller
Main controller → SAS controller PS normal control (restrictions on
FE-5 FE-5
communication error (2) some functions)
FF FF D15V over current Display turned OFF Main controller
G4-1 G4-1 Brake solenoid open
Traveling stop
G4-2 G4-2 Brake solenoid short-circuit Main controller
G4-3 G4-3 Brake solenoid drive circuit error Display only
H1-1 H1-1 Lift potention error (1)
H1-2 H1-2 Lift potention error (2)
H1-3 H1-3 Lift potention error (3) Lift operation stopped Main controller
H1-4 H1-4 Lift potention neutral error
H1-5 H1-5 Lift potention matching error
3-61
Display Diag
indication memory
H2-1 H2-1 Tilt potention error (1)
H2-2 H2-2 Tilt potention error (2)
H2-3 H2-3 Tilt potention error (3) Tilt operation stopped Main controller
H2-4 H2-4 Tilt potention neutral position error
H2-5 H2-5 Tilt potention matching error
H3-1 H3-1 Attachment 1 potention error (1)
Attachment 1 potention neutral Attachment 1 operation stopped Main controller
H3-4 H3-4
position error
Attachment 1 potention matching
H3-5 H3-5
error
H4-1 H4-1 Attachment 2 potention error (1)*1
Attachment 2 potention neutral Attachment 2 operation stopped Main controller
H4-4 H4-4
position error*1
Attachment 2 potention matching
H4-5 H4-5
error*1
H5-1 H5-1 Lift upward solenoid error (1) Lift operation stopped
H5-2 H5-2 Lift upward solenoid error (2) Material-handling completely stopped
H5-3 H5-3 Lift downward solenoid error (1) Lift operation stopped Main controller
H5-4 H5-4 Lift downward solenoid error (2) Material-handling completely stopped
H5-5 H5-5 Lift solenoid drive circuit error Material-handling completely stopped
H6-1 H6-1 Tilt forward tilt solenoid error (1) Tilt operation stopped
H6-2 H6-2 Tilt forward tilt solenoid error (2) Material-handling completely stopped
H6-3 H6-3 Tilt backward tilt solenoid error (1) Tilt operation stopped Main controller
H6-4 H6-4 Tilt backward tilt solenoid error (2) Material-handling completely stopped
H6-5 H6-5 Tilt solenoid drive circuit error Material-handling completely stopped
Attachment 1 upward solenoid
H7-1 H7-1 Attachment 1 operation stopped
error (1)
H7-2 H7-2 Material-handling completely stopped
error (2)
Attachment 1 downward solenoid
H7-3 H7-3 Attachment 1 operation stopped Main controller
error (1)
error (2)
Attachment 1 solenoid drive cir-
cuit error
H8-1 H8-1 Attachment 2 operation stopped
error (1)
error (2)
H8-3 H8-3 Attachment 2 operation stopped Main controller
error (1)
error (2)
Attachment 2 solenoid drive cir-
cuit error
3-62
Display Diag
indication memory
H9-1 H9-1 Unload valve solenoid open*2
Unload valve solenoid short-cir-
H9-2 H9-2
cuit*2 Material-handling completely stopped Main controller
Unload valve solenoid drive circuit
H9-3 H9-3
error*2
(*1) 4-way lever specifications only
(*2) Models 40 ~ 50 only
3-63
Toyota 7FBMF 16-50 Lösenord för maskerade funktioner
Programmering och felsökning [1] (Turtle) [2] (Clock)
1. Tryck samtidigt på “[1]” och “[2]”.
De maskerade funktionerna i displayen blir 2. Tryck på “[1]” inom 10 sekunder.
tillgängliga efter att man har knappat in ett 3. Tryck på “[2]” inom 10 sekunder.
lösenord. 4. Tryck samtidigt på “[3]” och “[2]” och håll
För en närmare beskrivning av respektive dessa nedtryckta i minst 2 sekunder.
parameter, följ sidhänvisningen till
servicemanualen. Ett kort “pip” hörs efter varje knapptryckning, och
ett längre “pip” hörs när lösenordet är accepterat. [3] (Menu)
Funktion Knappval Meny Knappval Ämne Beskrivning Knappval

1. ANALYZER (Menu): Enter. → 1. Diag Memory (Sid. 3-23) (Menu): Enter. → DIAG-1 Felkod 1 (senaste) (Menu): Gå till nästa parameter. ↓
(Sid. 3-19) (Turtle): Stega uppåt. ↑ (Turtle): Stega uppåt. ↑ I I
(Clock): Stega nedåt. ↓ (Clock): Stega nedåt. ↓ DIAG-10 Felkod 10 (äldsta lagrade)
(Menu): Tillbaka till Meny 1.

2. I/O Monitor 1 (Sid. 3-25) (Menu): Enter. → I/O 1-1 THCD (temperatur på åktransistorerna) (Menu): Gå till nästa parameter. ↓
(spänning och temperaturer) (Turtle): Stega uppåt. ↑ I/O 1-2 THCP (temperatur på hydraultransistorerna)
(Clock): Stega nedåt. ↓ I/O 1-3 TD (temperatur på drivmotor)
I/O 1-4 TP (temperatur på pumpmotor)
I/O 1-5 TBD (temperatur på åkpanelens kretskort)
I/O 1-6 TBP (temperatur på hydraulpanelens kretskort)
I/O 1-7 TEMP (temperatur på CPU kortet)
I/O 1-8 VB80 (batterispänning )
I/O 1-9 VBKS (spänning efter nyckel)
I/O 1-10 VBSOL (spänning till solenoider)
I/O 1-11 VBMB(M) (CPU inspänning efter säkring F6)
I/O 1-12 VBMB(S) (DC/SD inspänning efter säkring F6)
I/O 1-13 VBBD (åkpanelens inspänning efter säkring F1)
I/O 1-14 VBBP (hydraulpanelens inspänning efter säkring F1) (Menu): Tillbaka till Meny 2.
3. I/O Monitor 2 (Sid. 3-28) (Menu): Enter. → Se i servicemanualen Se i servicemanualen Lika som I/O Monitor 1 ovan.
(åkfunktioner) (Turtle): Stega uppåt. ↑
(Clock): Stega nedåt. ↓
(hydraulikfunktioner) (Turtle): Stega uppåt. ↑
(funktioner för styrning) (Turtle): Stega uppåt. ↑
6. Active Test (Sid. 3-35) (Menu): Enter. → ACT-1 FAN (fläkt för paneler) (Menu): Gå till nästa parameter. ↓
(test av komponenter) (Turtle): Stega uppåt. ↑ ACT-2 DSOL (p-bromsventil) (Turtle)(Clock): ON/OFF
(Clock): Stega nedåt. ↓ ACT-3 SSOL (stabiliseringscylinder)
ACT-4 KSOL (shuntventil för styrning)
ACT-5 PSOL (avlastningsventil) (Menu): Tillbaka till Meny 6.
7. END (Menu): Tillbaka till huvudmenyn.
2. TUNING (Menu): Enter. → (Menu): Enter. → (Menu): Gå till nästa parameter. ↓

(Sid. 3-37) (Turtle): Stega uppåt. ↑ (Turtle): Stega (Turtle)(Clock): Justering av värde ← →
(Clock): Stega nedåt. ↓ uppåt. ↑
(Clock): Stega
nedåt. ↓
TUNING 1: NO. 1-12 Broms, Batteriindikator, Hastighet & Hydraulmotorvarv
TUNING 2: NO. 20-29 Minispakar för lyft och sänk
TUNING 3: NO. 30-39 Minispakar för tilt
TUNING 4: NO. 40-49 Minispakar för extrafunktion 1
TUNING 5: NO. 50-59 Minispakar för extrafunktion 2
(Menu): Tillbaka till “Tuning”menyn.

(Efter sista parametern i varje grupp)
3. OPTION SET (Menu): Enter. → OPT-1 DEMO MODE (Menu): Gå till nästa parameter. ↓
(Sid. 3-46) (Turtle): Stega uppåt. ↑ OPT-2 H/M START (Sid. 3-48) (Turtle)(Clock): Ändra värde ← →
(Clock): Stega nedåt. ↓ OPT-3 P/C LOCK
OPT-4 DESTI
OPT-5 B LEVEL
OPT-6 MPH
OPT-7 C/CNT RES
OPT-8 BATTERY
OPT-9 SHOU-TOKU
OPT-10 AUTO P-OFF
OPT-11 PARKING ERR
OPT-12 TILT CONT
OPT-13 SWG W-LOCK
OPT-14 TILT F-LIM
OPT-15 B-TYPE
OPT-16 72V
OPT-17 2-WAY VALVE
OPT-18 FISHERMAN
OPT-19 används ej! (Menu): Tillbaka till huvudmenyn.
4. MATCHING (Menu): Enter. → TILTL Kalibrering av tiltvinkelsensor. Horisontella gafflar. (Menu): Gå till nästa parameter. ↓
(Kalibrering) (Turtle): Stega uppåt. ↑ TILTF Kalibrering av tiltvinkelsensor. Vertikal mast. (Clock): Kalibrering, lagrar nytt värde →
(Sid. 3-51) (Clock): Stega nedåt. ↓ LOAD Kalibrering av lastsensor. Grundlast.
TIRE Kalibrering av raka styrhjul.
SWG (används ej)
LIFT Kalibrering av lyftspak
TILT Kalibrering av tiltspak
ATT 1 Kalibrering av spak till extrafunktion 1
ATT 2 Kalibrering av spak till extrafunktion 2 (Menu): Tillbaka till huvudmenyn.
5. WHEEL DIA (Menu): Enter. → WHEEL DIA Kompensation för drivhjulsdiameter (Turtle)(Clock): Ändra värde . ← →
(Sid. 3-56) (Turtle): Stega uppåt. ↑ (Menu): Tillbaka till huvudmenyn .
6. END (Menu): Avsluta. Tillbaka till

normal visning i displayen.
(Turtle): Stega uppåt. ↑
4-1
TROUBLESHOOTING
Page Page
BEFORE MATERIAL HANDLING
TROUBLESHOOTING .................. 4-2 CONTROLLER CONNECTOR • 0
COMPONENT................................ 4-19
CONNECTOR HANDLING ................ 4-2
CONTACTOR PANEL 1
WIRE HARNESS AND CONNECTOR
INSPECTION PROCEDURE ........... 4-2
CONNECTOR • COMPONENT ....... 4-20
2
OIL CONTROL VALVE
TROUBLESHOOTING CONNECTOR • COMPONENT ....... 4-21 3
METHOD .......................................... 4-4
BRAKE CHANGE VALVE 4
EXPLANATION OF BOXES .............. 4-4 CONNECTOR • COMPONENT ....... 4-22
5
TROUBLESHOOTING TROUBLESHOOTING .................. 4-23
WITH ERROR CODES .................... 4-5
COMPOSITION LIST ....................... 4-23 6
SST SETTING METHODS.............. 4-5 7
MAIN CONTROLLER SYSTEM ...4-26
CPU BOARD CONNECTOR
(16 ~ 35 MODEL)........................... 4-10 WHEN A DIAGNOSIS ERROR 8
CODE IS DISPLAYED................... 4-26
CPU BOARD CONNECTOR 9
(40 ~ 50 MODEL)........................... 4-11 TRAVELING CONTROLLER
SYSTEM ....................................... 4-109 10
SCPU BOARD CONNECTOR
CODE IS DISPLAYED................. 4-109
SCPU BOARD CONNECTOR
(40 ~ 50 MODEL)........................... 4-13 MATERIAL HANDLING
12
DC/SD BOARD CONNECTOR CONTROLLER SYSTEM ......... 4-123 13
DC/SD BOARD CONNECTOR CODE IS DISPLAYED................. 4-123
(40 ~ 50 MODEL)........................... 4-15 SAS SYSTEM ................................ 4-136 15
MAIN CONTROLLER WHEN A DIAGNOSIS ERROR 16
CONNECTOR • COMPONENT ....... 4-16 CODE IS DISPLAYED................. 4-136
SAS CONTROLLER
17
MULTI-DISPLAY
CONNECTOR • COMPONENT
COMMUNICATION SYSTEM ...4-152 18
(16 ~ 35 MODEL)........................... 4-17
SAS CONTROLLER
WHEN A DIAGNOSIS ERROR 19
CODE IS DISPLAYED................. 4-152
CONNECTOR • COMPONENT 20
(40 ~ 50 MODEL)........................... 4-18 WHEN NO DIAGNOSIS ERROR
TRAVELING CONTROLLER
CODE IS DISPLAYED................. 4-153 21
CONNECTOR • COMPONENT ....... 4-19 22
4-2
BEFORE TROUBLESHOOTING
4
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull it at the
harness but hold the connector itself and pull it after
unlocking it.
To connect, push the connector fully until it is locked in
position.
3. Bring a tester probe into contact with a connector

terminal from the rear side of the connector (harness
side).
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe
carefully into contact with the terminal so as not to cause
deformation of the connector terminal.
5. Do not touch connector terminals directly with your
hand.
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other.
WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and

wire harness of the related circuit according to the following
procedure:
Continuity check
1. Disconnect the connectors at both ends of the
corresponding harness.
2. Measure the resistance between corresponding
terminals of the connectors at both ends.
Standard: 10 Ω or less
Note:
Measure while lightly shaking the wire harness up and
down and sideways.
[Reference] Open circuit at the wire harness occurs rarely

partway through a vehicle wiring but mostly at
connectors. Inspect especially the sensor
connectors with sufficient care.
4-3
Short circuit check

1. Disconnect the connectors at both ends of the
2. Measure the resistance between the corresponding
connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 MΩ or more. 0
Note:
Measure while lightly shaking the wire harness up and
1
2
down and sideways.
3
4
5
3. Measure the resistance between a terminal
corresponding to the connector terminal and N1. Be
sure to inspect the connectors at both ends.
6
Standard: 1 MΩ or more. 7
Note:
The wiring may short-circuit due to pinching by the body
8
or defective clamping.
9
10
Visual and contact pressure checks
• Disconnect the connectors at both ends of the 11
• Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals.
12
• Inspect that there is no loosening or damage at the locked
portion. Also, lightly pull the wire harness from the
13
14
connector to check that it does not come off.
15
• Insert a male terminal same as that of the connector to a
female terminal and check the extracting force. 16
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals.
Note:
17
Even if there is rust or foreign matter trapped at the
terminal, or the contact pressure between male and
18
female terminals is low, abnormal contact condition may
be changed to normal by disconnecting and 19
reconnecting the connector. In that case, repeat
connector connection and disconnection several times. 20
If defect is perceived even once, terminal contact may be
defective. 21
22
4-4
TROUBLESHOOTING METHOD
Disconnect the battery plug.
Connect SST1 to CN111 and
connect A and 1.
Faulty section
• Repair or replace
ANL : ACTIVE TEST ACT-1 0 (ON)
Turn the cooling fan on. • CPU board defect
1 (ON) To the next step depending on the result
CN100-9 (43) OK (48 V)

Voltage measurement
↔
• Replace the cooling fan

CN111-4 (N1)
NG (0 V)
Connector and harness NG

inspection between CN100 and • Repair or replace the faulty section
CN111.
OK
EXPLANATION OF BOXES
Potential No.
Upper row: Tester positive (+) probe
A single box indicates measurement with a tester
CN100-9 (43) or an ordinary step.
↔
Voltage measurement
CN111-4 (N1)
Lower row: Tester negative (-) probe
Connector and pin No.

Test item
ANL : ACTIVE TEST ACT-1 A double box indicates inspection by a MASK FUNCTION.
Turn the cooling fan on. Perform inspection by referring to page 3-15.
Test method
A dashed-line box indicates SST connection.

Perform inspection by referring to page 4-5.
An rounded-corner box indicates connector or wire

harness inspection. Perform inspection by
referring to page 4-2.
4-5
TROUBLESHOOTING WITH ERROR CODES

1. Error code occasionally appears and disappears because of faulty connection of connectors. Before
carrying out troubleshooting, connect battery plug and turn ON the key switch for checking the error
code. When there is not an error code, check the connection of relating connectors.
2. Once an error code comes off, the error code is recorded to the controller. Even though an error code
temporarily appears and disappears afterwards because of faulty connection of connectors, that error
code is recorded to the controller.
3. This manual describes the troubleshooting method for the procedures after the error code comes off. 0
SST SETTING METHODS 1
Use SSTs for quick, accurate troubleshooting of the 7FBMF series electrical system. 2
Incorrect connection will fail in correct check. Since boards may be damaged by incorrect connection,
careful operation is necessary.
3
SST No. Part No. Part Name Note 4
SST2 09232-13130-71
Shorting harness (for CN1, CN52, CN55, CN86,
CN90 and CN94)
5
SST5 09235-13130-71
Steering synchronizer solenoid (Knob position cor-
recting valve) (for CN146 and CN147) SST 09230-13130-71 6
Controller check harness
SST7 09237-13130-71
Steering wheel angle sensor check harness (for 7FB) 7
(for CN19)
SST8 09238-13130-71
Accelerator potentiometer check harness 8
(for CN41 and CN42)
SST19 09231-21320-71
Drive/Pump motor speed sensor check harness 9
(for CN110 and CN111)
SST20 09232-21320-71
Lift, Tilt, ATT1, ATT2 solenoid check harness 10
(for CN87 and CN88)
Potentiometer shorting harness 11
 09240-23400-71
(for CN101 and CN102)
12
Caution:
• Be sure to disconnect the battery plug before installing and removing each SST. 13
If the battery plug is kept connected, board damage may result.
• Before connecting SST, measure the voltage between P3 and N2; if there is any voltage, insert a 14
15
16
17
18
19
20
21
22
4-6
1. SST5 setting method for troubleshooting for “Error code 54-1, 54-2, 73-1”
SST5 is used for judging the quality of the swing lock solenoid and steering knob position correcting
valve drive signals.
It is used to check whether the drive signal from the SCPU board in the drive signal from the DC/SD
board is defective.
(1) Disconnect the wiring between CN146 and CN147 and set SST5.
(2) Check the ON state of each solenoid in the ANL. ACTIVE mode.
CN147 DC/SD board CN147
CN146
CN146
SST5
SCPU board
4-7
2. SST7 setting method for troubleshooting for “Steering angle sensor abnormality”
SST7 is used for judging the steering sensor signal quality.
(1) Disconnect the CN19 connector and set SST7 (The 3-pin connector must be connected before
reconnection).
(2) Check the steering angle sensor by using ANL.I/O monitor 4.
(3) Voltage check (connector B side) the steering angle sensor with a circuit tester.
CN19
Steering angle sensor check

CN19-1 (+) – CN19-3 (-)
(CN A-3 (+) – CN A-1 (-))
CN19-4 (+) – CN19-3 (-)
(CN B-8 (+) – CN A-1 (-))
CN19-5 (+) – CN19-3 (-)
(CN B-7 (+) – CN A-1 (-))
CN19-6 (+) – CN19-3 (-)
(CN B-4 (+) – CN A-1 (-))
CN A
(For voltage check)
CN B
3-pin connector
4-8
3. SST19 setting method for troubleshooting for “Error code C8-1 and E8”
(1) Disconnect the battery plug.
(2) Connect SST19 to CN110 (CN111) and connect CN2 and CN3 of SST19.
(3) Connect the battery plug.
(4) Turn the key switch to ON and check the state of LED of SST at the time of running.
CN110
SST19
CN1
Two LEDs CN3

CN2
SST19
CN3 CN111
CN1 Two LEDs
CN2
4-9
4. SST20 setting method for troubleshooting for “Error code H5-1, H5-3, H6-1, H6-3, H7-1, H7-3, H8-1,
H8-3”
(1) Disconnect the battery plug.
(2) CN87 and CN88 are replaced and connected by SST20.
(3) Connect the battery plug.
(4) Turn the key switch to ON, and carry out material handling operation.
.
16 ~ 35 model
CN87
SST20 CN88
40 ~ 50 model
CN87
SST20
CN88
4-10
CPU BOARD CONNECTOR (16 ~ 35 MODEL)
CN104 CN103 CN102 CN101
CN105
CN107
CN100
CN101 CN102 CN103 CN104
No. P J No. P J No. P J No. P J

1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B80V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B80V
3 65 LSB 3  AOPT 3 147 CANGND 3 3 SOLL+
4 66 LSPB 4 56 POTTA 4 43 VBKY 4 4 SOLLU
5 67 LSD 5 59 SPL 5 324 SSO+ 5 5 SOLLD
6   6 20 POTL1 6 325 SSO– 6 6 SOLT+
7  OPTO 7 21 POTL2 7 41 VBBT 7 7 SOLTF
8 72 LEDTK 8 22 POTT1 8  CHK15V 8 8 SOLTR
9 39 FAN– 9 23 POTT2 9  CHK5V 9 55 CPR
10 39 FAN– 10 24 POTAT11 10 16 D15V 10 55 CPR
11 63 LSAT1+ 11 25 POTAT12 11  CHK3.3V 11 9 SOLAT1+
12 309 SSTMA 12 26 POTAT21 12 14 GNDD 12 10 SOLAT1U
13 310 SSTMK 13 27 POTAT22 13 144 SMTDK 13 11 SOLAT1L
14 307 SMTSA 14 53 POTA+ 14 143 SDTMK 14 44 VBMB
15 308 SMTSK 15  AOPT+ 15 142 SDTMA 15 44 VBMB
16 51 LS– 16 57 POTTA+ 16 141 SMTDA 16 34 SOLAT2+
17 62 LSTR+ 17 58 SPL+ 17 35 SOLAT2U
18 70 SWTK 18 28 POTL+ 18 36 SOLAT2L
19 90 MH1 19 29 POTT+ 19 1 MB+
20 91 MH2 – 1 20 30 POTAT1 20 2 MB–
21 92 MH2 – 2 21 31 POTAT2 21 37 SOLD+
22 68 LSAT2+ 22 51 POT– 22 N2 N2
23 61 LSTF+ 23 N2 N2
24  LSOPT 24 39 FAN–
25   25 42 KEYSTART
26 51 LS– 26  SOLP+
27 71 SWLE 27  SOLP–
28   28 38 SOLD–
29  
30 73 LSPA
31  
32 60 LSL+
33  
34 51 POT–
CN100 CN105 CN107
No. P J No. P J No. P J

1  C5V 1 39 FAN– 1 127 FANR+
2  GNDC 2 39 FAN– 2 128 FANR–
3  FTXD 3 39 FAN–
4  FWE 4 130 FAN1
5  MD1 5 131 FAN2
6  FRES 6 132 FAN3
7  FRXD 7 133 FAN4
8  SELR 8 134 FAN5
9 135 FAN6
10  FAN7
11  CHKG
4-11
CPU BOARD CONNECTOR (40 ~ 50 MODEL)
CN104 CN103 CN102 CN101
CN105
CN107
CN100
CN101 CN102 CN103 CN104
No. P J No. P J No. P J No. P J

1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B80V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B80V
3 65 LSB 3  AOPT 3 147 CANGND 3 3 SOLL+
5 67 LSD 5 59 SPL 5 324 SSO+ 5 5 SOLLD
6   6 20 POTL1 6 325 SSO– 6 6 SOLT+
7  OPTO 7 21 POTL2 7 41 VBBT 7 7 SOLTF
8 72 LEDTK 8 22 POTT1 8  CHK15V 8 8 SOLTR
9 39 FAN– 9 23 POTT2 9  CHK5V 9 55 CPR
10 39 FAN– 10 24 POTAT11 10 16 D15V 10 55 CPR
11 63 LSAT1+ 11 25 POTAT12 11  CHK3.3V 11 9 SOLAT1+
15 308 SMTSK 15  AOPT+ 15 142 SDTMA 15 44 VBMB
17 62 LSTR+ 17 58 SPL+ 17 35 SOLAT2U
18 70 SWTK 18 28 POTL+ 18 36 SOLAT2L
19 90 MH1 19 29 POTT+ 19 1 MB+
20 91 MH2 – 1 20 30 POTAT1 20 2 MB–
21 92 MH2 – 2 21 31 POTAT2 21 37 SOLD+
22 68 LSAT2+ 22 51 POT– 22 N2 N2
23 61 LSTF+ 23 N2 N2
24  LSOPT 24 39 FAN–
25   25 42 KEYSTART
26 51 LS– 26 12 SOLP+
27 71 SWLE 27 13 SOLP–
28   28 38 SOLD–
29  
30 73 LSPA
31  
32 60 LSL+
33  
34 51 POT–
CN100 CN105 CN107

1  C5V 1 39 FAN– 1 127 FANR+
2  GNDC 2 39 FAN– 2 128 FANR–
3  FTXD 3 39 FAN–
4  FWE 4 130 FAN1
5  MD1 5 131 FAN2
6  FRES 6 132 FAN3
7  FRXD 7 133 FAN4
8  SELR 8 134 FAN5
9 135 FAN6
10  FAN7
11  CHKG
4-12
SCPU BOARD CONNECTOR (16 ~ 35 MODEL)
CN146
CN145
CN144
CN140
CN141 CN142
CN140 CN141 CN142

1  C5V 1  SSTXA 1 65 SLSB
2  GNDC 2  SXTSA 2 319 POTS
3  FTXD 3 309 SSTMA 3 317 POTH
4  VPP 4 307 SMTSA 4 324 SSN+
5  MD1 5  SS+ 5 325 SSN–
6  FRES 6 312 STS1 6  
7  FRXD 7 313 STS2 7  POTOPT–
8  SELR 8 314 STSC 8 320 SPOT–
9  SSTXK 9  POTOPT+
10  SXTSK 10 318 POTS+
11 310 SSTMK 11 316 POTH+
12 308 SMTSK 12  
13 138 SL/L–
14 137 SL/L+
15  SS–
16 315 STS–
17 311 STS+
18  
CN144 CN145 CN146

1 321 SYR+ 1 340 TMPSG 1  PS15V
2 323 SYR– 2 P24 SH+ 2 44 VBMB
3 322 SYR 3 N1 SH– 3 350 PS20V
4 351 GNDPS
5 352 SC15V
6 353 GNDSC
7 331 DRSOL+
8 332 DRSOL–
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14  
4-13
SCPU BOARD CONNECTOR (40 ~ 50 MODEL)
CN146
CN145
CN144
CN140
CN141 CN142
CN140 CN141 CN142

1  C5V 1  SSTXA 1  SLSB
2  GNDC 2  SXTSA 2 319 POTS
3  FTXD 3 309 SSTMA 3 317 POTH
4  VPP 4 307 SMTSA 4 324 SSN+
5  MD1 5  SS+ 5 325 SSN–
6  FRES 6 312 STS1 6  
7  FRXD 7 313 STS2 7  POTOPT–
8  SELR 8 314 STSC 8 320 SPOT–
9  SSTXK 9  POTOPT+
10  SSTSK 10 318 POTS+
11 310 SSTMK 11 316 POTH+
12 308 SMTSK 12  
13 138 SL/L–
14 137 SL/L+
15  SS–
16 315 STS–
17 311 STS+
18  
CN144 CN145 CN146

1 321 SYR+ 1  TMPSG 1  PS15V
2 323 SYR– 2  SH+ 2 44 VBMB
3 322 SYR 3  SH– 3 350 PS20V
4 351 GNDPS
5 352 SC15V
6 353 GNDSC
7 331 DRSOL+
8 332 DRSOL–
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14  
4-14
DC/SD BOARD CONNECTOR (16 ~ 35 MODEL)
CN147
CN148
CN147 CN148
No. P J No. P J
1   1 327 SOLS+
2 44 VBMB 2 329 SOLST+
3 350 PS20V 3 44 VBMB
4 351 GNDPS 4  CK20V
5 352 SC15V 5 330 SOLST–
6 353 GNDSC 6 328 SOLS–
7 331 DRSOL+ 7 N2 N2
8 332 DRSOL– 8  CK15V
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14  CKT-G
4-15
DC/SD BOARD CONNECTOR (40 ~ 50 MODEL)
CN147
CN148
CN147 CN148
No. P J No. P J
1   1 327 SOLS+
3 350 PS20V 3 44 VBMB
4 351 GNDPS 4  CK20V
5 352 SC15V 5 330 SOLST–
6 353 GNDSC 6 328 SOLS–
7 331 DRSOL+ 7 N2 N2
8 332 DRSOL– 8  CK15V
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14  CKT-G
4-16
MAIN CONTROLLER CONNECTOR • COMPONENT
CN104
CN103
CN102
CN101
CN126
4-17
SAS CONTROLLER CONNECTOR • COMPONENT (16 ~ 35 MODEL)
CN147
CN145
CN146
Yaw rate
sensor
CN144 CN140
CN141 CN142
CN148
CN51
CN141
CN142
CN51
CN148
4-18
SAS CONTROLLER CONNECTOR • COMPONENT (40 ~ 50 MODEL)
CN147
CN145
Yaw rate CN146

sensor
CN144 CN140
CN141 CN142
CN148
CN141
CN142
CN148
4-19
TRAVELING CONTROLLER CONNECTOR • COMPONENT
P3
P7
P8
CN110
P9
N1
MATERIAL HANDLING CONTROLLER CONNECTOR • COMPONENT
P3
P14
P15
CN111
P16
N2
4-20
CONTACTOR PANEL CONNECTOR • COMPONENT
P1
F1
P3
CN134
CN135
CN136
4-22
BRAKE CHANGE VALVE CONNECTOR • COMPONENT
Brake solenoid
CN82
4-23
TROUBLESHOOTING
COMPOSITION LIST
WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
Displayed code Diag memory code Defect mode Page
30-1 30-1 Traveling controller low voltage 4-109
30-3 30-3 Material handling controller low voltage 4-123
31-1 31-1 Traveling controller starting voltage drops 4-110
31-3 31-3 Material handling controller starting voltage drops 4-124
32-1 32-1 Traveling controller EEP-ROM abnormality 4-111
32-3 32-3 Material handling controller EEP-ROM abnormality 4-125
33-1 33-1 CPU → Traveling controller communication abnormality 4-112
CPU → Material handling controller communication
33-3 33-3 4-126
abnormality
51-1 51-1 Drive motor speed sensor abnormality 4-136
52-1, 2, 3 52-1, 2, 3 Yaw rate sensor abnormality 4-137
54-1, 2 54-1, 2 Swing lock solenoid abnormality 4-138
61-1, 2 61-1, 2 Load sensor abnormality 4-26
62-1, 2 62-1, 2 Tilt angle sensor abnormality 4-28
66-1 66-1 Tilt matching value abnormality 4-30
67-1 67-1 Lifting height switch abnormality 4-31
71-1, 2 71-1, 2 Tire angle sensor abnormality 4-140
72-1, 2, 3, 4 72-1, 2, 3, 4 Steering angle sensor abnormality 4-142
73-1, 2 73-1, 2 Steering knob position correcting solenoid abnormality 4-145
74-1 74-1 Tire angle matching value abnormality 4-147
DCR/PCR A0-1, 2 Main drive circuit overheat main pump circuit overheat
•
4-113
A0-4 A0-4 Controller cooling fan abnormality 4-33

A0-5 A0-5 Main controller cooling fan abnormality 4-35
A1-1 A1-1 Main controller high voltage 4-36
A1-2 A1-2 Traveling controller high voltage 4-114
A1-4 A1-4 Material handling controller high voltage 4-127
C/R A2-1 CPU board overheat 4-37
DCR A2-2 Traveling controller board overheat 4-115
PCR A2-3 Material handling controller board overheat 4-128
A4 A4 Acceleration switch abnormality 4-38

4-24

AA-1 AA-1 CPU board thermo-sensor abnormality 4-39
AA-2 AA-2 Traveling controller thermo-sensor abnormality 4-116
AA-4 AA-4 Material handling controller thermo-sensor abnormality 4-129
AC AC Semi-conductor switch abnormality 4-40
AD-1 AD-1 Traveling controller → CPU communication abnormality 4-42
AD-2 AD-2 Traveling controller → CPU communication abnormality 4-43
Material handling controller → CPU communication
AD-5 AD-5 4-44
abnormality
Material handling controller → CPU communication
AD-6 AD-6 4-45
abnormality
AF-1, 2, 3, 4 AF-1, 2, 3, 4 CPU board abnormality 4-46
AF-5, 6, 7, 8 AF-5, 6, 7, 8 SCPU board abnormality 4-148
C1-1 C1-1 Traveling controller current sensor offset abnormality 4-117
C1-2 C1-2 Traveling controller over current abnormality 4-118
DM C2-1 Drive motor overheat 4-119
C2-2 C2-2 Drive motor thermo-sensor abnormality 4-120

Traveling controller main circuit thermo-sensor abnor-
C3-1 C3-1 4-121
mality
C4-1, 2, 3, 4 C4-1, 2, 3, 4 Accelerator potentiometer abnormality 4-47
C7 C7 Direction switch abnormality 4-49
C8-1 C8-1 Drive motor speed sensor abnormality 4-122
CB-1 CB-1 MB contactor abnormality 4-50
CB-2 CB-2 MB contactor fusion 4-52
Material handling controller current sensor offset abnor-
E1-1 E1-1 4-130
mality
E1-2 E1-2 Material handling controller over current abnormality 4-131
PM E2-1 Pump motor overheat 4-132
E2-2 E2-2 Pump motor thermo-sensor abnormality 4-133

Material handling controller main circuit thermo-sensor
E3 E3 4-134
abnormality
E8 E8 Pump motor speed sensor abnormality 4-135
EE-1, 2, 3 EE-1, 2, 3 Abnormal communication from multi-display 4-53
EF-1, 2, 4 EF-1, 2, 4 Main controller EEP-ROM abnormality 4-54
EF-3 EF-3 Main controller CPU abnormality 4-54
EF-5, 6 EF-5, 6 EEP-ROM abnormality 4-149
F0 F0 PS main circuit abnormality 4-151
Main controller → Multi display communication abnor-
F1-1, 2 F1-1, 2 4-152
mality
E0 = avbrott i pumpmotorkretsen (kablar, anslutningar)
4-25

SAS controller → Main controller communication
FE-1, 2 FE-1, 2 4-55
abnormality
Main controller → SAS controller communication
FE-4, 5 FE-4, 5 4-150
abnormality
FF FF D15 over current 4-56
G4-1, 2, 3 G4-1, 2, 3 Brake solenoid abnormality 4-57
H1-1, 2 H1-1, 2 Lift lever potentiometer abnormality 4-59
H1-3 H1-3 Lift lever potentiometer abnormality 4-64
H2-1, 2 H2-1, 2 Tilt lever potentiometer abnormality 4-68
H2-3 H2-3 Tilt lever potentiometer abnormality 4-73
H3-1, 2 H3-1, 2 Attachment1 lever potentiometer abnormality 4-77
H3-3 H3-3 Attachment1 lever potentiometer abnormality 4-82
H4-1, 2 H4-1, 2 Attachment2 lever potentiometer abnormality 4-86
H5-1, 2, 3, 4, 5 H5-1, 2, 3, 4, 5 Lift solenoid abnormality 4-95
H6-1, 2, 3, 4, 5 H6-1, 2, 3, 4, 5 Tilt solenoid abnormality 4-98
H7-1, 2, 3, 4, 5 H7-1, 2, 3, 4, 5 Attachment1 solenoid abnormality 4-101
H8-1, 2, 3, 4, 5 H8-1, 2, 3, 4, 5 Attachment2 solenoid abnormality 4-104
H9-1, 2, 3 H9-1, 2, 3 Unload valve solenoid abnormality (*) 4-107
(*) : 40 ~ 50 model only
WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED Page

Multi-display is not displayed. 4-153
Vehicle does not move. 4-154
Only a run is impossible. 4-155
Only material handling operation cannot be performed. 4-156
PS motor does not rotate ( 16 ~ 35 model ). 4-157
4-26
MAIN CONTROLLER SYSTEM

61-1, 2 Load sensor abnormality
Related portion
CN90 CN91
CN102-17 (58, SPL+)
4 3
CPU CN102-5 (59, SPL) Load

board 3 2 sensor
CN102-22 (51, POT–)

J2 8 1
Condition for error detection

Output if the load sensor output voltage is outside the standard range.
61-1 Load sensor open-circuit defect.
61-2 Load sensor short-circuit defect.
• 61-1
Disconnect battery plug.
Disconnect CN90. 61-2 error is indicated.
Connect SST2 between CN90-3 and CN90-4 • Load sensor defect
(Main harness side). • Sub-harness defect
Connect battery plug and turn the key switch to
ON.
61-2 error is not indicated.

Disconnect CN102.
No continuity
(SST2 is connection state.) • Main harness defect
CN102-17 (58)
↔
Continuity check
CN102-5 (59)
Continuity
CN102-5 (59) No continuity

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

4-27
• 61-2
Disconnect battery plug, disconnect CN90, Change to 61-1 error.

connect battery plug, and turn the key switch to
ON.
61-2 error remains.

Disconnect CN102
Connect SST2 between CN90-3 and CN90-8
Disconnect CN102
(Main harness side).
CN102-17 (58)
CN102-5 (59)
↔
Continuity check
↔
Continuity check
CN102-5 (59)
CN102-22 (51)
Continuity No continuity
Continuity No continuity
• Main harness • CPU board defect

• Load sensor defect • Main harness defect
defect
• Sub-harness defect
4-28
62-1, 2 Tilt angle sensor abnormality
Related portion
CN86
CN102-16 (57, POTT+)
1
CPU CN102-4 (56, POTT) Tilt angle

board 2 sensor
CN102-22 (51, POT–)

J2 3

Output if the tilt angle sensor output voltage is outside the standard range.
62-1 Tilt angle sensor open-circuit defect.
62-2 Tilt angle sensor short-circuit defect.
• 62-1
Disconnect CN86.
62-2 error is indicated.
Connect SST2 between CN86-1 and CN86-2
• Tilt angle sensor defect
(Main harness side).
ON.

Disconnect CN102 No continuity
(SST2 is connection state.) • Main harness defect
CN102-16 (57)
↔
Continuity check
CN102-4 (56)
Continuity
CN102-4 (56) No continuity

↔
Continuity check • CPU board defect

CN102-22 (51)
Continuity

4-29
• 62-2
Disconnect battery plug, disconnect CN86, Change to 62-1 error.

ON.
62-2 error remains.

Disconnect CN102.
Disconnect battery plug. Connect SST2 between CN86-2 and CN86-3
Disconnect CN102. (Main harness side).
CN102-16 (57) CN102-4 (56)
↔
↔
Continuity check Continuity check
CN102-4 (56) CN102-22 (51)
Continuity No continuity Continuity No continuity
• Main harness defect • CPU board defect • Tilt angle sensor defect • Main harness defect
4-30
66-1 Tilt matching value abnormality
Related portion
CPU
board

Output if any of the tilt neutral position angle, forward tilt angle or pressure sensor
matching values is outside the standard range.
• To correct, replace the CPU board.

4-31
67-1 Lifting height switch abnormality
Related portion
CN90
CN101-21 (92, MH2)
N.C. 5
CN92 Lifting height switch
CN101-20 (91, MH2-1)
CPU 1 3
board
CN101-19 (90, MH1)
6 2
CN101-16 (51, LS–)

J1 2 1

Output if the lifting height switch line from the CPU board to the lifting height switch is
open or shorted.
67-1 Lifting height switch abnormality.
ANL. : I/O MONITOR 3-11 MH: 000 What is the mast lifting height when an
Check the lifting height switch input value. error is detected?
Other than MH: 000 Less than From H4500 or
H2000 H2000 to more
Disconnect battery plug and disconnect CN90.

A B C
ANL. : I/O MONITOR 3-11 Disconnect battery plug and disconnect

Other than MH: 000
Check the lifting height switch input value. CN101, and check the continuity.
(with battery plug connected) CN101-21 (92) ~ CN101-16 (51)
CN101-20 (91) ~ CN101-16 (51)
MH: 000
CN101-19 (90) ~ CN101-16 (51)
CN101-21 (92) ~ CN101-20 (91)
CN101-20 (91) ~ CN101-19 (90)
• Sub-harness defect CN101-19 (90) ~ CN101-21 (92)
• Lifting height switch defect Continuity No
• Main harness defect • CPU board defect

4-32
C B A
Disconnect battery plug and CN90, and check

continuity.
CN90-6 (90) ~ CN90-2 (51) OK
[OK] Continuity, [NG] No continuity
CN90-1 (91) ~ CN90-2 (51)
[OK] No continuity, [NG] Continuity
CN90-5 (92) ~ CN90-2 (51)
NG
• Lifting height switch defect
Disconnect battery plug and CN90, and check Disconnect battery plug, disconnect CN101 and
continuity. CN103, and check the continuity.
CN90-6 (90) ~ CN90-2 (51) OK • Connect SST2 between CN90-6 (90) and
[OK] No continuity, [NG] Continuity CN90-2 (51), and check the harness continuity.
CN90-1 (91) ~ CN90-2 (51) CN101-19 (90)
↔
[OK] Continuity, [NG] No continuity Continuity check
CN90-5 (92) ~ CN90-2 (51) CN101-16 (51)
[OK] No continuity, [NG] Continuity • Connect SST2 between CN90-1 (91) and
NG CN90-2 (51), and check the harness continuity.
CN101-20 (91)
• Sub-harness defect ↔ Continuity check
• Lifting height switch defect CN101-16 (51)
• Connect SST2 between CN90-5 (92) and
Disconnect battery plug and CN90, and check CN90-2 (51), and check the harness continuity.
continuity. CN101-21 (92)
↔
CN90-6 (90) ~ CN90-2 (51) OK Continuity check

[OK] No continuity, [NG] Continuity CN101-16 (51)
CN90-1 (91) ~ CN90-2 (51) • Connect SST2 between CN90-7 (16) and
[OK] No continuity, [NG] Continuity CN90-2 (51), and check the harness continuity.
CN90-5 (92) ~ CN90-2 (51) CN103-10 (16)
↔
[OK] Continuity, [NG] No continuity Continuity check

NG CN101-16 (51)
Continuity No
• Lifting height switch defect
• CPU board defect • Main harness defect

4-33
A0-4 Controller cooling fan abnormality
Related portion
CN113
F6 J51
1
MB Controller
cooling fan
2
CN114
1
Controller
cooling fan
2
CN115
CPU board CN104-14 (44, VBMB)
1
Cooling
CN104-24 (39, FAN–) fan
2
J31
CN101-9 (39, FAN–)
CN105-7 (133, FAN4)
CN105-4 (130, FAN1)

R V
Resistance Resistance
B B
CN105-8 (134, FAN5)
CN105-5 (131, FAN2)

G BR
B B
CN105-9 (135, FAN6)
CN105-6 (132, FAN3)

Y GR
CN105-3 (39, FAN–)

B B
CN105-2 (39, FAN–)
Main controller inside

4-34

Outputs when the cooling fan line from the CPU board to the cooling fan is open or short.
A0-4 Controller cooling fan abnormality.
Disconnect battery plug, disconnect CN113,

CN114, and CN115. Short-circuit (0 Ω)
CN113-1 (44) ~ CN113-2 (39) • Cooling fan defect
CN114-1 (44) ~ CN114-2 (39)
CN115-1 (44) ~ CN115-2 (39)
The tester's (-) is connected to 1pin and (+) is
connected to 2 pin.
Other than short-circuit (0 Ω)
Disconnect CN101 and CN104.

CN104-14 (44) ~ CN113-1 (44)
CN104-14 (44) ~ CN114-1 (44)
CN104-14 (44) ~ CN115-1 (44) No continuity (∞Ω)
CN104-24 (39) ~ CN113-2 (39)
CN104-24 (39) ~ CN114-2 (39)
CN104-24 (39) ~ CN115-2 (39)
CN104-24 (39) ~ CN101-9 (39)
Continuity (0 Ω)
CN104-14 (44) ~ CN104-24 (39) Continuity (0 Ω)

CN104-14 (44) ~ CN101-9 (39)
No continuity (∞Ω)
Open the main controller cover and disconnect

CN105.
(The tester check of the harness side of CN105.)
330 ± 30 Ω (at 25
CN105-2 (39) ~ CN105-3 (39) • CPU board defect or cooling fan defect
CN105-2 (39) ~ CN105-4 (130) (Open two or more pieces.)
CN105-2 (39) ~ CN105-5 (131)
CN105-2 (39) ~ CN105-6 (132)
CN105-2 (39) ~ CN105-7 (133)
CN105-2 (39) ~ CN105-8 (134)
CN105-2 (39) ~ CN105-9 (135)
Other than 330 ± 30 Ω (at 25 °C)
Check the fan resistance of the circuit used as 330 ± 30 Ω (at 25 °C)
NG. • Internal harness defect
Other than 330 ± 30 Ω (at 25 °C)
• Fan resistance defect

4-35
A0-5 Main controller cooling fan abnormality
Related portion
CN107-1 (127, FANR+)

CPU CPU
board cooling
CN107-2 (128, FANR–)
fan

Output when the cooling fan line of the CPU board to the main controller cooling fan
disconnects or short-circuit, or when the main controller overheats.
A0-5 CPU cooling fan defect.
ACTIVE TEST : ACT-1 FAN Fan rotates.

The cooling fan is set to ON by the active test. • It is left for a while in overheat state.
Fan stops.
Disconnect battery plug, and disconnect CN107.

Connect battery plug, and turn the key switch to
ON.
ACTIVE TEST : ACT-1 FAN

The cooling fan is set to ON by the active test.
CN107-1 Other than 20 ± 5 V

↔
Voltage measurement • CPU board defect

CN107-2
20 ± 5 V
• Cooling fan defect

4-36
A1-1 Main controller high voltage
Related portion
P2
CN104-14, 15 (44, VBMB)
CPU
board

Output when VBMB line overvoltage is detected.
Turn the key switch to OFF and then ON

again.
Less than
Yes ANL : I/O MONITOR 1 I/O1-11 110 V
Is A1-1 error displayed?
VBMB: Voltage value check. • CPU board
No defect
110 V or more
110 V or
more
Battery voltage check. • Replace battery
80 V spec. : approx. 80 V

NG (∞ Ω)
F6 fuse inspection. • Replace F6 fuse
OK (0 Ω)
Was the battery plug disconnected during Yes

• Do not disconnect battery plug during
traveling?
traveling except in an emergency.
No
• Check battery plug.

4-37
A2-1 CPU board overheat
Related portion
CPU board
Thermo-sensor
TH101

Output when the voltage detected by the thermo-sensor on the CPU board exceeds the
specified level.
If A0-4, 5 occur at the same time, perform troubleshooting for A0-4, 5 first.
ANL : I/O MONITOR 1 I/O1-7 80 °C or more

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

4-38
A4 Acceleration switch abnormality
Related portion
Accelerator
potentiometer
CN26
CN102-1 (64, SWAC) CN26-2
CPU
board CN102-22 (51, PTO-) CN26-1
J2

Output when the accelerator ON signal is detected upon battery plug connection.
Was the accelerator pedal operated upon battery Yes

plug connection? • Normal
No
Disconnect CN26.
Reconnect battery plug.
No
Is A4 error displayed? • Adjust acceleration switch
Yes

CN102-1 (64) Continuity (Less than 20 Ω)
• Harness defect
↔
Continuity check
CN102-22 (51)
No continuity (∞ Ω)

4-39
AA-1 CPU board thermo-sensor abnormality
Related portion
CPU board
Thermo-sensor
TH101

Output when CPU board thermo-sensor abnormality is detected.

4-40
AC Semi-conductor switch abnormality
Related portion
CN126
F1 CN104-9 (55, CPR)
CPR
P1 P2
P3
F7 CN104-1, 2 (18, B80V)
CN104-25 CPU
Traveling CN110-7 (42, KEYSTART) board
controller
Material
handling
controller CN111-7

Outputs when over current flows on the semi-conductor switch in CPU.
If CB-1 occurs at the same time, perform troubleshooting for CB-1 first.
Disconnect CN126, connect battery plug and turn AC error is not indicated.
the key switch to ON. A
AC error is indicated.
AC error is not indicated. Disconnect CN110, and resistance

Disconnect CN110, connect battery plug and turn measurement between 7 pins by the side
the key switch to ON. of harness, and N1.
AC error is indicated. 7 pin [Tester probe -]
↔
Resistance measurement
N1 [Tester probe +]
Disconnect CN111, connect battery plug and turn Approx. 20 Ω Approx. 20 Ω
the key switch to ON. or less or more
AC error is AC error is not
indicated. indicated. • Harness check • Traveling
controller defect

• Harness defect
Disconnect CN111, and resistance
measurement between 7 pins by the side of
harness, and N1.
7 pin [Tester probe -]
↔
N1 [Tester probe +]
Approx. 20 Ω Approx. 20 Ω
or less or more
• Harness check • Material handling

controller defect
4-41
NG (Other than OK)

CPR resistance check • CPR defect
OK (Approx. 20 Ω)
Resistance measurement between P2 and N1. It short-circuits for a moment

P2 [Tester probe -] and resistance rises gradually.
↔
N1 [Tester probe +]
Short-circuit
Disconnect P3 and N1 cable or copper bar from

the traveling controller. Resistance measurement
between P3 of controller side and N1. Short-circuit
• Traveling controller defect
P3 [Tester probe -]
↔
N1 [Tester probe +]
Open-circuit
Disconnect P3 and N1 cable or copper bar from

the traveling controller. Resistance measurement
between P3 of controller side and N1. Short-circuit
• Material handling controller defect
P3 [Tester probe -]
↔
N1 [Tester probe +]
Open-circuit
• P3 or N1 cable check
4-42
AD-1 Traveling controller → CPU communication abnormality
Related portion
CN103-1 (145, CANH) CN110-3 (145, CANH)

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

Outputs when CPU board cannot receive the communication data from traveling
controller within fixed time.
Yes
Is AD-2 error displayed? • See AD-2 error.
No
Was traveling controller exchanged immediate- Yes

ly before? • The plug check of CN103, CN104, CN110 and
CN112 connector is performed, the key switch
No is set to OFF and ON, and it checks that an er-
ror is not displayed.
ANL. : I/O MONITOR 1 Indicate data
• Traveling controller resets on the way.
I/O1-1, 3, 5, 13
(Traveling controller is the defect possibility.)
The data check from the traveling controller.
• Harness check (Especially the line NO. 42)
Blank display • The plug check of CN103, CN104, CN110 and
CN112 connector
CN110-7 (42) Less than 20 V Disconnect CN110 and check the voltage.
↔
Voltage check
CN110-7 (42)
N1
↔
20 V or more Voltage check

N1
Less than 20 V 20 V or more
and check the resistance.
CN112-1
CN104-25 (42)
↔
↔
CN112-2 Voltage check

120 ± 10 Ω Other than 120 ± 10 Ω N1
20 V or more Less than 20 V
• Resistance defect
Check the continuity of communication line • Harness defect • CPU board defect
harness No continuity (∞ Ω)
CN103-1 (145) ~ CN110-3 (145) • Harness defect
CN103-1 (145) ~ CN112-1 (145)
Continuity (0 Ω)
CN103-2 (146) ~ CN110-4 (146)
CN103-2 (146) ~ CN112-2 (146) (CPU board is the defect possibility.)
CN103-3 (147) ~ CN110-6 (147)
4-43
AD-2 Traveling controller → CPU communication abnormality
Related portion
CN103-1 (145, CANH) CN110-3 (145, CANH)

CN103-2 (146, CANL) CN110-4 (146, CANL)
Traveling
CPU board
controller
CN104-25 (42, KEYSTART) CN110-7 (42, KEYSTART)
CN112
1
R
2
3

Outputs when CPU board cannot receive the ID code from the traveling controller with
the key switch ON.
Yes
Was traveling controller exchanged • The plug check of CN103, CN104,
immediately before? CN110 and CN112 connector
No • Harness check (Especially No. 42 line.)
Is AD-2 error displayed even if it repeats No

the key switch with OFF and ON?
Yes
CN110-7 (42) Less than 20 V Disconnect CN110 and check the voltage.
Voltage check CN110-7 (42)
↔
N1 Voltage check
↔
20 V or more N1
Disconnect battery plug, disconnect
CN112, and check the resistance. • Traveling controller defect
CN112-1 CN104-25 (42)
↔
Resistance measurement Voltage check

↔
CN112-2 N1
120 ± 10 Ω Other than 120 ± 10 Ω 20 V or more Less than 20 V
• Resistance defect
• Harness defect • CPU board defect
Check the continuity of communication
line harness. No continuity (∞ Ω)
• Harness defect
CN103-1 (145) ~ CN110-3 (145)
CN103-1 (145) ~ CN112-1 (145) Continuity (0 Ω)
CN103-2 (146) ~ CN110-4 (146) • Traveling controller defect
CN103-3 (147) ~ CN110-6 (147)
4-44
AD-5 Material handling controller → CPU communication abnormality
Related portion
CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
Material
CPU board
handling
CN112
1
R
2
3

Outputs when CPU board cannot receive the communication data from material handling
controller within fixed time.
Yes
Is AD-6 error displayed? • See AD-6 error.
No
Is material handling controller exchanged im- Yes

• The plug check of CN103, CN104, CN111 and
mediately before?
CN112 connector is performed, the key switch
No is set to OFF and ON, and it checks that an er-
ror is not displayed.
ANL. : I/O MONITOR 1 Indicate data
I/O1-2, 4, 6, 14 • Material handling controller resets on the way.
The data check from the material handling con- (Material handling controller is the defect pos-
troller. sibility.)
• Harness check (Especially the line NO. 42)
Blank display
• The plug check of CN103, CN104, CN111 and
CN112 connector
CN111-7 (42) Less than 20 V
Disconnect CN111 and check the voltage.
↔
Voltage check
N1 CN111-7 (42)
↔
Voltage check
20 V or more
N1
Disconnect battery plug, disconnect CN112, Less than 20 V 20 V or more
and check the resistance.
• Material handling control-
CN112-1
ler defect
↔
CN112-2 CN104-25 (42)
↔
120 ± 10 Ω Voltage check

Other than 120 ± 10 Ω
N1
• Resistance defect 20 V or more Less than 20 V
Check the continuity of communication line
• Harness defect • CPU board defect
harness No continuity (∞ Ω)
CN103-1 (145) ~ CN111-3 (145) • Harness defect
CN103-1 (145) ~ CN112-1 (145)
Continuity (0 Ω)
CN103-2 (146) ~ CN111-4 (146) • Material handling controller defect
CN103-3 (147) ~ CN111-6 (147)
4-45
AD-6 Material handling controller → CPU communication abnormality
Related portion
CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
CPU board Material
handling
CN104-25 (42, KEYSTART) CN111-7 (42, KEYSTART)
controller
CN112 CN111-2
1 (87, CUPID1)
R
2
3 CN111-10
(87, SSP-, TP-)

Outputs when CPU board cannot receive the ID code from the material handling
controller with the key switch ON.
Yes
Is material handling controller exchanged im- • The plug check of CN103, CN104, CN111 and
mediately before? CN112 connector
No • Harness check (Especially the line NO. 42)
Is AD-6 error displayed even if it repeats the key No

switch with OFF and ON?
Yes
CN111-7 (42) Disconnect CN111 and check the voltage.

Less than 20 V
Voltage check CN111-7 (42)
↔
N1 Voltage check
20 V or more N1
and check the resistance. • Material handling control-
CN112-1 ler defect
↔
Resistance measurement CN104-25 (42)

CN112-2
↔
Voltage check
120 ± 10 Ω Other than 120 ± 10 Ω N1
• Resistance defect 20 V or more Less than 20 V
Check the continuity of communication line • Harness defect • CPU board defect
harness.
CN103-1 (145) ~ CN111-3 (145) The continuity check of the harness for ID
Continuity (0 Ω)
CN103-1 (145) ~ CN112-1 (145) CN111-2 (87)
CN103-2 (146) ~ CN111-4 (146)
↔
Continuity check
CN103-2 (146) ~ CN112-2 (146) CN111-10 (87)
CN103-3 (147) ~ CN111-6 (147) Continuity (0 Ω) No continuity
No continuity (∞ Ω) (∞ Ω)
• Harness defect
• Harness defect • Material handling controller defect
(CPU board is the defect possibility.)
4-46
AF1, 2, 3, 4 CPU board abnormality
Related portion
CPU board
CPU

Output when CPU board CPU element abnormality is detected.

4-47
C4-1, 2, 3, 4 Accelerator potentiometer abnormality
Related portion
CN26
CN102-1 (64, SWAC) CN26-2
CPU CN102-2 (52, POTA) CN26-3 Accelerator
board CN102-14 (53, POTA+) CN26-4 potentiometer
CN102-22 (51, POT-) CN26-1
J2
Conditions for error detection

C4-1 Output if the accelerator line voltage (POTA) is less than the standard when the
accelerator switch is turned to ON.
C4-2 Output if the accelerator line voltage (POTA) exceed the standard.
C4-3 Output if the accelerator line voltage (POTA) exceed the standard when the
accelerator switch is turned to OFF.
C4-4 Output if the accelerator line voltage (POTA) exceed the standard when the
accelerator switch state changes.
• C4-1
ANL : I/O MONITOR 2 I/O 2-1 0.3 V or more

Check the POTA value when the accelerator
switch SWAC is turned from 0 to 1.
Less than 0.3V
ANL : I/O MONITOR 2 I/O 2-1 The POTA value changes.

Check the POTA value as the accelerator is
depressed further.
• Potentiometer adjustment defect
The POTA value does not change.
Disconnect CN26, and short between POTA and

POTA+ with SST8.
Indication changes to Indication does not change to
C4-2. C4-2.
• Potentiometer defect CN102-2 (52)
↔
Voltage measurement
N1
4.8 V or more Less than 4.8 V

4-48
• C4-2
Yes
Does C4-2 go out after disconnecting CN26? • Accelerator potentiometer check
No
CN102-2 (52)
↔
Voltage measurement
N1
Less than 4.5 V 4.5 V or more
• C4-3
ANL : I/O MONITOR 2 I/O2-1 0 remains.

Check if the SWAC value changes from 0 to 1 as •Accelerator switch defect
the accelerator pedal is depressed.
Changes to 1.
Less than
ANL : I/O MONITOR 2 I/O2-1 2.5 V Yes
Is C4-3 error displayed? • CPU board
Check maximum POTA value when SWAC is 0. defect
No
2.5 V or more
Yes
Does C4-3 go out after disconnecting CN26? • Accelerator potentiometer check
No
CN102-2 (52)
↔
Voltage measurement
N1
· C4-4
If C4-2,3 occur at the same time, perform troubleshooting for C4-2, 3 first.
ANL : I/O MONITOR 2 I/O2-1

Check the POTA value when the SWAC display
is turned from 0 to 1 or from 1 to 0.
• CPU board defect • Potentiometer adjustment defect

4-49
C7 Direction switch abnormality
Related portion
CN9
CN101-1 (45, DSF) 5
CN101-2 (46, DSR) 4 Direction

CPU
Switch
board
CN101-16 (51, LS-) 1
J1

Output when both forward and reverse direction switches (DSF and DSR) are ON.
ANL : I/O MONITOR 2 I/O2-2 Becomes 0.

• Direction switch check
Check the direction switch ON/OFF.
DSF or DSR display will be 1.
CN101-1 (45)
CN101-2 (46)
↔
Voltage measurement
N1
OK (approx. 5 V) NG (Other than OK)
• CPU board defect • Harness short circuit

4-50
CB-1 MB contactor abnormality
Related portion
F6
P1 P2 CN104-14, 15 (44, VBMB)
F7 CN104-1, 2 (18, B80V) CPU

board
6 CN104-19 (1, MB+)
5 CN104-20 (2, MB–)
MB contactor coil CN134 CN136

Output when the voltage difference of B80V and VBMB line exceeds the setting value.
If 31-1, 3, A1-1, 2, 3, AD-2, 6, C1-2, E1-2 occur at the same time, perform troubleshooting for 31-1, 3, A1-
1, 2, 3, AD-2, 6, C1-2, E1-2 first.
No
Is there injection sound of MB contactor with the A
key switch ON?
Yes
ANL. : I/O MONITOR1 I/O1-8,11

VB80 Less than 30V ANL. : I/O MONITOR1 I/O1-8
VB80 : Battery voltage check
↔
Voltage difference check

VBMB(M) • 72 V or more • Less than 72 V
(80 V battery) (80V battery)
30 V or more
• 65 V or more • Less than 65 V
(72 V battery) (72 V battery)
F6 fuse check
OK (0 Ω) NG (∞ Ω) • Battery charge
B
• F6 fuse exchange
Voltage check
(1) P1 ~ N1 30 V or more
(2) P2 ~ N1 • MB contactor defect
The voltage difference check of (1) and (2).
Less than 30 V
Voltage check
(1) CN104-14 (44) ~ N1 30 V or more
(2) CN104-1 (8) ~ N1 • Harness check
The voltage difference check of (1) and (2).
Less than 30 V

4-51
Disconnect connector of MB contactor, and OK (9 V or more)

voltage checks between the CPU side connector • MB contactor defect
terminals.
NG (Less than 9 V)
Check the signal by connector of CPU.

CN104-19 (1) Less than 9 V
↔
Voltage measurement
CN104-20 (2)
9 V or more
• Check the harness between CN104 and MB contactor.
• 40 V or more (80 V battery)

ANL. : I/O MONITOR1 I/O1-11 • 25 V or more (72 V battery)
Check the VBMB voltage at the time of a run or • CPU board defect
lift operation.
• Less than 40 V (80 V battery)

Check the P2 voltage at the time of a run or lift
operation.
• F6 fuse check
P2
• Harness check
↔
Voltage measurement
N1
• MB contactor defect
4-52
CB-2 MB contactor fusion
Related portion
F6
P1 P2 CN104-14, 15 (44, VBMB)
CPU
board
6 CN104-19 (1, MB+)
5 CN104-20 (2, MB–)
MB contactor coil CN134 CN136

Output when the battery voltage (VBMB) line voltage does not drop after key switch is
turned to OFF.
If 30-3, 31-3, 33-3, A0-2, A1-3, A2-3, AC, AD-5, 6, E1-1, 2, E2-1 occur at the same time, perform
troubleshooting for 30-3, 31-3, 33-3, A0-2, A1-3, A2-3, AC, AD-5, 6, E1-1, 2, E2-1 first.
Yes
Is MB turned OFF when key switch is turned to P2
OFF from ON? Check voltage change when key
↔
No switch is turned to OFF.

A N1
Drop to 50 V or less No voltage change
in 5 seconds after when key switch is
Disconnect battery plug, and Inspect contactor turned to OFF.
key switch is turned
contact.
to OFF.
Normal Fusion
• CPU board defect • Material handling controller
• Replace MB contactor. abnormality
• Under Material handling
Connect battery plug, turn the key switch to ON, prohibition error generation
and check the error display. Although there was voltage change for a
moment after turning OFF the key switch,
No error Error it went up again more than 50 V.
• Troubleshooting of the corresponding
error is carried out. Except CB-2
Again, the key switch is turned to ON, and check
Is MB contactor turned OFF with the key switch
Yes the error display.
OFF?
No error CB-2 display
No
Turn the key switch to OFF, and check the volt- • Check the connector plug state.
age. A
CN104-19 (1)
↔
Voltage measurement
CN104-20 (2)
OK (0 V) NG (8 ~ 10 V)
• MB contactor defect • CPU board defect

• Harness leak
4-53
EE-1, 2, 3 Abnormal communication from multi-display
Related portion
CN1
CN103-13 (144, SMTDK) 7
CN103-14 (143, SDTMK) 4
CN103-15 (142, SDTMA) 8
CPU Display
board CN103-16 (141, SMTDA) 3
CN103-10 (16, D15V) 2

CN103-12 (14, GNDD) 1

Output when communication data abnormality is detected from display.
• EE-1
Yes
Is F1 error displayed? • See F1 error
No
Was the battery plug connected when the display Yes

• Connect the display
is removed?
No
Disconnect CN1
Does the display turn on when the key switch is No CN103-10 (16)
turned to ON?
↔
Voltage measurement
Yes CN103-12 (14)
• EE-2
• Sub-harness defect • CPU board defect

• Display defect
Error displayed when key
Disconnect battery plug, connect CN1-3 and switch is turned to ON.
CN1-8, and CN1-4 and CN1-7 using SST2 x 2. • Main harness defect
No error displayed when the key • CPU board defect
switch is turned to ON.
• Display defect
• EE-3
• Reset the tuning value.
• If EE-3 is displayed frequently, either the CPU board or the display may be defective.
4-54
EF-1, 2, 4 Main controller EEP-ROM abnormality

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

Output when CPU board CPU element abnormality is detected.

4-55
FE-1, 2 SAS controller → Main controller communication abnormality
Related portion
CN101-14 (307, SMTSA) CN141-4 (307, SMTSA)

CN101-15 (308, SMTSK) CN141-12 (308, SMTSK)
CN101-12 (309, SSTMA) CN141-3 (309, SSTMA) SCPU
CPU
CN101-13 (310, SSTMK) CN141-11 (310, SSTMK) board
board

Output when any abnormality in the communication data from the SCPU board is
detected.
Priority is given to the disposal of CB-1 if CB-1 error is carrying out simultaneous generation.
• FE-1
Indicated.
Is FE-4 or 5 error indicated? • See the explanation for FE-4, 5 error.
Not indicated.
Was the battery plug connected when the Yes

• Install SCPU board.
SCPU board is removed?
No
Not indicated
Is FE-1 error indicated • The plug check of CN101 and CN141
Indicated connector.
Voltage value of (1) and (3) CN141- 3 (309)
(1) CN101-12 (309) (2) same (4) CN141-11 (310)
↔
(2) CN101-13 (310) Voltage measurement

↔
Voltage measurement CN141-16 (315)

CN101-26 (51) Voltage value of (3) and
Voltage value of (1) and (2) different (4) same
• SCPU board defect
• CPU board defect Voltage value of (3) and (4) different
• Main harness open circuit

• FE-2
Check CN101 and CN141 for NG
• Repair the defective portion.
connection status.
OK

4-56
FF D15 over current
Related portion
CN1
CN103-10 (16, D15V) CN70-14 (16, D15V)

CPU Display
board CN103-12 (14, GNDD) CN70-30 (14, GNDD) board

Outputs when over current of D15V power supply is detected.
Disconnect CN70, connect battery plug, and turn No error

• Display defect
the key switch to ON.
FF error is indicated.
Disconnect battery plug, disconnect CN103, and

check the resistance between 10 pin and 12 pin
Approx. 1k Ω or less
of harness side. • Harness defect
10pin (Tester probe -)
↔
12 pin (Tester probe +)

Approx. 1k Ω or more

4-57
G4-1, 2, 3 Brake solenoid abnormality
Related portion
CN82
CN104-21 (37, SOLD+)
1
CPU Brake
board solenoid
CN104-28 (38, SOLD–)
2

Output if the brake solenoid line from the CPU board to the brake solenoid is open or
shorted.
G4-1 Brake solenoid open-circuit defect
G4-2 Brake solenoid load short-circuit defect
G4-3 Brake solenoid drive circuit MOS short-circuit defect
• G4-1
ACTIVE TEST : ACT-2 DSOL
G4-1 error is not indicated.
The brake solenoid is set to ON by the active test. • Connector connection check
G4-1 error is not indicated.

Disconnect CN82.

ON.
The brake solenoid is set to ON by the active test. 5 V or more • Brake solenoid defect
CN82-1 (37)
↔
Voltage measurement
CN82-2 (38)
Less than 5 V
Disconnect battery plug, disconnect CN104 and

check the continuity. Continuity
CN104-21 (37) ~ CN82-1 (37)
CN104-28 (38) ~ CN82-2 (38)
No continuity
• Harness defect
4-58
• G4-2
ACTIVE TEST : ACT-2 DSOL G4-2 error is not indicated.
• Connector connection check
The brake solenoid is set to ON by the active test.
G4-2 error is indicated.

Disconnect CN82.
ACTIVE TEST : ACT-2 DSOL G4-1 error is indicated.

• Brake solenoid defect

Disconnect CN104. Continuity
CN104-21 (37) • Harness defect
↔
Continuity check
CN104-28 (38)
No continuity
CPU board defect
• G4-3
ACTIVE TEST : ACT-2 DSOL G4-3 error is not indicated.

Disconnect CN104.
Connect battery plug and turn the key switch to 10 V or more
• Harness defect
ON and measure voltage.
CN104-21 (37) ~ CN104-23 (N2)
CN104-28 (38) ~ CN104-23 (N2)
Less than 10 V
CPU board defect

4-59
H1-1, 2 Lift lever potentiometer abnormality
Related portion
CN41 CN77
CN102-18 (28, POTL+)
3 1
CN102-6 (20, POTL1)

1 2
CPU
Lift lever
board
CN102-7 (21, POTL2)
2 3
CN101-34 (51, POT–)

10 J30 4

Output if the lift lever potentiometer voltage (POTL) is outside the standard range.
H1-1 Lift lever potentiometer (POTL) open-circuit abnormality
H1-2 Lift lever potentiometer (POTL) short-circuit abnormality
Caution:
Do not carry out material handling operation during troubleshooting. (Machine may function in a
different manner against ordinary conditions.)
• H1-1
ANL. : I/O MONITOR 3-1 L : (voltage 1) (voltage 2) (SW state)
Check the POTL voltage value.
Only voltage 1 is Only voltage 2 is Voltage 1 and voltage 2
less than 0.3 V. less than 0.3 V. are less than 0.3 V.
A B C
4-60
Disconnect battery plug, disconnect CN41, and Disconnect battery plug and connect CN41.
short between CN41-3 (28) and CN41-1 (20) H1-2 error is indicated. Replace the lift lever (CN77) and the tilt liver
(main harness side) with SST8, and connect (CN78), and connect battery plug and turn the
battery plug and turn the key switch to ON. key switch to ON.
H1-2 error is not indicated. H1-1 error H1-1 error is
disappears and displayed.
H2-1 error is
Disconnect battery plug, disconnect CN101 and indicated.
CN102. (SST8 is the connection state.) • Lift potentiometer • Sub-harness
CN102-18 (28) ~ CN102-6 (20) defect defect
CN102-6 (20) ~ CN101-34 (51)
OK NG

4-61
Disconnect battery plug, disconnect CN41, and H1-2 error is indicated. Disconnect battery plug and connect CN41.
short between CN41-3 (28) and CN41-2 (21) Replace the lift lever (CN77) and the tilt lever
battery plug and turn the key switch to ON. key swtich to ON.
H2-1 error is
CN102. • Lift potentiometer • Sub-harness
(SST8 is the connection state) defect defect
CN102-18 (28) ~ CN102-7 (21)
CN102-7 (21) ~ CN101-34 (51)
OK NG

4-62
Disconnect battery plug, disconnect CN41, and H1-2 error is indicated. Disconnect battery plug, disconnect SST8
short between CN41-3 (28) and CN41-1 (20) (CN41), and short between CN41-3 (28) and
(main harness side) with SST8, and connect CN41-2 (21) (main harness siede) with SST8,
battery plug and turn the key switch to ON. and connect battery plug and turn the key
H1-2 error is not indicated. switch to ON.
H1-2 error is indicated. H1-2 error is not

indicated.
CN102. (SST8 is the connection state.) Disconnect battery plug, disconnect CN101
and CN102. (SST8 is the connection state)
CN102-18 (28) ~ CN102-6 (20)
CN102-18 (28) ~ CN102-7 (21)
CN102-6 (20) ~ CN101-34 (51)
CN102-7 (21) ~ CN101-34 (51)
OK NG
OK NG

Disconnect battery plug and connect CN41.

Replace the lift lever (CN77) and the tilt lever
(CN78), and connect battery plug and turn the
key switch to ON.
H1-1 error disappears H1-1 error is
and H2-1 error is displayed.
indicated.
• Lift potentiometer • Sub-harness
defect defect
4-63
Caution:
• H1-2
H1-2 error disappears and
H1-1 error is indicated.
connect battery plug, and turn the key switch to Replace the lift lever (CN77) and the tilt lever
ON. (CN78), and connect battery plug and turn the
H1-2 error is displayed. key switch to ON.
H1-2 error H1-2 error is
Disconnect battery plug, disconnect CN101 and H2-2 error is
CN102. indicated.
CN102-18 (28) ~ CN102-6 (20) • Lift potentiometer • Sub-harness
[OK]No continuity, [NG]Continuity defect defect
CN102-18 (28) ~ CN102-7 (21)
[OK]No continuity, [NG]Continuity
CN101-34 (51) ~ CN41-10 (51)
[OK]Continuity, [NG]No continuity
OK NG

4-64
H1-3 Lift lever potentiometer abnormality
Related portion
CN41 CN77
CN102-18 (28, POTL+)
3 1
CN102-6 (20, POTL1)

1 2
CPU
board Lift lever
CN102-7 (21, POTL2)
2 3
CN101-34 (51, POT–)

10 J30 4

Output if the potentiometer voltage value of the lift lever potentiometer 1, 2 (POTL 1, 2) are
outside the standard range in the state of neutrality.
Caution:
ANL. : I/O MONITOR 3-1 L : (voltage1) (voltage2) (SW state)

Check the POTL voltage value [*1].
Disconnect battery plug. Replace the lift lever

(CN77) and the tilt lever (CN78), and connect
battery plug and turn the key switch to ON.
ANL. : I/O MONITOR 3-3 T : (voltage1) (voltage2) (SW state) Within the limits of [*1] ± 0.2 V
Check the tilt lever potentiometer (POTT) voltage value.
Outside of the range of [*1] ± 0.2 V
• Lift potentiometer defect

The lift lever (CN77) and the tilt lever (CN78) are
returned, and connect battery plug and turn the
key switch to ON.
A
4-65
ANL. : I/O MONITOR 3-1 L : (voltage1) (voltage2) (SW state) 0.3 V or more
Less than 0.3 V

Disconnect battery plug, and the following board
side connectors are short-circuited where the
alligator mouth clip of SST (09240-23400-71) is
connected, and connect battery plug and turn the
key switch to ON.
CN101-11 (63) ~ CN102-6 (20)
CN101-11 (63) ~ CN102-7 (21)
ANL. : I/O MONITOR 3-1 L : (voltage1) (voltage2) (SW state) 4.5 V or more
Less than 4.5 V
• Harness defect

4-66
Related portion
CN41 CN77
CN102-18 (28, POTL+)
3 1
CN102-6 (20, POTL1)

1 2
CPU
board Lift lever
CN102-7 (21, POTL2)
2 3
CN101-34 (51, POT–)

10 J30 4

Output if the lift lever voltage value is with the key switch ON.
H1-4 Lift lever neutral abnormality
Caution:
Check that the lift lever has returned to the H1-4 error disappears.
• Normal state
neutral state, and the key switch is turned to ON.
Note: The lever is not operated
H1-4 error is displayed.
with the key switch ON.
Check the reassemble state of the lift lever NG

potentiometer. • Readjustment
OK
MATCHING : LIFT Matching: OK

The POTL neutral voltage re-matching • It uses then.
Matching: NG
• Lift potentiometer defect

4-67
Related portion
• CPU board

Output if the lift lever neutral matching value is outside the standard range.
H1-5 Lift lever neutral matching value abnormality
Caution:
4-68
H2-1, 2 Tilt lever potentiometer abnormality
Related portion
CN41 CN77
CN102-19 (29, POTT+)
6 1
CN102-8 (22, POTT1)

4 2
CPU
board Tilt lever
CN102-9 (23, POTT2)
5 3
CN101-34 (51, POT–)

10 J30 4

Output if the tilt lever potentiometer voltage (POTT) is outside the standard range.
H2-1 Tilt lever potentiometer (POTT) open-circuit abnormality
H2-2 Tilt lever potentiometer (POTT) short-circuit abnormality
Caution:
• H2-1
ANL. : I/O MONITOR 3-3 T : (voltage 1) (voltage 2) (SW state)
Check the POTT voltage value.
Only voltage 1 is Only voltage 2 is Voltage 1 and voltage 2
A B C
4-69
short between CN41-6 (29) and CN41-4 (22) Replace the lift lever (CN77) and the tilt lever
H1-1 error is
CN102. (SST8 is the connection state.) • Tilt potentiometer • Sub-harness
CN102-19 (29) ~ CN102-8 (22) defect defect
CN102-8 (22) ~ CN101-34 (51)
OK NG

4-70
short between CN41-6 (29) and CN41-5 (23) H2-2 error is indicated. Replace the lift lever (CN77) and the tilt lever
H1-1 error is
indicated.
CN102. • Tilt potentiometer • Sub-harness
defect defect
(SST8 is the connection state)
CN102-19 (29) ~ CN102-9 (23)
CN102-9 (23) ~ CN101-34 (51)
OK NG

4-71
Disconnect battery plug, disconnect CN41, and Disconnect battery plug, disconnect SST8
(main harness side) with SST8, and connect CN41-5 (23) (main harness side) with SST8,
switch to ON.
H2-2 error is not indicated.
H2-2 error is indicated. H2-2 error is not
indicated.
Disconnect battery plug, disconnect CN101 and Disconnect battery plug, disconnect CN101
CN102. (SST8 is the connection state.) and CN102. (SST8 is the connection state)
CN102-19 (29) ~ CN102-8 (22) CN102-19 (29) ~ CN102-9 (23)
[OK] Continuity [NG] No continuity [OK] Continuity [NG] No continuity
CN102-8 (22) ~ CN101-34 (51) CN102-9 (23) ~ CN101-34 (51)
[OK] No continuity [NG] Continuity [OK] No continuity [NG] Continuity
OK NG
OK NG
• CPU board defect • Main harness defect • CPU board defect • Main harness defect

Replace the lift lever (CN77) and the tilt lever
(CN78), and connect battery plug and turn the
key switch to ON.
H2-1 error disappears H2-1 error is
and H1-1 error is displayed.
indicated.
• Tilt potentiometer • Sub-harness
defect defect
4-72
Caution:
• H2-2
H2-2 error disappears and Disconnect battery plug and connect CN41.
connect battery plug, and turn the key switch to Replace the lift lever (CN77) and the tilt lever
ON. (CN78), and connect battery plug and turn the
H2-2 error is displayed. key switch to ON.
Disconnect battery plug, disconnect CN101 and H1-2 error is
CN102. indicated.
• Tilt potentiometer • Sub-harness
CN102-19 (29) ~ CN102-8 (22)
defect defect
CN102-19 (29) ~ CN102-9 (23)
CN101-34 (51) ~ CN41-10 (51)
OK NG

4-73
H2-3 Tilt lever potentiometer abnormality
Related portion
CN41 CN78
CN102-19 (29, POTT+)
6 1
CN102-8 (22, POTT1)

4 2
CPU
board Tilt lever
CN102-9 (23, POTT2)
5 3
CN101-34 (51, POT–)

10 J30 4

Output if the potentiometer voltage value of the tilt lever potentiometer 1, 2 (POTT 1, 2)
are outside the standard range in the state of neutrality.
Caution:
ANL. : I/O MONITOR 3-3 T : (voltage1) (voltage2) (SW state)

Check the POTT voltage value [*1].

(CN77) and the tilt lever (CN78), and connect
ANL. : I/O MONITOR 3-1 L : (voltage1) (voltage2) (SW state) Within the limits of [*1] ± 0.2 V
Check the lift lever potentiometer (POTL) voltage value.
• Tilt potentiometer defect

The lift lever (CN77) and the tilt lever (CN78) are
returned, and connect battery plug and turn the
key switch to ON.
A
4-74
ANL. : I/O MONITOR 3-3 T : (voltage1) (voltage2) (SW state) 0.3 V or more
Less than 0.3 V

key switch to ON.
CN101-11 (63) ~ CN102-8 (22)
CN101-11 (63) ~ CN102-9 (23)
ANL. : I/O MONITOR 3-3 T : (voltage1) (voltage2) (SW state) 4.5 V or more
Less than 4.5 V
• Harness defect

4-75
Related portion
CN41 CN78
CN102-19 (29, POTT+)
6 1
CN102-8 (22, POTT1)

4 2
CPU
Tilt lever
board
CN102-9 (23, POTT2)
5 3
CN101-34 (51, POT–)

10 J30 4

Output if the tilt lever voltage value is the neutral range outside with the key switch ON.
H2-4 Tilt lever neutral abnormality
Caution:
Check that the tilt lever has returned to the H2-4 error disappears.
neutral state, and the key switch is turned to ON. • Normal state
H2-4 error is displayed. Note: The lever is not operated
with the key switch ON.
Check the reassemble state of the tilt lever NG

• Readjustment
potentiometer.
OK
MATCHING : TILT Matching: OK

• It uses then.
The POTL neutral voltage re-matching
Matching : NG
• Tilt potentiometer defect

4-76
Related portion
• CPU board

Output if the tilt lever neutral matching value is outside the standard range.
H2-5 Tilt lever neutral matching value abnormality
Caution:
4-77
H3-1, 2 Attachment 1 lever potentiometer abnormality
Related portion
CN41 CN79
CN102-20 (30, POTAT1+)
9 1
CN102-10 (24, POTAT11)

7 2 Attachment 1
CPU
board lever
CN102-11 (25, POTAT12)
8 3
CN101-34 (51, POT–)

10 J30 4

Output if the attachment 1 lever potentiometer voltage (POTAT1) is outside the standard
range.
H3-1 Attachment 1 lever potentiometer (POTAT1) open-circuit abnormality
H3-2 Attachment 1 lever potentiometer (POTAT1) short-circuit abnormality
Caution:
• H3-1
ANL. : I/O MONITOR 3-5 A1 : (voltage1) (voltage2) (SW state)
Check the POTAT1 voltage value
Only voltage1 is Only voltage2 is Voltage1 and voltage2
A B C
4-78
short between CN41-9 (30) and CN41-7 (24) Replace the lift lever (CN77) and the
(main harness side) with SST8, and connect attachment 1 lever (CN79), and connect
battery plug and turn the key switch to ON. battery plug and turn the key switch to ON.
H1-1 error is
indicated.
Disconnect battery plug, disconnect CN101 and • Attachment 1 • Sub-harness
CN102. (SST8 is the connection state) potentiometer defect defect
CN102-20 (30) ~ CN102-10 (24)
CN102-10 (24) ~ CN101-34 (51)
OK NG

4-79
short between CN41-9 (30) and CN41-8 (25) Replace the lift lever (CN77) and the
(main harness side) with SST8, and connect attachment 1 lever (CN79), and connect
battery plug and turn the key switch to ON. battery plug and turn the key switch to ON.
H1-1 error is
indicated.
• Attachment 1 • Sub-harness
CN102.
potentiometer defect defect
(SST8 is the connection state)
CN102-20 (30) ~ CN102-11 (25)
CN102-11 (25) ~ CN101-34 (51)
OK NG

4-80
Disconnect battery plug, disconnect CN41, and H3-2 error is indicated. Disconnect battery plug, disconnect SST8
(main harness side) with SST8, and connect CN41-8 (25) (main harness side) with SST8,
H3-2 error is not indicated. switch to ON.
H3-2 error is H3-2 error is not
indicated. indicated.
CN102. (SST8 is the connection state) and CN102. (SST8 is the connection state)
CN102-20 (30) ~ CN102-10 (24) CN102-20 (30) ~ CN102-11 (25)
[OK] Continuity, [NG] No continuity [OK] Continuity, [NG] No continuity
CN102-10 (24) ~ CN101-34 (51) CN102-11 (25) ~ CN101-34 (51)
[OK] No continuity, [NG] Continuity [OK] No continuity, [NG] Continuity
OK NG
OK NG


Replace the lift lever (CN77) and the
attachment 1 lever (CN79), and connect
H1-1 error is
indicated.
4-81
Caution:
• H3-2
Disconnect battery plug, disconnect CN41, and H3-2 error disappears and Disconnect battery plug and connect CN41.
connect battery plug, and turn the key switch to H3-1 error is indicated. Replace the lift lever (CN77) and the
ON. attachment 1 lever (CN79), and connect
H3-2 error is displayed. battery plug and turn the key switch to ON.
H1-2 error is
indicated.
CN102.
CN102-20 (30) ~ CN102-10 (24)
CN102-20 (30) ~ CN102-11 (25)
CN101-34 (51) ~ CN41-10 (51)
OK NG

4-82
H3-3 Attachment 1 lever potentiometer abnormality
Related portion
CN41 CN79
CN102-20 (30, POTAT1+)
9 1
CN102-10 (24, POTAT11)

7 2 Attachment
CPU
board 1 lever
CN102-11 (25, POTAT12)
8 3
CN101-34 (51, POT–)

10 J30 4

Output if the potentiometer voltage value of the attachment 1 lever potentiometer 1, 2
(POTAT 11, 12) are outside the standard range in the state of neutrality.
Caution:

Check the POTAT1 voltage value [*1].
Disconnect battery plug, replace the lift lever

(CN77) and the attachment 1 lever (CN79), and
connect battery plug and turn the key switch to
ON.
Check the lift lever potentiometer (POTAT1) voltage value.

• Attachment 1 potentiometer defect

The lift lever (CN77) and the attachment 1 lever
(CN79) are returned, and connect battery plug
and turn the key switch to ON.
A
4-83
ANL. : I/O MONITOR 3-5 A1 : (voltage1) (voltage2) (SW state) 0.3 V or more
Check the POTAT1 voltage value.
Less than 0.3 V

key switch to ON.
CN101-11 (63) ~ CN102-10 (24)
CN101-11 (63) ~ CN102-11 (25)
4.5 V or more
Check the POTAT1 voltage value.
Less than 4.5 V
• Harness defect

4-84
Related portion
CN41 CN79
CN102-20 (30, POTAT1+)
9 1
CN102-10 (24, POTAT11)

7 2
CPU Attachment
board 1 lever
CN102-11 (25, POTAT12)
8 3
CN101-34 (51, POT–)

10 J30 4

Output if the attachment 1 lever voltage value is the neutral range outside with the key
switch ON.
H3-4 Attachment 1 lever neutral abnormality
Caution:
Check that the attachment 1 lever has returned to

H3-4 error disappears.
the neutral state, and the key switch is turned to • Normal state
ON again. Note: The lever is not operated
H3-4 error is displayed. with the key switch ON.
Check the reassemble state of the attachment 1 NG

• Readjustment
lever potentiometer.
OK
MATCHING : ATT1 Matching: OK

• It uses then.
The POTATI neutral voltage re-matching
Matching: NG

4-85
Related portion
• CPU board

Output if the attachment 1 lever neutral matching value is outside the standard range.
H3-5 Attachment 1 lever potentiometer neutral matching value abnormality
Caution:
• H3-5
4-86
H4-1, 2 Attachment 2 lever potentiometer abnormality
Related portion
CN42 CN80
CN102-21 (31, POTAT2+) 3 1
CN102-12 (26, POTAT21)

1 2
CPU Attachment
board CN102-13 (27, POTAT22) 2 lever
2 3
CN41
CN101-34 (51, POT–) 10 4
J30

Output if the attachment 2 lever potentiometer voltage (POTAT2) is outside the standard
range.
H4-1 Attachment 2 lever potentiometer (POTAT2) open-circuit abnormality
H4-2 Attachment 2 lever potentiometer (POTAT2) short-circuit abnormality
Caution:
• H4-1
Only voltage1 is Only voltage2 is Voltage1 and voltage2
A B C
4-87
Disconnect battery plug, disconnect CN41, H4-2 error is indicated. Disconnect battery plug and connect CN41,
CN42, and short between CN42-3 (31) and CN42.
CN42-1 (26) (main harness side) with SST8, and Replace the lift lever (CN77) and the
connect battery plug and turn the key switch to attachment 2 lever (CN80), and connect
ON. battery plug and turn the key switch to ON.
H1-1 error is
indicated.
CN102. (SST8 is the connection state)
CN102-21 (31) ~ CN102-12 (26)
CN102-12 (26) ~ CN101-34 (51)
OK NG

4-88
Disconnect battery plug, disconnect CN41, CN42 H4-2 error is indicated. Disconnect battery plug and connect CN41,
and short between CN42-3 (31) and CN42-2 (27) CN42.
(main harness side) with SST8, and connect Replace the lift lever (CN77) and the
battery plug and turn the key switch to ON. attachment 2 lever (CN80), and connect
H4-2 error is not indicated.
H1-1 error is
CN102. • Attachment 2 • Sub-harness
(SST8 is the connection state) potentiometer defect defect
CN102-21 (31) ~ CN102-13 (27)
CN102-13 (27) ~ CN101-34 (51)
OK NG

4-89
Disconnect battery plug, disconnect CN41, H4-2 error is indicated. Disconnect battery plug, disconnect SST8
CN42, and short between CN42-3 (31) and (CN42), and short between CN42-3 (30) and
CN42-2 (26) (main harness side) with SST8, and CN42-2 (27) (main harness side) with SST8,
connect battery plug and turn the key switch to and connect battery plug and turn the key
ON. switch to ON.
H4-2 error is not indicated. H4-2 error is H4-2 error is not
indicated. indicated.
CN102. (SST8 is the connection state) and CN102. (SST8 is the connection state)
CN102-21 (31) ~ CN102-12 (26) CN102-21 (31) ~ CN102-13 (27)
[OK] Continuity, [NG] No continuity [OK] Continuity, [NG] No continuity
CN102-12 (26) ~ CN101-34 (51) CN102-13 (27) ~ CN101-34 (51)
[OK] No continuity, [NG] Continuity [OK] No continuity, [NG] Continuity
OK NG OK NG
• CPU board defect • Main harness defect • CPU board defect • Main harness defect
Disconnect battery plug and connect CN41,

CN42. Replace the lift lever (CN77) and the
attachment 2 lever (CN80), and connect
H1-1 error is
indicated.
4-90
Caution:
• H4-2
H4-2 error disappears and
Disconnect battery plug, disconnect CN41, Disconnect battery plug and connect CN41,
CN42, and connect battery plug, and turn the key CN42. Replace the lift lever (CN77) and the
switch to ON. attachment 2 lever (CN80), and connect
H4-2 error is displayed. battery plug and turn the key switch to ON.
disappears and H1-2 displayed.
error is indicated.
CN102. • Attachement 2 • Sub-harness
CN102-21 (31) ~ CN102-12 (26) potentiometer defect defect
CN102-21 (31) ~ CN102-13 (27)
CN101-34 (51) ~ CN41-10 (51)
[OK] Continuity, [NG]No continuity
OK NG

4-91
Related portion
CN42 CN80
CN102-21 (31, POTAT2+) 3 1
CN102-12 (26, POTAT21)

1 2
CPU Attachment
2 3
CN41
CN101-34 (51, POT–) 10 4
J30

Output if the potentiometer voltage value of the attachment 2 lever potentiometer 1, 2
(POTAT21, 22) are outside the standard range in the state of neutrality.
Caution:

Check the POTAT 2 voltage value [*1].

(CN77) and the attachment 2 lever (CN80), and
connect battery plug and turn the key switch to
ON.
Check the lift lever potentiometer (POTL) voltage value.

The lift lever (CN77) and the attachment 2 lever
(CN80) are returned, and connect battery plug
and turn the key switch to ON.
A
4-92
Less than 0.3 V

key switch to ON.
CN101-11 (63) ~ CN102-12 (26)
CN101-11 (63) ~ CN102-13 (27)
Less than 4.5 V
• Harness defect
4-93
Related portion
CN42 CN80
CN102-21 (31, POTAT2+) 3 1
CN102-12 (26, POTAT21)

1 2
CPU Attachment
2 3
CN41
CN101-34 (51, POT–) 10 4
J30

Output if the attachment 2 lever voltage value is the neutral range outside with the key
switch ON.
H4-4 Attachment 2 lever neutral abnormality
Caution:
Check that the attachment 2 lever has returned to H1-4 error disappears.
the neutral state, and the key switch is turned to • Normal state
ON again. Note:The lever is not operated
H4-4 error is displayed. with the key switch ON.
Check the reassemble state of the attachment 2 NG

• Readjustment
lever potentiometer.
OK
MATCHING: ATT2 Matching: OK

• It uses then.
The POTAT2 neutral voltage re-matching
Matching: NG

4-94
Related portion
• CPU board

Output if the attachment 2 lever neutral matching value is outside the standard range.
H4-5 Attachment 2 lever neutral matching value abnormality
Caution:
4-95
H5-1, 2, 3, 4, 5 Lift solenoid abnormality
Related portion
J31 CN87
CN104-3 (3, SOLL+)
4
Lift solenoid
CN104-5 (5, SOLLD) down
8
CPU
CN88
board
4
Lift
CN104-4 (4, SOLLU) 8 solenoid
up

Output if the lift solenoid line from the CPU board to the lift solenoid is open or shorted.
H5-1 Lift up side solenoid open-circuit abnormality
H5-2 Lift up side solenoid load short-circuit abnormality
H5-3 Lift down side solenoid open-circuit abnormality
H5-4 Lift down side solenoid load short-circuit abnormality
H5-5 Lift solenoid drive circuit MOS short-circuit abnormality
• H5-1
ANL. : I/O MONITOR 3-2 L (SOL) : (Solenoid current) 0.1 A or more

Check the Lift solenoid current value (Lift up operation).
Less than 0.1 A
Disconnect battery plug, and CN87 and CN88

are replaced by SST20.
Connect battery plug and turn the key switch to H5-1 error is not indicated.
ON, and lift up operation.*1 • Lift up side solenoid defect
*1:Cautions should be paid because machine functions in a
different manner against ordinary conditions.
• Harness defect
4-96
• H5-2
Connect battery plug and turn the key switch to H5-1 error is indicated.
ON, and lift up operation. • Lift up side solenoid defect

CN104-3 (3) Continuity
• Harness defect
↔
Continuity check
CN104-4 (4)
No continuity
• H5-3
ANL. : I/O MONITOR 3-2 L (SOL) : (Solenoid current) 0.1 A or more

Check the lift solenoid current value (lift down
Less than 0.1 A

• Lift down side solenoid defect
ON, and lift down operation. *1
*1: Cautions should be paid because machine functions in a
• Harness defect different manner against ordinary conditions.
4-97
• H5-4
ON, and lift down operation. • Lift down side solenoid defect

Continuity
Continuity check
↔
CN104-5 (5)
No continuity
• H5-5
ON, and lever neutral state. 10 V or more
CN104-3 (3) ~ CN104-23 (N2) • Harness defect
CN104-5 (5) ~ CN104-23 (N2)
CN104-4 (4) ~ CN104-23 (N2)
Less than 10 V

4-98
H6-1, 2, 3, 4, 5 Tilt solenoid abnormality
Related portion
J32 CN87
CN104-6 (6, SOLT+)
3 Tilt
solenoid
CN104-7 (7, SOLTF) 7 forward
CPU CN88
board
3
Tilt
CN104-8 (8, SOLTR) solenoid
7
backward

Output if the tilt solenoid line from the CPU board to the tilt solenoid is open or shorted.
H6-1 Tilt forward side solenoid open-circuit abnormality
H6-2 Tilt forward side solenoid load short-circuit abnormality
H6-3 Tilt backward side solenoid open-circuit abnormality
H6-4 Tilt backward side solenoid load short-circuit abnormality
H6-5 Tilt solenoid drive circuit MOS short-circuit abnormality
• H6-1
ANL. : I/O MONITOR 3-4 T (SOL) : (Solenoid current) 0.1 A or more

Check the tilt solenoid current value (tilt forward
operation).
Less than 0.1 A

• Tilt forward side solenoid defect
ON, and tilt forward operation. *1

• Harness defect
4-99
• H6-2
ON, and tilt forward operation. • Tilt forward side solenoid defect

• Harness defect
Continuity check
↔
CN104-7 (7)
No continuity
• H6-3
ANL. : I/O MONITOR 3-4 T (SOL) : (Solenoid current) 0.1 A or more

Check the tilt solenoid current value (tilt backward
operation).
Less than 0.1 A • CPU board defect

• Tilt backward side solenoid defect
ON, and tilt backward operation. *1
• Harness defect different manner against ordinary conditions.
4-100
• H6-4
Connect battery plug turn the key switch to ON, H6-3 error is indicated.
and tilt backward operation. • Tilt backward side solenoid defect

Continuity
↔
Continuity check
CN104-8 (8)
No continuity
• H6-5
CN104-7 (7) ~ CN104-23 (N2)
CN104-8 (8) ~ CN104-23 (N2)
Less than 10 V

4-101
H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality
Related portion
J33 CN87
CN104-11 (9, SOLAT1+)
2 Attachment
1 solenoid
CN104-12 (10, SOLAT1U) 6 down
CPU CN88
board
2
Attachment
CN104-13 (11, SOLAT1L) 6 1 solenoid
up

Output if the attachment 1 solenoid line from the CPU board to the attachment 1 solenoid is
open or shorted.
H7-1 Attachment 1 up side solenoid open-circuit abnormality
H7-2 Attachment 1 up side solenoid load short-circuit abnormality
H7-3 Attachment 1 down side solenoid open-circuit abnormality
H7-4 Attachment 1 down side solenoid load short-circuit abnormality
H7-5 Attachment 1 solenoid drive circuit MOS short-circuit abnormality
• H7-1
ANL. : I/O MONITOR 3-6 A1 (SOL) : (Solenoid current) 0.1 A or more

Check the attachment 1 solenoid current value
(Attachment 1 up operation).
Less than 0.1 A

• Attachment 1 up side solenoid defect
ON, and attachment 1 up operation. * 1

• Harness defect
4-102
• H7-2
ON, and attachment 1 up operation. • Attachment 1 up side solenoid defect

• Harness defect
↔
Continuity check
CN104-13 (11)
No continuity
• H7-3

(Attachment 1 down operation).

H7-3 error is not

Connect battery plug and turn the key switch to indicated.
• Attachment 1 down side solenoid
ON,and attachment 1 down operation. *1 defect
• Harness defect
4-103
• H7-4
ON, and attachment 1 down operation. • Attachment 1 down side solenoid
defect

• Harness defect
↔
Continuity check
CN104-12 (10)
No continuity
• H7-5
• Harness defect
CN104-11 (9) ~ CN104-23 (N2)
CN104-12 (10) ~ CN104-23 (N2)
CN104-13 (11) ~ CN104-23 (N2)
Less than 10 V

4-104
H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality
Related portion
CN87
CN104-16 (34, SOLAT2+) J34
3 Attachment
2 solenoid
CN104-17 (35, SOLAT2U) forward
7
CPU CN88
board
3
Attachment
CN104-18 (36, SOLAT2L) 2 solenoid
7
backward

Output if the attachment 2 solenoid line from the CPU board to the attachment 2 solenoid
is open or shorted.
H8-1 Attachment 2 forward side solenoid open-circuit abnormality
H8-2 Attachment 2 forward side solenoid load short-circuit abnormality
H8-3 Attachment 2 backward side solenoid open-circuit abnormality
H8-4 Attachment 2 backward side solenoid load short-circuit abnormality
H8-5 Attachment 2 solenoid drive circuit MOS short-circuit abnormality
• H8-1

(Attachment 2 forward operation).
Less than 0.1 A

• Attachment 2 forward side
ON, and attachment 2 forward operation. *1
solenoid defect

• Harness defect
4-105
• H8-2
H8-1 error is
ON, and attachment 2 forward operation. • Attachment 2 forward side solenoid defect

• Harness defect
↔
Continuity check
CN104-17 (35)
No continuity
• H8-3

(Attachment 2 backward operation).

H8-3 error is
not indicated.
• Attachment 2 backward side solenoid defect
ON, and attachment 2 backward operation. *1

• Harness defect
4-106
• H8-4
H8-3 error is
ON, and attachment 2 backward operation. • Attachment 2 backward side solenoid
defect

Continuity
↔
Continuity check
CN104-18 (36)
No continuity
• H8-5
CN104-17 (35) ~ CN104-23 (N2)
CN104-18 (36) ~ CN104-23 (N2)
Less than 10 V

4-107
H9-1, 2, 3 Unload valve solenoid abnormality
Related portion
CN89
CN104-26 (12, SOLP+)
1
CPU Unload valve
board solenoid
CN104-27 (13, SOLP–)
2

Output if the unload valve solenoid line from the CPU board to the unload valve solenoid
is open or shorted.
H9-1 Unload valve solenoid open-circuit defect
H9-2 Unload valve solenoid load short-circuit defect
H9-3 Unload valve solenoid drive circuit MOS short-circuit defect
• H9-1
ACTIVE TEST: ACT-5 PSOL H9-1 error is not indicated.

The unload valve solenoid is set to ON by the • Connector connection check
active test.

Disconnect CN104. 9.9 ± 1 Ω (at 25 °C)
CN104-26 (12) • CPU board defect
↔
CN104-27 (13)
Other than 9.9 ± 1 Ω
(at 25 °C)
Disconnect CN89.
9.9 ± 1 Ω (at 25 °C)
↔
CN89-2 (13)
(at 25 °C)
• Unload valve solenoid defect

4-108
• H9-2
ACTIVE TEST: ACT-5 PSOL H9-2 error is not indicated.

active test.

Disconnect CN89.
ACTIVE TEST: ACT-5 PSOL H9-1 error is indicated.

The unload valve solenoid is set to ON by the • Unload valve solenoid defect
active test.
H9-2 error is

↔
Continuity check
CN104-27 (13)
No continuity
• H9-3
H9-3 error is not
ACTIVE TEST: ACT-5 PSOL indicated.
active test.
Disconnect battery plug, disconnect CN104.

10 V or more
• Harness defect
ON.
CN104-26 (12) ~ CN104-23 (N2)
CN104-27 (13) ~ CN104-23 (N2)
Less than 10 V

4-109
TRAVELING CONTROLLER SYSTEM

30-1 Traveling controller low voltage
Related portion
F1
P1 P2 P3
Traveling
controller

Output when the battery voltage (P3) line of traveling controller detects low voltage.
If 31-1, CB-1 occur at the same time, perform troubleshooting for 31-1, CB-1 first.
Yes
Turn the key switch to OFF and then ON again. • Troubleshooting of 31-1 error is
Is 31-1 error displayed? performed.
No
CB-1 error is indicated.
If it runs, does an error come out? • Troubleshooting of CB-1 error is
30-1 error is performed.
No error
indicated. • P3 cable and terminal check
• F1 fuse check
Again, key switch is set to OFF and ON. Run and 32 V or more
check the VBBD voltage when an error occurs.
Less than 32 V

Again, key switch is set to OFF and ON. Run and Less than 32 V
• Battery plug check
check the VB80 voltage when an error occurs.
• Battery charge
32 V or more
check the traveling controller input voltage P3-N1 • Traveling controller defect
when on error occurs.
Less than 32 V
check the battery voltage P2-N1 when an error • P3 cable and terminal check
occurs. • F1 fuse check
Less than 32 V
4-110
31-1 Traveling controller starting voltage drops
Related portion
F1
P1 P2 P3 Traveling
controller
CPR
CN104-9 (55, CPR)
F7 CN136 CPU
CN104-1 (18, B80V) board
4
CN104-2
(18, B80V)

Output when it is detected that P3 voltage of traveling controller does not exceed the
setting value with the key switch ON.
No
Turn the key switch to OFF and then ON again. • Battery plug check
Is 31-1 error displayed? • Traveling controller cable and terminal
Yes check
• CPR check
ANL. : I/O MONITOR 1 I/O1-13 48 V or more • Harness check
VBBD : Traveling controller DC_BUS voltage • Traveling controller defect
check
Less than 48 V
P3 48 V or more
↔
Voltage measurement
N1
Less than 48
ANL. : I/O MONITOR 1 I/O1-9 48 V or more

VBKS : Key start voltage check CPR resistance value check
Less than 48 Approx. 20 Ω Other than
approx. 20 Ω
• F1 fuse check • CPR defect

B80V : Battery voltage check • CPU board defect
Less than 48
P1 48 V or more
• F7 fuse check
↔
Voltage measurement
N1
Less than 48 V
• Battery charge
4-111
32-1 Traveling controller EEP-ROM abnormality
Related portion
Traveling
controller

Internal data is abnormal at the time of traveling controller starting.
The EEP-ROM element on the CPU board in traveling controller is damaged.
Even if it repeats the key switch with OFF and No Was traveling controller exchanged
ON, does 32-1 error occur? immediately before?
Yes No Yes
• Traveling • Normal
controller
• Traveling controller defect connector check
(ID signal)
4-112
33-1 CPU → Traveling controller communication abnormality
Related portion
CN103-1 (145, CANH) CN110-3 (145, CANH)

CN103-2 (146, CANL) CN110-4 (146, CANL)
CPU board Traveling
CN112
1
R
2
3

Output when traveling controller cannot receive the communication data from the CPU board
within fixed time.
Does AD-1 error display or diagnosis memory Yes

• Troubleshooting of AD-1 error is performed.
memorize?
No
Was traveling controller exchanged immediately Yes

• The plug check of CN103, CN104, CN110
before?
and CN112 connectors is performed, the
No key switch is set to OFF and ON, and it
checks that an error is not displayed.
Do you switch OFF and turn ON the key switch No error

• CN103, CN104, CN110, CN112 connector
and generate an error?
check
33-1 error is indicated. AD-1 or AD-2 is indicated. • Harness check
(AD-1 and AD-2 are not • Troubleshooting of AD-1 or AD-2 error is
indicated.) performed.
• Harness check
(There is the possibility that CPU is defect.)
4-113
A0-1, 2 Main drive circuit overheat•main pump circuit overheat
Related portion
CN113
CN104-14, 15 (44, VBMB) 1
CN104-24 (39, FAN–) 2 FAN
CN114
CPU Traveling 1
board controller 2 FAN
Material handling CN115

controller 1
2 FAN

Output when the temperature detected by the traveling/material handling main circuit thermo-
sensor exceeds the specified level.
If A0-4 occurs at the same time, perform troubleshooting for A0-4 first.
(Fan arrangement)
No abnormality The controller cover was opened and it saw from
Allow the vehicle to stand for a while (about 15 • Normal the front of vehicle
min.) and operate. Material
Upper Traveling
Immediate indication of overheat symbol handling
controller
controller
ANL : ACTIVE TEST ACT-1

Turn all cooling fans ON and check that it is Fan
Not running
running. ANL : ACTIVE TEST ACT-1
Running FAN : ON/OFF (Fan voltage)
A0-2
The voltage check when the Fan is ON.
A0-1
ANL. : I/O MONITOR 1 I/O1-1
THCD : Traveling controller thermo-sensor CN113 (4) (5)-1
reading while traveling.
↔
Voltage measurement
The temperature The temperature CN113 (4) (5)-2
does not change. changes. 20 V or more Less than 20 V
• Traveling con- • Is the exhaust port cov-

troller defect ered with paper? • Fan check • Harness defect between
• Is it overloaded? • Connector CN104 and CN113 (4) (5)
disconnection
ANL. : I/O MONITOR 1 I/O1-2 CN105-4 (5)

THCP : Material handling controller thermo-
↔
Voltage measurement
sensor reading while material handling N1
The temperature The temperature Either is more All are less than
does not change. changes. than 5 V. 5 V.
• Material han- • Is the exhaust port cov- • CPU board defect • Resistance check in the
dling controller ered with paper? main controller
defect • Is it overloaded?
4-114
A1-2 Traveling controller
Related portion
F1
P3
Traveling
controller

Output when the battery voltage line of the traveling controller overvoltage is detected.
Turn the key switch to OFF and then ON again.
Less than
Yes ANL: I/O MONITOR 1 I/O1-13 110 V
Is A1-2 error displayed? • Traveling
VBBD: Traveling controller
No controller defect.
DC_BUS voltage value
110 V or more
110 V or
more
Battery voltage check. • Replace battery.
NG (∞ Ω)
F1 fuse inspection • Replace F1 fuse.
OK (0 Ω)
Yes
Was the battery plug disconnected during • Do not disconnect battery plug during
traveling? traveling except in an emergency.
No

4-115
A2-2 Traveling controller board overheat
Related portion
PCB Thermo-sensor

Output when the voltage detected by the thermo-sensor in the controller exceeds the
specified level.

TBD: Traveling controller board temperature • Allow vehicle to stand for a while.
check. (approx. 30 min.)
Less than 100 °C
Has the vehicle been subjected to continuous Yes

• Stop vehicle and perform check test with
overloaded operation?
standard load after 30 minutes.
No
• Traveling controller
4-116
AA-2 Traveling controller thermo-sensor abnormality
Related portion
PCB Thermo-sensor

Output when the thermo-sensor in the controller abnormality is detected.
If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
• To correct, replace the traveling controller.
4-117
C1-1 Traveling controller current sensor offset abnormality
Related portion
Current sensor

Output when the current sensor offset compensation is detected at the time of the
traveling controller starting.

4-118
C1-2 Traveling controller over current abnormality
Related portion
P7
Traveling P8
Drive motor
controller
P9

Output when the traveling controller over current is detected.
Even if it repeats the key switch with ON-OFF, No

does C1-2 error occur? • Drive motor cable check
• Drive motor continuity check
Yes

4-119
C2-1 Drive motor overheat
Related portion
Drive motor
Traveling
controller
Temperature sensor

Output when the temperature sensor value of drive motor exceeds the setting value.
• To correct, allow the vehicle to stand for a while (about 30 minutes).
4-120
C2-2 Drive motor thermo-sensor abnormality
Related portion
CN52
CN110-13 (88, TD+) 1
Traveling Drive motor
controller CN1110-10 (83, TD-) thermo-sensor
2
J53

Output when motor thermo-sensor output value outside the specified range (open or
short circuit) is detected.
ANL : I/O MONITOR 1 I/O1-3 –50 °C or less

TD: Temperature check
195°C or more
Disconnect battery plug, disconnect CN52, and connect

SST2 to the harness.
195 °C or more –50 °C or less
CN110-13 (88)
↔
Voltage measurement
•Thermo-sensor N1
defect Less than 1 V 1 V or more
• Harness defect • Traveling controller

defect
4-121
C3-1 Traveling controller main circuit thermo-sensor abnormality
Related portion
Thermo-sensor

Output when the heat sink thermo-sensor in the driver is abnormal.
4-122
C8-1 Drive motor speed sensor abnormality
Related portion
CN110-9 (80, SSD+) CN53-1 (80, SSD+)
CN110-11 (81, SSD1) CN53-2 (81, SSD1)

Traveling
controller CN110-12 (82, SSD2) CN53-3 (82, SSD2)
CN110-10 (83, SSD–) CN53-4 (83, SSD–)
Drive motor
CN53
speed sensor

Output when the traveling controller detects abnormality of drive motor speed sensor.
C8-1 Drive motor speed sensor defect
Disconnect battery plug, connect SST19 to

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

and check the state of LED of SST at the time of One of LEDs turns OFF.
• Check the CN1 and CN3 connection of SST.
running.
2 LEDs ON 2 LEDs OFF

Connect battery plug, turn the key switch to ON, NG (Both 2 LEDs blink).
and check the state of LED of SST at the time of • Traveling controller defect
running.
Other than NG
Disconnect CN53, and check the voltage of

CN53 of harness side. NG (all 8 V ~ 13 V)
1 pin (+) ~ 4 pin (-) • Drive motor speed sensor defect
2 pin (+) ~ 4 pin (-)
3 pin (+) ~ 4 pin (-)
Other than NG
• Harness defect
4-123
MATERIAL HANDLING CONTROLLER SYSTEM

30-3 Material handling controller low voltage
Related portion
F1
P1 P2 P3
Material
handling
controller

Output when the battery voltage (P3) line of material handling controller detects low voltage.
If 31-3, CB-1 occur at the same time, perform troubleshooting for 31-3, CB-1 first.
Yes
Turn the key switch to OFF and then ON again. Troubleshooting of 31-3 error is
Is 31-3 error displayed? performed.
No
CB-1 error is indicated.
If lift operation is carried out, does an error come Troubleshooting of CB-1 error is performed.
out?
30-3 error is No error
indicated. • P3 cable and terminal check
• F1 fuse check
ANL : I/O MONITOR 1 I/O1-14 32 V or more
Again, key switch is set to OFF and ON. Carry out
lift operation and check the VBBP voltage when
an error occurs.
Less than 32 V

Again, key switch is set to OFF and ON. Carry out Less than 32 V
• Battery plug check
lift operation and check the VB80 voltage at the
• Battery charge
time of an error.
32 V or more
Again, key switch is set to OFF and ON. Carry out 32 V or more
lift operation and check the material handling • Material handling controller defect
controller input voltage P3-N1 when an error
occurs.
Less than 32 V
Again, key switch is set to OFF and ON. Carry out 32 V or more
lift operation and check the battery voltage P2-N1 • P3 cable and terminal check
when an error occurs. • F1 fuse check
Less than 32 V
4-124
31-3 Material handling controller starting voltage drops
Related portion
F1
P1 P2 P3 Material
handling
controller
CPR
CN104-9 (55, CPR)
F7 CN136 CPU
CN104-1 (18, B80V)
4 board
CN104-2 (18, B80V)

Output when it is detected that P3 voltage of material handling controller does not
exceed the setting value with the key switch ON.
No
Turn the key switch to OFF and then ON again. • Battery plug check
Is 31-3 error displayed? • Material handling controller cable and
Yes terminal check
• CPR check
ANL. : I/O MONITOR 1 I/O1-14 48 V or more • Harness check
VBBP : Material handling controller DC_BUS • Material handling controller defect
voltage check
Less than 48 V
P3 48 V or more
↔
Voltage measurement • Material handling controller defect

N1
Less than 48 V

CPR resistance value check
VBKS : Key start voltage check
Approx. 20 Ω Other than
Less than 48 V approx. 20 Ω
• F1 fuse check • CPR defect

B80V : Battery voltage check
Less than 48 V
P1 48 V or more
• F7 fuse check
↔
Voltage measurement
N1
Less than 48 V
• Battery charge
4-125
32-3 Material handling controller EEP-ROM abnormality
Related portion
Material
handling
controller

Internal data is abnormal at the time of material handling controller starting.
The EEP-ROM element on the CPU board in material handling controller is damaged.
Even if it repeats the key switch with OFF and No Was material handling controller
ON, does 32-3 error occur? exchanged immediately before?
Yes No Yes
• Material handling • Normal

controller
• Material handling controller defect connector check
(ID signal)
4-126
33-3 CPU → Material handling controller communication abnormality
Related portion
CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
Material
CPU board handling
CN112
1
R
2
3

Output when material handling controller cannot receive the communication data from the CPU
board within fixed time.
Does AD-5 error display or diagnosis memory Yes

• Troubleshooting of AD-5 error is performed.
memorize?
No
Is material handling controller exchanged Yes

• The plug check of CN103, CN104, CN111
immediately before?
and CN112 connectors is performed, the
No key switch is set to OFF and ON, and it
checks that an error is not displayed.
Did an error occur when the key switch was No error

• CN103, CN104, CN111, CN112
turned to ON from OFF?
connector check
33-3 error is indicated. AD-5 or AD-6 is indicated. • Harness check
(AD-5 and AD-6 are not • Troubleshooting of AD-5 or AD-6 error is
indicated.) performed.
• Harness check
(There is the possibility that CPU is
defect.)
4-127
A1-4 Material handling controller high voltage
Related portion
F1
P3
Material
handling
controller

Output when the battery voltage line of the material handling controller overvoltage is detected.
Turn the key switch to OFF and then ON again.
Less than
Yes ANL: I/O MONITOR 1 I/O1-14
110 V
Is A1-4 error displayed? VBBP: Material handling controller • Material
No DC_BUS voltage value handling
controller defect
110 V or more
110 V or
more
Battery voltage check • Replace battery.
NG (∞ Ω)
F1 fuse inspection • Replace F1 fuse.
OK (0 Ω)
Yes
Was the battery plug disconnected during • Do not disconnect battery plug during
traveling? traveling except in an emergency.
No

4-128
A2-3 Material handling controller board overheat
Related portion
Material handling
controller
PCB Thermo-sensor

Output when the voltage detected by the thermo-sensor in the controller exceeds the
specified level.

TBP: Material handling controller board • Allow vehicle to stand for a
temperature check. while. (approx. 30 min.)
Less than 100 °C
Has the vehicle been subjected to continuous Yes

• Stop vehicle and perform check test with
overloaded operation?
standard load after 30 minutes.
No

4-129
AA-4 Material handling controller thermo-sensor abnormality
Related portion
Material handling
controller
PCB Thermo-sensor

Output when the thermo-sensor in the controller abnormality is detected.
• To correct, replace the material handling controller.
4-130
E1-1 Material handling controller current sensor offset abnormality
Related portion
Material handling
controller
Current sensor

Output when the current sensor offset compensation is detected at the time of the
material handling controller starting.

4-131
E1-2 Material handling controller over current abnormality
Related portion
P14
Material P15
handling Pump motor
controller P16

Output when the material handling controller over current is detected.
Even if it repeats the key switch with ON-OFF, No

• Pump motor cable check
does E1-2 error occur?
• Pump motor continuity check
Yes

4-132
E2-1 Pump motor overheat
Related portion
Pump motor
Material
handling
controller
Temperature sensor

Output when the temperature sensor value of pump motor exceeds the setting value.
• To correct, allow the vehicle to stand for a while (about 30 minutes).
4-133
E2-2 Pump motor thermo-sensor abnormality
Related portion
CN57 CN55
CN111-13 (89, TP+) 6 2
Material Pump motor
handling CN111-10 (87, TP-) 5 1 thermo-sensor
controller J19

Output when motor thermo-sensor output is outside the standard range (open or short
circuit) is detected.
ANL : I/O MONITOR 1 I/O1-4 –50 °C or less

TP: Temperature check
195°C or more

connect SST2 to the harness.
CN111-13 (89)
↔
Voltage measurement
•Thermo-sensor defect N1
•Harness defect • Material handling

controller defect
4-134
E3 Material handling controller main circuit thermo-sensor abnormality
Related portion
Thermo-sensor

Output when the heat sink thermo-sensor in the driver is abnormal.
4-135
E8 Pump motor speed sensor abnormality
Related portion
CN111-9 (84, SSP+) CN57-1 (84, SSP+)
CN111-11 (85, SSP1) CN57-2 (85, SSP1)

Material
handling CN111-12 (86, SSP2) CN57-3 (86, SSP2)
controller
CN111-10 (87, SSP–) CN57-4 (87, SSP–)
Pump motor
CN57
speed sensor

Output when the material handling controller detects abnormality of pump motor speed
sensor.
E8 Pump motor speed sensor defect

Connect battery plug, turn the key switch to ON, One of LEDs turns OFF.
and check the state of LED of SST at the time of • Check the CN1 and CN3 connection of SST.
lift operation.
2 LEDs ON 2 LEDs OFF

Connect battery plug, turn the key switch to ON, NG (Both 2 LEDs blink.)
and check the state of LED of SST at the time of • Material handling controller defect
lift operation.
Other than NG
Disconnect CN57, and check the voltage of

CN57 of harness side. NG (all 8 V ~ 13 V)
1 pin (+) ~ 4 pin (-) • Pump motor speed sensor defect
2 pin (+) ~ 4 pin (-)
3 pin (+) ~ 4 pin (-)
Other than NG
• Harness defect
4-136
SAS SYSTEM
51-1 Drive motor speed sensor abnormality
Related portion
Main harness Sub-harness

CN151
CN103-5 (324, SSO+) CN142-4 (324, SSN+)
4
SCPU
CPU CN103-6 (325, SSO–) CN142-5 (325, SSN–) board
5
board
CN103-3 (147, CANGND)

Output if the speed detection line from the CPU board to the SCPU board is disconnected.
51-1 Speed sensor open-circuit defect
Disconnect battery plug, disconnect CN103 and No continuity (∞ Ω)

CN151.
CN103-5 (324) ~ CN151-4 (324)
CN103-6 (325) ~ CN151-5 (325)
Continuity (0 Ω)
Other than (1) 5 V
Connect CN103, connect battery plug, and check and (2) 0 V
the continuity.
(1) CN151-4 (324) ~ CN103-3 (147)
(2) CN151-5 (325) ~ CN103-3 (147)
(1) 5 V
(2) 0 V
Disconnect battery plug, disconnect CN142. No continuity (∞ Ω)
CN151-4 (324) ~ CN142-4 (324)
CN151-5 (325) ~ CN142-5 (325)
Continuity (0 Ω)
Other than (1) approx. 1
Connect CN142 and CN151, connect battery V and (2) 0 V
plug and turn the key switch to ON, and check the
or
voltage.
(1) CN142-4 (324) ~ CN103-3 (147)
(2) CN142-5 (325) ~ CN103-3 (147)
(1) Approx. 1 V
(2) 0 V
4-137
52-1, 2, 3 Yaw rate sensor abnormality
Related portion
CN144-1 (321, SYR+)
SCPU CN144-3 (322, SYR) Yaw rate

board sensor
CN144-2 (323, SYR–)

Output if the yaw rate sensor output voltage is outside the standard range (open or short
circuit), or if the yaw rate sensor output voltage while the vehicle is stationary is outside
the standard range (neutral voltage).
52-1 Yaw rate sensor open-circuit defect
52-2 Yaw rate sensor short-circuit defect
52-3 Yaw rate sensor neutral voltage defect
• 52-1, 2
ANL. : I/O MONITOR 2
Measure the yaw rate sensor voltage. Less than 0.1 V
0.1 V or more
Check the CN144 connector
(visually). Abnormal
Normal
Does 52-1 remain? Yes • Repair or replace.
No (No indication) (Indicated)
• Yaw rate sensor defect
• Disconnect and reconnect CN144 to make sure
that 52-1 is not indicated.
• 52-3
ANL. : I/O MONITOR 2
Measure the yaw rate sensor voltage while the Outside the standard range 2.2 V
vehicle is stationary. or less, or 2.8 V or more
Within the standard
Check the CN144 connector
range (2.2 ~ 2.8 V) Abnormal
(visually).
Normal
Does 52-3 remain? • Repair or replace.
Yes
No (No indication) (Indicated)
• Yaw rate sensor defect
• Disconnect and reconnect CN144 to make sure
that 52-3 is not indicated.
4-138
54-1, 2 Swing lock solenoid abnormality
Related portion
Sub-harness Main harness
CN152 CN94
CN148-1
SCPU
DC/SD (327, SOLS+)
board 1 4
board
CN148-6 Swing lock
(328, SOLS–) solenoid
6 5
CN146 CN147

Output if the swing lock solenoid line from the DC/SD board to the swing lock solenoid is
open or shorted.
54-1 Swing lock solenoid open-circuit defect
54-2 Swing lock solenoid OCL defect
• 54-1
54-1 error is not
ACTIVE TEST: ACT-3 SSOL indicated.
The swing lock solenoid is set to ON by the active • Connector connection check
test.

Disconnect CN152. (main harness side)
CN152-1 (327) 5.5 ± 1 Ω
(at 25 °C)
↔
CN152-6 (328)
(at 25 °C) ACTIVE TEST: ACT-3 SSOL
The SST5 and the CN146 ~ CN147 harness are
replaced , and the swing lock solenoid is set to ON by the
active test.
Check signal “1”. Check signal “0”.
(Normality) (Abnormality)
• DC/SD board defect
• CN146 ~ CN147 harness
Disconnect CN94. 5.5 ± 1 Ω (at 25 °C)
(Swing lock solenoid harness side)
CN94-4 (327)
↔
CN94-5 (328)
(at 25 °C)
• Swing lock solenoid defect
4-139
• 54-2
ACTIVE TEST: ACT-3 SSOL 54-2 error is not indicated.

The swing lock solenoid is set to ON by the active • Connector connection check
test.

Disconnect CN94.
ACTIVE TEST: ACT-3 SSOL

The swing lock solenoid is set to ON by the active • Sub-harness defect
test. • Swing lock solenoid defect

CN152-1 (327) • Main Harness defect
↔
Continuity check
CN152-6 (328)
No continuity
ACTIVE TEST: ACT-3 SSOL

The SST-5 and the CN146 ~ CN147 harness are Check signal "0”. (Abnormality)
replaced, and the swing lock solenoid is set to
ON by the active test.
Check signal • SCPU board defect

“1”. (Normality)
• CN146 ~ CN147 harness defect
4-140
71-1,2 Tire angle sensor abnormality
Related portion
Sub-harness CN151 Main harness CN94

CN142-11 (316, POTH+)
11 1
SCPU CN142-3 (317, POTH) Tire angle

board 3 2
sensor
CN142-8 (320, SPOT–)

8 3

Output if the tire angle sensor output voltage is outside the standard range.
71-1 Tire angle sensor open-circuit defect
71-2 Tire angle sensor short-circuit defect
• 71-1
71-2 error is
Disconnect battery plug, disconnect CN94. indicated.
• Tire angle sensor defect
Connect SST2 between CN94-1 and
CN94-2(Main harness side).
Connect battery plug and turn the key switch to ON.

Disconnect CN151. No continuity
(SST2 is the connection state.)
CN151-11(316)
Continuity check
↔
CN151-3(317)
Continuity
CN151-3(317)
Continuity check No continuity
↔
CN151-8(320) • Sub-harness defect

Continuity

4-141
• 71-2

Change to 71-1 error.
ON.
Disconnect CN142.
Connect SST2 between CN94-2 and
Disconnect battery plug. CN94-3.
Disconnect CN151. (Main harness side)
CN151-11 (316) CN142-3 (317)
Continuity check
↔
Continuity check
↔
CN151-3 (317) CN142-8 (320)
Continuity No continuity Continuity No
continuity
• Main harness defect • SCPU board defect • Tire angle sensor defect • Harness defect
4-142
72-1, 2, 3, 4 Steering angle sensor abnormality
Related portion
Sub-harness CN150 Main harness CN19
CN141-17 (311, STS+)
17 1
Cn141-6 (312, STS1) 6 4

SCPU Steering an-
CN141-7 (313, STS2)
board 7 5 gle sensor
CN141-8 (314, STSC)
8 6
CN141-16 (315, STS–)

16 3

Output if the sensor line from the SCPU board to the steering angle sensor is open or
shorted.
72-1 Steering angle sensor STS1 defect
72-2 Steering angle sensor STS2 defect
72-3 Steering angle sensor STSC defect
72-4 Steering angle sensor open-circuit defect
• 72-1
Connect battery plug and turn the key switch to ON. 72-1 error is not indicated.
Turn the steering wheel.
72-1 error disappears and

Disconnect battery plug, and connect SST7 to CN19. Connect 72-2 error is indicated.
72-1 error is indicated. • Steering angle sensor defect
Check voltage value change upon turning the steering wheel.

CN141-6 (312) Not change
↔
Voltage measurement
CN141-16 (315)
Change

4-143
• 72-2
72-2 error disappears and

Disconnect battery plug, and connect SST7 to CN19. Connect 72-1 error is indicated.
battery plug and turn the key switch to ON. Turn the steering
wheel.
• Steering angle sensor defect

CN141-7 (313) Not change
↔
Voltage measurement
CN141-16 (315)
Change • Sub-harness defect
• 72-3
Disconnect battery plug, and connect SST7 to CN19. Connect

ANL. : I/O MONITOR 4-1 STS : (STS1) (STS2) (STSC) ON (“1” indication)
Check the steering angle indication (STSC).
OFF (“0” indication)
• Steering angle sensor defect

CN150-8 (314) Approx. 5 V
↔
Voltage measurement
CN150-16 (315)
Approx. 0 V

4-144
• 72-4
Disconnect battery plug , and connect SST7 to CN19. Connect

CN19-1 (311) [SST7 : CN A-3]

↔
Voltage measurement Approx. 0 V

CN19-3 (315) [SST7 : CN A-1]
Approx. 15 V
(Controlle side connector)
Approx. 15 V CN150-17 (311)
↔
Voltage measurement
CN150-16 (315)
• Main harness defect Approx. 0 V

Not change
STS1 : CN B-8 (312) ~ CN A-1(315)
STS2 : CN B-7 (313) ~ CN A-1(315)
STSC : CN B-4 (314) ~ CN A-1(315) • Steering angle sensor defect
Change

Not change
(SCPU board side)
CN141-6 (312) ~ CN141-16 (315)
CN141-7 (313) ~ CN141-16 (315) • Main harness defect
Change • Sub-harness defect

4-145
73-1, 2 Steering knob position correcting solenoid abnormality
Related portion
Sub-harness Main harness

CN152 CN98
SCPU DC/SD CN148-2 Steering
board board 2 1 knob
(329, SOLST+)
position
CN148-5 correcting
5 2
(330, SOLST-) solenoid
CN146 CN147

Output if the steering knob position correcting solenoid line from the SCPU board to the steering
knob position correcting solenoid is open or shorted.
73-1 Steering knob position correcting solenoid open-circuit defect
73-2 Steering knob position correcting solenoid OCL defect
• 73-1
ACTIVE TEST : ACT-4 KSOL 73-1 error is not indicated.

The steering knob position correcting solenoid is set to ON by • Connector connection check
the active test .

Disconnect CN152.
10 ± 1 Ω
CN152-2 (329) (at 25°C)
↔
CN152-5 (330)
Other than 10 ± 1 Ω ACTIVE TEST : ACT-4 KSOL
(at 25°C) The SST5 and the CN146 ~ CN147 harness are
Check signal “1”. replaced, and the steering knob position correcting
(Normality) solenoid is set to ON by the active test.
Check signal “0”.
• Sub-harness defect (Abnormality)
• CN146 ~ CN147 harness defect • SCPU board defect

Disconnect CN98. 10 ± 1 Ω (at 25°C)
CN98-1 (329) • Main harness defect
↔
CN98-2 (330)
Other than 10 ± 1 Ω
(at 25°C)
• Steering knob position correcting solenoid defect
4-146
• 73-2
73-2 error is
ACTIVE TEST : ACT-4 KSOL not indicated.
The steering knob position correcting solenoid is set to ON by • Connector connection check
the active test.

Disconnect CN98.
73-1 error is
ACTIVE TEST : ACT-4 KSOL not indicated.
The steering knob position correcting solenoid is set to ON by • Sub-harness defect
the active test. • Steering knob position correcting solenoid
73-2 error is indicated. defect

CN152-2 (329) • Main harness defect
↔
Continuity check
CN152-5 (330)
No continuity
ACTIVE TEST : ACT-4 KSOL

The SST5 and the CN146 ~ CN147 harness are replaced, and
the steering knob position correcting solenoid is set to ON by Check signal “0”.
the active test. (Abnormality)
Check signal “1”.

(Normality) • SCPU board defect
• CN146 ~ CN147 harness defect
4-147
74-1 Tire angle matching value abnormality
Related portion
• SCPU board

Output if the tire angle matching value is outside the standard range.
74-1 Tire angle matching value abnormality
• 74-1
4-148
AF-5, 6, 7, 8 SCPU board abnormality
Related portion
SCPU board
CPU

Output when the abnormality of CPU operation is detected.
AF-5, 6, 7, 8 SCPU board abnormality
• AF-5, 6, 7, 8
4-149
EF-5, 6 EEP-ROM abnormality
Related portion
SCPU board
EEP-ROM

Output when abnormality of the EEP-ROM is detected.
EF-5, 6 SCPU board abnormality
• EF-5, 6
4-150
FE-4, 5 Main controller → SAS controller communication abnormality
Related portion
Main harness Sub-harness

CN150
CN101-14 (307, SMTSA) CN141-4 (307, SMTSA)
4
CPU SCPU
board board
CN101-15 (308, SMTSK) CN141-12 (308, SMTSK)
12

Output upon no communication within the specified time period or frequent error
detection in the received data.
FE-4 Communication defect
FE-5 Communication data defect
• FE-4, 5

CN141. No continuity
CN101-14 (307) ~ CN141-4 (307)
CN101-15 (308) ~ CN141-12 (308)
Continuity

or
4-151
F0 PS main circuit abnormality
Related portion
CN145-1 CN51 CN49

(340, TMPSG)
CN149 2 2
CN145-2 Main
(P24, SH+) controller
4 4
SCPU CN50
board
CN145-3 (N1, SH–)
1 1 1
PS
PS main motor
circuit 3 3 2

Output when short-circuit of PS main circuit transistor is detected.
F0 PS main circuit defect.
Disconnect battery plug, disconnect CN49 and turn the key F0 error is not indicated.
switch to ON.
F0 error is indicated.
NG Check the connection of CN149.

OK
• Reconnects
TMPS defect
Disconnect battery plug, connect CN149 and turn the

key switch to ON.
OK (0.5 ~ 4 V) CN149-1 (340)
Voltage measurement
↔
SH (shunt) - Level side

• SCPU board is normal. NG (Other than 0.5 ~ 4 V)

Turn the key switch to OFF, and disconnect
battery plug. No continuity (∞ Ω)
CN145-2 (P24)
↔
Continuity check
CN145-3 (N1)
Continuity (0 Ω) • Harness defect
or
• Shunt resistance defect
4-152
MULTI-DISPLAY COMMUNICATION SYSTEM

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

Output when abnormality of communication data from the CPU board is detected.
F1-1,2 : Main controller → Multi display communication abnormality
Other error codes, if any, cannot be displayed because communication from the CPU board is disabled
when F1-1 occurs. F1-1 remains on the multi-display screen regardless of key switch ON or OFF.
CN103, CN70 and CN1 connection condition NG

• Correct the defect.
check
OK

CN70. No continuity
• Harness defect
CN103-16 (141) ~ CN70-22 (141) (Between CN103 and CN70)
CN103-13 (144) ~ CN70-23 (144)
Continuity

• Multi-display defect
4-153
WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED

Multi-display is not displayed.
Related portion
CPU CN1
Multi-
board
CN103-10 (16, D15V) 2 display
CN70-14 (16, D15V)
CN103-12 (14, GNDD) 1 CN70-30 (14, GNDD)

The power supply is not supplied to the multi-display.
Multi-display defect
NO
Run and cargo work operation can be performed. See page 4-151. (Vehicle does not move.)
YES
Disconnect battery plug, disconnect CN1, and Disconnect battery plug, disconnect CN1
connect battery plug. and CN103.
NG (0 V)
CN1-2 (16) 1. Continuity check
↔
Voltage measurement CN1-2 (16) ~ CN103-10

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

(Between CN1 and CN70)
4-154
Vehicle does not move.
Related portion
F6
P1 P2 CN104-14, 15 (44, VBMB)
F7 CN104-1, 2 (18, B80V)

CPU
board
P0 F5 CN103-4 (43, VBKY)
CN103-7 (41, VBBT)

N2 CN104-22 (N2, N2)
P1 (+)
Less than 25 V
• Battery charge
↔
Voltage measurement
N1 (-)
25 V or more
NG (∞ Ω)
Check the F7 fuse • F7 fuse exchange
OK (0 Ω)
Check the voltage between 1pin and 22pin of

CN104. Less than 25 V
1pin (+) • Harness check
↔
Voltage measurement
22pin (-)
25 V or more OK
(Voltage of (2) is 15 V or
more, and voltage
difference of (1) and (2) is
Check the voltage with the key switch ON. less than 13 V.)
(1) CN103-4 pin (+) ~ CN104-22 pin (-) • CPU board defect
(2) CN103-7 pin (+) ~ CN104-23 pin (-)
Other than OK
NG
Check the F5 fuse. • F5 fuse exchange
OK
NG
Check the key switch. • Key switch exchange
OK
P0 (+) Other than approx. 48 V

• Battery plug or battery check
↔
Voltage measurement
N1 (-)
Approx. 48 V
• Harness check
4-155
Only a run is impossible.
Related portion
CN9
CN101-1 (45, DSF) 5
CN101-2 (46, DSR) 4 Direction
switch
CN101-16 (51, LS–) 1
J1
CN26
CN102-1 (64, SWAC)
CPU
board CN102-2 (52, POTA)
Accelerator
CN102-14 (53, POTA+) potentiometer
CN102-22 (51, POT–)
J2
CN142
CN101-5 (67, LSD) 7
8 Seat switch
J1
Yes
Has beep sound come out? • Accelerator OFF, direction OFF, and
No parking OFF (It returns.)
ANL. : I/O MONITOR 2 I/O2-1 Both have no change.

Check the accelerator switch SWAC and POTA • Accelerator check
value when an accelerator is stepped on.
Both are changeful.
ANL. ; I/O MONITOR 2 I/O2-2 No change

DSF and DSR value check when direction • Direction check
operation of is done.
Changes.
ANL. ; I/O MONITOR 2 I/O2-3 Display “0”

• Seat switch check
LSD value check when sitting on a seat.
Display “1”
Voltage measures with direction ON and

accelerator ON.*1 Other than OK
P7 (+) ~ N1 (-) • Traveling controller defect
P8 (+) ~ N1 (-) *1: When it cannot measure, even if it does
P9 (+) ~ N1 (-) not sit on the seat, it can measure by
OK disconnecting CN43 and connecting
All approx. 40 V (approx. 36 V) The SST8.
inside of ( ) is 72 V battery.
Yes
Does it run slowly? Motor cable check
No OK NG
• C8-1 troubleshooting • Cable repair
No implementation
Is there sound from the motor? • Motor cable and motor check
Yes 40 ~ 50 model
16 ~ 35 model
Rotates.
Does a turn of the handle rotate PS motor? • Machine part check of brake, piping, gear,
Does not rotate. etc.
• Troubleshooting implementation in case

PS motor does not rotate.
4-156
Only material handling operation cannot be performed.
Lift operation cannot be carried out only when a Yes ANL. I/O MONITOR 3
certain specific lever is operated. The value check when operating the lever
No which cannot carry out material handling
operation.
Value change With no value
Display “1” change
Voltage measures by Lift ON. • Lever potentiometer check
P14 (+) ~ N1 (-)
P15 (+) ~ N1 (-) ANL. I/O MONITOR 3
P16 (+) ~ N1 (-) The current value of the proportionality
Other than OK OK valve which cannot carry out material
All approx. 40 V (approx. 36 V) handling operation is checked.
• Material handling controller The inside of ( ) is 72 V battery. Less than Approx. 0.5 A
defect approx. 0.5 A or more
Motor cable check
• Control valve check
NG OK
The solenoid resistance of the
• Cable repair proportionality valve which cannot carry
out material handling operation is
checked.
Other than Approx. 7 Ω
approx. 7 Ω
• Solenoid check • Harness check
40 ~ 50 model Check the solenoid resistance of unload

valve.
Approx. 10 Ω Other than
approx. 10 Ω
• Solenoid check
16 ~ 35 model
The harness connected to CN89 is
checked.
OK NG
• Harness defect
• E8 troubleshooting implementation
4-157
PS motor does not rotate (16 ~ 35 model).
Related portion
CN51 CN49
CN145-1 2 2
(340, TMPSG) Contactor
CN149 panel
SCPU 4 4
CN145-2 (P24, SH+) CN50
board
1 1 1
CN145-3 (N1, SH–) PS
motor
PS main
3 3 2
circuit
F3 fuse check NG • F3 fuse exchange

OK
Voltage measurement when turning the handle

Other than 0 V
CN50-1 pin • PS motor check
↔
Voltage measurement
CN50-2 pin
0V
Open-circuit
Shunt resistance value check • Shunt resistance defect
Short-circuit
NG • TMPS defect
TMPS check
OK

5-1
MOTOR
Page
DRIVE MOTOR .................................................................5-2
0
GENERAL..........................................................................5-2
1
SPECIFICATIONS .............................................................5-2
COMPONENTS..................................................................5-3 2
REMOVAL • INSTALLATION..............................................5-4 3
DISASSEMBLY • INSPECTION • REASSEMBLY................5-6 4
PUMP MOTOR ..................................................................5-9
5
GENERAL..........................................................................5-9
6
SPECIFICATIONS ...........................................................5-10
COMPONENTS................................................................5-10 7
REMOVAL • INSTALLATION............................................5-12 8
DISASSEMBLY • INSPECTION • REASSEMBLY..............5-14 9
POWER STEERING MOTOR (16 ~ 35 MODEL) ....5-17
10
GENERAL........................................................................5-17
SPECIFICATIONS ...........................................................5-17
11
COMPONENTS................................................................5-18 12
DISASSEMBLY • INSPECTION • REASSEMBLY..............5-21
14
Motorlager, lista över P/N.....................................5-25 15
16
17
18
19
20
21
22
5-2
DRIVE MOTOR
GENERAL
SPECIFICATIONS
Model
16⋅18 20 ~ 35 40 ~ 50
Item
Type 3-phase AC ← ←
Nominal voltage V 72/80 ← ←
Rated output kW 12.0/13.3 15.4/17.1 14.9/16.6
Dimensions mm(in) φ270 × 260 φ270 × 285 φ270 × 340
(outside diameter × length) (10.63 × 10.24) (10.63 × 11.22) (10.63 × 13.39)
Weight kg (lb) 62 (137) 73 (161) 96 (212)
Insulation class Class F ← ←
5-3
COMPONENTS
1401
0
1
2
3
4
5
6
7
8
FJ [NO.1]
9
10
11
12
13
FJ [NO.2]
14
15
16
17
18
19
20
21
22
5-4
T = N·m (kgf·cm) [ft·lbf]
2 6
T = 45.0 ~ 55.0 (460 ~ 560)

[33.3 ~ 40.5]
Removal Procedure
1 Remove the drive unit & drive motor W/front axle ASSY. (See page 6-6.)
2 Remove the drive motor sensor bracket, terminal bracket, and sensor cover.
3 Place match marks between the end bracket, stator ASSY, and gear case.
4 Remove the nuts and through bolts. [Point 1]
5 Remove the end bracket. [Point 2]
6 Remove the stator ASSY W/rotor ASSY.
Note:
Apply MP grease to the rotor ASSY spline.
5-5
Point Operations
[Point 1]
Removal:
After removing the through bolts, use a hoist to lift the yoke
ASSY.
0
1
Installation:
2
4
2
After tightening the through bolts until they touch bottom,
tighten the nuts in the order shown in the figure.
3
1
4
5
3
6
7
Installation:
When replacing the motor with a new one, be sure to re-
move the stopper bolt and spacer installed in the center of
Spacer
the end bracket. (They are not installed hereafter.) 8
Stopper bolt
9
10
11
[Point 2]
12
Removal:
Use a plastic hammer to tap lightly on the end bracket to 13
remove it.
14
Installation:
Use a plastic hammer to tap lightly on the end bracket to 15
install it.
16
Installation: 17
Wave Align the speed sensor harness with the notch in the end
washer bracket and install the end bracket.
When doing this, do not forget to install the wave washer.
18
19
20
21
22
5-6

Note:
• Do not apply a shock to the bearing W/speed sensor.
OBS! Lager finns som separat reservdel. P/N på sensorlagret:

7FBMF 16-35 = 14160-F9802-71
7FBMF 40-50 = 14160-F9801-71
1
2
Disassembly Procedure
1 Remove the rotor ASSY W/bearing. [Point 1]
2 Remove the bearing. [Point 2]
Reassembly Procedure
5-7
Point Operations
[Point 1]
Inspection:
Measure the stator ASSY insulation resistance.
Measurement locations: Between the stator and each ter-
minal (U, V, W)
Inspection:
Measure the speed sensor insulation resistance.
Measurement locations: Between the stator and the speed
sensor connector terminals (4 locations)
Standard: ∞ Ω
Inspection:
Measure the temperature sensor insulation resistance.
Measurement locations: Between the stator and the tem-
perature sensor connector terminals (2 locations).
Standard: ∞ Ω
Measurement locations: Between the temperature sensor

connector terminals
Standard: 0.5 ~ 1.0 kΩ
[Point 2]
Disassembly:
SST SST 09950-76014-71
(SST 09950-40011)
5-8
L/speed sensor Reassembly:

Use the following procedure to install the bearing.
1. Install the bearing (L/speed sensor).

SST 09370-20270-71
SST
W/speed sensor 2. Install the bearing (W/speed sensor).

Tapping on the bearing could damage the sensor. Use
a press to install the bearing.
SST SST 09411-41800-71
5-9
PUMP MOTOR
GENERAL
16 ~ 35 model
40 ~ 50 model
5-10
SPECIFICATIONS
Model
16⋅18 20 ~ 35 40 ~ 50
Item
Type 3-phase ← ←
Nominal voltage V 72/80 ← ←
Rated output kW 12.0/13.5 16.9/18.6 22.8/25.4
Dimensions mm (in) φ240 × 324 φ240 × 339 φ260 × 427
(outside diameter × length) (9.45 × 12.76) (9.45 × 13.35) (10.24 × 16.81)
Weight kg (lb) 57 (126) 60 (132) 97 (214)
Insulation class Class F ← ←
COMPONENTS
16 ~ 35 model 1402
5-11
40 ~ 50 model 1402
5-12
16 ~ 35 model
T = 16.2 ~ 37.8
8 T = 39.0 ~ 91.0 (165 ~ 385)
8
(398 ~ 928) [11.9 ~ 27.9]
[28.8 ~ 67.1]
40 ~ 50 model
T = 16.2 ~ 37.8
8 T = 39.0 ~ 91.0 8 (165 ~ 385)
(398 ~ 928) [11.9 ~ 27.9]
[28.8 ~ 67.1]
5-13
Removal Procedure
1 Remove the battery. (See page 13-10.)
2 Remove the counterweight. (See page 11-10.)
3 Remove the motor cable.
4 Disconnect the speed sensor and temperature sensor connectors.
5 Remove the oil pump set bolts and separate the oil pump from the pump motor.
6 Disconnect the swing lock solenoid connector.
7 Remove the lock cylinder cover.
8 Remove the lock cylinder lower pin and slide the swing lock cylinder to the left. [Point 1]
9 Remove the pump motor. [Point 2]
Note:
Apply lock agent (08833-76001-71 (08833-00070)) to the threads of the lock cylinder lower pin set
bolt and tighten the bolt.
Point Operations
[Point 1]
•
Jack up the rear axle and support the frame on wooden

blocks.
[Point 2] (40 ~ 50 model)
•
To prevent the right rear insulator bolt from being dam-

aged, connect shackles to the two left side wire ropes, and
then tilt and raise up the pump motor.
Installation:
Apply lock agent (08833-76002-71 (08833-00080)) to the
threads of the right rear insulator bolts and tighten the
Apply lock bolts.
agent here
5-14

Note:
• Do not apply a shock to the bearing W/speed sensor.
• The minimum unit of the parts supply for the bearing consists of “Rotor ASSY W/bearing” even
though the bearing is seperable on actual service.
16 ~ 35 model: 40 ~ 50 model:
T = 22.5 ~ 27.5 (229 ~ 280) T = 45 ~ 55 (459 ~ 561)
[16.6 ~ 20.3] [33.2 ~ 40.6]
1 Remove the end bracket (terminal side). [Point 1]
2 Remove the rotor ASSY W/bearing. [Point 2]
3 Remove the bearing. [Point 3]
4 Remove the stator ASSY. [Point 4]
5-15
Match marks Point Operations

[Point 1]
Disassembly:
Put match marks between the end bracket, stator ASSY,
and end bracket (terminal side).
Reassembly:
Align the match marks when installing.
Reassembly:
Align the speed sensor harness with the slot in the end
bracket (terminal side) and install the end bracket.
[Point 2]
Inspection:
Measure the speed sensor insulation resistance.
Measurement locations: Between the stator and the speed
sensor connector terminals (4 locations).
Standard: ∞ Ω
[Point 3]
SST (1)
Disassembly:
SST 09950-76014-71 ............(1)
(SST 09950-40011)
SST 09950-76018-71 ............(2)
(SST 09950-60010)
SST (2)
L/speed sensor Reassembly:

SST Use the following procedure to install the bearing.
1. Install the bearing (L/speed sensor).

SST 09370-20270-71
5-16
W/speed sensor 2. Install the bearing (W/speed sensor).

Tapping on the bearing could damage the sensor. Use
a press to install the bearing.
SST SST 09411-41800-71
[Point 4]
Inspection:
Measure the stator ASSY insulation resistance.
Measurement locations: Between the stator and each ter-
minal (U, V, W)
Inspection:
Measure the temperature sensor insulation resistance.
Measurement locations: Between the stator and the tem-
perature sensor connector terminals (2 locations)
Standard: ∞ Ω
Measurement locations: Between the temperature sensor

connector terminals
Standard: 0.5 ~ 1.0 kΩ
Installation:
Do not forget to install the wave washer in the end bracket.
Wave washer
5-17
POWER STEERING MOTOR (16 ~ 35 MODEL)

GENERAL
SPECIFICATIONS
Model
16 ~ 35
Item
Type DC permanent magnet type enclosed motor
Nominal voltage V 70
Rated output kW 1.0
Dimensions (outside diameter × length) mm φ114 × 268
(in) (4.49 × 10.55)
Insulation class F
Brush size (thickness × width × length) mm 8 × 20 × 25
(in) (0.31 × 0.79 × 0.98)
Number of brushes 4
Weight kg (lb) 10.6 (23.4)
5-18
COMPONENTS
1403
5-19
7 5
T = 20 ~ 30 (200 ~ 300)
[14.7 ~ 21.7]
Removal Procedure
2 Remove the front toe board.
3 Disconnect the PS motor connector.
4 Disconnect the piping.
5 Remove the fitting. (outlet)
6 Remove the PS motor ASSY W/PS pump ASSY.
7 Remove the PS pump ASSY from the PS motor ASSY. [Point1]
5-20
Pump set bolt Point Operations

[Point 1]
Removal:
PS pump set bolts are located as shown in the figure.
Pump set bolt
Oldham’s joint
Installation:
When assembling the PS motor and pump, fill molybde-
num disulfide grease in the groove on the oldham’s joint.
PS motor
Apply Molybdenum disulfide

grease to fill the groove.
5-21
3 5
1
5
3
5
5
1 Remove the cover connector ASSY. [Point1]
2 Remove the brushes.
3 Remove the commutator frame ASSY W/brush holder ASSY. [Point2]
4 Remove the brush holder ASSY from the commutator frame ASSY.
5 Remove the harness, brush spring and brushes from the brush holder. [Point3]
6 Remove the No.2 bracket.
7 Remove the armature ASSY from the yoke ASSY. [Point4]
Note:
Check the insulation between the motor connector terminal and the motor body after reassembly.
Standard: 1MΩ or more (with a DC 500 V megohmmeter)
5-22

[Point 1]
Disassembly:
Apply match marks between the commutator frame ASSY,
yoke ASSY, and No.2 bracket.
Reassembly:
Align the match marks and assemble.
Inspection:
Measure the insulation resistance between the connector
terminal and the motor body.
[Point 2]
SST
Disassembly:
SST 09950-76014-71
(SST 09950-40011)
Inspection:
Reassemble the armature coil and commutator frame
ASSY W/brush holder ASSY. Hook a spring balance to the
brush spring. Measure the reading on the instant when the
spring comes off from the brush.
Spring force
Standard: 4.7 N (0.48 kgf) [1.26 lbf]
Limit: 4.3 N (0.43 kgf) [0.95 lbf]
Inspection:
Measure the insulation resistance between the brush hold-
er ASSY and commutator frame ASSY.
5-23
[Point 3]
Inspection:
Inspect the brush for wear and contact state.
Brush length
Standard : 25 mm (0.98 in)
Limit : 15 mm (0.59 in)
[Point 4]
Disassembly:
1. Remove the bearings.
SST
SST 09950-76014-71
(SST 09950-40011)
Commutator frame ASSY side 2. Install the bearings.

SST 09950-76018-71......(1)
SST (2) (SST 09950-60010)
SST 09950-76020-71......(2)
(SST 09950-70010)
SST (1)
No.2 bracket side SST 09700-30200-71
Inspection:
If the commutator surface is roughened, correct it with
sandpaper (#600 or similar) and clean it well.
If the surface is excessively rough, repair with a lathe.
Commutator outside diameter

Standard: 50 mm (1.97 in)
Limit: 45 mm (1.77 in)
5-24
Inspection:
When the commutator is repaired, undercut the mica.
Undercut
Undercut depth
Standard: 0.8 mm (0.031 in)
Limit: 0.3 mm (0.012 in)
Mica
Inspection:
Measure the commutator runout.
Standard: 0.03 mm (0.0012 in) or less
Inspection:
Measure the insulation resistance of the armature coil.
TOYOTA INDUSTRIAL EQUIPMENT 5-25
SERVICE Internal Use Only
INFORMATION
REF . NO. TIEE –SI0401 DATE : 19/01/04
TITLE: 7FBMF motor bearings part number list
1°) Applicable models:
7FBMF Range
2 °) Content:
Find the availability of the 7FBMF bearings as spare parts
Motor PN Motor Range Std bearings Bearing Rpm sensor
14110-F1132-71 Drive 1t 14160-F9803-71 14160-F9801-71

14120-F1131-71 Drive 1t 14160-F9803-71 14160-F9801-71
14110-F2132-71 Drive 2-3t 14160-F9803-71 14160-F9801-71
14120-F2131-71 Drive 2-3t 14160-F9803-71 14160-F9801-71
14110-F3072-71 Drive 4-5t 14160-F9803-71 14160-F9801-71
14310-F1130-71 Pump 1t 14160-F9804-71 14160-F9802-71
14310-F2130-71 Pump 2-3t 14160-F9804-71 14160-F9802-71
14310-F3070-71 Pump 4-5t 14160-F9805-71 14160-F9801-71
04145-F1010-71 (kit
14150-F1090-71 Steering pump 1-3,5
2 x bearings)
A] DRIVE MOTOR
Bearing Rpm sensor

16-50: 14160-F9801-71
Bearing
16-50: 14160-F9803-71
TOYOTA INDUSTRIAL EQUIPMENT EUROPE

If you have any questions about this issue, Technical Department
please contact the tehnical department.
TOYOTA INDUSTRIAL EQUIPMENT
5-26
SERVICE
INFORMATION
B] PUMP MOTOR
Bearing Rpm sensor

16-35: 14160-F9802-71
40-50: 14160-F9801-71
Bearing
16-35: 14160-F9804-71
40-50 : 14160-F9805-71
C] STEERING MOTOR
Bearing kit (2 bearings+washer)

16-35 : 04145-F1010-71
TOYOTA INDUSTRIAL EQUIPMENT EUROPE

If you have any questions about this issue, Technical Department
please contact the tehnical department.
6-1
DRIVE UNIT
Page
GENERAL ..........................................................................6-2
0
SPECIFICATIONS ............................................................6-3
1
COMPONENTS .................................................................6-4
2
DRIVE UNIT ASSEMBLY ...............................................6-6
DIFFERENTIAL CASE ASSEMBLY ..........................6-15 5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
6-2
GENERAL
16·18 model
20 ~ 35 model
6-3
40 ~ 50 model
0
1
2
3
4
5
6
7
8
9
SPECIFICATIONS
Model 10
16 18
•
20 25
•
30 35
•
40 ~ 50
Item
Drive unit gear No.1 number of teeth 11
16 15 ← 15
(Motor shaft gear)
Drive unit gear No.2 number of teeth Large: 89 Large: 96 Large: 88 12
←
(Idle gear) Small: 11 Small: 11 Small: 19
Drive unit gear No.3 number of teeth 13
54 60 ← 51
(Differential gear)
Total reduction ratio 27.307 34.909 ← 15.747*
14
Drive unit oil level (US gal) 5.9 (1.56) ← 6.5 (1.72) 11 (2.90) 15
*: Excluding wheel reduction
16
17
18
19
20
21
22
6-4
COMPONENTS
16 ~ 35 model 3305
40 ~ 50 model
6-5
16·18 model, 40 ~ 50 model 4101
0
1
2
3
4
5
6
7
8
20 ~ 35 model 9
10
11
12
13
14
15
16
17
18
19
20
21
22
6-6
DRIVE UNIT ASSEMBLY

16 ~ 35 model
11
T = 185 ~ 344
(1900 ~ 3500)
[137.5 ~ 253.2]
16 15
18 17
19
21
T = 51.0 ~ 64.7
(520 ~ 660)
19 [37.6 ~ 47.8]
T = 45.0 ~ 55.0 (460 ~ 560)

[33.3 ~ 40.5]
13
20
14
13
T = 108 ~ 137
(1100 ~ 1400)
[79.5 ~ 101.3]
14
T = 108 ~ 137
(1100 ~ 1400)
[79.5 ~ 101.3]
6-7

40 ~ 50 model
11
T = 235 ~ 294 (2400 ~ 3000)

[173.6~217.1]
16 15
21 18 17
19
19 T = 51.0 ~ 64.7 (520 ~ 660)

[37.6 ~ 47.8]
T = 45.0~55.0 (460~560)
[33.3~40.5]
20
14
13 13
14 13
T = 221 ~ 323 (2250 ~ 3300)

13 [162.8~238.8]
6-8
Removal Procedure
1 Remove the mast ASSY. (See page 13-10.)
3 Drain the drive unit oil. [Point 1]
4 Jack up the vehicle and remove the front wheels. [Point 2]
6 Remove the lower panel. (40 ~ 50 model)
7 Disconnect the drive motor wiring.
8 Disconnect the speed sensor connector and temperature sensor connector.
9 Disconnect the front brake piping.
10 Disconnect the parking brake piping.
11 Remove the drive unit & front axle ASSY. [Point 3]
12 Support the drive unit & front axle ASSY with wooden blocks or other suitable objects.
13 Remove the front axle ASSY with front axle bracket and the O-ring. [Point 4]
14 Remove the front axle shaft (inner).
15 Remove the parking brake cover. [Point 5]
16 Remove the gasket, cone spring washer, and washer. [Point 6]
17 Remove the parking brake piston with parking brake housing.
18 Remove the brake disc, plate, and gasket.
19 Remove the drive motor sensor bracket and terminal bracket.
20 Remove the drive motor set nut and through bolt. [Point 7]
21 Remove the drive motor ASSY. [Point 8]
Note:
• Apply MP grease to the drive motor ASSY splines.
• After installation, bleed air from the brake. (See page 10-25.)
Point Operations
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit gear
case and the bottom of the front axle ASSY, then drain the
oil.
Installation:
A A
Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the reinstal-
lation. (The renewal of the plug needs no sealing agent.)
6-9
Installation:
After installation, fill with the specified oil to the prescribed
level.
B = Within 15 mm (0.59 in)
[Point 2]
Removal:
Jack up the vehicle and then support the frame on both
sides with wooden blocks.
[Point 3]
Removal:
Perform the following procedure.
1. Use a hoist and garage jack to support the drive unit &
front axle ASSY.
2. Remove the front axel bracket set bolts (for joining the
RH LH
frame). Use an SST to remove the reamer bolt shown
in the figure.
16⋅18 model
20⋅25 model
30⋅35 model
40 ~ 50
model
6-10
SST 09310-23320-71
3. Operate the hoist and garage jack to remove the drive

SST unit and drive motor with front axle bracket with front
axle ASSY.
40 ~ 50 model Reamer bolts [Point 4]

Installation:
40 ~ 50 model
Install the reamer bolts in the positions shown in the figure.
Installation:
40 ~ 50 model
set nut threads and tighten the nut.
Installation:
LH RH
Reamer bolts Apply MP grease to the O-ring and then install the O-ring.
[Point 5]
•
Uniformly loosen (tighten) the parking break cover set bolts

in order in opposing pairs. Otherwise the bolt deformation
by the inclined cover should occur.
[Point 6]
Installation:
Make sure the cone spring washer is oriented correctly and
then install it.
4 [Point 7]
2 Installation:
After tightening the through bolts until they contact the bot-
tom, tighten the nuts in the order shown in the figure.
1
3
6-11
[Point 8]
Removal:
Use a hoist and fiber rope to lift the drive motor ASSY and
then install it while keeping it level.
6-12

16 ~ 35 model:
2 T = 49.0 ~ 78.5 (500 ~ 800)
[36.2 ~ 57.9]
40 ~ 50 model:
T = 94.5 ~ 175.5 (960 ~ 1800)
[69.5 ~ 130.2]
1 Remove the oil seal. [Point 1]
2 Turn the gear case LH upward, stand it up, and remove it. [Point 2]
3 Remove drive unit gear No.1. [Point 3]
4 Remove drive unit gear No.2 and the differential ASSY with drive unit gear No.3. [Point 4]
Note:
After reassembly, apply MP grease to the oil seal lip and drive unit gear No.1 inner spline.
6-13
SST (1) Point Operations

[Point 1]
SST (2)
Reassembly:
SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
[Point 2]
Disassembly:
Insert a flathead screwdriver into the gear case notch, and
then tap the opposite side with a plastic hammer.
Reassembly:
Apply liquid gasket (08826-76002-71 (08826-00090)) to
the gear case LH and the mating surface.
[Point 3]
Disassembly:
SST 09950-76014-71 ............(1)
(SST 09950-40011)
SST 09950-76018-71 ............(2)
(SST 09950-60010)
SST (1)
SST (2)
6-14
Drive motor side Reassembly:

SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST (2)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
Seal surface
SST (1) Orient the bearing seal surface upward (motor side) and
reassemble.
Parking brake side SST 09700-30200-71
SST
[Point 4]
Disassembly:
SST 09950-76014-71
(SST 09950-40011)
SST
Reassembly:
SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST 09950-76020-71 ............(2)
SST (2)
(SST 09950-70010)
SST (1)
No.2 Reassembly:
Engage drive unit gears No.2 and No.3 and reinstall them
No.3
in the gear case.
6-15
DIFFERENTIAL CASE ASSEMBLY

16 18 model, 40 ~ 50 model
•
T = 127.5 ~ 176.5 (1300 ~ 1800)

[94.1 ~ 130.2]
4
1
T = 43.1 ~ 53.9 (440 ~ 550)

20 ~ 35 model [31.8 ~ 39.8]
T = 127.5 ~ 176.5 (1300 ~ 1800)
[94.1 ~ 130.2]
T = 43.1 ~ 53.9
(440 ~ 550)
[31.8 ~ 39.8]
6-16
1 Remove the differential case bearing. [Point 1]
2 Remove the differential upper case. [Point 2]
3 Remove the side gear, pinion gear, and spider. [Point 3]
4 Remove drive unit gear No.3. [Point 4]
Point Operations
SST(2) [Point 1]
Disassembly:
SST 09950-76014-71 ............(1)
SST(2)
(SST 09950-40011)
SST 09950-76018-71 ............(2)
(SST 09950-60010)
Reassembly:
SST SST 09421-33020-71
[Point 2]
Match mark Disassembly:

Put match marks on the case.
Reassembly:
Reassemble the case making sure the alignment marks
are aligned.
Reassembly:
set bolt threads and install the case.
[Point 3]
Inspection:
Measure the differential pinion inside diameter.

Limit: 22.22 mm (0.8748 in)
6-17
16⋅18 model, 40 ~ 50 model Inspection:

Measure the spider outside diameter.
Limit: 21.75 mm (0.8563 in)
20 ~ 35 model
Inspection:
Measure the side gear thrust washer thickness.
Limit: 1.3 mm (0.051 in)
Inspection:
Measure the pinion gear thrust washer thickness.
Limit: 1.0 mm (0.039 in)
Reassembly:
Position the side gear thrust washer with the oil groove fac-
ing the tooth surface side and install the washer.
Oil groove
Apply grease in Reassembly:

these locations. Evenly apply washer grease (molybdenum disulfide
grease) to both sides of the pinion gear thrust washer and
install the washer.
6-18
[Point 4]
Reassembly:
set bolt threads and install the washer. Incrementally tight-
en the bolts in order in opposing pairs, and then make the
final tightening in circular order to the specified torque.
7-1
FRONT AXLE
Page
GENERAL ..........................................................................7-2
0
SPECIFICATIONS ............................................................7-6
1
COMPONENTS .................................................................7-6
2
TIRES • WHEELS .............................................................7-10
FRONT AXLE ASSY (16 ~ 35 MODEL) ....................7-11 3
FRONT AXLE ASSY (40 ~ 50 MODEL) ....................7-16 6
REMOVAL • INSTALLATION............................................7-16
7
FRONT AXLE BRACKET .............................................7-23
8
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ..............7-23 9
11
12
13
14
15
16
17
18
19
20
21
22
7-2
GENERAL
7
16 • 18 model
2
7-3
20 • 25 model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
7-4
30 • 35 model
7-5
40 ~ 50 model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
7-6
SPECIFICATIONS
Model
16 ~ 35 40 ~ 50
Item
Front axle type Half-floating
Suspension type Fixed frame
Reduction unit type  Planetary gear reduction
Reduction ratio  3.0
COMPONENTS
16 ~ 35 model 4201
7-7
16 ~ 35 model 4201
7-8
40 ~ 50 model 4201
7-9
40 ~ 50 model 4201
'28%/(
7-10
TIRES • WHEELS
1. Adjusting the Inflating Pressure
Caution:
• Do not inflate tires beyond the specified pressure
because it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it
in a safety fence.
Specified Inflating Pressure

Classification Specification Tire size Rim type Inflating pressure kPa (kgf/cm2) [psi]
STD 21×8-9-14PR Side ring 900 (9.0) [128]
16 18 model
•
Wide 21×8-9-14PR Side ring 900 (9.0) [128]
Oversize 6.50-10-14PR Side ring 1000 (10.0) [142]
STD 21×8-9-14PR Side ring 900 (9.0) [128]
Wide 21×8-9-14PR Side ring 900 (9.0) [128]
20 model
Oversize 23×9-10-18PR Side ring 900 (9.0) [128]
Oversize wide 23×9-10-18PR Side ring 900 (9.0) [128]
STD 23×9-10-18PR Side ring 900 (9.0) [128]
25 model
Wide 23×9-10-18PR Side ring 900 (9.0) [128]
STD 250-15-18PR Side ring 950 (9.5) [135]
40 model
Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
45 model STD 250-15-18PR Side ring 950 (9.5) [135]
V FV mast Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
45 model
Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
FSV mast
50 model Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
2. Wheel Disassembly Reassembly

•
Caution:
Always discharge air fully before disassembling the
wheel. Otherwise, it is very dangerous since the rim may
come off suddenly due to the internal pressure.
7-11
FRONT AXLE ASSY (16 ~ 35 MODEL)

T = 80 ~ 120 (820 ~ 1220)

[59.3 ~ 88.3]
Removal Procedure
1 Drain the oil from the drive unit. [Point 1]
2 Jack up the vehicle and remove the front wheel. [Point 2]
3 Remove the front axle assembly and O-ring.
Note:
Apply MP grease to the O-ring.
7-12
Point Operation
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit
gear case and the bottom of the front axle assembly, and
drain the oil.
Installation:
A A Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the
reinstallation. (The renewal of the plug needs no sealing
agent.)
Installation:
level.
B B = Within 15 mm (0.59 in)
[Point 2]
Removal:
7-13

T = 2.0 ~ 3.9 (20 ~ 40)

[1.5 ~ 2.9]
T = 196.0 ~ 343.0 (2000 ~ 3500)
[144 ~ 253]
1
2
3 6
5
4
1 Remove the lock nuts. [Point 1]
2 Remove the inner bearing.
3 Remove the front axle hub assembly.
5 Remove the outer bearing.
6 Remove the bearing outer race. [Point 3]
7 Remove the front axle shaft (outer). [Point 4]
8 Remove the hub bolts.
7-14
Point Operation
SST [Point 1]
Reassembly:
Adjust the front axle shaft starting force.
1. Tighten the lock nuts to the specified torque.
SST 09509-76002-71 (SST 09509-55020)
2. Rotate the hub 4 to 5 times to break in the bearing.
3. Back off the lock nut 30º to 60º, and align the lock nut
plate hole and the screw hole of the lock nut. Turn the
hub 4 to 5 times again at this position.
4. Install a knock pin in the front axle hub and use a
spring scale to measure the starting force.
Standard:
16 ~ 25 model:
15.0 ~ 42.4 N (1.5 ~ 4.3 kgf) [3.3 ~ 9.5 lbf]
30 • 35 model:
19.9 ~ 63.7 N (2.0 ~ 6.5 kgf) [4.4 ~ 14.3 lbf]
When not within the standard, adjust by increasing or
decreasing the lock nut tightness.
5. Apply lock agent (08833-76002-71 (08833-00080)) to

the lock nut screw threads and tighten the nut to the
specified torque.
[Point 2]
Reassembly:
SST Tap in the oil seal to the front axle hub end surface.
SST 09700-30200-71
Reassembly:
Apply MP grease to the lip of the oil seal.
[Point 3]
Disassembly:
Use a brass bar to remove the bearing outer race.
7-15
[Point 4]
Disassembly:
When the outer bearing still remains on the front axle
(2)
(1)
shaft (outer), use an SST to remove it.
SST 09420-23001-71 ............(1)
SST 09950-76019-71 ............(2)
(SST 09950-60020)
7-16
FRONT AXLE ASSY (40 ~ 50 MODEL)

4 3
3
T = 221 ~ 323 (2250 ~ 3300)

[162.8 ~ 238.8]
Removal Procedure
3 Remove the front axle assembly, plate, and O-ring. [Point 3]
Note:
Apply MP grease to the O-ring.
7-17
Point Operation
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit
gear case and the bottom of the front axle assembly, and
drain the oil.
Installation:
agent.)
Installation:
level.
[Point 2]
Removal:
[Point 3]
Match mark
Removal:
Place match marks on the front axle assembly and front
axle bracket.
Installation:
Install making sure the match marks are aligned properly.
Removal installation:
•
SST 09421-30840-71 ............(1)

SST 09010-20111-71.............(2)
SST (2)
There is a danger the plate will fall down, so lay out waste
cloths under the front axle assembly to soften the fall of
SST (1)
the plate in case it falls.
7-18
Installation:
Apply MP grease to the O-ring and then insert it to the
position shown in the figure.
Installation:
Always be sure to tighten the set nuts after the bolts have
been secured to prevent the O-ring from being damaged.
(Bolts do not rotate.)
Installation:
O-ring set nut threads and screw on the nuts.
7-19

T = 294.0 ~ 343.0
T = 176.4 ~ 235.2 (3000 ~ 3500)
(1800 ~ 2400) [217.1 ~ 253.2]
[130.2 ~ 173.6]
2
1
T = 264.8 ~ 294.2 4
(2700 ~ 3000)
7
[195.3 ~ 217.1]
12
9
5 8
11
10
1 Remove the lock nuts. [Point 1]
2 Remove the planet gear carrier assembly W/inner bearing.
3 Remove the inner bearing. [Point 2]
4 Remove the planetary gear. [Point 3]
5 Remove the front axle hub assembly.
6 Remove the internal gear.
7 Remove the inner bearing outer race. [Point 4]
9 Remove the outer bearing outer race. [Point 6]
10 Remove the front axle shaft (outer) W/outer bearing.
11 Remove the outer bearing. [Point 7]
12 Remove the hub bolts.
Note:
• Apply lock agent (08833-76001-71 (08833-00070)) to the internal gear set bolt threads and screw
in the bolts.
• Apply lock agent (08833-76001-71 (08833-00070)) to the hub bolt set nut threads and screw on
the nuts.
7-20
Point Operations
[Point 1]
Reassembly:
Adjust the front axle shaft startup force.
1. Tighten a new lock nut to the specified torque.
T = 294.0 ~ 343.0 N⋅m (3000 ~ 3500 kgf⋅cm)
[217.1 ~ 253.2 ft⋅lbf]
2. Rotate the front axle hub 4 to 5 times to break in the
bearing.
3. Install a knock pin in the front axle hub and use a

spring scale to measure the starting force.
Standard:
56 ~ 100 N (5.7 ~ 10.2 kgf) [13 ~ 22 lbf]
When not within the standard, increase or decrease

the shim thickness to adjust the starting force.
Increase the shim thickness to increase the startup
Lock nut plate
force, and decrease the shim thickness to decrease
Shim the startup force.
Shim thickness:
0.1 • 0.4 • 1.0 mm (0.004 • 0.016 • 0.039 in)
Orient the lock nut plate with the oil groove facing up
and then install the plate.
4. Tighten down the lock nut.

Do not tighten down so much that the lock nut is
cracked.
A = 1 mm (0.039 in) or less.
[Point 2]
Disassembly:
SST 09420-23001-71 ............(1)
SST (2) SST 09950-76019-71 ............(2)
(SST 09950-60020)
SST (1)
7-21
[Point 3]
Inspection:
Measure the planetary gear shaft outside diameter.

Limit: 21.85 mm (0.8602 in)
Reassembly:
Tap in the needle bearing up to the end of the planetary gear.
SST 09950-76018-71 ............(1)
Make flush Make flush (SST 09950-60010)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
Tap the needle bearings up to both ends of the planetary
gear. When doing this, make sure the marked surface of
the needle bearing is facing outward.
SST (2) Make flush Make flush Do not apply grease to the needle bearing and the plane-
tary gear shaft.
SST (1)
[Point 4]
Disassembly:
[Point 5]
Reassembly:
SST Tap in the oil seal up to the end of the front axle hub.
SST 09700-30200-71
Reassembly:
Apply MP grease to the lip of the oil seal.
[Point 6]
Disassembly:
7-22
[Point 7]
Disassembly:
SST 09420-23001-71
SST
7-23
FRONT AXLE BRACKET

Note:
The following work is for removing and installing only one side of the front axle bracket. When
installing/removing both sides at the same time, remove the drive unit & front axle assembly from
the vehicle before removing front axle brackets. (See page 6-6.)
T = 185 ~ 344
(1900 ~ 3500)
[137.5 ~ 253.2]
7
T = 108 ~ 137 (1100 ~ 1400)

[79.5 ~ 101.3]
T = 46 ~ 66 (470 ~ 670)
[34 ~ 48]
11
10 T = 80 ~ 120
(820 ~ 1220)
[59 ~ 88]
7-24
Removal Procedure
1 Move the mast assembly. (See page 13-10.)
5 Support the gear case on wooden block.
6 Remove the front axle assembly W/front axle bracket and the O-ring. [Point 3]
9 Remove the disc and pressure plate.
10 Remove the 1 brake piston guide W/piston. [Point 4]
11 Remove the O-ring and D-ring from the front axle bracket.
Note:
• Apply MP grease to the O-ring and D-ring.
Point Operations
[Point 1]
Removal:
case and the bottom of the front axle assembly, and drain
the oil.
Installation:
agent.)
Installation:
level.
[Point 2]
Removal:
7-25
[Point 3]
Removal:
Perform the following procedure.
1. Remove the front axle bracket set bolts (that connect
with the gear case).
2. Use a hoist and garage jack to support the front axle
assembly with front axle bracket.
RH LH 3. Remove the front axle bracket set bolts (that connect

with the frame). Use an SST to remove the reamer
16 • 18 model bolts shown in the figure.
20 • 25 model
30 • 35 model
SST 09310-23320-71
SST
4. Operate the hoist and garage jack to remove the front

axle assembly W/front axle bracket.
[Point 4]
Service bolts
Removal:
After removing the set bolts, use service bolts to remove
the brake piston guide W/piston.
Service bolt size: M10 × 1.25
Installation:
piston guide set bolt screw threads and then uniformly
tighten the bolts.
7-26

Note:
The following work is for removing and installing only one side of the front axle bracket. When
installing/removing both sides at the same time, remove the drive unit & front axle assembly from
the vehicle before removing front axle brackets. (See page 6-6.)
T = 235 ~ 294
(2400 ~ 3000)
7 [173.6 ~ 217.1]
T = 221 ~ 323
(2250 ~ 3300)
6
[162.8 ~ 238.8]
11 T = 45 ~ 60 (460 ~ 610)
[33.3 ~ 44.1]
10
9
8
T = 221 ~ 323
(2250 ~ 3300)
12
[162.8 ~ 238.8]
8
7-27
Removal Procedure
1 Move the mast assembly. (See page 13-10.)
5 Support the gear case on wooden block.
6 Remove the front axle assembly W/front axle bracket and the O-ring. [Point 3]
9 Remove the plate.
10 Remove the disc and pressure plate.
11 Remove the brake piston guide W/piston. [Point 5]
12 Remove the O-ring, D-ring, and backup ring from the front axle bracket. [Point 6]
Note:
Point Operations
[Point 1]
Removal:
case and the bottom of the front axle assembly, and drain
the oil.
Installation:
agent.)
Installation:
level.

7-28
[Point 2]
Removal:
Jack up the vehicle and support both sides of the frame on
wooden blocks.
[Point 3]
Removal:
Perform using the following procedure.
1. Remove the front axle bracket set nuts (that connect
with the gear case).
2. Use a hoist to suspend the front axle assembly with
front axle bracket.
3. Remove the front axle bracket set bolts (that connect

RH LH with the frame). Use an SST to remove the reamer
bolts shown in the figure.
SST 09310-23320-71
4. Operate the hoist to remove the front axle assembly

W/front axle bracket.
SST
Reamer bolts Installation:

Install the reamer bolts in the position shown in the figure.
Installation:
front axle bracket set nut screw threads and then tighten
the nuts.
LH Reamer bolts RH
7-29
[Point 4]
Removal:
Place match marks on the front axle assembly and front
axle bracket.
Installation:
Install making sure the match marks are aligned properly.
Match mark
Installation:
Apply MP grease to the O-ring and then insert it to the
position shown in the figure.
Installation:
Always be sure to tighten the set nuts after the bolts have
been secured to prevent the O-ring from being damaged.
(Bolts do not rotate.)
Installation:
O-ring
set nut threads and screw on the nuts.
[Point 5]
Removal:
SST After removing the set bolts, use an SST to remove the
brake piston guide W/piston.
SST 09810-20172-71
Removal:
set bolt screw threads and then uniformly tighten the bolts.
[Point 6]
Piston
Installation:
Make sure to install the backup ring in the correct position.
Backup ring
8-1
REAR AXLE
Page
GENERAL ..........................................................................8-2
0
SPECIFICATIONS ............................................................8-6
1
COMPONENTS .................................................................8-7
2
TIRES • WHEELS .............................................................8-10
REAR AXLE ASSY (16 ~ 35 MODEL) ......................8-11 3
REAR AXLE ASSY (40 ~ 50 MODEL) ......................8-13 5
REAR AXLE HUB • STEERING KNUCKLE
(16 ~ 35 MODEL) .........................................................8-15
7
REAR AXLE HUB • STEERING KNUCKLE 9
(40 ~ 50 MODEL) .........................................................8-20
10
REMOVAL INSTALLATION............................................8-20
•
11
REAR AXLE CYLINDER ..............................................8-24
REAR WHEEL ALIGNMENT (16 ~ 35 MODEL) .....8-30
15
REAR WHEEL ALIGNMENT (40 ~ 50 MODEL) .....8-32
16
17
18
19
20
21
22
8-2
GENERAL
8
16 ~ 25 model
8-3
30⋅35 model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
8-4
40 ~ 50 model
8-5
Rear Axle Cylinder

16 ~ 35 model
0
1
2
3
4
5
6
7
8
40 ~ 50 model
9
10
11
12
13
14
15
16
17
18
19
20
21
22
8-6
SPECIFICATIONS
Rear axle type Elliot type
Rear axle suspension type Center-supported right-left rocking type
Toe-in mm (in) 0 (0)
Camber degree 16 ~ 35 model: 1.5°, 40 ~ 50 model: 0°
Wheel alignment
Caster degree 0°
King pin angle 0°
16 model: 1870 (73.6)
18 model: 1870 (73.6)
20 model: 2020 (79.5)
25 model: 2030 (79.9)
Minimum turning radius (outermost) mm (in) 30 model: 2160 (85.0)
35 model: 2215 (87.2)
40 model: 2680 (105.5)
45 model: 2680 (105.5)
50 model: 2740 (107.9)
Cylinder type Double acting
Piston rod outside 16 ~ 35 model: 50.0 (1.969)
Rear axle cylinder diameter mm (in) 40 ~ 50 model: 55.0 (2.165)
16 ~ 35 model: 76.0 (2.992)
Cylinder bore mm (in)
40 ~ 50 model: 90.0 (3.543)
8-7
COMPONENTS
16 ~ 25 model 4301
30 35 model
•
8-8
40 ~ 50 model 4301
16 ~ 35 model 4302
8-9
40 ~ 50 model 4302
8-10
TIRES • WHEELS
1. Adjusting the Inflating Pressure
Caution:
• Do not inflate tires beyond the specified pressure
because it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it
in a safety fence.
Specified Inflating Pressure

Inflating pressure
Model Tire size Rim type
kPa (kgf/cm2) [psi]
16 18 model
•
5.00-8-8PR Divided 800 (8.0) [114]
5.00-8-8PR Side ring 800 (8.0) [114]
20 model 5.00-8-10PR Side ring 1000 (10.0) [142]
25 model 18 × 7-8-16PR Divided 750 (7.5) [107]
18 × 7-8-16PR Side ring 750 (7.5) [107]
30 35 model
•
– – –
– – –
40 45 model
•
7.00-12-12PR Divided 850 (8.5) [121]
7.00-12-12PR Side ring 850 (8.5) [121]
50 model 7.00-12-14PR Side ring 900 (9.0) [128]
Chamfering
2. Wheel Disassemly⋅Reassembly
Caution:
Always discharge air fully before disassembling the
wheel. Otherwise, it is very dangerous since the rim may
come off suddenly due to the internal pressure.
Note:
Install each divided rim set bolt with its head on the
Outer rim
outer rim side and the chamfered portion facing the
center of the wheel.

T = 29.4 ~ 44.1 (300 ~ 450)
16 ~ 20 model
[21.7 ~ 32.6]
T = 78.5 ~ 117.7 (800 ~ 1200)
25 model
[57.9 ~ 86.8]
T = 117.7 ~ 176.5 (1200 ~ 1800)
40 ~ 50 model
[86.8 ~ 130.2]
8-11
REAR AXLE ASSY (16 ~ 35 MODEL)

T = N m (kgf cm) [ft lbf]
• • •
8
3 9
2*
T = 128 ~ 175 (1310 ~ 1780)

2* Hub nut [94.78 ~ 128.8]
16 ~ 20 model T = 88.3 ~ 157.0 (900 ~ 1600) [65.12 ~ 115.8]
25 ~ 35 model T = 117.6 ~ 196 (1200 ~ 2000) [86.82 ~ 144.7]
Removal Procedure
1 Chock the front wheels.
2 Jack up the vehicle and remove rear wheels.
3 Remove the swing lock cylinder lower pin.
4 Disconnect the rear axle cylinder hose.
5 Disconnect the tire angle sensor connector.
6 Support the rear axle ASSY with a garage jack.
7 Remove the rear axle ASSY. [Point 1]
8 Remove the center pin bushing. [Point 2]
9 Remove the rear axle damper.
Note:
After installation, add grease through each grease fitting. Add molybdenum disulfide grease at the
rear axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease to other
grease fittings.
8-12
Point Operations
[Point 1]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the
front to rear clearance on the rear side.
Standard clearance: 0.7 mm (0.028 in) or less
2. If the measured value does not satisfy the standard,

remove the rear axle ASSY and make adjustment by
selecting the spacer.
Spacer thickness:
0.5⋅1.2⋅2.3⋅3.0⋅3.5⋅4.0⋅4.5 and 5.0 mm
(0.020⋅0.047⋅0.091⋅0.118⋅0.138⋅0.157⋅0.177 and
0.197 in)
Removal:
Draw different match marks on the rear axle bracket caps
front and rear to prevent confusion.
Installation:
Install after aligning the match mark.
Match mark
[Point 2]
Inspection:
Inspect the inside diameter of the rear axle center pin
bushing.
Limit: 52.0 mm (2.047 in)
Installation:
Apply molybdenum disulfide grease to the bushing before
installation.
16 ~ 30 model Installation:
Install the bushing by aligning the grease groove in the
bushing with the grease fitting position. (16 ~ 30 model)
Grease
groove
8-13
REAR AXLE ASSY (40 ~ 50 MODEL)

• • •
8
7
3
T = 176.4 ~ 392 (1800 ~ 4000)

[130.2 ~ 289.4]
T = 128 ~ 175 (1310 ~ 1780)

[94.78 ~ 128.8]
Removal Procedure
1 Chock the front wheels.
4 Disconnect the rear axle cylinder hose.
6 Support the rear axle ASSY with a garage jack.
7 Remove the rear axle ASSY. [Point 1]
8 Remove the center pin bushing. [Point 2]
Note:
After installation, add grease through each grease fitting. Add molybdenum disulfide grease at the
rear axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease to other
grease fittings.
8-14
Point Operations
[Point 1]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the
front to rear clearance on the rear side.
Standard clearance: 1.0 mm (0.039 in) or less

remove the rear axle ASSY and make adjustment by
selecting the spacer.
Spacer thickness:
0.6⋅1.2⋅2.3⋅3.2 and 4.5 mm
(0.024⋅0.047⋅0.091⋅0.125 and 0.177 in)
3. Install the spacer at the rear side center pin.
Removal:
Draw different match marks on the rear axle bracket caps
front and rear to prevent confusion.
Installation:
Install after aligning the match mark.
Match mark
[Point 2]
Inspection:
Inspect the inside diameter of the rear axle center pin
bushing.
Limit: 67.0 mm (2.638 in)
Installation:
Apply molybdenum disulfide grease to the bushing before
installation.
8-15
REAR AXLE HUB • STEERING KNUCKLE (16 ~ 35 MODEL)

• • •
9 7
11
12
10
T = 49.0 ~ 78.5 (500 ~ 800)

[36.2 ~ 57.9]
11
9
3
5
2
11 6
5
T = 44.1 ~ 53.9 (450 ~ 550)
[32.6 ~ 39.8]
4
Removal Procedure
1. Jack up the vehicle and remove rear wheels.
2. Remove the hub caps. [Point 1]
3. Remove the castle nut and claw washer. [Point 2]
4. Remove the outer bearing and axle hub. [Point 3]
5. Remove the bearing outer race from the axle hub. [Point 4]
6. Remove the inner bearing and oil seal. [Point 5]
7. Disconnect the tie rod (on the knuckle side). [Point 6]
8. Remove the king pin cover (on the LH side) or the tire angle sensor (on the RH side).
9. Remove the king pin lock bolt and king pin. [Point 7]
10. Remove the thrust bearing, spacer and steering knuckle.
11. Remove the king pin oil seal and needle bearing. [Point 8]
12. Remove the bushing from the steering knuckle. [Point 9]
Note:
After installation, add MP grease through grease fittings.
8-16
Point Operations
[Point 1]
Installation:
Fill MP grease in the hub cap, and install by tapping the
flange portion.
(Instead of MP grease filling, spraying grease over the
castle nut is also usable.)
[Point 2]
Installation:
Adjust the rear axle hub starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a
torque of 15 to 32 N⋅m (150 to 330 kgf⋅cm) [10.9 to
23.9 ft⋅lbf].
3. Rotate the hub by 3 to 5 turns to run in the bearing.
Claw washer 4. Set a spring scale on a hub bolt, and measure the
starting force.
Standards:
16 ~ 20 model 15 ~ 39 N (1.5 ~ 4.0 kgf) [3.3 ~ 8.5 lbf]
25 ~ 35 model 15 ~ 44 N (1.5 ~ 4.5 kgf) [3.3 ~ 9.9 lbf]
adjust the degree of castle nut tightening for
adjustment.
6. Install a new cotter pin.
[Point 3]
SST Removal:
SST 09950-76014-71
(SST 09950-40011)
Installation:
Install the axle hub and outer bearing.
1. Fill MP grease in the axle hub and knuckle spindle.
2. Install the axle hub.
3. Use the SST and install the outer bearing roller.
SST 09370-20270-71
SST
8-17
[Point 4]
Removal:
SST(2)
Use a brass bar and remove the bearing outer race.
SST(1) Installation:
SST 09950-76019-71 ............(1)
(SST 09950-60020)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
[Point 5]
SST Removal:
SST 09950-76014-71
(SST 09950-40011)
Installation:
Install the oil seal and inner bearing.
1. Use the SST and install the oil seal.
SST 09370-10410-71
SST
2. Use the SST and install the inner bearing.

SST 09370-20270-71
SST
[Point 6]
Match mark
Removal:
Mark the end pin punch mark position to the plate side.
Installation:
Install by matching the end pin punch mark position to the
marking on the plate side.
8-18
Installation:
To install the end pin lock nut, install the cone washer in
the direction shown in the figure and tighten to a specified
torque.
T = 49.0 ~ 78.5 N⋅m (500 ~ 800 kgf⋅cm)

[36.2 ~ 57.9 ft⋅lbf]
Cone washer
[Point 7]
Inspection:
Measure the king pin outside diameter.
Limit: 27.8 mm (1.094 in)
Installation:
Measure the steering knuckle starting force.
1. Temporarily install the king pin and king pin lock bolt.
Select the spacer so as to minimize vertical looseness
of the knuckle, and install it on top of the thrust bearing.
Spacer thickness:
16 ~ 20 model : 0.5 and 1.0 mm
(0.020 and 0.039 in)
25 ~ 35 model : 3.0, 3.5, 4.0 and 4.5 mm
(0.118, 0.138, 0.157 and 0.177 in)
2. Set a spring scale at the tip end of the knuckle
spindle, and measure the starting force.
Spacer Standard: 19.3 N (2.0 kgf) [4.4 lbf] or less

installing
position
3. If the measured value exceeds the standard, check
the king pin for bend, the needle bearing for damage
and axle beam for deformation.
4. Tighten the lock nut for the king pin lock bolt.
8-19
[Point 8]
SST(2) Removal:
Remove the king pin oil seal and needle bearing.
1. Use a straight-edge screwdriver to remove the dust
seal and oil seal.
2. Use the SST and remove the needle bearing.
SST 09950-76018-71 .....(1)
SST(1) (SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
Installation:
Install the needle bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
Check the needle bearing press-fitting surface,
0 mm pressing direction and installation depth.
(0 in)
SST 09950-76018-71 .....(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
2. Install the dust seal.
4 mm 3. Use the SST and install the oil seal.
(0.16 in) SST 09950-76018-71 .....(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
Punched
surface
(SST 09950-70010)
Needle bearing
Press-fitting direction
[Point 9]
Bushing
Installation:
Press-in the bushing flush to the lower surface of the
knuckle. (Clearance on the upper side will be used for the
grease well.)
Flush
8-20
REAR AXLE HUB • STEERING KNUCKLE (40 ~ 50 MODEL)

• • •
11
10
11 10
11
9 3
6 2
T = 44.1 ~ 53.9
(450 ~ 550) 5
T = [32.6 ~ 39.8]
4
Removal Procedure
2 Remove the hub caps. [Point 1]
3 Remove the castle nut and claw washer. [Point 2]
4 Remove the outer bearing and axle hub. [Point 3]
5 Remove the bearing outer race from the axle hub. [Point 4]
6 Remove the inner bearing and oil seal. [Point 5]
7 Disconnect the tie rod (on the knuckle side).
8 Remove the king pin cover (on the LH side) or the tire angle sensor (on the RH side).
9 Remove the king pin lock bolt and king pin. [Point 6]
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seal and needle bearing. [Point 7]
Note:
After installation, add MP grease through grease fittings.
8-21
Point Operations
[Point 1]
Installation:
Fill MP grease in the hub cap, and install by tapping the
flange portion.
(Instead of MP grease filling, spraying grease over the
castle nut is also usable.)
[Point 2]
Installation:
Adjust the rear axle hub starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a
torque of 15 to 32 N·m (150 to 330 kgf·cm) [10.9 to
23.9 ft·lbf].
3. Rotate the hub by 3 to 5 turns to run in the bearing.
Claw washer
4. Set a spring scale on a hub bolt, and measure the

starting force.
Standard: 43 ~ 72 N (4.4 ~ 7.3 kgf) [9.7 ~ 16.1 lbf]

adjust the degree of castle nut tightening for
adjustment.
6. Install a new cotter pin.
[Point 3]
SST Removal:
SST 09120-23600-71
Installation:
Install the axle hub and outer bearing.
1. Fill MP grease in the axle hub and knuckle spindle.
2. Install the axle hub.
3. Use the SST and install the outer bearing roller.
SST 09370-20270-71
SST
Fill grease
8-22
[Point 4]
Removal:
SST (2) Use a brass bar and remove the bearing outer race.
SST (1) Installation:

SST 09950-76019-71 ............(1)
(SST 09950-60020)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
SST
[Point 5]
Removal:
SST 09950-76014-71
(SST 09950-40011)
Installation:
Install the oil seal and inner bearing.
1. Install the oil seal.
2. Use the SST and install the inner bearing.
SST 09316-76008-71
(SST 09316-60011)
SST
[Point 6]
Installation:
Measure the king pin outside diameter.
Limit: 34.8 mm (1.370 in)

8-23
Installation:
Measure the steering knuckle starting force.
1. Temporarily install the king pin and king pin lock bolt.
Select the spacer so as to minimize vertical looseness
of the knuckle, and install it to lower side of the
steering knuckle.
Spacer thickness: 0.15, 0.25, and 0.35 mm
(0.006, 0.010, and 0.014 in)
2. Set a spring scale at the tip end of the knuckle
spindle, and measure the starting force.
Standard: 19.3 N (2.0 kgf) [4.4 lbf] or less
3. If the measured value exceeds the standard, check

the king pin for bend, the needle bearing for damage
and axle beam for deformation.
4. Tighten the lock nut for the king pin lock bolt.
[Point 7]
SST(2) Removal:
Remove the king pin oil seal and needle bearing.
1. Use a straight-edge screwdriver to remove the dust
seal and oil seal.
2. Use the SST and remove the needle bearing.
SST 09950-76018-71 .....(1)
SST(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
Installation:
Install the needle bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
0 mm
(0 in)
Check the needle bearing press-fitting surface,
pressing direction and installation depth.
SST 09950-76018-71 .....(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
4 mm 2. Install the dust seal.
(0.16 in)
3. Use the SST and install the oil seal.
SST 09950-76018-71 .....(1)
Punched
(SST 09950-60010)
surface
SST 09950-76020-71 .....(2)
(SST 09950-70010)
Needle bearing
Press-fitting direction
8-24
REAR AXLE CYLINDER

• • •
T = 166.7 ~ 215.8
(1700 ~ 2200)
[123.0 ~ 159.1]
3
3
2
5
Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder.
5 Remove the bushing from the piston rod. [Point 3]
8-25
Point Operations
Match mark
[Point 1]
Removal:
Mark the end pin punch mark position to the plate side.
Installation:
Install by matching the end pin punch mark position to the
marking on the plate side.
Installation:
To install the end pin lock nut, install the cone washer in
the direction shown in the figure and tighten to a specified
torque.
T = 49.0 ~ 78.5 N⋅m (500 ~ 800 kgf⋅cm)

[36.2 ~ 57.9 ft⋅lbf]
Cone washer
[Point 2]
Installation:
Install the fitting in the direction shown in the figure.
A = 60°
A A
Bushing [Point 3]
Installation:
Press-in the bushing flush to the lower surface of the rod
on both ends. (Clearance on the upper side will be used
for the grease well.)
Flush
8-26

• • •
T = 421.7 ~ 470.7
(4300 ~ 4800)
[311.1 ~ 347.3]
3
3
2
4
Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder.
8-27
Point Operations
Match mark
[Point 1]
Removal:
Mark the punch mark position on each of cylinder end pins
LH and RH.
Installation:
Install each cylinder end pin by aligning the punch mark
with the mark.
[Point 2]
Installation:
Install the fitting in the direction shown in the figure.
A = 20°
A
A A
A
8-28

• • •
16 ~ 35 model
T = 88 ~ 118 1 4
T = (900 ~ 1200)
T = [65.1 ~ 86.8]
T = 88 ~ 118
T = (900 ~ 1200)
T = [65.1 ~ 86.8]
40 ~ 50 model
1
T = 117.7 ~ 137.3 4
T = (1220 ~ 1400)
T = [86.82 ~ 101.3]
2
3
1
T = 117.7 ~ 137.3
T = (1220 ~ 1400)
T = [86.82 ~ 101.3]
8-29
1 Remove the through bolt.
2 Remove the piston rod guide.
3 Remove the piston rod. [Point 1]
4 Inspect the cylinder. [Point 2]
Note:
Coat hydraulic oil before reassembly.
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Limit:
16 ~ 35 model: 49.92 (1.9654 in)
40 ~ 50 model: 54.91 (2.1618 in)
Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)
Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil
or water before installation.
Do not stretch it excessively.
Caution:
Operate carefully to avoid scalding.
[Point 2]
Inspection:
Measure the rear axle cylinder bore.
Limit:
16 ~ 35 model: 76.35 mm (3.0059 in)
40 ~ 50 model: 90.40 mm (3.5591 in)
8-30
REAR WHEEL ALIGNMENT (16 ~ 35 MODEL)

Toe-in Inspection
1. Check to see that dimensions Ar and Al of the rear axle cylinder are equal.
2. Measure the toe-in (Bf-Br).
Standard: 0 ± 4 mm (0 ± 0.16 in)
Bf
OUT IN IN OUT
Al Ar
Rl Rr
Br
Toe-in Adjustment
Plate
Front side
1. Check to see that Ar and Al of the rear axle cylinder are
equal.
2. Match the punch marks on the end pin (eccentric pin)
RH
and the plate to the front side for all four points as shown
LH
in the figure.
Punch mark
8-31
3. Measure and adjust the toe-in (Bf-Br).

OUT
OUT Standard: 0 ± 4 mm (0 ± 0.16 in)
IN IN
IN IN If the measured value exceeds the standard, remove the
lock plate and make adjustment using end pins (1) and (2)
in the range where the difference between Rl and Rr is
within 0 ± 3 mm (0 ± 0.12 in).
(1) (1)
(2) (2) (1) When measured value > 4 mm (0.16 in)
Measure Rl and Rr. Adjust the end pins (1) and (2) of
the smaller value to the IN side.
(2) When measured value < 4 mm (0.16 in)
Measure Rl and Rr. Adjust the end pins (1) and (2) of
the greater value to the OUT side.
Note:
• If Rl equals to Rr, adjust the same amount of the LH
and RH sides.
• If the standard is not attained by adjustment on one
side, make adjustment also on other side.
4. After adjustment, fully steer the tires and check to see

that they do not come into contact with the vehicle body.
8-32
REAR WHEEL ALIGNMENT (40 ~ 50 MODEL)

Toe-in Inspection
1. Check to see that dimensions Ar and Al of the rear axle cylinder are equal.
2. Measure the toe-in (Bf-Br).
Standard: 0 ± 4 mm (0 ± 0.16 in)
Bf
OUT IN IN OUT
Al Ar
Rl Rr
Br
Toe-in Adjustment
Punch mark on plate side 1. Check to see that Ar and Al of the rear axle cylinder are
equal.
2. Align the punch mark on the cylinder end pin (eccentric
pin) with the punch mark on the plate on the front side
for both the LH and RH sides.
3. Measure and adjust the toe-in (Bf-Br).
Standard: 0 ± 4 mm (0 ± 0.16 in)
If the measured value does not satisfy the standard,
Punch mark on cylinder end pin side make adjustment by the cylinder end pin in the range
where the difference between Rl and Rr is within 0 ± 3
mm (0.12 in).
(1) When measured value > 4 mm (0.16 in):
Measure Rl and Rr, and adjust the cylinder end pin on
OUT OUT
the smaller side toward IN.
IN
IN (2) When measured value < 4 mm (0.16 in):
Measure Rl and Rr, and adjust the cylinder end pin on
the greater side toward OUT.
Note:
• If Rl equals to Rr, adjust the same amount on the LH
and RH sides.
• If the standard is not attained by adjustment on one
side, make adjustment also on the other side.
4. Install the plate. The plate can be installed with either face up.
5. After adjustment, fully steer the tires and check to see
that they do not come into contact with the vehicle body.
9-1
STEERING
Page
GENERAL ..........................................................................9-2
0
SPECIFICATIONS ............................................................9-4
1
COMPONENTS .................................................................9-4
2
STEERING WHEEL • MAST JACKET ..........................9-7
HYDROSTATIC STEERING VALVE ASSY .............9-12 5
TROUBLESHOOTING .....................................................9-12
6
7
RELIEF PRESSURE 8
INSPECTION • ADJUSTMENT ...................................9-18 9
POWER STEERING PUMP ASSY 10
(16 ~ 35 MODEL) .........................................................9-19
GENERAL........................................................................9-19
11
SPECIFICATIONS ...........................................................9-19 12
COMPONENTS................................................................9-19 13
14
15
16
17
18
19
20
21
22
9-2
GENERAL
9
9-3
Hydrostatic Steering Valve
1 9 2 5 4 6 7
0
1. Neutral position spring
2. Housing
3. Check valve
1
2
4. Spool
5. Sleeve
6. Cardan shaft
7. Gear rim
8. Gear wheel (rotor) 3
9. Relief valve
4
5
6
3
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
9-4
SPECIFICATIONS
Model
16 ~ 35 40 ~ 50
Item
Steering wheel diameter mm (in) 360 (14.2)
Steering wheel play (at idling) mm (in) 20 ~ 50 (0.79 ~ 1.97)
Power steering type Hydrostatic steering
Type (manufacturer) OSPC (Danfoss)
Delivery cm (in)/rev 80 (4.88) 125 (7.63)
Hydrostatic steering
valve Rated flow rate (US gal)/min 18 (4.8) 15 (4.0)
Relief set pressure kPa
8040 (82)[1170] 11770 (120) [1710]
(kgf/cm2) [psi]
COMPONENTS
4501
48
01
10
49
BF
AE
30
94120-40800
46
AC
AK
AC
4501-050A
9-5
4502
0
1
2
3
4
5
6
7
8
9
16 ~ 35 model 4507
10
11
12
13
14
15
16
17
18
19
20
21
22
9-6
40 ~ 50 model 4507
4503
9-7
STEERING WHEEL • MAST JACKET

T = 25 ~ 26
5
(255 ~ 612)
[18.4 ~ 44.3]
2
16 ~ 35 model
11
10
12
3
T = 10 ~ 14
(102 ~ 143)
[7.4 ~ 10.3]
9 13
14 T = 8.4 ~ 14
(86 ~ 143)
17 [6.2 ~ 10.3]
14
16
T = 29.4 ~ 39.2
T = 34.3 ~ 53.9 (300 ~ 400)
(350 ~ 550) [21.7 ~ 28.9]
[25.3 ~ 39.8]
15
9
9
9-8
Removal Procedure
2 Remove the steering wheel. [Point 1]
3 Remove the steering column cover.
4 Disconnect the connectors of the display, key switch and lamp switch.
5 Remove the steering column cover W/display. [Point 2]
8 Disconnect the parking brake switch ASSY connector.
9 Remove the instrument panel.
10 Disconnect the direction switch connector and remove the direction switch.
11 Disconnect the turn signal switch connector and remove the turn signal switch ASSY. [Point 3]
12 Disconnect the steering sensor connector and remove the steering sensor. [Point 4]
13 Remove the spring pin and collar. [Point 5]
14 Remove the tilt lock mechanism. [Point 6]
15 Remove the steering valve set bolts and keep the valve free.
16 Remove the tension spring.
17 Remove the mast jacket ASSY.
Note:
• Apply MP grease to the sliding surface of the tilt lock device and the collar of the mast jacket set
bolt.
• Fill MP grease at the coupling between the tilt steering shaft and steering valve.
9-9
SST Point Operations

[Point 1]
Removal:
SST 09950-76003-71
(SST 09950-50012)
Installation:
Steering wheel installation procedure.
Shaft
1. Apply rubber grease on sliding face A of the turn
mark signal switch.
2. Make a hole at the surface of the cancelcam become
driver’s seat side.
3. Install the steering wheel while aligning the steering
knob end shaft mark and steering knob at the angle
shown in the figure.
A Hele
Standard: B = 14° ± 6°
4. After installation, rotate the steering wheel. As the
steering wheel is rotated, the 3 pins on the turn signal
B
switch ASSY are automatically set in the holes on the
steering wheel side.
Shaft
mark
Steering
knob
[Point 2]
Collar Sensor
Installation:
Thin Install the collar and rubber in the illustrated direction.
Thick Rubber
[Point 3]
Installation:
Install the screw as shown in the figure.
9-10
[Point 4]
Installation:
Fix the installed sensor by tightening the tapping screw
after inserting the positioning pin on the sensor side into
the hole on the bracket side.
Fixing without pin insertion may damage the sensor due to
concentricity error. Tighten the tapping screw carefully so
as not to damage the plastic portion by overtightening.
Pin Drilled hole for pin
Positioning [Point 5]
Large notch
Small notch
mark
Steering shaft Installation:
Install the collar with the larger notch aligned with the
steering shaft positioning mark.
Collar
Pay sufficient attention so as not to damage the collar
Dia.
when the spring pin is removed and installed.
Drive in the spring pin so as not to allow it to come out of
collar diameter.
Driving in
Spring pin
Steering shaft
Column cover [Point 6]

line
Tilt lever Installation:
Install so that the tilt lever line and column-cover line are
in parallel as shown in the figure, and check to see if tilt
lock operation is normal.
Tilt lever line

9-11
1 Remove the snap ring.
2 Remove the tilt steering shaft.
3 Remove the bearing.
4 Remove the turn signal switch bracket.
The reassembly procedure is the reverse of the removal procedure.
9-12
HYDROSTATIC STEERING VALVE ASSY

TROUBLESHOOTING
Fault Possible cause Remedy
1. Steering wheel is 1.1 No or insufficient oil pressure • Repair or replace oil pump.
heavy to turn • Repair or replace flow divider valve.
1.2 Pressure relief valve is stuck in • Repair or clean pressure relief
open position or setting pres- valve.
sure is too low. • Adjust the valve to the correct pres-
sure.
1.3 Too much friction at mechani- • Lubricate joints of steering link or
cal parts of the vehicle repair if necessary.
• Check steering column installation.
2. Regular adjustments of 2.1 Leaf spring without sufficient • Replace leaf springs.
the steering wheel are spring force or broken
necessary. (“Meander- 2.2 Worn gear wheel set • Replace gear wheel set.
ing”)
2.3 Seized cylinder or worn piston • Replace defects parts.
seal.
3. The steering wheel 3.1 Leaf springs are stuck or bro- • Replace leaf springs.
turns on its own. ken and have therefore
reduced spring force.
3.2 Inner and outer spools are • Clean steering unit.
stuck, possibly due to dirt.
4. Backlash 4.1 Cardan shaft worn or broken • Replace Cardan shaft.
4.2 Leaf springs without spring • Replace leaf springs.
force or broken
4.3 Worn splines on the steering • Replace steering column.
column
5. Steering wheel turns 5.1 Gear wheel set worn • Replace gear wheel set.
completely without
moving the wheels.
6. Steering is too slow 6.1 Insufficient oil supply to steer- • Repair or replace oil pump.
and heavy when oper- ing unit
ated quickly. 6.2 Relief valve setting too low • Adjust valve to correct setting.
6.3 Relief valve stuck due to dirt • Clean the valve.
7. Heavy kick-back in 7.1 Wrong setting of Cardan shaft • Correct setting as shown in Repair
steering wheel in both and gear-wheel set Manual.
directions
8. Turning the steering 8.1 Hydraulic hoses for the steer- • Reverse the hoses.
wheel moves the ing cylinders have been con-
steered wheels in nected reversely.
opposite direction.
9. Leakage at either input 9.1 Shaft seal defective • Replace shaft seal.
shaft, end cover, gear- 9.2 Screws loose • Tighten screws.
wheel set, housing or
9.3 O-rings defective • Replace O-ring.
top part.
9-13
5
T = 29.4 ~ 39.2
(300 ~ 400)
[21.7 ~ 28.9]
Removal Procedure
5 Remove the instrument panel (LH).
7 Remove the steering valve ASSY.
8 Remove the fitting.
Note:
Fill MP grease at the coupling between the tilt steering shaft and steering valve.
9-14

T = 40 ~ 60 (408 ~ 612) [29.5 ~ 44.3]
5
6
3
5
4 4
T = 24 ~ 36 (245 ~ 367) [17.7 ~ 26.6]
1 Remove the end cover. [Point 1]
2 Remove the gear wheel set, cardan shaft and distributor plate. [Point 2]
3 Remove the check valve.
4 Remove the sleeve W/spool and bearing. [Point 3]
5 Remove the O-ring, kin-ring and dust seal ring. [Point 4]
6 Remove the relief valve. [Point 5]
Note:
Wash each part with clean hydraulic oil before assembly.
9-15
Point Operations
[Point 1]
Disassembly:
Put a match mark.
Reassembly:
Align the match marks.
Disassembly:
When removing each set bolt, carefully operate so as not
to lose the steel ball.
Reassembly:
Put the steel ball in the position shown in the figure before
installing each set bolts.
Reassembly:
As one out of seven set bolt is a bolt with pin, install it in
Steel ball the correct position.
[Point 2]
Reassembly:
Pay attention to the following points at the time of
Parallel reassembly.
1. Fit the gearwheel (rotor) and cardan shaft so that the
tooth base in the rotor is positioned in relation to the
shaft slot as shown. Turn the gear rim so that the
seven through holes match the holes in the housing.
2. Guide the carden shaft down into the bore so that the
Parallel
slot is parallel with the connection flange.
Flange
3. Align the match marks on the distributor plate and gear

wheel made at the time of disassembly.
When these parts are replaced, match the holes in the
housing and plate at the time of reassembly.
9-16
[Point 3]
Disassembly:
Extract the spool W/sleeve upward. Otherwise, the spool
cross pin may move during extraction and cause sticking.
Reassembly:
Set and install the neutral position spring correctly.
Reassembly:
Pay attention to the bearing direction for installation. (See
the figure.)
Chamfering
Sleeve
Reassembly:
Place the housing with its flanged side facing down, and
insert the spool W/sleeve into the housing. Set the cross
pin of the spool in horizontal state during insertion.
O-ring [Point 4]
Reassembly:
Install the kin-ring and O-ring correctly.
Note:
For SST No. SJ150-9000-11, please inquire at the nearest
Danfoss service shop.
Kin-ring
(Refer to Parts & Service News Ref. No. GE-7022 of July
1, 1997 for detail.)
9-17
1. Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool into the bore
for the spool W/sleeve.
2. Apply O-ring and kin-ring with hydraulic oil and place
them on the tool.
3. Hold the outer part of the assembly tool in the bottom

of the steering unit housing and guide the inner part of
the tool right to the bottom.
4. Press and turn the O-ring W/kin-ring into position in

the housing.
5. Draw the inner and outer parts of the assembly tool
out of the steering unit bore, leaving the guide from
the inner part in the bore.
[Point 5]
Disassembly:
Do not remove the relief valve unless it is judged
defective.
The valve seat cannot be removed.
Disassembly:
Measure the screwed-in depth of the relief valve adjusting
screw before starting disassembly.
Reassembly:
Reassemble by adjusting to the screwed-in depth of the
valve spring retainer measured before disassembly. After
installing the steering valve ASSY on the vehicle,
measure the relief pressure. If it is not within the standard
range, adjust it by changing the screwed-in depth of the
retainer.
9-18
RELIEF PRESSURE
INSPECTION • ADJUSTMENT
1. Install a pressure gauge on the P port of the brake
change valve.
P 2. Set the knob position control solenoid to off in the

ANALYZER MENU screen. (See page 3-19.)
3. When the steering wheel is rotated beyond the end,

relief state is obtained. Read the pressure on the
pressure gauge at this time.
Standard:
kPa (kg/cm2) [psi]

+490 +5 +70
16 ~ 35 model 8040 0 (85 0 ) [1170 0 ]
+490 +5 +70
40 ~ 50 model 11770 0 (120 0 ) [1710 0 ]
3. If the standard is not satisfied, remove the steering valve

and make adjustment by turning the steering valve
adjusting screw.
9-19
POWER STEERING PUMP ASSY (16 ~ 35 MODEL)

GENERAL
SPECIFICATIONS
Pump model 16 ~ 35 model TCP-031-A
Theoretical delivery cm3(in3)/rev. 3.15 (0.1922)
COMPONENTS
4510
9-20
4
7
5
T = 20 ~ 30
4 (200 ~ 300)
[14.7 ~ 21.7]
Removal Procedure
3 Disconnect the PS motor connector.
5 Remove the fitting (outlet).
6 Remove the PS motor W/PS pump ASSY.
7 Remove the PS pump ASSY from PS motor. [Point 1]
8 Remove the fitting (inlet).
9-21
PS pump
PS motor Point Operations
[Point 1]
Oil tank
side fitting Removal⋅Installation:
PS pump set bolts are located as shown in the figure.
High pressure
side fitting
PS pump set bolts
Oldham’s joint
Installation:
When assembling the PS motor and pump, fill molybde-
num disulfide grease in the groove on the oldham’s joint.
PS motor
Apply Molybdenum disulfide

grease to fill the groove.
10-1
BRAKE
Page
GENERAL ........................................................................10-2
0
SPECIFICATIONS ..........................................................10-6
1
COMPONENTS ...............................................................10-7
2
FRONT BRAKE.............................................................10-10
DISASSEMBLY • INSPECTION • REASSEMBLY 3
(16 ~ 35 MODEL).........................................................10-10
4
(40 ~ 50 MODEL).........................................................10-12 5
PARKING BRAKE ........................................................10-15 6
DISASSEMBLY • INSPECTION • REASSEMBLY............10-15 7
BRAKE VALVE .............................................................10-18
8
TROUBLESHOOTING ...................................................10-18
9
REMOVAL • INSTALLATION..........................................10-18
BRAKE CHANGE VALVE ..........................................10-22 11
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ............10-22 12
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ............10-23
13
DISASSEMBLY • INSPECTION • REASSEMBLY............10-24
14
BRAKE AIR BLEEDING .............................................10-25
BRAKING FORCE INSPECTION .............................10-25
15
BRAKE HYDRAULIC PRESSURE INSPECTION 16
(16 ~ 35 MODEL) .......................................................10-26 17
BRAKE HYDRAULIC PRESSURE INSPECTION
18
(40 ~ 50 MODEL) .......................................................10-27
PARKING BRAKE SWITCH INSPECTION............10-28 19
BRAKE PEDAL INSPECTION • ADJUSTMENT ....10-29 20
21
22
10-2
GENERAL
Front Brake
10
16 ~ 25 model
30 ~ 35 model
10-3
40 ~ 50 model
0
1
2
3
4
5
6
7
8
9
Parking Brake
10
11
12
13
14
15
16
17
18
19
20
21
22
10-4
Brake Valve
16 ~ 35 model
From
oil pump To oil tank
To PS
To front brake
40 ~ 50 model
From
To front brake oil pump To oil tank
To PS
10-5
Brake Change Valve
X X
0
1
Y A 2
T
3
4
P
5
6
PS 7
8
Y
9
X - X sectional view Y - Y sectional view
10
11
12
13
14
15
16
17
18
19
20
21
22
10-6
Hydraulic circuit diagram
T (till tank) A (till p-broms)
P (från pump) PS (till bromsventil)
SPECIFICATIONS
Model
16 ~ 25 30⋅35 40 ~ 50
Item
Type Wet disc brake
Brake lining dimensions
0.5 × 221 × 150 0.8 × 276 × 200
(Thickness × Outside diameter ×
Foot brake (0.02 × 8.70 × 5.91) (0.03 × 10.9 × 7.87)
Inside diameter) mm (in)
Number of discs 2 discs × 2 3 discs × 2 1 disc × 2
Lubricating oil SHELL DONAX TD
Type Full power CHPS
Input piston outside diameter
25.4 (1.00)
mm (in)
Brake valve Input piston stroke mm (in) 11.5 (0.45) 12.2 (0.48)
Maximum hydraulic pressure
7.85 (80.0) [1138] 12.7 (130) [1849]
MPa (kgf/cm2) [psi]
Oil used Hydraulic oil ISO VG32
Type Wet disc brake
Parking brake Number of discs 2
Lubricating oil SHELL DONAX TD
10-7
COMPONENTS
16 ~ 35 model 4201
40 ~ 50 model
(DOUBLE)
10-8
4601
16 ~ 35 model 4704
10-9
40 ~ 50 model 4704
10-10
FRONT BRAKE
DISASSEMBLY • INSPECTION • REASSEMBLY (16 ~ 35 MODEL)
T = 31 ~ 45 (320 ~ 460)
5 [23.2 ~ 33.3]
T = 46 ~ 66 (470 ~ 670)
[34.0 ~ 48.5]
1 Remove the front axle ASSY and front axle shaft (inner). (See page 7-11.)
2 Remove the disc and pressure plate. [Point 1]
4 Remove the O-ring and D-ring from the front axle bracket.
5 Remove the spring. [Point 3]
6 Remove the piston guide and D-ring. [Point 4]
Note:
• After reassembly, bleed the air from the brakes. (See page 10-25.)
10-11
Point Operations
[Point 1]
Inspection:
Measure the disc thickness.

Limit: 5.6 mm (0.220 in)
Inspection:
Measure the pressure plate thickness.

Limit: 2.6 mm (0.102 in)
[Point 2]
Disassembly:
After removing the set bolts, use service bolts to remove
the brake piston guide W/piston.
Service bolt size M10 × 1.25
Reassembly:
Service bolts Apply lock agent (08833-76001-71 (08833-00070) to the
set bolt threads and then uniformly tighten the set bolts in
order in opposing pairs.
A [Point 3]
Inspection:
Measure the spring warp.
Limit: A = 1.2 mm (0.047 in)
Reassembly:
Apply lock agent (08833-76001-71 (08833-00070) to the
set bolt threads, and tighten the set bolt.
[Point 4]
SST
SST Disassembly Reassembly:
•
Use a press and SST.

SST: 09950-76019-71
(SST: 09950-60020)
Disassembly Reassembly:
•
Be sure the press is oriented correctly.

10-12

T = 10.5 ~ 24.5
(110 ~ 250)
[7.8 ~ 18.1]
T = 45 ~ 60 3
(460 ~ 610)
[33.2 ~ 44.1]
1 Remove the front axle ASSY and front axle shaft (inner). (See page 7-16.)
2 Remove the disc and pressure plate. [Point 1]
4 Remove the O-ring, D-ring, and backup ring from the front axle bracket. [Point 3]
5 Remove the spring. [Point 4]
6 Remove the piston guide, D-ring, and backup ring. [Point 5]
Note:
• After reassembly, bleed the air from the brakes. (See page 10-25.)
10-13
Point Operations
[Point 1]
Inspection:
Measure the disc thickness.

Limit: 5.2 mm (0.205 in)
Inspection:
Measure the pressure plate thickness.

Limit: 2.6 mm (0.102 in)
[Point 2]
SST Disassembly:
After removing the set bolts, use an SST to remove the
brake piston guide W/piston.
SST 09810-20172-71
Reassembly:
set bolt threads and then uniformly tighten the set bolts in
order in opposing pairs.
Front axle [Point 3]

bracket Backup ring
Reassembly:
Make sure the backup ring reassembly position is correct.
[Point 4]
Disassembly:
Use the press to push down the spring and then remove
the set bolts.
Reassembly:
set bolt threads.
Reassembly:
Use the press to push down the spring and then screw in
the set bolts.
10-14
Inspection:
Measure the free length of the spring.
Standard: 38 mm (1.50 in)

Service bolts [Point 5]
Disassembly:
Use service bolts to remove the piston guide.
Service bolt size: M10 × 1.25
Reassembly:
Piston
Use the press to reassemble the components.
Make sure the backup ring reassembly position is correct.
Backup ring
10-15
PARKING BRAKE
T = 26 ~ 48
(265 ~ 490) 3
[19.2 ~ 35.5]
6
4
T = 51.0 ~ 64.7 (520 ~ 660)

[37.6 ~ 47.8]
1 Remove the drive unit & front axle ASSY. (See page 6-6.)
2 Remove the parking brake cover. [Point 1]
3 Remove the gasket, cone spring washer, and washer. [Point 2]
4 Remove the parking brake piston W/parking brake housing.
5 Remove the parking brake piston and ring seal (D-ring). [Point 3]
6 Remove the brake disc, plate, and gasket. [Point 4]
Note:
• Apply MP grease to the ring seal (D-ring).
10-16
Point Operations
[Point 1]
•
Uniformly loosen (tighten) the set bolts in order in opposing

pairs. Otherwise the bolt deformation by the inclined cover
should occur.
[Point 2]
Inspection:
A Measure the cone height of the cone spring washer.

Limit: 6.35 mm (0.250 in)
Reassembly:
Make sure the cone spring washer reassembly position is
correct.
[Point 3]
•
Use a press.
[Point 4]
Inspection:
Measure the brake disc thickness.

Limit: 3.06 mm (0.1205 in)
10-17
Inspection:
Measure the plate thickness.

Limit: 2.26 mm (0.0890 in)
10-18
BRAKE VALVE
TROUBLESHOOTING
Phenomenon Probable Cause Corrective Action
• Fluid leak from the hydraulic piping • Repair, add hydraulic fluid
causing the fluid level in the tank to drop
• Insufficient stroke due to a loose input • Adjust
piston double nut
Braking is poor, delayed • Fatigue breakage of input spring • Replace
• Damaged reaction piston O-ring • Replace
• Debris in spool • Clean, repair
• Excessive play due to loose clevis lock nut • Adjust the clevis
• Air has gotten in • Bleed out the air
• Spool remains depressed due to a loose • Adjust
Brakes drag clevis lock nut
• Debris in spool • Clean, repair
16 ~ 35 model
5
10-19
40 ~ 50 model
4
4
5
3
2 16 ~ 35 model: Remove the instrument panel LH.
40 ~ 50 model: Remove the lower panel.
4 Remove the push rod clevis pin.
5 Remove the brake valve.
The installation rocedure is the reverse of the removal procedure.
Note:
• After installation, bleed the air from the brakes. (See page 10-25.)
• After installation, perform brake pedal adjustment. (See page 10-29.)
10-20

Note:
• All components are machined to a high-precision finish. Be careful not to damage them while
working.
• Conduct the work in a clean location.
1
3
4
T = 49.0 ~ 78.4 (500 ~ 800)
[36.2 ~ 57.9]
T = 67.7 ~ 107.9
(690 ~ 1100)
[49.9 ~ 79.6] 9
10
8
7
6
1 Remove the push rod.
2 Remove the boots.
3 Remove the lock nut, snap ring, and plate washer. [Point 1]
4 Remove the input piston and compression spring. [Point 2]
5 Remove the cylinder cap from the input piston. [Point 3]
6 Remove the hole plug.
7 Remove the closed valve, valve return spring, and spring retainer. [Point 4]
8 Remove the reaction piston guide W/reaction piston and the brake valve spool.
9 Remove the reaction piston guide.
10 Remove the reaction piston.
Note:
• Carefully clean all components, blow them off with compressed air to remove dirt, coat them
with hydraulic oil, and then reassembly them.
• Apply silicon grease to the cylinder cap and then reinstall the cap.
• Apply MP grease to the end of the push rod.
10-21
Point Operations
[Point 1]
Reassembly:
Adjust the input piston stroke.
1. Install the plate washer.
2. Place the snap ring onto the input piston.
3. Screw on the lock nut and adjust the input piston stroke.
Standard:16 ~ 35 model: A = 11.5 ± 1.0 mm

(0.453 ± 0.039 in)
A
40 ~ 50 model: A = 12.2 ± 1.0 mm
(0.480 ± 0.039 in)
4. Tighten the lock nuts.
5. Reinstall the snap ring.
Adjust:
After reassembly, check the brake hydraulic pressure.
(16 ~ 35 model: See page 10-26, 40 ~ 50 model: See page
10-27)
When lower than the standard value: Enlarge dimension A.
When higher than the standard value: Decrease dimension A.
[Point 2]
Inspection:
Measure the free length of the compression spring.
Standard: 16 ~ 35 model: 20 mm (0.79 in)

40 ~ 50 model: 21 mm (0.83 in)
Limit: 16 ~ 35 model: 18.0 mm (0.709 in)
40 ~ 50 model: 18.9 mm (0.744 in)
[Point 3]
Reassembly:
Make sure the cylinder cap is reinstalled in the correct ori-
entation.
SST 09471-22000-71
SST
[Point 4]
Inspection:
Measure the free length of the valve return spring.
Standard: 16 ~ 35 model: 20 mm (0.79 in)

40 ~ 50 model: 21.9 mm (0.862 in)
Limit: 16 ~ 35 model: 18.0 mm (0.709 in)
40 ~ 50 model: 19.7 mm (0.776 in)
10-22
BRAKE CHANGE VALVE

4
3
Removal Procedure
2 Disconnect the change valve solenoid connector.
4 Remove the change valve.
Note:
After installation, bleed the air from the brakes. (See page 10-25.)
10-23
5
4
4 3
Removal Procedure
2 Disconnect the change valve solenoid connector.
3 Disconnect the parking brake pipe from the parking brake side.
5 Remove the change valve W/bracket.
6 Remove the bracket and parking brake pipe.
Note:
After installation, bleed the air from the brakes. (See page 10-25.)
10-24

Note:
• All components are machined to a high-precision finish. Be careful not to damage them while
working.
• Conduct the work in a clean location.
2
T = 49 (500)
[36.2]
1
4
T = 19.6 (200)
[14.5]
1 Remove the compression spring and steel ball.
2 Remove the filter.
3 Remove the spring.
4 Remove the solenoid. [Point 1]
Point Operations
[Point 1]
Inspection
Check the solenoid continuity.
Measurement locations: Between both solenoid con-

nector terminals.
Standard: Continuity exists.
10-25
BRAKE AIR BLEEDING

Note:
Use two people to bleed the air.
1. Remove the bleeder plug cap and connect an air bleed
hose.
2. Turn the key switch to ON.
3. Step on the brake pedal.
4. Loosen the bleeder plug, and when the air stops
escaping from the air bleed hose, tighten the bleeder
plug and return the brake pedal.
5. Move the air bleed hose and replace the cap.
BRAKING FORCE INSPECTION

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)
Initial speed of braking km/h (mph) Max. speed

Braking distance m (ft) 5.0 (16.4) or less
PARKING BRAKE RELEASE PRESSURE
1. Install a pressure gauge in the P port of the brake

change valve.
2. Turn the key switch and seat switch to ON.
3. Select forward or reverse travel direction switch.
4. Read the pressure gauge while releasing, and applying
the parking brake.
5. The pressure should be between 25-30 bar.
P
10-26
BRAKE HYDRAULIC PRESSURE

INSPECTION (16 ~ 35 MODEL)
change valve.
2. Turn the key switch to ON and then measure the

P hydraulic pressure when the brake pedal is completely
depressed.
Standard: 7850 ± 500 kPa (80 ± 5 kgf/cm2)
[1138 ± 71 psi]
The following are probable causes when the measured

value does not satisfy the standard.
• Brake valve abnormality (incorrect input piston stroke
adjustment, defective seal, clogged pipe, wearing, etc.)
• Abnormality between the oil tank and the brake valve.
3. Turn the key switch to OFF.
4. Remove the SST and connect the brake pipe.
5. Disconnect the pipe on one of the sides of the three-way
valve and connect the oil pressure gauge via the SST.
SST
SST 09472-22000-71
6. Turn the key switch to ON and measure the hydraulic
pressure when the brake pedal is completely depressed
for 15 sec.
[1138 ± 71 psi]
7. Disconnect the pipe from the opposite side of the three-

way from the one that was disconnected in Step 7 and
repeat Steps 7 and 8.
When the measured value in Step 4 is normal and the

measured values in Steps 8 to 9 do not satisfy the
standard, the following are probable causes.
• Front brake abnormality (Defective disc brake piston
seal, debris, wearing, etc.)
• When the measurement is taken at the three-way RH,
the LH front brake is abnormal.
• When the measurement is taken at the three-way LH,
the RH front brake is abnormal.
Note:
If the disc brake piston seal is defective, the hydraulic oil
could get into the drive unit oil and excessively raise the
level of the drive unit oil.
8. Remove the oil pressure gauge, reconnect the pipe, and
bleed the air from the brakes. (See page 10-25.)
10-27
BRAKE HYDRAULIC PRESSURE

INSPECTION (40 ~ 50 MODEL)
change valve.
2. Turn the key switch to ON and then measure the

P hydraulic pressure when the brake pedal is completely
depressed.
[1849 ± 71 psi]
The following are probable causes when the measured
value does not satisfy the standard.
• Brake valve abnormality (incorrect input piston stroke
adjustment, defective seal, clogged pipe, wearing, etc.)
• Abnormality between the oil tank and the brake valve.
3. Turn the key switch to OFF.

4. Remove the SST and Union and connect the brake pipe.
5. Disconnect one of the pipes from the three-way valve,
connect the union, and connect the oil pressure gauge
SST via the SST.
Union: 47711-21320-71
SST 09472-22000-71
6. Turn the key switch to ON and measure the hydraulic
pressure when the brake pedal is completely depressed
Union for 15 sec.
Standard: 12700 ± 500 kpa (130 ± 5 kgf/cm2)
[1849 ± 71 psi]
7. Disconnect the pipe from the opposite side of the three-
way from the one that was disconnected in Step 7 and
repeat Steps 7 and 8.
When the measured value in Step 4 is normal and the
measured values in Steps 8 to 9 do not satisfy the
standard, the following are probable causes.
• Front brake abnormality (Defective disc brake piston
seal, debris, wearing, etc.)
• When the measurement is taken at the three-way RH,
the LH front brake is abnormal.
• When the measurement is taken at the three-way LH,
the RH front brake is abnormal.
Note:
If the disc brake piston seal is defective, the hydraulic oil
could get into the drive unit oil and excessively raise the
level of the drive unit oil.
8. Remove the oil pressure gauge, reconnect the pipe, and
bleed the air from the brakes. (See page 10-25.)
10-28
Unlock PARKING BRAKE SWITCH INSPECTION

Lock
1. Remove the instrument panel LH and disconnect the

parking brake switch connector.
2. Release the lock and remove the parking brake switch.
3. Check the continuity when the parking brake switch is

OFF turned to ON/OFF.
ON Measurement locations: Between both terminals of the
parking brake key switch connector.
Standard: ON 0 Ω
OFF ∞ Ω
10-29
BRAKE PEDAL INSPECTION • ADJUSTMENT
Stopper bolt
Brake valve Stopper bolt protrusion
B
C
A
D
1. Inspect brake pedal height A. (From toe board to top of pedal)
16 ~ 35 model: Standard: A = 143 ~ 148 mm (5.63 ~ 5.87 in) (with pedal pad)
40 ~ 50 model: Standard: A = 135.5 ~ 140.5 mm (5.33 ~ 5.53 in) (with pedal pad)
If the measured value does not satisfy the standard, make adjustment by changing the stopper bolt
protrusion.
2. Inspect brake pedal play B.
Standard: B = 5 ~ 9 mm (0.20 ~ 0.35 in)
If the measured value does not satisfy the standard, make adjustment by changing the brake valve
push rod length.
3. Check brake valve push rod play C with the brake pedal in the above state.
Standard: C = 1 mm (0.04 in)
4. After the adjustment, fully depress the brake pedal and inspect the pedal height D in that state.
16 ~ 35 model: Standard: D = 100 mm (3.94 in) or more

40 ~ 50 model: Standard: D = 100 mm (3.94 in) or more
11-1
BODY
Page
COMPONENTS ...............................................................11-2
0
OPEN THE SEAT STAND METHOD.........................11-7
1
SEAT STAND ASSY ......................................................11-8
2
SEAT STAND ADJUSTMENT .........................................11-9 3
COUNTERWEIGHT......................................................11-10 4
REMOVAL • INSTALLATION..........................................11-10 5
DRIVER’S SEAT ...........................................................11-11
6
7
FUSE ................................................................................11-12
FUSE INSTALLATION POSITION.................................11-12
8
NAMES (APPLICABLE PORTIONS) AND 9
CAPACITIES ...............................................................11-12
10
11
12
13
14
15
16
17
18
19
20
21
22
11-2
COMPONENTS
16 ~ 35 model 5101
(20, 25, 30, 35 WIDE TREAD)
(BATT.ROLL OUT,HI-HEIGHT BATT)
16 ~ 35 model
11-3
40 ~ 50 model 5101
(DOUBLE) (BATT.ROLL OUT) (HI-HEIGHT BATT)
0
83[RH, REAR]
83[RH, FRONT]
1
2
3
4
(BATT.ROLL OUT,HI-HEIGHT BATT)
5
6
7
8
40 ~ 50 model 9
10
11
12
13
14
15
16
17
18
19
20
21
22
11-4
16 ~ 35 model 5201
40 ~ 50 model
11-5
16 ~ 35 model 40 ~ 50 model 5301
0
1
2
3
4
5
6
7
8
40 ~ 50 model 9
10
11
12
13
14
15
16
17
18
19
20
21
22
11-6
16 ~ 35 model 5702
[L/RR COMBI]
[BUZZER]
40 ~ 50 model
DK[L/RR COMBI]
[L/RR COMBI]
11-7
OPEN THE SEAT STAND METHOD

1. Pull the lock release lever and incline the steering post forward.
2. Move the mini lever box to the most backward position. (16 ~ 35 model)
Tilt up the mini lever box to the most backward position. (40 ~ 50 model)
3. Move the seat to the most forward position. (16 ~ 35 model)
Move the seat to the most backward position. (40 ~ 50 model)
4. Open the seat stand.
16 ~ 35 model
1 2 3 4
40 ~ 50 model
1 2 3 4
11-8
SEAT STAND ASSY

2 4
16·18 model
T = 10.5 ~ 24.5
(107 ~ 250)
[7.7 ~ 18.1]
Removal Procedure
1 Open the seat stand ASSY and disconnect the battery plug.
2 Remove the mini lever. (See page 16-27)
3 Remove the mini lever stand.
4 Remove the driver’s seat. (See page 11-11)
5 16 18 model: Disconnect the damper stay from the seat stand ASSY.
•
20 25 model: Disconnect the two damper stays from the seat stand ASSY.
•
30 ~ 50 model: Disconnect the three damper stays from the seat stand ASSY.
6 Disconnect the wiring.
7 Close the seat stand ASSY and remove the seat stand ASSY set bolts.
8 Remove the seat stand ASSY.
Note:
After installation, perform seat stand adjustment. (See page 11-9)
11-9
16 ~ 35 model Striker SEAT STAND ADJUSTMENT

Ellipse
A
1. Striker adjustment
(1) Install the bolts in the middle of the striker ellipse.
Forward
(2) 16 ~ 35 model:
Backward
Adjust by moving the striker backward when the lock
is too tight, or forward when the lock is too loose.
40 ~ 50 model:
Adjust by adding a shim when the lock is too tight, or
removing the shim when the lock is too loose.
40 ~ 50 model (3) Apply MP grease to area A shown in the figure.
Note:
When adjustment cannot be sufficiently made using the
striker alone, adjust the lock bracket.
Shim
2. Seat stand release wire and lock bracket adjustment

(1) Install the seat stand release wire in the position
(2) Loosen the lock bracket set bolt and adjust the
bracket ellipse.
Ellipes
11-10
COUNTERWEIGHT
2
16 ~ 35 model:
T = 300 ~ or more
(3060 ~ or more)
[221.4 ~ or more]
40 ~ 50 model:
T = 420 ~ or more
(4280 ~ or more)
[309.7 ~ or more]
Removal Procedure
1 Remove the weight cap and temporarily hoist the counterweight slinging with a wire rope.
2 Remove the drawbar, and remove the counterweight set bolt.
3 Remove the counterweight.
Note:
See page 0-17 for the mass of the counterweight.
11-11
DRIVER’S SEAT
4
3
Removal Procedure
2 Disconnect the seat switch connector.
3 Hang the driver’s seat Temporarily.
4 Remove the driver’s seat set nuts.
5 Remove the driver’s seat. [Point 1]
Point Operation
[Point 1]
Inspection:
Push on the seat cushion and check continuity of the seat
switch.
Free : OFF (∞ Ω)
Push : ON (0 Ω)
11-12
FUSE
FUSE INSTALLATION POSITION
All other fuses are installed on the contactor panel.
F5 F4
F6 F3
F7
F1
NAMES (APPLICABLE PORTIONS) AND CAPACITIES

16 ~ 18 model 20 ~ 35 model 40 ~ 50 modle
F1 For drive 500A 600A 700A
F3 For PS 40A ← ←
F4 For lamps 10A ← ←
F5 For control circuit 10A ← ←
F6 For SAS & solenoid 10A ← ←
F7 For DC-DC converter 10A ← ←
Caution for fuse replacement

Always disconnect the battery plug and discharge CO (overall capacitor) by connection between P3 and
N1 with a resistance of about 100 Ω before replacing any fuse.
Instrumentpanel 11-13
Modellkod 7FBMF16-50
Serienummer
5702145 METER & SWITCH
(0208- )[2/2]
12-1

Page
HYDRAULIC SYSTEM DIAGRAM .............................12-2
0
COMPONENTS ...............................................................12-3
1
RETURN FILTER ............................................................12-6
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ..............12-6
2
SUCTION FILTER ..........................................................12-8 4
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ..............12-9
6
NATURAL DROP TEST ..............................................12-10
7
NATURAL FORWARD TILT TEST ..........................12-10
OIL LEAK TEST............................................................12-11
8
LIFT CYLINDER ............................................................12-11 9
TILT CYLINDER ............................................................12-12 10
11
12
13
14
15
16
17
18
19
20
21
22
12-2
HYDRAULIC SYSTEM DIAGRAM

12
16 ~ 35 model
Lift cylinder
Oil control valve
Return filter
Oil tank
Tilt cylinder
Steering valve
Brake valve
Brake
change Suction filter Oil pump
valve
Solenoid
valve
PS pump
Pump
Parking motor
brake
PS motor
Power steering cylinder Front brake
40 ~ 50 model
Lift cylinder
Oil control valve
Tilt cylinder
Return
filter
Steering
valve Brake valve
Oil pump
Suction filter
Solenoid Brake Pump

valve change motor
valve
Parking
brake
Power steering cylinder Front brake
12-3
COMPONENTS
16 18 model
•
6801
45 [REAR] [BATT.ROLL OUT,HI-HEIGHT BATT]
45 [FRONT]
45 [FRONT]
45 [REAR]
0
[OIL FULL]
1
2
[MAST LESS]
3
4
5
6
7
8
9
20 ~ 35 model
[OIL FULL]
10
59 [FRONT]
11
45 [REAR]
45 [FRONT] 59 [REAR]
45 [FRONT]
45 [REAR]
12
[BATT.ROLL OUT,HI-HEIGHT BATT]
[OIL FULL] 13
[MAST LESS] 14
15
16
17
18
19
20
21
22
12-4
40 ~ 50 model 6801
40 ~ 50 model
(MAST LESS)
12-5
16 ~ 50 model (V) 6801
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
12-6
RETURN FILTER
Removal Procedure
1 Drain hydraulic oil.
4 Remove the return filter.
12-7

T = 11.5 (117)
[8.46]
5
4
Removal Procedure
1 Remove the hood (LH).
2 Remove the guard.
3 Remove the oil tank cover.
5 Remove the return filter.
12-8
SUCTION FILTER
20 ~ 35 model
3
6
7
5
T = 11.5 (117)
[8.46]
T=9.8 ~ 14.7 (100 ~ 150)

[7.24 ~ 10.9]
Removal Procedure
3 Remove the battery plug set bolts.
4 Disconnect the motor fan connector.
5 Remove the motor fan W/bracket.
6 Remove the motor fan (lower). (20 ~ 35 model)
7 Remove the oil tank cover W/oil level gage.
8 Remove the suction filter.
12-9

Note:
Do not subject the SAS controller to shocks as it cannot withstand them.
6
T = 11.5 (117) [8.46]
4
3
8
9
Removal Procedure
5 Disconnect the SAS connector.
6 Remove the SAS controller W/bracket.
8 Remove the oil tank cover W/suction filter.
9 Remove the suction filter.
12-10
NATURAL DROP TEST

1. Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in),
and turn the key switch to OFF.
2. Draw datum lines on the inner and outer masts, and

measure the drop in 15 minutes.
NATURAL FORWARD TILT TEST

1. Set the mast in the vertical position with standard load
on the fork. Lift the fork by about 50 cm (19.7 in) and
turn the key switch to OFF.
2. Measure the tilt cylinder rod extension in 15 minutes.

12-11
OIL LEAK TEST

LIFT CYLINDER
1. Set the mast in the vertical position with the standard

load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in).
2. 16 ~ 35 model:
(1) Slowly tilt the mast fully forward, and turn the key switch
to OFF.
(2) Drain hydraulic oil.
(3) After waiting for 5 minutes, disconnect the oil control
16 ~ 35 model
valve to oil tank hose. Place a measuring cylinder
under the fitting and measure the amount of oil
leaking in one minute.
(4) After measurement, replenish hydraulic oil to tank.
3. 40 ~ 50 model:
(1) Slowly tilt the mast fully foward, and turn the key switch
to OFF.
40 ~ 50 model
Standard (at lift port):
16 ~ 35 model: 8 cm3 (0.49 in3) or less
Note:
If the natural drop is great even though the oil leak
amount is within the standard, the lift lock valve or lift
cylinder packing is defective.
12-12
TILT CYLINDER
1. Set the mast in the vertical position with standard load

on the fork. Lift the fork by about 50 cm (19.7 in) and
turn the key switch to OFF.
2. 16 ~ 35 model:
(1) Drain hydraulic oil.
16 ~ 35 model
(3) After measurement, replenish hydraulic oil to tank.
3. 40 ~ 50 model:
Standard (total for lift and tilt):

40 ~ 50 model 4. The leak amount at the tilt port is the total leak amount
less the leak amount from the lift port.
Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard, either the tilt lock valve or
the tilt cylinder packing is defective.
13-1
MAST
Page Page
V MAST ASSY................................. 13-2 COMPONENTS.............................. 13-36 0
COMPONENTS................................ 13-2 MAST ADJUSTMENT 1
(FV • FSV MAST, 16 ~ 35 MODEL) 13-41
REMOVAL • INSTALLATION............ 13-7 2
MAST ADJUSTMENT
(W/LIFT BRACKET) .................... 13-10
(FV • FSV MAST, 3
40 ~ 50 MODEL).......................... 13-45
MAST DISASSEMBLY • INSPECTION 4
LIFT CYLINDER ROD SHIM
REASSEMBLY ............................ 13-12
ADJUSTMENT (PREVENTION 5
LIFT BRACKET DISASSEMBLY • OF UNEVEN LIFTING) ............. 13-56
INSPECTION • REASSEMBLY..... 13-15 6
MAST ADJUSTMENT 7
(V MAST, 16 ~ 35 MODEL) ......... 13-17
MAST ADJUSTMENT
8
(V MAST, 40 ~ 50 MODEL) ......... 13-22 9
MAST ROLLER REMOVAL •
INSTALLATION........................... 13-29 10
CHAIN (16 ~ 35 MODEL)............ 13-30 11
INSPECTION ................................. 13-30 12
REASSEMBLY (V • FV • FSV) .......... 13-30
13
ADJUSTMENT ............................... 13-31
14
CHAIN (40 ~ 50 MODEL)............ 13-32
INSPECTION ................................. 13-32
15
REASSEMBLY (V • FV • FSV) .......... 13-32 16
ADJUSTMENT ............................... 13-35 17
FORK ............................................... 13-35 18
REMOVAL ..................................... 13-35
19
INSTALLATION ............................. 13-35
INSPECTION ................................. 13-35
20
FV • FSV MAST ASSY .................. 13-36 21
22
13-2
V MAST ASSY
6
COMPONENTS
16 ~ 30 model 35 model 6101
40 ~ 50 model
13-3
16 18 model
•
6301
0
1
2
3
4
5
6
7
8
20 25 model
•
9
10
11
12
13
14
15
16
17
18
19
20
21
22
13-4
30 model 6301
35 model
13-5
40 45 model
•
50 model 6301
0
(BACKREST LESS) (BACKREST LESS) 1
2
3
4
5
6
7
8
9
16 ~ 25 model 30 model 6302
10
11
12
13
14
15
16
17
18
19
20
21
22
13-6
35 model 6302
40 45 model
•
50 model
13-7
10
11
2 T = 86.3 ~ 129.4
(880 ~ 1320)
[63.7 ~ 95.48]
4
T = 147.1 ~ 343.2
(1500 ~ 3500)
[108.5 ~ 253.2]
Removal Procedure
1 Set the mast vertically and fully lower the fork.
2 Disconnect the chain. [Point 1]
3 Remove the chain wheel. [Point 2]
4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift
bracket, and slowly run the vehicle backward to depart from the lift bracket.)
6 Disconnect the fork height switch and load sensor wiring.
7 Disconnect the overflow hose and high pressure hose.
8 Slightly hoist the mast.
9 Remove the mast support cap. [Point 3]
10 Remove the tilt cylinder front pin. [Point 4]
11 Remove the mast ASSY.
13-8
Note:
• Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease on the tilt cylinder front pin.
• Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast, or either lift
cylinder is replaced. (See page 13-56.)
• Adjust the chain tension after installation. (See page 13-31 and 13-35.)
• When the mast is replaced, perform SAS matching after installation. (See page 3-51.)
Point Operations
SST [Point 1]
•
16 ~ 35 model
SST 09630-23600-71
40⋅55 model
SST 09630-31720-71
50 model
SST 09630-33900-71
[Point 2]
SST
Removal:
If the fitting is hard, use the SST for removal.
SST 09950-76014-71
(SST 09950-40011)
[Point 3]
Removal:
40 ~ 50 model
Put match marks.
Installation:
40 ~ 50 model
Align the match marks.
Match mark
[Point 4]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate, and lock bolt. Match marks, however,
are unnecessary when the mast or mast ASSY is replaced
since mast tilt angle adjustment is to be done after the
replacement.
13-9
Removal:
SST 09810-20172-71
SST
13-10
REMOVAL • INSTALLATION (W/LIFT BRACKET)

T = 86.3 ~ 129.4
(880 ~ 1320)
[63.7 ~ 95.48]
T = 147.1 ~ 343.2
(1500 ~ 3500) 7
[108.5 ~ 253.2]
Removal Procedure
1 Set the mast vertically.
2 Remove the fork. (See page 13-35.)
4 Disconnect the wiring of the fork height switch and load sensor.
6 Slightly hoist the mast.
7 Remove the mast support cap. [Point 1]
9 Remove the mast ASSY W/lift bracket.
13-11
Note:
• Apply MP grease on the mast support bushing and mast support cap interior surfaces and on
the tilt cylinder front pin.
• Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast, or either
lift cylinder is replaced. (See page 13-56.)
• When the mast is replaced, perform SAS matching after installation. (See page 3-51.)
Point Operations
[Point 1]
Removal:
40 ~ 50 model
Put match marks.
Installation:
40 ~ 50 model
Match mark Align the match marks.
[Point 2]
Removal:
pin, stopper plate, and lock bolt. Match marks, however,
replacement.
Removal:
SST 09810-20172-71
SST
13-12
MAST DISASSEMBLY • INSPECTION REASSEMBLY
40⋅45 model 16 ~ 35 model 50 model
3 3
3
4
2
7
8 7
1 Remove the fork height switch.
3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]
4 Remove each cylinder support. [Point 2]
5 Remove each cylinder bottom set bolt. (16 ~ 35 model)
6 Remove each lift cylinder.
7 Slide the inner mast in the lowering direction, and remove the lift rollers.
8 Remove the mast strip. [Point 3]
9 Remove the outer mast.
13-13
Point Operations
Shim
[Point 1]
Disassembly:
Shim adjustment has been made at the lift cylinder rod
end for prevention of cylinder uneven motion between the
left and right sides. Take a note on which side the shim
adjustment is made and the number of shims in use.
16 ~ 35 model [Point 2]
16 ~ 35 model
Disassembly:
Take a note of the number of cylinder support shims in
Shim use.
Reassembly:
Adjust the cylinder support shim if the mast or either
cylinder is replaced.
With the cylinder rod end inserted in the inner mast, insert
shim(s) between the cylinder support and outer mast to
40⋅45 model
eliminate the clearance. The shim thickness should be
slightly greater than the clearance.
Shim 40⋅45 model
Disassembly:
Take a note of the number of cylinder support shims used.
Reassembly:
When the mast or cylinder is replaced, adjust the shim at
40⋅45 model Support the cylinder support. With the cylinder rod end inserted in
(0.20 in)
5 mm
the inner mast, eliminate the clearance between the cylin-

Clearance
der support and outer mast by inserting shims. The shim

thickness should be slightly thicker than the clearance.
Reassembly:
Clearance
The supports can be used in either the upper or lower di-

rection. Since a level difference of 5 mm (0.20 in) will arise
depending on the direction, install in the direction with the
Cylinder least clearance with the cylinder.
50 model 50 model
Disassembly:
Take a note of the number of cylinder support shims in
use.
Reassembly:
Shim
Adjust the cylinder support shim if the mast or either
cylinder is replaced.
With the cylinder rod end inserted to the inner mast, insert
shim(s) between the cylinder support and outer mast to
eliminate the clearance. The shim thickness should be
slightly greater than the clearance.
13-14
[Point 3]
Inspection:
16 ~ 30 model
Measure the mast strip thickness.
Thickness limit: 1.5 mm (0.059 in)
35 ~ 50 model
Oil sump
Inspect the mast strip for wear.
Limit: Worn to leave no oil sump

13-15
LIFT BRACKET DISASSEMBLY • INSPECTION • REASSEMBLY

16 ~ 35 model
2
2
3
1
2
1
T = 99.54 ~ 184.9
(1015 ~ 1885)
[73.42 ~ 136.3] 1
40 45 model
•
50 model
3 3
2
1
2
1
1 1
13-16
1 Remove lift rollers. [Point 1]
2 Remove side rollers. [Point 2]
3 Remove the back rest.
Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71
(SST 09950-40011)
SST
Front side [Point 2]

Reassembly:
Rounded 16 18 30 ~ 45 model:
• •
chamfering Install the side roller in the correct direction.

The side chamfered with a greater radius of the roller shall
be on the front side of the vehicle.
13-17
MAST ADJUSTMENT (V MAST, 16 ~ 35 MODEL)

Lift Roller Adjustment at Mast
1. Clearance between inner mast roller and outer mast
Inner mast
Outer mast
Bring into contact
These rollers
Bring into
contact
A
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into
contact with the outer mast, and inspect the clearance
between the roller side face and mast where they are
the closest.
Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)

make adjustment by changing the inner mast roller
shim thickness. (See page 13-29 for the mast roller
removal and installation.)
Shim thickness: 0.5 and 1.0 mm

(0.020 and 0.039 in)
(3) Distribute shims equally to the rollers on the left and

right sides.
(4) After the adjustment, see that the inner mast moves
smoothly in the outer mast.
13-18
2. Clearance between outer mast roller and inner mast
These rollers
Bring into contact
Outer mast
Inner mast
Bring into
B contact

contact with the outer mast, and inspect the clearance
between the roller side face and mast where they are
the closest.
Standard: B = 0 ~ 0.5 mm (0 ~ 0.020 in)

make adjustment by changing the outer mast roller
Shims
(0.020 and 0.039 in)

right sides.
13-19
Roller Adjustment at Lift Bracket

1. Middle/lower lift roller and side roller clearance adjustment
Bring into contact
D
Bring into contact
Bring into contact
(3.94 in)
100 mm
(3.94 in)
100 mm
(3.94 in)
100 mm
Outer mast
Outer mast Outer mast
Inner mast Inner mast

Inner mast
Lift bracket Lift bracket Lift bracket

Vmast: 16 18 30 model
• • Vmast: 20 25 model
• Vmast: 35 model
(1) Bring the center of the side roller or lift roller in the
upper part of the lift bracket to approx. 100 mm (3.94
in) from the top of the inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect on the opposite
side the clearance between the roller side face and the
mast where they are the closest. (16 ~ 30 model: The
upper lift rollers need no adjustment since they are
fastened by snap rings. 35 model: The upper lift rollers
and the intermediate lift rollers need no adjustment since
they are fastened by snap rings.)
Standard: C = 0 ~ 0.8 mm (0 ~ 0.031 in)

make adjustment by changing the lift roller shim
thickness.

(0.020 and 0.039 in)
13-20
(4) Distribute shims equally to the left and right sides.

(5) Install the side rollers.
Shim
(6) After adjusting the middle and lower lift rollers, bring
the side roller on one side into contact with the outer
mast and measure on the opposite side the clearance
between the side roller and inner mast surface.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)

make adjustment by changing the side roller shim
thickness.

(0.020 and 0.039 in)
Shims (7) Distribute shims equally to the left and right sides.
(See Lift Bracket Disassembly Inspection
• •
Reassembly section for the side roller installation

method. Shim replacement is possible on the vehicle.)
(8) After the adjustment, see that the lift bracket moves
smoothly over the entire length of the mast.
13-21
Mast Strip Adjustment

1. Mast strip clearance adjustment
Roller
Inner mast
Bring into contact
E
Outer mast
(1) Lower the inner mast fully.

(2) With the inner mast in contact with the outer mast
roller, measure the clearance between the mast strip
and inner mast.
Standard: E = 0 ~ 0.8 mm (0 ~ 0.031 in)

make adjustment by changing the mast strip shim
thickness. (See page 13-29 for the mast roller
removal installatio method.)
•

Shim (0.020 and 0.039 in)
(3) After the adjustment, see that the mast moves

smoothly.
13-22
MAST ADJUSTMENT (V MAST, 40 ~ 50 MODEL)

1. Inner mast roller clearance adjustment
Inner mast
Outer mast
Bring into contact
These rollers
Bring into
contact
A

contact with the outer mast, and measure the
clearance between the roller side face and mast on
the opposite side where they are the closest.
Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)


(0.020 and 0.039 in)

right sides.
13-23
2. Outer mast roller clearance adjustment
These rollers
Bring into contact
Outer mast
Inner mast
Bring into
B contact

clearance between the roller side face and mast on
the opposite side where they are the closest.
Standard: B = 0 ~ 0.8 mm (0 ~ 0.031 in)

shim thickness.
(See page 13-29 for the mast roller removal and
installation.)
Shims
(0.020 and 0.039 in)

right sides.
13-24
3. Roller selection
(1) In 40⋅45 models, use oversize No. 2 as a rule for the inner mast roller. Use No. 1 only when the
mast inside width (rolling contact surface) is narrow. The roller size may be different between the
right and left sides.
Inner mast roller

Outside diameter Outer mast inside width
Model No. Remarks
mm (in) mm (in)
No. 1 124.5 (4.902) 
40 45 model
•
125.0 (4.921)
No. 2 125.2 (4.929) Oversize
50 model No. 1 164.5 (6.476) 165.0 (6.496) 
Outer mast roller

Model Outside diameter mm (in)
40 45 model
•
124.5 (4.902)
50 model 164.5 (6.476)
13-25
Roller Adjustment at Lift Bracket

1. Lift roller clearance adjustment
40⋅45 model
(3.94 in)
100 mm
Outer mast
E Bring into contact
Inner mast
Lift bracket
Middle lift roller
Bring into contact
D
Bring into contact
Bring into contact
Side roller
C
Lower lift roller
(1) Bring the center of the lift roller in the upper part of the
lift bracket to 100 mm (3.94 in) from the top of the
inner mast.
(2) The upper lift rollers need no adjustment since they
are fastened by snap rings.
(3) Adjust the lower rollers after removing the side rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast and inspect the lift roller
clearance at the position on the opposite side where
the roller side is closest to the mast.
Standard
Lower lift roller: C = 0 ~ 0.8 mm (0 ~ 0.031 in)

thickness.

(0.020 and 0,039 in)
13-26
(4) Distribute shims equally to the left and right sides.

(For the shim replacement procedure, see the lift
bracket disassembly section on page 13-29.)
(5) Install the side rollers.
Shim
(6) Adjust the side rollers after adjusting the lower lift
rollers.
Bring the side roller on one side into contact with the
mast side surface and make adjustment by changing
the side roller shims to make the clearance between
the side roller and inner mast side surface on the
opposite side satisfy the following standard.
Standard: D = 0 ~ 0.5 mm (0 ~ 0.020 in)

Shim thickness: 0.5⋅1.0 mm (0.020⋅0.039 in)
(7) Distribute shims equally between the side rollers RH

and LH.
(8) Adjust the intermediate lift rollers after adjusting the
lower lift rollers and side rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect the lift roller
clearance on the opposite side where the roller side
face is closest to the mast.
Standard:
Shims
Intermediate lift roller: E = 0.5 ~ 1.0 mm (0.020 ~
0.039 in)

thickness.
Intermediate Shim thickness: 0.5 and 1.0 mm

lift roller
(0.020 and 0.039 in)
Distribute shims equally to the rollers on the right and

left sides.
(9) At the time of adjustment, see that the lift bracket moves smoothly along the entire length of the
mast. Check that the intermediate lift roller does not rotate in contact with the mast side surface. If
the intermediate lift roller rotates in contact, repeat adjustment in step (8) to widen the clearance
between the roller and mast side surface so that the intermediate lift roller does not rotate over the
entire mast length.
13-27
50 model
(1) Perform measurement where the center of lift bracket upper lift roller is 100 mm (3.94 in) from the
top end of the inner mast.
(2) Lift rollers out of lift bracket rollers need no adjustment since they are fastened by snap rings.
For side rollers, bring the side roller on one side into contact with the mast side surface, and adjust
the side roller shim to make the clearance between the side roller and mast surface.
Standard: 0 ~ 0.8 mm (0 ~ 0.031 in)
(3) After the adjustment, see that the lift bracket moves smoothly along the entire length of the mast.
2. Roller selection
(1) As a rule, use only middle roller No. 6. (40 45 model)
•
(2) As a rule, use upper and lower roller No. 2 (oversize). Use No. 1 only when the mast inside width
(at rolling contact surface) is narrow. The roller size may be different between the left and right or
between the upper and lower side. (40 45 model)
•
Lift bracket roller list

Outside diameter
Model No. Place used Remarks
mm (in)
No. 1 124.5 (4.902) Upper and lower lift roller 
No. 2 125.2 (4.929) Upper and lower lift roller Oversize
40 45 model
•
No. 3 93.3 (3.673) Side roller 

No. 6 123.5 (4.862) Intermediate lift roller 
No. 4 124.5 (4.902) Lift roller 
50 model
No. 5 100.0 (3.937) Side roller 
13-28

Roller
Inner mast
Bring into contact
E
Outer mast
(1) Lower the inner mast fully.

(2) With the inner mast in contact with the outer mast
roller, measure the clearance between the mast strip
and inner mast.
Standard: E = 0 ~ 0.8 mm (0 ~ 0.031 in)

make adjustment by changing the mast strip shim
thickness. (See page 13-29 for the mast roller
removal/installation method.)
Shims
(0.020 and 0.039 in)
(3) After the adjustment, see that the mast moves

smoothly.
13-29
MAST ROLLER REMOVAL • INSTALLATION
1. Remove the lift bracket. (See steps 1 to 4 of the mast

ASSY removal procedure on page 13-7.)
2. Jack up the vehicle, and support tires with wooden
blocks. Also lock the front and rear tires from rotation.
3. Remove the lift cylinders. (See page 14-17, 19.)
4. Remove the mast rollers.

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

5. The installation procedure is the reverse of the removal
Shims procedure.
13-30
CHAIN (16 ~ 35 MODEL)

SST
INSPECTION
1. Inspect the chain elongation according to the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement line varies with the chain
type, set the corresponding line on the chain as
illustrated.
(2) Check the number of the chain to be inspected, and
check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, it is the limit.
Chain Link Pitch Standard (V⋅FV⋅FSV)

Model Pitch mm (in) Type Chain No.
16⋅18 model 15.88 (0.6252) BL534 50
20⋅25 model 19.05 (0.7500) BL634 60
30 model 25.4 (1.0) BL823 80
35 model 25.4 (1.0) BL834 80
Note:
• Perform measurement without removing the chain
from the vehicle.
• Inspect elongation over the entire chain length since it
may be localized.
REASSEMBLY (V • FV • FSV)
1. Installing direction
Applicable mast FV: Lift bracket
V: Lift bracket FSV: Inner mast
and portion FSV: Lift bracket
Center of Center of Front of

vehicle vehicle vehicle
Split pin Split pin

Sketch Split pin
Install with the split pin on the vehicle Install with the split pin on the vehicle Install with the split pin on the vehicle
center side. center side. front side.
2. Chain adjusting nut tightening order

(1) Tighten nuts (1) and (2). T = 49.0 ~ 78.0 N⋅m (500 ~ 800 kgf⋅cm) [36.1 ~ 57.5 ft⋅lbf]
(2) Tighten nut (3).
Applicable mast V: Outer mast FV: Front cylinder
and portion FSV: Outer mast FSV: Front cylinder
(3)
Sketch
(2) (2)
(1) (1)
13-31
ADJUSTMENT
1. Park the vehicle on a flat ground and set the mast vertically.
2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting
nut.
3. Check to see that the chain tension is equal on the left and right sides.
4. Check to see there is no chain twist.
5. See that the fork height is the standard.
6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast
is not in contact with the lift bracket.
Stopper Note:
Inner mast The stopper shows the instance of the V mast.
Depending on the models, the type of the stopper differs
although the principal of the stopper means is the same.
13-32
CHAIN (40 ~ 50 MODEL)

SST
INSPECTION
1. Inspect the chain elongation according to the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement line varies with the chain
type, set the corresponding line on the chain as
illustrated.
(2) Check the number of the chain to be inspected, and
check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, it is the limit.
Chain Link Pitch Standard

Model Pitch mm (in) Type Chain No.
40⋅45 model 25.4 (1.0) BL834 80
50 model 31.75 (1.2500) BL1034 100
Note:
• Perform measurement without removing the chain
from the vehicle.
• Inspect elongation over the entire chain length since it
may be localized.
REASSEMBLY (V • FV • FSV)
Note:
• Assemble in the order of the fixed side and adjusting side.
• Tighten (or install) in the order of illustrated numbers so as not to twist the chain.
Tightening Order & Tightening Torque

1. The chain stud bolt nuts (1), (2) should be tightened to the specified torque, as shown:
Mast V FV
Model Outer mast Lift bracket Front cylinder Lift bracket

98 ~ 147 98 ~ 147 98 ~ 147 98 ~ 147
40 45
•
A (1000 ~ 1500) B (1000 ~ 1500) A (1000 ~ 1500) B (1000 ~ 1500)

model
[72 ~ 108] [72 ~ 108] [72 ~ 108] [72 ~ 108]
167 ~ 225 167 ~ 225 167 ~ 225 167 ~ 225
50 model D (1700 ~ 2300) E (1700 ~ 2300) D (1700 ~ 2300) E (1700 ~ 2300)
[123 ~ 166] [123 ~ 166] [123 ~ 166] [123 ~ 166]
13-33
Mast FSV
Model Outer mast Inner mast Front cylinder Lift bracket

98 ~ 147 98 ~ 147 98 ~ 147
40 45
•
A
(1000 ~ 1500) C  A (1000 ~ 1500) B (1000 ~ 1500)
model G
[72 ~ 108] [72 ~ 108] [72 ~ 108]
167 ~ 225 167 ~ 225 167 ~ 225 167 ~ 225
50 model D (1700 ~ 2300) F (1700 ~ 2300) D (1700 ~ 2300) F (1700 ~ 2300)
[217 ~ 239] [217 ~ 239] [217 ~ 239] [217 ~ 239]
A B C D
0 ~ 1 mm (0 ~ 0.04 in)
(3) (3)
(3)
Hard lock nut Hard

(2) (2) lock nut (2)
(1) (1)
(1)
E F G
(4)
0 ~ 1 mm (0 ~ 0.04 in)
0 ~ 1 mm (0 ~ 0.04 in)
Washer
(2)
(2) (2)
(1)
(1) (1)
2. Tighten the nut (3), or (4).

13-34
3. 40 45 model FSV H3700 ~ H5500 mm (145 ~ 216.5 in)

•
Step 1 Step 2 Step 3
T = 98 ~ 147
Tighten
T = (1000 ~ 1500)
T = [72 ~ 108]
T = 98 ~ 147
T = (1000 ~ 1500)
T = [72 ~ 108]
*: Before assemble a piece to the

*: chain, put it through the rod.
The clamp installed angle:
A A
45°
AA
13-35
ADJUSTMENT
1. Park the vehicle on a flat ground and set the mast vertically.
2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting
nut.
3. Check to see that the chain tension is equal on the left and right sides.
4. Check to see there is no chain twist.
5. See that the fork height is the standard.
6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast
is not in contact with the lift bracket.
Stopper Note:
Inner mast The stopper shows the instance of the V mast.
Depending on the models, the type of the stopper differs
although the principal of the stopper means is the same.
FORK
REMOVAL
1. Set the fork at approx. 20 cm (7.9 in) above the ground.

2. Place a wooden block under the knotched portion of the
fork rail.
3. Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1. Inspect misalignment of the fork tip ends.
If the measued value exceeds the limit, inspect

individual fork bend, looseness of fork installation and lift
bracket finger bar distortion.
13-36
FV • FSV MAST ASSY

COMPONENTS
FV: 16 ~ 30 model FV: 40 ~ 50 model 6101
FSV: 16 ~ 30 model FSV: 35 model

13-37
FSV: 40 45 model
•
FSV: 50 model 6101
FV·FSV: 40 45 model
•
FSV: 50 model 6301
(BACKREST LESS) (BACKREST LESS)

13-38
FV: 16 ~ 25 model FV: 30 model 6302
FV: 40 45 model
•
T
ON
FR
13-39
FSV: 16 ~ 25 model FSV: 30 model 6302
FSV: 35 model
13-40
FSV: 40 45 model (H3700 ~ H5500)

•
FSV: 40 45 model (H6000)
•
6302
FSV: 50 model
13-41
MAST ADJUSTMENT (FV • FSV MAST, 16 ~ 35 MODEL)

1. Clearance between:
Inner mast roller and outer mast (FV).
Inner mast lower roller and middle mast (FSV).
Middle mast lower roller and outer mast (FSV).
Bring into contact
A
Position where the
roller is the closest
FV mast FSV mast
Inner mast
Inner mast
Outer mast
Outer mast
Middle mast
These rollers These rollers

(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the
clearance between the roller side face and mast where they are the closest.
Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)
If the measured value does not satisfy the standard, make adjustment by changing the inner mast
roller shim thickness.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast moves smoothly.
13-42
2. Clearance between:
Outer mast roller and inner mast (FV).
Middle mast upper roller and inner mast (FSV).
Outer mast upper roller and middle mast (FSV).
Bring into contact
Bring into
B contact
FV mast FSV mast
These rollers These rollers
Outer mast
Outer mast
Middle mast
Inner mast
Inner mast

(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on
the opposite side the clearance between the roller side face and mast where they are the closest.
Standard: B = 0 ~ 0.5 mm (0 ~ 0.020 in)
If the measured value does not satisfy the standard, make adjustment by changing the outer mast
roller shim thickness.
13-43
Lift/Side Roller Adjustment at Lift Bracket

FV FSV mast
•
Lower lift roller

D
Side roller
Bring into contact
Bring into
C contact
100 mm (3.94 in.)
Lift
Lift bracket bracket
FSV: 16·18·30·35 model FV: 20·25 model FV: 16·18·30 model

FSV: 20·25 model
(1) Raise the lift bracket to the uppermost position for the FSV mast and FV mast (20 25 model), and •
bring the center of the upper lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for
FV mast (16 18 30 model).
• •
(2) The upper lift rollers and intermediate rollers need no adjustment since they are fastened by snap
rings.
(3) Shift the lift bracket to one side to bring the lower lift roller, and measure on the opposite side the
clearance between the roller side face and the mast where they are the closest.
Standard: C = 0 ~ 0.5 mm (0 ~ 0.020 in)
If the measured value does not satisfy the standard, make adjustment by changing the shim
thickness. (Distribute shims equally to the rollers on the left and right sides.)
(4) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers.
Bring the side roller on one side into contact with mast side surface, measure on the opposite side
the clearance between the side roller and the inner mast side surface where they are the closest.
Standard: D = 0 ~ 0.5 mm (0 ~ 0.020 in)
If the measured value does not satisfy the standard, make adjustment by changing the shim
thickness. (Distribute shims equally to the rollers on the left and right sides.)
(5) After the adjustment, see that the lift bracket moves smoothly over the entire length of the mast.
13-44

Mast strip clearance adjustment
FV mast
Upper roller
Inner mast
Bring into contact
Outer mast
E
Middle mast
FSV mast
Upper roller
Bring into contact
Inner mast
Outer mast
(1) Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.
Standard: E = 0 ~ 0.8 mm (0 ~ 0.031 in)
If the measured value does not satisfy the standard, make adjustment by changing the mast strip
shim thickness.
(3) After the adjustment see that the mast moves smoothly.
13-45
MAST ADJUSTMENT (FV • FSV MAST, 40 ~ 50 MODEL)

Lift Roller Adjustment at Mast (FV)
1. Inner mast roller clearance adjustment
Inner mast
Outer mast
Bring into contact
These rollers
Bring into
A contact

clearance between the roller side face and mast
where they are the closest.
Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)

shim thickness.

(0.020 and 0.039 in)

right sides.
13-46
2. Outer mast roller clearance adjustment
These rollers
Bring into contact
Outer mast
Inner mast
Bring into
B contact

clearance between the roller side face on the opposite
side and mast where they are the closest.
Standard: B = 0 ~ 0.8 mm (0 ~ 0.031 in)

shim thickness.

(0.020 and 0.039 in)
Shims

right sides.
13-47
3. Roller selection
(1) In 40 45 models, use oversize No. 2 as a rule for the inner mast roller. Use No. 1 only when the
•
mast inside width (rolling contact surface) is narrow. The roller size may be different between the
right and left sides.
Inner mast roller

Outside diameter Outer mast inside width
Model No. Remarks
mm (in) mm (in)
No. 1 124.5 (4.902) 
40 45 model
•
125.0 (4.921)
No. 2 125.2 (4.929) Oversize
50 model No. 1 164.5 (6.476) 165.0 (6.496) 
Outer mast roller

40 45 model
•
124.5 (4.902)
50 model 164.5 (6.476)
13-48
Lift Roller Adjustment at Mast (FSV)

1. 40 45 model
•
(2) (4) (4) (2)
Bring into contact
Bring into contact
B
Position where the
(1) (3) (3) (1)
Bring into contact
Bring into contact
A
Position where the
roller is the closet
(2) (4) (4) (2)
Outer mast
Middle mast
Inner mast
(1) (3) (3) (1)

13-49
Adjustment Sequence
The encircled Nos. (1) ~ (4) indicate the rollers to be adjusted in due order in accordance with the following
steps:
(2) Shift the mast to one side to bring the roller into contact with the mast, and measure the clearance
on opposite side between the roller and the mast where they are the closest.
Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)

B = 0 ~ 0.8 mm (0 ~ 0.031 in)
If the measured value does not satisfy the standard, make adjustment by changing the mast roller
shim thickness.
(4) After the adjustment, see that the mutual mast moves smoothly.
13-50
2. 50 model
(2) (3) (3) (2)
Bring into contact
Bring into contact
B
Position where the
C
(1)
(1)
Bring into contact
(4) (4)
Bring into contact
A
Position where the
(2) (3) (3) (2)
Outer mast
Middle mast
(4) (4)
Inner mast
* *
(1) (1)
*: No adjustment due to snap ring fitting

13-51
Adjustment Sequence
The encircled Nos. (1) ~ (4) indicate the rollers to be adjusted in due order in accordance with the following
steps:
(2) Shift the mast to one side to bring the roller into contact with the mast, and measure the clearance
on opposite side between the roller and the mast where they are the closest.
For lift rollers ((1) ~ (3))

Standard: A = 0 ~ 0.8 mm (0 ~ 0.031 in)
B = 0 ~ 0.8 mm (0 ~ 0.031 in)
For side rollers ((4))

Standard: C = 0 ~ 0.8 mm (0 ~ 0.031 in)
If the measured value does not satisfy the standard, make adjustment by changing the mast roller
shim thickness.
Shim thickness:
For lift rollers ((1) ~ (3))
0.5 and 1.0 mm (0.020 and 0.039 in)
For side rollers ((4))

0.5 and 1.0 mm (0.020 and 0.039 in)
Side roller
Shim
13-52
3. Roller selection
Inner mast rollers and middle mast lower rollers
• In the case of 35 45 models, use oversize No. 2 rollers as a rule, and use No. 1 only when the mast
•
inside width (rolling contact surface) is narrow. The roller size may be different between the left and
right sides.
Outside diameter Mast inside width
Model No. Remarks
mm (in) mm (in)
No. 1 124.5 (4.902) 
40 45 model
•
125.0 (4.921)
No. 2 125.2 (4.929) Oversize
50 model No. 1 164.5 (6.476) 165.0 (6.496) 
Outer mast rollers and middle mast upper rollers

40 45 model
•
124.5 (4.902)
50 model 164.5 (6.476)
13-53
Lift Bracket Portion Lift/Side Roller Adjustment

1. 40 45 model
•
FV mast
100 mm
(3.9 in)
Lower lift roller Outer mast
Upper side roller
Inner mast
E
Bring into
contact
Lift bracket
FSV mast
100 mm
(3.9 in)
Outer mast
D
(Position where the
roller is the closest) Middle mast
Inner mast
Lift bracket
(1) Perform adjustment where the lift bracket upper lift roller is 100 mm (3.9 in) from the top end of the
inner mast.
(2) The upper lift rollers and intermediate rollers need no adjustment since they are fastened by snap
rings.
(3) For lower lift rollers, shift the lift bracket to one side to bring the roller on one side into contact with
the mast and adjust the clearance between the lift roller and mast on the opposite side,
Standard: D = 0 ~ 0.5 mm (0 ~ 0.020 in)
(4) Adjust the upper side rollers after adjusting the lower lift rollers (in step 3 above). Bring the side
roller on one side into contact with the mast side surface, and adjust the clearance between the
side roller and mast on the opposite side.
Standard: E = 0 ~ 0.5 mm (0 ~ 0.020 in)
(5) Adjust lower side rollers after adjusting the lower lift rollers and upper side rollers (in steps 3 and 4).
Shift the lift bracket to one side to bring the upper side roller and lower lift roller into contact with the
mast, and adjust the clearance between the mast and lower side roller to 0.5 to 1.0 mm (0.02 to
0.04 in). Repeat the same on the opposite side.
(6) After adjustments in steps 3 to 5 see that the lift bracket moves smoothly along the entire mast
length. See that the lower side roller does not rotate in contact with the mast in this state. If the
side roller rotates in contact, repeat step 5 to widen the clearance between the roller and mast to
prevent the lower side roller from being rotated in contact along the entire mast length.
13-54
2. 50 model
(1) Perform adjustment where the center of the lift bracket upper roller is 100 mm (3.94 in) from the
inner mast top end.
(2) Out of lift bracket rollers and lift rollers need no adjustment since they are fastened by snap rings.
For side rollers, bring the side roller on one side into contact with the mast, and adjust the
clearance between the side roller and mast on the opposite side.
Standard: 0 ~ 0.8 mm (0 ~ 0.031 in)
(3) After the adjustment see that the lift bracket moves smoothly along the entire length of the mast.
3. Roller selection
• Use only No. 1 as middle rollers. (40 45 model)
•
• As a rule, use No. 2 (oversize) as upper and lower rollers. Use No. 1 only when the mast inside
width (rolling contact surface) is narrow. The roller size may be different between the left and right
or between the upper and lower sides. (40 45 model)
•
Lift bracket roller list

Outside diameter
Model No. Place used Remarks
mm (in)
No. 1 124.5 (4.902) Lift roller 
40 45 model
•
No. 2 125.2 (4.929) Lift roller Oversize
No. 3 93.3 (3.673) Side roller 
No. 4 124.5 (4.902) Lift roller 
50 model
No. 5 100.0 (3.937) Side roller 
13-55

FV mast
Upper roller
Inner mast
Bring into contact
Outer mast
FSV mast (40 45 model)
•
Middle mast F
Upper roller
Bring into contact
Inner mast
Outer mast
F
FSV mast (50 model) Middle mast
Upper roller Bring into contact
Inner mast
Outer mast
F
(1) Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.
Standard: F = 0 ~ 0.8 mm (0 ~ 0.031 in)
If the measured value does not satisfy the standard, make adjustment by changing the mast strip
shim thickness.
(3) After the adjustment, see that the mast moves smoothly.
13-56
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN

LIFTING)
Note:
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY, and inner mast SUB-ASSY.
1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rod at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rod stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast.
Support the bottom of the inner mast with wooden
blocks and fix the blocks by taping them onto the
outer mast.
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
Shim
(7) Repeat the inspection and adjustment until the
number of shims is determined.
Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)
14-1
CYLINDER
Page Page
LIFT CYLINDER (V) • REAR LIFT REMOVAL • INSTALLATION.......... 14-45 0
CYLINDER (FV • FSV) .................. 14-2 DISASSEMBLY • INSPECTION • 1
GENERAL ........................................ 14-2 REASSEMBLY
(16 ~ 30 MODEL)......................... 14-46 2
SPECIFICATIONS ........................... 14-8
DISASSEMBLY • INSPECTION • 3
COMPONENTS.............................. 14-10 REASSEMBLY
REMOVAL • INSTALLATION (35 ~ 50 MODEL)......................... 14-48 4
(16 ~ 35 MODEL)......................... 14-17 TILT CYLINDER............................ 14-50 5
(40 ~ 50 MODEL)......................... 14-19
GENERAL...................................... 14-50 6
SPECIFICATIONS ......................... 14-50
DISASSEMBLY • INSPECTION • 7
REASSEMBLY COMPONENTS.............................. 14-51
(16 ~ 35 MODEL)......................... 14-21 REMOVAL • INSTALLATION.......... 14-52
8
DISASSEMBLY • INSPECTION • DISASSEMBLY • INSPECTION • 9
REASSEMBLY REASSEMBLY ............................ 14-54
(40 ~ 50 MODEL)......................... 14-27 10
MAST FORWARD BACKWARD
FLOW REGULATOR VALVE .... 14-33 TILTING ANGLE ADJUSTMENT 11
(PREVENTION OF
(16 ~ 35 MODEL)......................... 14-34 UNEVEN TILTING) ...................... 14-57 12
(40 ~ 50 MODEL)......................... 14-35
14
SAFETY DOWN VALVE ............. 14-36
15
(16 ~ 35 MODEL)......................... 14-37 16
(40 ~ 50 MODEL)......................... 14-39
FRONT LIFT CYLINDER 18
(FV • FSV) ....................................... 14-40 19
GENERAL ...................................... 14-40
20
SPECIFICATIONS ......................... 14-42
21
COMPONENTS.............................. 14-43
22
14-2
LIFT CYLINDER (V) • REAR LIFT CYLINDER (FV • FSV)

14
GENERAL
Lift Cylinder (V/16 • 18 Model)
Lift Cylinder (V/20 • 25 Model)
Lift Cylinder (V/30 Model)

14-3
Lift Cylinder (V/35 Model)
RH
0
1
2
LH
3
4
5
6
7
8
Lift Cylinder (V/40 • 45 Model) 9
RH 10
11
12
13
14
LH
15
16
17
18
19
20
21
22
14-4
Lift Cylinder (FV/50 Model)
RH
LH
Rear Lift Cylinder (FV/16 ~ 30 Model)
RH
LH
14-5
Rear Lift Cylinder (FV/40 • 45 Model)
RH
0
1
2
LH
3
4
5
6
7
8
Rear Lift Cylinder (FSV/16 ~ 30 Model) 9
10
11
12
13
14
15
16
17
18
19
20
21
22
14-6
Rear Lift Cylinder (FSV/35 Model)
RH
LH
Rear Lift Cylinder (FSV/40 • 45 Model)
RH
LH
14-7
Rear Lift Cylinder (FSV/50 Model)
RH
LH
14-8
SPECIFICATIONS
Lift Cylinder (V/16 ~ 35 Model)
Model
16 18
•
20 25
•
30 35
Item
Cylinder type Single-acting type ← ← ←
Cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.17) 60 (2.36)
Piston rod outside diameter mm (in) 35 (1.38) 40 (1.57) 45 (1.77) 45 (1.77)
Piston seal type U packing ← ← ←
Rod seal type U packing ← ← ←
Built-in flow regulator valve (RH)
Others
Built-in safety down valve (LH)
Lift Cylinder (V/40 ~ 50 Model)

Model
40 45
•
50
Item
Cylinder type Single-acting ←
Cylinder bore mm (in) 65 (2.56) 70 (2.76)
Piston rod outside diameter mm (in) 50 (1.97) ←
Piston seal type U packing ←
Rod seal type U packing ←
Others
Rear Lift Cylinder (FV/16 ~ 30 Model)

Model
16 18
•
20 25
•
30
Item
Cylinder type Single-acting type ← ←
Cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.17)
Piston rod outside diameter mm (in) 32 (1.26) 35 (1.38) 40
Rod seal type U packing ← ←
Others
14-9
Rear Lift Cylinder (FV/40 • 45 Model)

Model
40 45
•
Item
Cylinder type Single-acting
Cylinder bore mm (in) 65 (2.56)
Piston rod outside diameter mm (in) 45 (1.77)
Piston seal type 
Rod seal type U packing
Others
Rear Lift Cylinder (FSV/16 ~ 35 Model)

Model
16 18
•
20 25
•
30 35
Item
Cylinder type Single-acting type ← ← ←
Piston rod outside diameter mm (in) 35 (1.38) 40 (1.57) 45 (1.77) ←
Piston seal type U packing ← ← ←
Others Built-in safety down valve (RH)
Rear Lift Cylinder (FSV/40 ~ 50 Model)

Model
40 45
•
50
Item
Others
14-10
COMPONENTS
Lift Cylinder (V)
16 18 model
•
6501
20 ~ 30 model
14-11
35 model 6501
40 45 model
•
14-12
50 model 6501
Rear Lift Cylinder (FV)

16 ~ 30 model 6503
14-13
40 45 model
•
6503
Rear Lift Cylinder (FSV)

16 18 model
•
6503
14-14
20 25 model
•
6503
30 model
14-15
35 model 6503
40 45 model
•
14-16
50 model 6503
14-17
11
10
Removal Procedure
1 Set the mast vertically and lower the fork fully.
2 Remove the lift cylinder rod end set bolt.
3 Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point 1]
4 Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space.
5 Support the bottom of the inner mast with wooden blocks and fix the blocks by taping them onto the
outer mast.
6 Remove the hose cover.
7 Disconnect the hose.
8 Disconnect the load sensor wiring.
9 Remove the lift cylinder bottom end set bolt.
10 Remove the lift cylinder support. [Point 2]
11 Remove the lift cylinder ASSY.
14-18
Note:
After installing the lift cylinder, follow the steps below.
• Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal functioning.
• Check the hydraulic oil level, and and add if insufficient.
• Inspect lift cylinders for uneven lifting, and make necessary adjustment. (See page 13-56.)
Point Operations
[Point 1]
Removal:
Shim adjustment is made at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH. Take
notes of the cylinder where adjustment is made and the
number of shims used.
[Point 2]
Installation:
Temporarily fasten the cylinder support here, and
Shim eliminate any clearance between the cylinder support and
outer mast by shim insertion after connecting the rod end.
(Use shim (s) slightly thicker than the clearance.)
14-19
Removal Procedure
1 Remove the lift bracket. (See removal procedure steps 1 to 4 in mast removal installation section on
•
page 13-7.)
2 Remove the cylinder rod end set bolt.
3 Disconnect the cylinder rod end. [Point 1]
5 Disconnect the load sensor wiring.
6 Remove the lift cylinder support. [Point 2]
7 Remove the lift cylinder ASSY.
Note:
Perform the following operations after installing the lift cylinder:
• Repeat lifting and lowering to stroke ends without load to bleed the air and to check normal
operation.
• After the operation check, check the hydraulic oil level and add oil if insufficient.
• Inspect the lift cylinders for uneven movements and make adjustment if necessary. (See the lift
cylinder rod shim adjustment section on page 13-56.)
14-20
Point Operations
[Point 1]
Removal:
Hoist the inner mast.
Support the bottom of the inner mast with wooden blocks
and fix the blocks by taping them onto the outer mast.
Removal:
Shim adjustment has been made at the lift cylinder rod
end for prevention of cylinder uneven motion between the
40⋅45 model left and right sides. Take a note on which side the
adjustment is made and the number of shims in use.
[Point 2]
Installation:
Temporarily tighten the cylinder support here and adjust
the shim after rod end is connected.
Adjustment:
Eliminate any clearance between the cylinder support and
outer mast by shim insertion after connecting the rod end.
50 model (Use shim (s) slightly thicker than the clearance.)
Shim
14-21

Lift Cylinder (V)
16 ~ 30 model 35 model
T = 343 ~ 441 (3500 ~ 4500) T = 284 ~ 421 (2900 ~ 4300)

[253 ~ 326] [210 ~ 311]
4 4
4
2
4 2
4
8
3 4
1 5
5 7
7
6 6
6 6
6 T = 58.8 ~ 68.6 (600 ~ 700) 6
Flow regulator valve [43.4 ~ 50.6]
T = 58.8 ~ 68.6 (600 ~ 700) [43.4 ~ 50.6]
Safety down valve
T = 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9]
1 Remove the safety down valve or the flow regulator valve.
2 Remove the cylinder cover.
3 Remove the rod guide. (16 ~ 30 model)
4 Remove the seals from the cylinder cover.
6 Remove the seals on the piston rod.
7 Remove the bushing from the piston rod (35 model).
8 Remove the cylinder. [Point 2]
Note:
• Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
• Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the cylinder cover
before tightening.
14-22
Point Operations
[Point 1]
Inspection:
16 18 model
•

Limit: 34.92 mm (1.3748 in)
20 25 model
•

Limit: 39.92 mm (1.5717 in)
30 35 model
•

Limit: 44.92 mm (1.7685 in)
Inspection:
Measure the piston rod bend.
Limit: 2.0 mm (0.079 in)
[Point 2]
Inspection:
Measure the cylinder bore.
16 18 model
•

Limit: 45.20 mm (1.7795 in)
20 25 model
•

Limit: 50.20 mm (1.9764 in)
30 model
Limit: 55.35 mm (2.1791 in)
35 model
Limit: 60.35 mm (2.3760 in)
14-23

T = 343 ~ 441 (3500 ~ 4500)

[253 ~ 326]
4 4
2 2
4 4
4 4
3
3
7 7
4 4
4 4
1
5
6 Flow regulator valve 6

Safety down valve T = 58.8 ~ 68.6
T = 29.4 ~ 39.2 (600 ~ 700) [43.4 ~ 50.6]
(300 ~ 400) [21.7 ~ 28.9]
1 Remove the safety down valve or the flow regulator valve.
3 Remove the rod guide.
4 Remove the seals from the cylinder cover and rod guide.
6 Remove the wear ring on the piston rod.
Note:
before tightening.
14-24
Point Operations
[Point 1]
Inspection:
16 18 model
•

Limit: 31.92 mm (1.2567 in)
20 25 model
•

Limit: 34.92 mm (1.3748 in)
30 model
Limit: 39.92 mm (1.5717 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 2]
Inspection:
16 18 model
•

Limit: 45.20 mm (1.7795 in)
20 25 model
•

Limit: 50.20 mm (1.9764 in)
30 model
Limit: 55.35 mm (2.1791 in)
14-25

16 ~ 30 model 35 model
T = 343 ~ 441 T = 284 ~ 421

(3500 ~ 4500) [253 ~ 326] 4 (2900 ~ 4300) [284 ~ 421] 4
4 4
2 2
4 4
9
9
1 1
6
6
6
5
8 5
T = 29.4 ~ 39.2 7 T = 58.8 ~ 68.6
(300 ~ 400) [21.7 ~ 28.9] (600 ~ 700) [43.4 ~ 50.6] 6
6
6
1 Remove the safety down valve. (RH cylinder)
3 Remove the rod guide. (16 ~ 30 model)
4 Remove the seals from the cylinder cover.
7 Remove the check valve from the piston rod. (16 ~ 30 model)
8 Remove the bushing from the piston rod. (35 model)
Note:
before tightening.
14-26
Point Operations
[Point 1]
Inspection:
16 18 model
•

Limit: 34.92 mm (1.3748 in)
20 25 model
•

Limit: 39.92 mm (1.5717 in)
30 35 model
•

Limit: 44.92 mm (1.7685 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 2]
Inspection:
16 18 model
•

Limit: 45.20 mm (1.7795 in)
20 25 model
•

Limit: 50.20 mm (1.9764 in)
30 model
Limit: 55.35 mm (2.1791 in)
35 model
Limit: 60.35 mm (2.3760 in)
14-27

Lift Cylinder (V)
T = 343 ~ 441 (3500 ~ 4500) [253 ~ 326]
4
4
2 2
4 4
2 3
4 4
7 7
1
1
5
5
6
6 6
6 Safety down valve 6
Flow regulator valve
6 T = 58.8 ~ 68.6 (600 ~ 700) T = 88.2 ~ 98.0 (900 ~ 1000)
[43.4 ~ 50.6] [65.1 ~ 72.4]
1 Remove the flow regulator valve or the safety down valve.
2 Remove the cylinder cover. [Point 1]
Note:
before tightening.
14-28
Point Operations
[Point 1]
SST
•
SST 09620-10100-71
[Point 2]
Inspection:
40 ~ 50 model
Limit: 49.92 mm (1.9654 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 3]
Inspection:
40 45 model
•

Limit: 65.35 mm (2.5728 in)
50 model
Limit: 70.35 mm (2.7697 in)
14-29

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

4 4
2 2
4 4
4 4
3
3
7 7
4
4
4
4
1
1
5 5
Safety down valve Flow regulator valve

6 T = 58.8 ~ 68.6 (600 ~ 700) 6
T = 88.2 ~ 98.0
[43.4 ~ 50.6] (900 ~ 1000) [65.1 ~ 72.4]
4 Remove the seals from the rod guide.
6 Remove the wear ring on the piston rod.
Note:
before tightening.
14-30
Point Operations
[Point 1]
SST
•
SST 09620-10100-71
[Point 2]
Inspection:
40 45 model
•

Limit: 44.92 mm (1.7685 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 3]
Inspection:
40 45 model
•

Limit: 65.35 mm (2.5728 in)
14-31

4 T = 284 ~ 421 (2900 ~ 4300) [284 ~ 421]

4
2 2
4 4
3 3
4 4
8 8
1
1
6 5
5
6
6
6 6
6
Safety down valve Flow regulator valve 7

7 T = 58.8 ~ 68.6 (600 ~ 700) T = 88.2 ~ 98.0
[43.4 ~ 50.6] (900 ~ 1000) [65.1 ~ 72.4]
7 Remove the bushing from the piston rod.
Note:
before tightening.
14-32
Point Operations
[Point 1]
SST
•
SST 09620-10100-71
[Point 2]
Inspection:
40 ~ 50 model
Limit: 49.92 mm (1.9654 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 3]
Inspection:
40 45 model
•

Limit: 65.35 mm (2.5728 in)
50 model
Limit: 70.35 mm (2.7697 in)
14-33
FLOW REGULATOR VALVE
Steel ball
IN port
Piston
OUT port
Spring
Lowering Speed Specifications

Unit: mm/sec (fpm)
V mast FV mast FSV mast
Model
No load Full load No load Full load No load Full load
16 550 (108) 500 (98) 420 (83) 480 (94) 450 (89) 480 (94)
18 ↑ ↑ ↑ ↑ ↑ ↑
20 500 (98) ↑ ↑ ↑ ↑ ↑
25 ↑ ↑ ↑ ↑ ↑ ↑
30 450 (89) ↑ 390 (77) 460 (91) 420 (83) 460 (91)
35 ↑ ↑   ↑ ↑
40 500 (98) ↑ 500 (98) 450 (89) 500 (98) 450 (89)
45 ↑ ↑ ↑ ↑ ↑ ↑
50 ↑ ↑   400 (79) 400 (79)
14-34

Note:
The explanation here is for the flow regulator valve for the V or FV mast.
In the case of the FSV mast, the flow regulator valve is installed on the outer mast.
T = 58.8 ~ 68.6 (600 ~ 700) 2

T = [43.4 ~ 50.6]
Removal Procedure
1 Hoist the inner mast. [Point 1]
2 Remove the flow regulator valve.
Point Operations
[Point 1]
SST
•
Hoist the inner mast by slinging with a wire, set the SST
on the inner mast tie beam, and lower the inner mast until
it comes into contact with the SST.
SST 09610-22000-71
14-35

3
T = 88.3 ~ 98.1
T = (900 ~ 1000)
T = [65.1 ~ 72.4]
Removal Procedure
2 Remove the flow regulator valve.
Point Operations
[Point 1]
Removal:
14-36
SAFETY DOWN VALVE

Safety Down Valve Sectional View (for V) (for FV • FSV Rear Lift Cylinder)
V FV
•
FSV (16 ~ 30 model)
FSV (35 ~ 50 model)
Safety Down Valve Sectional View (for FV • FSV Front Lift Cylinder)
14-37

V FV
•
FSV
6
7
6
9 10
7
Removal Procedure
V·FV
3 Remove the front hose cover. (V mast)
4 Remove the lift cylinder (LH) bottom end set bolt.
5 Loosen the lift cylinder (LH) support set bolt.
6 Remove the load sensor cover.
9 With the lift cylinder (LH) hoisted slightly upward, remove the three-way.
10 Remove the safety down valve.
FSV
2 Hoist the middle mast. [Point 1]
3 Remove the front hose cover.
14-38
Point Operations
[Point 1]
SST
Removal:
Hoist the inner (middle) mast by slinging with a wire, set
the SST on the inner (middle) mast tie beam, and lower
the inner mast until it comes into contact with the SST.
SST 09610-22000-71
14-39

4
4
5
5
7 8
T = 58.8 ~ 68.6
T = (600 ~ 700)
T = [43.4 ~ 50.6]
Removal Procedure
3 Remove the lift cylinder (LH) support.
4 Remove the load sensor cover.
7 With the lift cylinder (LH) hoisted slightly upward, remove the three-way.
Point Operations
[Point 1]
Removal:
14-40
FRONT LIFT CYLINDER (FV • FSV)

GENERAL
FV: 16 ~ 30 model
FSV: 16 ~ 30 model
FSV: 35 model
14-41
FV: 40 45 model
•
FSV: 40 45 model
•
FSV: 50 model
14-42
SPECIFICATIONS
16 ~ 30 Model (FV)
Model
16 18
•
20 25
•
30
Item
Cylinder type Single acting ← ←
Cylinder bore mm (in) 85 (3.35) 90 (3.54) 105 (4.13)
Piston rod outside diameter mm (in) 70 (2.76) 75 (2.95) 85 (3.35)
Rod seal type U packing ← ←
Piston seal type   
Others Built-in safety down valve
16 ~ 35 Model (FSV)
Model
16 18
• 20 25
• 30 35
Item
Single
Cylinder type ← ← ←
acting
Piston rod outside diameter mm (in) 70 (2.76) 75 (2.95) 85 (3.35) 60 (2.36)
Piston seal type    U packing
40 ~ 50 Model (FV•FSV)
Model 40 45 • 50
Item FV FSV
• FSV
14-43
COMPONENTS
Front Lift Cylinder (FV • FSV)
16 ~ 30 model (FV FSV)
•
6502
35 model (FSV)
14-44
40 45 model (FV FSV)

• •
6502
50 model (FSV)
14-45
Removal Procedure
1 Remove the lift bracket W/fork.
3 Remove the front lift cylinder.
Note:
After installing the lift cylinder, follow the steps below.
• Repeat full-stroke raising and lowering “without load” to bleed air and check normal
functioning.
• Check the hydraulic oil level, and add if insufficient.
• Adjust the lift chain tension equally on the left and right sides.
14-46

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

3
3
3
3
3
3
6
1
5
T = 29.4 ~ 39.2 (300 ~ 400)
[21.7 ~ 28.9]
2 Remove the rod guide. [Point 1]
3 Remove the rod guide seals.
5 Remove the wear ring.
Note:
before tightening.
14-47
Point Operations
[Point 1]
SST
•
SST 09620-10100-71
[Point 2]
Inspection:
16 18 model
•

Limit: 69.91 mm (2.7524 in)
20 25 model
•

Limit: 74.91 mm (2.9429 in)
30 model
Limit: 84.90 mm (3.3425 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 3]
Inspection:
16 18 model
•

Limit: 85.40 mm (3.3622 in)
20 25 model
•

Limit: 90.40 mm (3.5591 in)
30 model
Limit: 105.40 mm (4.1496 in)
14-48

FSV: 35 model FV: 40 45 model
•
FSV: 40 ~ 50 model
T = 343 ~ 441 40·45 model: 50 model:
(3500 ~ 4500) T = 343 ~ 441 T = 392 ~ 490
3 [253 ~ 326] 3 (3500 ~ 4500) (4000 ~ 5000)
3 [253 ~ 326] [289 ~ 362]
3
3
2
2
3
3 8
3
3
3
4
6
1
4 5
1
5
6
T = 107.8 ~ 127.4 (1100 ~ 1300)
[79.6 ~ 94.1]
1 Remove the safety down valve. [Point 1]
3 Remove the rod guide seals.
5 Remove the piston seals.
6 Remove the check valve. [Point 3]
7 Remove the pipe. (35 model)
Note:
before tightening.
• Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the
cylinder cover.
Filling amount cm3 (in3): FSV 35 model 55 ~ 85 (3.36 ~ 5.19)

FV/FSV 40 • 45 model 140 ~ 170 (8.54 ~ 10.37)
FSV 50 model 200 ~ 230 (12.20 ~ 14.04)
14-49
Point Operations
[Point 1]
Reassembly:
35 model
Pay attention to the installation orientation of safety down
valve.
Safety down valve
[Point 2]
Inspection:
35 model (FSV)
Limit: 59.91 mm (2.3587 in)
40 45 model (FV FSV), 50 model (FSV)
• •

Limit: 69.91 mm (2.7524 in)
Inspection:
Limit: 2.0 mm (0.079 in)
[Point 3]
Reassembly:
Check Pay attention to the installation orientation of check valve.
valve
[Point 4]
Inspection:
Measure the lift cylinder bore.
35 model (FSV)
Limit: 90.40 mm (3.5591 in)
40 45 model (FV FSV)
• •

Limit: 95.40 mm (3.7559 in)
50 model (FSV)
Limit: 105.40 mm (4.1496 in)
14-50
TILT CYLINDER
GENERAL
16 ~ 35 model
40 ~ 50 model
SPECIFICATIONS
Model
16 ~ 35 40 ~ 50
Item
Cylinder type Double acting type
Piston rod outside diameter mm (in) 30 (1.18) 40 (1.57)
14-51
COMPONENTS
16 ~ 35 model 6511
(TILT BOOTS)
(COLD FISHER)
40 ~ 50 model
(TILT BOOTS)
14-52
16 ~ 35 model 40 ~ 50 model
T = 86.3 ~ 129.4
(880 ~ 1320)
[63.7 ~ 95.48]
5 5
7
9
6
6
9
8 T = 86.3 ~ 129.4
(880 ~ 1320)
T = 21.6 ~ 50.4 (220 ~ 514) [63.7 ~ 95.48]
T = 21.6 ~ 50.4 (220 ~ 514) 8 [15.92 ~ 37.19]
[15.92 ~ 37.19]
Removal Procedure
1 Remove the toe board and lower panel.
2 Remove the instrument panel (RH).
3 Remove the fender cover.
4 Hoist the mast slightly.
6 Disconnect the tilt angle sensor link rod. (RH cylinder)
8 Remove the tilt cylinder rear pin.
9 Remove the tilt cylinder ASSY.
Note:
• Apply MP grease on the portions for inserting tilt cylinder front and rear pins before installation.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portion of the rear pin set
bolt before tightening.
• Apply thread tightener (08833-76002-71 (08833-00080)) to the threaded portion of the angle
sensor link rod set bolt before tightening.
• After installation, slowly tilt the mast forward and backward a few times to check normal
functioning.
• Check the hydraulic oil level, and add if insufficient.
• After installation, perform SAS matching. (See page 3-51.)
14-53
[Point 1]
Removal:
pin, stopper plate and lock bolt. Match marks, however,
replacement.
Removal:
SST 09810-20172-71
SST
14-54

16 ~ 35 model
T = 260 ~ 350
1⋅6
(2650 ~ 2570)
[192 ~ 186]
T = 260 ~ 350
(2650 ~ 2570)
5 [192 ~ 186]
4
40 ~ 50 model
1⋅6
T = 343.2 ~ 441.3
(3500 ~ 4500)
[253.2 ~ 325.5]
3
4
T = 245.2 ~ 343.2
(2500 ~ 3500)
[180.9 ~ 253.2]
5
14-55
1 Loosen the rod guide. [Point 1]
2 Extract the piston rod W/piston.
3 Remove the tilt cylinder. [Point 2]
4 Remove the bushing. [Point 3]
5 Remove the piston.
Note:
• Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the rod guide before
reassembly.
• Apply MP grease to front and rear pin insertion portions of the cylinder.
Point Operations
SST [Point 1]
•
SST 09620-10100-71
[Point 2]
Inspection:
16 ~ 35 model
Limit: 70.35 mm (2.7697 in)
40 ~ 50 model
Limit: 90.40 mm (3.5591 in)
14-56
16 ~ 35 model [Point 3]
SST (2) Removal Installation:
•
SST 09950-76018-71 ............(1)

(SST 09950-60010)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
SST (1)
40 ~ 50 model
(0.12 in)
3 mm
SST (2)
(0.12 in)
3 mm
SST (1)
[Point 4]
Inspection:
16 ~ 35 model
Limit: 29.92 mm (1.1780 in)
40 ~ 50 model
Limit: 39.92 mm (1.5717 in)
Inspection:
Measure the bend of the piston rod.
Limit: 1.0 mm (0.039 in)

14-57
MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF

UNEVEN TILTING)
Note:
Adjust the mast forward and backward tilting angles (to prevent uneven tilting) when the tilt
cylinder and mast ASSY are replaced or overhauled.
After adjustment, perform SAS matching. (See page 3-51.)
1. With the mast in the neutral position, install the stopper with the tilt cylinder pin eccentric direction on
the lower side.
16 ~ 35 model
Eccentric
direction
40 ~ 50 model
Eccentric
direction
2. Inspect the forward and backward tilting angles and unevenness in tilting at the pin position above.
Standard:
Mast forward tilting angle: Standard set angle -0.6° ~ +1.6°
Mast backward tilting angle: Standard set angle -0.8° ~ +0.6°
Unevenness: 1 mm (0.04 in) or less
3. If the measured value does not satisfy the standard, make adjustment by turning the fixation angle of
the eccentric pin in alliance with the stopper bolt hole matching in the stopper plate. To align the hole
with the tapped hole in the tilt bracket, either of two holes in the plate is selective and the plate is
reversible on side to find desirous position.
4. After the adjustment, tighten the stopper set bolt to lock the front pin.
15-1
OIL PUMP
Page
GENERAL ........................................................................15-2
0
SPECIFICATIONS ..........................................................15-2
1
COMPONENTS ...............................................................15-3
2
OIL PUMP ASSY ............................................................15-4
DISASSEMBLY • INSPECTION • REASSEMBLY 4
(16 ~ 35 MODEL)...........................................................15-6
5
(40 ~ 50 MODEL)...........................................................15-9 6
TEST METHOD .............................................................15-13 7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
15-5
Removal Procedure
1 Remove the battery ASSY. (See page 1-5)
2 Drain hydraulic oil. (16 ~ 35 model)
3 Disconnect the inlet hose.
4 Disconnect the outlet hose.
5 Remove the oil pump ASSY.
6 Remove the fitting. 0
Installation Procedure 1
The installation procedure is the reverse of the removal procedure. 2
Note:
• Apply grease (molybdenum disulfide grease) on the pump shaft spline portion before
3
installation.
• Clean the fitting mounting portion thoroughly to prevent damage to the O-ring.
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
15-6

(16 ~ 35 MODEL)
T = N⋅m (kgf·cm) [ft·lbf]
T = 46.1 ~ 48.6
(470 ~ 500)
[34.0 ~ 36.2]
3
4
1 Put match marks on the cover, body and mounting flange. [Point 1]
2 Remove the cover.
3 Remove the mounting flange.
4 Remove the bushing set and pump gear set. [Point 2]
6 Inspect the body. [Point 4]
Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
15-7

[Point 1]
Disassembly:
Put match marks between the cover and body, and
between the mounting flange and body.
Reassembly:
Align match marks at the time of reassembly.
[Point 2]
Disassembly:
Put match marks on the teeth of the drive and driven
gears.
Reassembly:
Inspection:
Discharge side Inspect the bushing set contact trace.
Standard:
Relatively stronger contact trace on the suction side,
with slight trace on the discharge side.
Suction side
Contact trace
Length Inspection:
Measure the bushing set length.
Limit: 26.411 mm (1.03980 in)
Inspection:
Inside
Inspect the bushing set for wear at the interior surface.
diameter
Limit:
Replace if the teflon coating layer is worn out even
locally.
Inspection:
Measure the outside diameter of each gear shaft.
Limit: 18.935 mm (0.74547 in)
Shaft diameter
15-8
[Point 3]
Disassembly:
SST 09319-76001-71
(SST 09319-60020)
SST
Reassembly:
SST 09950-76018-71 ..........(1)
SST (2) (SST 09950-60010)
SST 09950-76020-71 ..........(2)
(SST 09950-70010)
After installation, apply MP grease on the oil seal lip
SST (1) portion.
[Point 4]
Inspection:
Inspect the contact trace on the inner surface of the body
(suction side).
Contact trace
of gear teeth
Limit: Contact trace covers more than half of the
crests circumference.
Inspection:
Discharge side
Measure the depth of flaw on the inner surface of the
body.
Limit: 0.1 mm (0.004 in)

15-9

T = 88 ~ 98 (897 ~ 999)
[64.9 ~ 72.3]
10
1
11
6
2
3
1 Remove the body (2nd). [Point 1]
2 Remove the steel ball.
3 Remove the “3” in shape gasket and side plate (2nd). [Point 2]
4 Remove the drive gear (2nd) and driven gear (2nd). [Point 3]
5 Remove the gasket, “3” in shape gasket and side plate (2nd). [Point 2]
6 Remove the adapter plate. [Point 4]
7 Remove the gasket, “3” in shape gasket and side plate (1st). [Point 5]
8 Remove the body (1st). [Point 6]
9 Remove the drive gear (1st) and driven gear (1st). [Point 7]
10 Remove the gasket, “3” in, shape gasket and side plate (1st). [Point 5]
Note:
• Wash each part, blow compressed air and apply hydraulic oil before installation.
• Use new seals for reassembly.
15-10
Match marks
Point Operations
[Point 1]
Disassembly:
Put match marks between the body (2nd) and adapter
plate and between the body (1st) and body.
Reassembly:
[Point 2]
Inspection:
Measure the side plate thickness.
Limit: 2.65 mm (0.1043 in)
Inspection:
Inspect the contact mark on the side plate.
Standard:
Somewhat apparent mark on the suction side and
slight mark on the discharge side.
[Point 3]
Match marks
Disassembly:
Put match marks on the tooth flanks of the drive gear
Drive gear (2nd) (2nd) and driven gear (2nd).
Driven gear (2nd)
Reassembly:
Inspection:
Drive gear (2nd) Driven gear (2nd) Inspect the gear side surface for no wear and the tooth
flanks for no roughening of each gear shaft.
Shaft diameter wear limit: 21.997 mm (0.86602 in)

Tooth width wear limit: 33.3 mm (1.311 in)
[Point 4]
Inspection:
Measure the bushing inside diameter.
Limit:
Front side (flange side): 24.1 mm (0.949 in)
Rear side: 17.1 mm (0.673 in)
Inspection:
Inspect the contact mark on the inner sliding contact face.
Standard:
Glossy contact mark on about half on the suction side.
15-11
[Point 5]
Inspection:
Measure the side plate thickness.
Limit: 2.65 mm (0.1043 in)
Wear limit: 0.15 mm

Inspection:
(0.0059 in) or less The side plate surface (LBC surface) in contact with gears
shall not be worn beyond the limit shown at left.
LBC surface
(yellow)
Strong
Discharge Suction contact
port port around here
Erosion by
cavitation
around this
portion
Wipe depth [Point 6]

0.01 ~ 0.06 mm (0.0004 ~ 0.0024 in)
Discharge
port Inspection:
Inspect the body inner surface for the wipe mark.
Suction
port Normal wipe depth: 0.01 ~ 0.06 mm
(0.0004 ~ 0.0024 in)
Wipe mark
[Point 7]
Match mark Disassembly:
Put match marks on the tooth flanks of the drive gear (1st)
and driven gear (1st).
Driven gear (1st)
Drive gear (1st)
Reassembly:
Drive gear (1st) Inspection:

Inspect the gear side surface for no wear and the tooth
flanks for no roughening of each gear shaft.
Driven gear (1st) Shaft diameter wear limit: 21.997 mm (0.86602 in)
Tooth width wear limit: 33.3 mm (1.311 in)
15-12
[Point 8]
Disassembly:
SST 09319-76001-71
(SST 09319-60020)
SST
Reassembly:
SST 09950-76018-71 ..........(1)
SST (2) (SST 09950-60010)
SST 09950-76020-71 ..........(2)
(SST 09950-70010)
SST (1) After installation, apply MP grease on the oil seal lip
portion.
15-13
TEST METHOD
A bench test should be performed for strict testing, but as this is generally impossible during practical
service operation, install the oil pump in the vehicle and determine the oil pump discharge performance
based on the cylinder operation.
• Check that the battery charge is sufficient by observing the battery charge indicators.
• Check that the oil control valve set relief pressure is as specified. (See page 16-22.)
• Measure the lift cylinder full stroke operation time when the hydraulic oil temperature is 50 to 55°C (122
to 131°F), and calculate the lifting speed.
Because of the soft start by the material handling chopper circuit, the lifting speed is 10 to 20 mm/sec
(2.0 to 3.9 fpm) lower than the value obtained from the table below. The precision of the lifting speed,
therefore, is higher if measured excluding the soft start period.
The lifting speed depends slightly on the battery, hydraulic oil temperature and mast adjustment.
The value below is for the case where given conditions are satisfied.
Lifting Speed Table (Approx.value)
Lifting speed mm/sec (fpm)
V mast FV mast FSV mast
Vehicle model
No-load Loaded No-load Loaded No-load Loaded
H 780 (154) 520 (102) 700 (138) 475 (94) 720 (142) 470 (93)
7FBMF16 P 750 (148) 470 (93) 675 (133) 435 (86) 690 (136) 430 (85)
S 750 (148) 470 (93) 675 (133) 435 (86) 690 (136) 430 (85)
H 780 (154) 480 (95) 700 (138) 430 (85) 720 (142) 420 (83)
7FBMF18 P 750 (148) 420 (83) 675 (133) 400 (79) 690 (136) 390 (77)
S 750 (148) 420 (83) 675 (133) 400 (79) 690 (136) 390 (77)
H 630 (124) 480 (95) 595 (117) 450 (89) 600 (118) 450 (89)
7FBMF20 P 600 (118) 440 (87) 565 (111) 425 (84) 570 (112) 420 (83)
S 600 (118) 440 (87) 565 (111) 425 (84) 570 (112) 420 (83)
H 630 (124) 460 (91) 595 (117) 405 (80) 595 (117) 400 (79)
7FBMF25 P 600 (118) 420 (83) 565 (111) 385 (76) 585 (115) 380 (75)
S 600 (118) 420 (83) 565 (111) 385 (76) 585 (115) 380 (75)
H 550 (108) 440 (87) 500 (99) 400 (79) 525 (103) 395 (78)
7FBMF30 P 520 (102) 400 (79) 480 (95) 370 (73) 500 (99) 365 (72)
S 520 (102) 400 (79) 480 (95) 370 (73) 500 (99) 365 (72)
H 470 (93) 370 (73) – – 455 (90) 345 (68)
7FBMF35 P 450 (89) 330 (65) – – 435 (86) 320 (63)
S 450 (89) 330 (65) – – 435 (86) 320 (63)
H 510 (100) 330 (65) 495 (98) 335 (66) 490 (97) 330 (65)
7FBMF40 P 460 (91) 320 (63) 465 (92) 310 (61) 460 (91) 310 (61)
S 460 (91) 320 (63) 465 (92) 310 (61) 460 (91) 310 (61)
H 510 (100) 320 (63) 495 (98) 320 (63) 490 (97) 320 (63)
7FBMF45 P 460 (91) 290 (57) 465 (92) 290 (57) 460 (91) 290 (57)
S 460 (91) 290 (57) 465 (92) 290 (57) 460 (91) 290 (57)
H 420 (83) 280 (55) – – 405 (80) 275 (54)
7FBMF50 P 390 (77) 260 (51) – – 380 (75) 250 (49)
S 390 (77) 260 (51) – – 380 (75) 250 (49)
16-1
OIL CONTROL VALVE

Page
GENERAL ........................................................................16-2
0
SPECIFICATIONS ........................................................16-10
1
COMPONENTS .............................................................16-11
2
OIL CONTROL VALVE ASSY...................................16-13
MATERIAL HANDLING OPERATION START TIMING
ADJUSTMENT.............................................................16-21 6
RELIEF PRESSURE ADJUSTMENT ......................16-22 7
LIFT LOCK RELEASE BOLT ....................................16-24 8
MINI LEVER BOX .........................................................16-25 9
GENERAL......................................................................16-25
10
COMPONENTS..............................................................16-26
11
13
14
15
16
17
18
19
20
21
22
16-2
GENERAL
16
Oil Control Valve

16 ~ 35 model
T2
C1
C3
C5
T1
C4
G
C2
16-3
Inlet Block Sectional View

16 ~ 35 model
Unload valve
Relief valve
0
1
2
3
4
5
Pressure
compensated
valve
6
7
8
Pressure reducing valve 9
Lift Block Sectional View 10
16 ~ 35 model
11
Lift lock check valve
12
13
Lift select
valve
14
15
16
17
18
19
20
Proportional solenoid valve
21
22
16-4
Tilt Block Sectional View

16 ~ 35 model
Tilt lock check valve
Tilt select
valve
Attachment Block Sectional View

16 ~ 35 model
T1 P (4) (5) C1 (6) C2 C3 C4 C5
(3)
T2
(2) Inlopp (1) Lyft (7) Tilt (8) Aux1
(1) Tryckreduceringsventil, huvudtryck

(2) Överströmningsventil
(3) Kompenseringsventil
(4) Tryckreduceringsventil, servotryck
(5) Lasthållningsventil, lyft
(6) Tiltlåsventil
(7) Väljarventil för sänk
7FBMF 16-35
16-5
(8) Väljarventil för tilt framåt
G : Tryckuttag
16-6
Oil Control Valve

40 ~ 50 model (~2003.7)
C2
C4 G
T1
C5
C3
C1
40-50 model
16-7
Inlet Block Sectional View

40 ~ 50 model
Unload valve
Relief valve
Solenoid valve
Pressure
compensated valve
Pressure reducing valve
Lift Block Sectional View

40 ~ 50 model
Lift lock check valve
Lift select valve
Proportional solenoid valve

16-8
Tilt Block Sectional View

40 ~ 50 model
Tilt lock check valve
Tilt select valve
Attachment Block Sectional View

40 ~ 50 model
T1 P (4) (5) C1 (6) C2 C3 C4 C5
(3)
(2) Inlopp (1) (9) Lyft (7) Tilt (8) Aux1

(6) Tiltlåsventil
7FBMF 40-50 (~2003.7)
16-9
(9) Solenoid ventil
G : Tryckuttag
16-9a
7FBMF 40-50 (2003.7~)
(1) Prioriteringsventil
(7) Tiltlåsventil
G: Tryckuttag
16-11
COMPONENTS
16 ~ 35 model 6705
16-13
OIL CONTROL VALVE ASSY

4
7
Removal Procedure
3 Drain out the hydraulic oil.
5 Disconnect the connector.
6 Remove the oil control valve W/bracket. [Point 1]
7 Remove the oil control valve.
Note:
After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
16-14
Point Operations
[Point 1]
Removal:
Use a wire rope and shackle to hoist the oil control valve
and then remove the set bolts.
16-15
Removal Procedure
2 Remove the front toe board and lower panel.
3 Remove the instrument panel (RH).
6 Remove the oil control valve W/bracket. [Point 1]
7 Remove the oil control valve.
Note:
After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
16-16
Point Operations
[Point 1]
Removal:
Use a fiber rope to hoist the oil control valve and then
remove the set bolts.
Be careful not to drop the oil control valve.
16-17

Note:
• Since parts are finished with high precision, carefully disassemble and reassemble them to
prevent any damage.
• Use a clean location for the job.
• When disassembling the blocks, be careful not to lose the springs, pistons, and O-rings.
26 29
T = 58.8 (600) [43.4]
27
T = 6.9 (70) [5.1]
30
17 18
28
19
20
25
19 ]
31 [7.2
(1 00)
.8
21 19
T =9
9
23
T = 58.8 (600) 10
[43.4]
22 11
16
24
10
T = 9.8 (100) 12
[7.2] 14 2]
[7.
0 0)
1
9. 8(
13 T= T = 9.8 (100)
[7.2]
8
15 4
T = 9.8 (100)
[7.2]
6 3
7 2
T = 39.2 (400)
1 [28.9] T = 9.8 (100)
[7.2]
16-18
1 Remove the outlet housing. [Point 1]
2 Remove the ATT block ASSY.
3 Remove the spring cover W/adjusting screw. [Point 2]
4 Remove the spring set.
6 Remove the spring set and ATT spool. [Point 3]
7 Remove the proportional solenoid valve ASSY. [Point 4]
8 Remove the tilt block ASSY.
9 Remove the tilt select valve. [Point 5]
10 Remove the body W/adjusting screw. [Point 2]
11 Remove the tilt lock check valve. [Point 6]
14 Remove the spring set and tilt spool. [Point 3]
16 Remove the lift block ASSY.
17 Remove the lift block release bolt.
18 Remove the lift select valve. [Point 5]
19 Remove the body W/adjusting screw. [Point 2]
20 Remove the lift lock check valve. [Point 6]
23 Remove the spring set and lift spool. [Point 3]
25 Remove the inlet block ASSY.
26 Remove the relief valve. [Point 7]
27 Remove the unload valve. [Point 3]
28 Remove the plug.
29 Remove the solenoid valve and pressure compensated valve. (40 ~ 50 model) [Point 8]
30 Remove the pressure compensated valve. (16 ~ 35 model)
31 Remove the pressure reducing valve.
Note:
Carefully clean all of the components, blow them with compressed air, apply hydraulic oil, and
reassemble.
16-19
Point Operations
Match [Point 1]
mark
Disassembly:
Put match marks and then remove the solenoid valve.
Reassembly:
Align the match marks and then reassemble the solenoid
valve.
Adjusting screw [Point 2]

Reassembly:
Adjust the adjusting screw set dimension A to the
following value.
Standard: A = 1.8 mm (0.071 in)
A
After installing the oil control valve ASSY in the vehicle,
adjust the material handling operation start timing. (See
page 16-21.)
[Point 3]
Inspection:
Check to see if the orifice is clogged, and if it is, clean it
out.
[Point 4]
Inspection:
Check the solenoid valve continuity.
Between 4 and 8, 3 and 7, 2 and 6, 1 and 5.
Standard: 7.3 Ω
Inspection:
out.
16-20
[Point 5]
Inspection:
out.
[Point 6]
Inspection:
out.
[Point 7]
Reassembly:
When the relief valve is disassembled, leave the adjusting
screw completely loosened.
[Point 8]
Inspection:
Check to see if the filter is clogged, and if it is, clean it out.
Inspection:
Inspect the inlet sleeve solenoid valve continuity.
Standard: Continuity exists

16-21
16 ~ 35 model MATERIAL HANDLING OPERATION START

Raise lift Tilt backward
TIMING ADJUSTMENT
Note:
When the oil control valve is disassembled or a
component is replaced, check and adjust the material
handling operation start timing.
Lower lift 1. Slowly operate the lever, check each operation start
Tilt forward timing, and adjust the timing when it is off.
40 ~ 50 model 2. Loosen the lock nuts on the end of each spool and turn
Tilt forward
Lower lift
the adjusting screw to adjust the material handling
operation start timing.
Turn to the right (tightening side):
Delays the start timing.
Turn to the left (loosening side):
Advances the start timing.
Note:
Tilt backward Raise lift • For the screw turning angle, use ±45º as a reference.
• If the adjusting screw is tightened too much, material
handling speed will be slow with the lever full-stroke.
Fix • If the adjusting screw is loosened too much, jolt will
happen at the start of material handling operation.
3. Use the lock nut to lock the adjusting screw, and then
check the timing again.
16-22
RELIEF PRESSURE ADJUSTMENT

Note:
• Always follow the procedure below for adjustment. Careless adjustment may cause high-
pressure generation, resulting in damage to hydraulic units such as the oil pump.
• No adjustment is needed when the relief valve is not disassembled or is replaced with a new
one.
• The tilt side relief pressure does not need to be adjusted.
16 ~ 35 model 40 ~ 50 model
1 Remove the oil control valve pressure detection port plug, and then attach an oil pressure gauge.
Oil pressure gauge: Pressure resistance 19600 kPa (200 kgf/cm2) [2844 psi] or more.
Plug size: 9/16-18UNF-2B
2 Remove globe nut A, loosen lock nut B to just before the point where it comes off from the body, and
then loosen adjusting screw C.
3 Adjust the relief pressure.
(1) Turn the key switch to ON.
(2) Move the lift lever upward while gradually tightening adjusting screw C, and then move the fork to
the top most position.
(3) Sette adjusting screw C so that the hydraulic pressure when the forks are in the top most position
(relief state) is within the standard.
(4) Tighten the lock nut and globe nut, and then recheck the relief pressure.
(5) Remove the oil pressure gauge and reinstall the plug.
16-23
Relief pressure standard value

Unit: kPa (kgf/cm2) [psi]
16 18 model
•
20 ~ 50 model
+490 +5 +70 +490 +5 +70
Lift relief pressure 16180 (165 ) [2350 ] 18140 (185 ) [2630 ]
0 0 0 0 0 0
16-24
LIFT LOCK RELEASE BOLT

16 ~ 35 model 40 ~ 50 model
Lift lock
unlocking bolt
T = 3.5 ~ 4.3
T = (36 ~ 44) Lift lock unlocking bolt T = 3.5 ~ 4.3 (36 ~ 44)
T = [2.6 ~ 3.2] T = [2.6 ~ 3.2]
When the forks do not descend, due to a malfunction or other cause, loosen the lift lock unlocking bolt to
lower the forks in emergencies.
After making repairs, be sure to reinstall the lift lock unlocking bolt to the original position and tighten the
lock nut.
16-25
MINI LEVER BOX

GENERAL
ATT2
ATT1
Tilt
Lilt
Fork automatic leveling switch
E2 VTA2 VTA1 VC
E2 VTA2 VTA1 VC
16-26
COMPONENTS
6712
16 ~ 35 model 40 ~ 50 model
16-27
3
2
Removal Procedure
2 Remove the harness clamp and disconnect the wiring.
3 Close the seat stand and remove the knob, spacer, and slide adjusting bolt.
4 Remove the mini lever box. [Point 1]
Point Operations
[Point 1]
•
Slide the mini lever box to the rear, lift up the rear side,
and remove the mini lever box.
16-28

2
3
4
5
1.0 ~ 2.0
(10 ~ 20) 1
[0.7 ~ 1.4]
1.0 ~ 2.0
(10 ~ 20)
[0.7 ~ 1.4] *
*: Apply locking agent (08833-76002-71 (08833-00080))
1 Remove the lower box.
2 Remove the arm pad ASSY.
3 Disconnect the connector and remove the fork automatic leveling switch. [Point 1]
4 Disconnect the connector and remove the potentiometer. [Point 2]
5 Disassemble the potentiometer. [Point 3]
Note:
Conduct matching when removing, reinstalling, or replacing the lift lever potentiometer, tilt lever
potentiometer, attachment lever 1 potentiometer, or attachment lever 2 potentiometer (OPT). (See
page 3-51.)
16-29
Point Operations
[Point 1]
Reassembly:
Orient the washer in the direction shown in the figure and
then install the washer.
Washer
Inspection:
Check the continuity of the fork automatic leveling switch.
Standard ON : 0 Ω
OFF : ∞ Ω
ON
OFF
[Point 2]
Disassembly:
Attach a number to the connector that matches the
4-1 number of the upper box.
Reassembly:
Be certain to make the correct wiring connections and
connect the connectors to match the numbers.
Inspection:
A standalone inspection of the potentiometer cannot be
performed. Check the voltage on the display's analyzer
screen. (See page 3-19.)
16-30
[Point 3]
Reassembly:
1. Loosely connect the potentiometer to the position
2. Rotate the potentiometer all the way to the left and
tighten the screw.
3. Check to see if the lever operates normally.
Reassembly:
Align the plate A hole with the lever body pin point and
install the plate.
A
Plate
Reassembly:
Apply MP grease to the locations shown by arrows in the
figure and install the component.
17-1
SAS FUNCTIONS
Page Page
GENERAL ........................................ 17-2 MAST LIFTING HEIGHT 0
COMPONENTS ............................... 17-3 SWITCH ........................................ 17-30 1
REMOVAL • INSTALLATION.......... 17-30
BEFORE STARTING REPAIR 2
WORK ........................................... 17-11 MATCHING .................................... 17-31
3
YAW RATE SENSOR .................. 17-13 SAS MATCHING............................ 17-31
MINI LEVER MATCHING .............. 17-32
4
(16 ~ 35 MODEL)......................... 17-13 STANDARD STATE 5
OF VEHICLE ............................... 17-33
6
(40 ~ 50 MODEL)......................... 17-15 CAUTIONS ON MODIFYING
STEERING WHEEL ANGLE VEHICLES.................................... 17-35 7
SENSOR ....................................... 17-17 8
9
STEERING KNOB POSITION
CORRECTING VALVE ............. 17-20 10
REMOVAL • INSTALLATION.......... 17-20 11
TIRE ANGLE SENSOR ............... 17-21 12
13
SWING LOCK CYLINDER ......... 17-22
14
REMOVAL INSTALLATION.......... 17-22
•
TILT ANGLE SENSOR................ 17-24

15
(16 ~ 35 MODEL)......................... 17-24
17
(40 ~ 50 MODEL)......................... 17-26 18
LOAD SENSOR ............................ 17-27 19
REMOVAL • INSTALLATION.......... 17-27 20
SPEED SENSOR .......................... 17-28
21
22
17-2
GENERAL
SAS (System of Active Stability) Configuration
Sensors and switches installed in various places on the vehicle detect the motions of the vehicle and send
respective signals to the controller. According to these signals, each actuator is driven to effect rear wheel
swing control (S), mast tilting control (T) and knob position correction (K).
Control Control
SAS controller, Main controller, Traveling

Functional part Functional part
controller, Material handing controller

S T K S T K
Lifting height switch Output
Swing lock cylinder
Tilt angle sensor Electric proportional oil con-
Tilt lever potentiometer trol valve
Input
Fork automatic leveling switch Steering synchronizer sole-
noid (Knob position correct-
Load sensor ing valve)
Speed sensor
Steering wheel angle sensor
Output Swing lock
Tire angle sensor LCD indicator
display
Yaw rate sensor Diagnosis

Lifting height switch
Tilt angle sensor
LCD display
Tilt lever potentiometer*

Fork automatic leveling
switch*
Main controller
Knob position correcting valve

Material handing controller
Load sensor
Electric proportional
oil control valve (40 ~ 50 model)
Tire angle sensor
Speed sensor
Electric proportional
oil control valve (16 ~ 35 model)
SAS controller (40 ~ 50 model)
Swing lock cylinder
SAS controller (16 ~ 35 model)
* See section 16 for tilt lever potentiometer (mini lever).

17-3
COMPONENTS
Speed sensor 1401
Speed sensor
0
1
2
3
4
5
6
7
8
9
2401
Yaw rate sensor
16 ~ 35 model
10
11
12
13
14
15
16
17
18
19
Yaw rate sensor 20
21
22
17-4
Yaw rate sensor 2401

40 ~ 50 model
Yaw rate sensor
Tire angle sensor 4301

17-5
Swing lock cylinder 4301

16 ~ 25 model
0
1
2
3
4
5
6
7
8
Swing lock cylinder
30 35 model
•
9
10
11
12
13
14
15
16
17
18
19
20
21
22
17-6
Swing lock cylinder 4301

40 ~ 50 model
Steering wheel angle sensor 4502

17-7
Steering knob position correcting valve 4507
Lifting height switch (V) 5803
RH SIDE OF OUTER MAST

17-8
Lifting height switch 5803

(16 ~ 30 model: FV, 16 ~ 35 model: FSV)
(40 45 model: FV, 50 model: FSV)
•
Lifting height switch (40 45 model: FSV)

•
17-9
Tilt angle sensor (16 ~ 35 model) 5803
RH TILT CYLINDER
Tilt angle sensor (40 ~ 50 model)
RH TILT CYLINDER
17-10
Load sensor (16 ~ 35 model: V, 16 ~ 30 model: FV, 40 ~ 50 model) 5803

Load sensor
LH LIFT CYLINDER
Load sensor (16 ~ 35 model: FSV)
Load sensor
17-11
BEFORE STARTING REPAIR WORK

Before starting SAS repair, fully understand the SAS function.
1. Preparation for repairing
(1) Avoid vehicle washing as far as possible. For cleaning, blow compressed air. If washing with water
is required, avoid water jet washing. Always blow compressed air to remove water after washing.
(2) Transport the SAS controller in packed state. Keep it packed until installation. Never transport it in
exposed state. Full care should be taken not to drop the controller, allow contact with elsewhere or
impact against it.
(3) If matching is required, park the vehicle in a flat place in advance.
2. During repair work

(1) Never use an impact wrench for removing or installing the SAS controller. Full care should be
taken not to drop SAS controller by mistake to avoid impact from dropping that may damage parts
inside.
(2) Do not turn the key switch to ON or OFF carelessly when the sensor wiring is disconnected. Key
switch ON in this state may cause an error and the error code will be stored in the controller. Error
codes cannot be cleared and up to ten error codes can be stored. Beyond ten, older error codes
will be eliminated sequentially.
(3) During matching, SAS function will stop. Do not operate the vehicle.
(4) Do not turn the key switch to ON with one side (either right- or left-hand side) of the vehicle jacked
up. Turning the key switch to ON unlocks the swing lock and causes the vehicle to be tilted
suddenly, leading to great danger.
(5) When the vehicle is in tilted state for repairing a flat tire, for instance, keep the key switch at ON all
the time from jacking up, tire replacement and to grounding of the vehicle.
(6) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(7) If the oil control valve lift lock release bolt is loosened, tighten it properly to the specified torque to
the initial state before the repair work.
(8) Tighten the set bolts of respective functional parts to the specified torque levels.
(9) Though sensors do not require adjustment upon installation, initialize them by matching.
(10) When disconnecting a connector, do not pull it at the harness.
(11) When inspecting the harness, care should be taken not to damage the connector terminals.
(12) Swing lock cylinder cannot be disassembled. If disassembled, the air will enter, making it non-
reusable.
(13) The meanings of high and low fork heights in the troubleshooting section are as follows:
Low fork height: From the lowermost position to immediately before actuation of the fork height
switch.
High fork height: Height above the position where the fork height switch is actuated.
17-12
3. Emergency Action
(1) If swing lock cannot be unlocked because of a trouble
when the key switch is turned to ON, it can manually
be unlocked as an emergency action as follows:
Loosen the illustrated plug of the swing lock cylinder
(by 1 to 2 turns). Do not overloosen it, though.
T = 8.0 ~ 10.0 N • m (80 ~ 100 kgf • cm)

T = [5.8 ~ 7.24 ft • lbf]
16 ~ 35 model (2) If the mast fails to be lowered because of a trouble

when so operated, it can be lowered manually as
follows:
Loosen the lift unlock bolt.
After repair, do not forget to re-tighten the lift unlock
bolt. If forgotten, the lift speed becomes remarkably
delayed.
40 ~ 50 model
17-13
YAW RATE SENSOR

Note:
Take the utmost care so as not to give a shock or impact on the yaw rate sensor. Do not use an air
impact wrench on controller parts wholly. If dropped, replace with a new one.
3
5
T = 0.6 ~ 0.8
(6 ~ 8)
6
T =[0.43 ~ 0.58]
Removal Procedure
1 Remove SAS (W/PS) controller. (See page 2-28.)
3 Disconnect the SCPU board harness and TMPS connector.
4 Remove the SCPU bracket ASSY.
5 Disconnect the jumper on the SCPU board connector. [Point 1]
6 Remove the yaw rate sensor. [Point 2]
17-14
Point Operations
[Point 1]
Removal⋅Installation:
When removing or installing the jumper, take care so as not
to harm the SCPU board connector.
Insert firmly when installing. And avoid adverse contact
such as to element.
[Point 2]
Installation:
Do not change the direction (or orientation) of the yaw rate
sensor when re-installing.
17-15

Note:
Take the utmost care so as not to give a shock or impact on the yaw rate sensor. Do not use an air
impact wrench on controller parts wholly. If dropped, replace with a new one.
• • •
6
8
T = 0.6 ~ 0.8
(6 ~ 8) 7
T =[0.43 ~ 0.58]
Removal Procedure
2 Remove the hood ASSY LH.
3 Remove the cover.
5 Disconnect the SCPU board harness.
6 Remove the SCPU bracket ASSY.
7 Disconnect the jumper on the SCPU board connector. [Point 1]
8 Remove the yaw rate sensor. [Point 2]
17-16
Point Operations
[Point 1]
Removal⋅Installation:
When removing or installing the jumper, take care so as not
to harm the SCPU board connector.
Insert firmly when installing. And avoid adverse contact
such as to element.
[Point 2]
Installation:
Do not change the direction (or orientation) of the yaw rate
sensor when re-installing.
17-17
STEERING WHEEL ANGLE SENSOR

• • •
T = 25 ~ 60 (255 ~ 612)
T =[18.4 ~ 44.3]
6 7
3
10
Removal Procedure
2 16 ~ 35 model: Remove the instrument panel RH.
40 ~ 50 model: Remove the front toe board and lower panel.
3 Remove the steering wheel. [Point 1]
5 Disconnect the connectors of the display and key switch W/lamp switch.
6 Remove the meter cover W/display. [Point 2]
7 Disconnect the turn signal switch connector.
8 Remove the turn signal switch. [Point 3]
9 Disconnect the steering wheel angle sensor connector.
10 Remove the steering wheel angle sensor. [Point 4]
17-18
SST Point Operations

[Point 1]
Removal:
SST 09950-76003-71
(SST 09950-50012)
Installation:
Shaft mark
Steering wheel installation procedure.
(1) Apply rubber grease on sliding face A of the turn
signal switch.
(2) Make a hole at the surface of the cancelcam become
driver’s seat side.
(3) Install the steering wheel while aligning the steering
knob end shaft mark and steering knob at the angle
A
Hole
Standard: B = 14° ± 6°
(4) After installation, rotate the steering wheel. When the
steering wheel is rotated, pin (3 pcs.) on the turn
B
signal switch.
ASSY are automatically set in the holes on the
steering wheel side.
Steering
knob
Shaft mark
[Point 2]
Collar
Thick Installation:
Thin Install the collar and rubber in the direction shown in the
figure.
Rubber
[Point 3]
Installation:
Install the screw as shown in the figure.
17-19
[Point 4]
Installation:
Fix the installed sensor by tightening the tapping screw af-
ter inserting the positioning pin on the sensor side into the
hole on the bracket side.
Fixing without pin insertion may damage the sensor due to
concentricity error. Tighten the tapping screw carefully so
as not to damage the plastic portion by overtightening.
Pin Drilled hole for pin

17-20
STEERING KNOB POSITION CORRECTING VALVE

Removal Procedure
3 Disconnect the wiring connector.
4 Remove the steering knob position correcting valve.
17-21
TIRE ANGLE SENSOR

Note:
Correct tire angle may not be detected if any play exists between the tire angle sensor shaft and the
bushing. Remove the sensor carefully in the vertical direction. Unless necessary, do not remove the
bushing.
• • •
T = 7.0~16.0
(71~163)
[5.14~11.79]
1
2 3
T = 1.0~2.0
4
(10~20)
[0.72~1.45]
Removal Procedure
2 Remove the harness protector.
3 Remove the sensor cover.
4 Remove the tire angle sensor.
5 Remove the gasket.
6 Remove the sensor base.
7 Remove the bushing.
Note:
Carry out matching if the tire angle sensor or sensor cover is removed or replaced.
17-22
SWING LOCK CYLINDER

• • •
T = 10.5~24.5 (107~250)
[7.74~18.1]
4
6
7
T = 16.2~37.8 (165~385)
[11.9~27.9]
Removal Procedure
1 16 ~ 35 model: Remove the battery ASSY. (See page 1-5)
40 ~ 50 model: Open the seat stand and disconnect the battery plug.
2 Jack up the vehicle until the rear wheels leave the ground.
3 Remove the controller cover. (40 ~ 50 model)
4 Disconnect the swing lock solenoid connector.
6 Remove the swing lock cylinder upper pin. [Point 1]
7 Remove the swing lock cylinder. [Point 2]
Note:
• Apply molybdenum grease to the spherical portion of the upper pin and its mounting hole before
installation.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the thread portions of the upper and
lower pin set bolts before tightening them.
• After installation, apply molybdenum grease from the grease fitting.
17-23
16 ~ 35 model Point Operations

[Point 1]
Removal:
SST 09810-20172-71
SST
40 ~ 50 model
SST
[Point 2]
Inspection:
(1) Use a coin or screwdriver, remove the plug from the
tip end of the accumulator.
(2) Measure accumulator depth L.
16 ~ 35 model:
Standard: L = 46 mm (1.81 in) (20°C (68°F))
L = 42 mm (1.65 in) (40°C (104°F))
Limit: L = 52 mm (2.05 in) (20°C (68°F))
L = 48 mm (1.89 in) (40°C (104°F))
40 ~ 50 model:
Standard: L = 45 mm (1.77 in) (40°C (104°F))
Limit: L = 52 mm (2.05 in) (40°C (104°F))
Correct judgment on the standard is difficult at

L
low temperatures because of much variation due
to the oil temperature in the lock cylinder.
Perform inspection after raising the oil
temperature (to approx. 40°C (104°F) or the
cylinder body at near your temperature) by
traveling back and forth on a rough road (or by
heating with an external heater).
If the measured value exceeds the standard, replace

the swing lock cylinder ASSY.
(3) After the inspection, install the plug by pushing it with
a finger.
Installation:
Install with the mark (protruded portion) at the rod end fac-
ing outward.
17-24
TILT ANGLE SENSOR

• • •
T = 6.9 ~ 16.1 (70 ~ 161)

[5.0 ~ 11.6]
T = 6.9 ~ 16.1 (70 ~ 161)

[5.0 ~ 11.6]
Removal Procedure
2 Remove the instrument panel RH.
3 Remove the fender cover RH.
4 Disconnect the tilt angle sensor link.
6 Remove the tilt angle sensor. [Point 1]
Note:
• Carry out matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is
adjusted in length or replaced.
• Apply thread tightener (08833-76002-71 (08833-00080)) to the threaded portion of the tilt angle
sensor link set bolt before tightening them.
17-25
16·18 model Point Operations

[Point 1]
Installation:
The tilt angle sensor installation position differs depending
on the model. Make sure the position is correct for the
model.
20 ~ 35 model
17-26

• • •
T = 6.9 ~ 16.1 (70 ~ 161)

T = [5.0 ~ 11.6]
T = 6.9 ~ 16.1 (70 ~ 161)

T = [5.0 ~ 11.6]
Removal Procedure
2 Remove the lower panel.
3 Remove the instrument panel RH.
4 Remove the fender cover RH.
5 Remove the tilt cylinder side cover RH.
6 Disconnect the tilt angle sensor link.
8 Remove the tilt angle sensor.
Note:
• Carry out matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is
adjusted in length or replaced.
• Apply thread tightener (08833-76002-71 (08833-00080)) to the threaded portion of the tilt angle
sensor link set bolt before tightening them.
17-27
LOAD SENSOR
• • •
V·FV mast FSV mast

T = 35.3 ~ 43.1
5 (360 ~ 440)
[26.0 ~ 31.8]
T = 35.3 ~ 43.1
(360 ~ 440)
1
[26.0 ~ 31.8]
Removal Procedure
V·FV mast
1 Hoist the inner mast. (16 ~ 35 model: See page 14-34, 40 ~ 50 model: See page 14-35.)
2 Remove the hose cover.
3 Remove the insulator guard and insulator.
4 Disconnect the wiring of the load sensor.
5 Remove the load sensor.
FSV mast
1 Remove the insulator.

2 Disconnect the wiring of the load sensor.
3 Remove the load sensor.
Note:
Carry out matching if the load sensor is removed or replaced.
17-28
SPEED SENSOR
Note:
Take the utmost care so as not to give a shock or impact on the sensor bearing.

• • •
Removal Procedure
1 Remove the drive motor. (See page 5-4)
2 Disassemble the drive motor and remove the speed sensor. [Point 1]
17-29
Point Operations
[Point 1]
SST
Removal:
Remove the bearing (speed sensor).
SST 09950-76014-71
(SST 09950-40011)
Installation:
Install the bearing (speed sensor).
SST
SST 09411-41800-71
The bearing (speed sensor) is susceptible to shocks.

Make sure to use a press to install the bearing.
17-30
MAST LIFTING HEIGHT SWITCH

• • •
V mast
T = 14.4 ~ 33.6 (147 ~ 343)

3 T = [10.6 ~ 24.8]
FV FSV mast
•
T = 14.4 ~ 33.6 (147 ~ 343) [10.6 ~ 24.8]
Removal Procedure
1 Remove the lower cover.
3 Remove the mast lifting height switch.
17-31
MATCHING
SAS MATCHING
For the tilt angle sensor, load sensor and tire angle sensor among sensors used for SAS, the signal
voltage values for the mast vertical state, no-load state, tires in straight traveling direction respectively, are
stored in the SAS controller as the bases for control. Therefore, if maintenance or parts replacement
related to these sensors is made, matching (updating sensor signal voltage values of the vehicle in the
standard state) becomes necessary. Matching is also required for the tilt angle sensor if the vehicle
posture changes greatly, and for the load sensor if the weight is changed because of addition/removal of
an attachment.
Matching can be done by selecting “MATCHING” of the display mask function. (See page 3-51)
Forward tilt Tire right
Automatic No-load
Content of matching restriction Tire straight
fork leveling standard load
position travel signal
Mast in Mast in Tires at
Matching condition vertical vertical No-load straight travel
position position*1 angle
Analyzer indication TILTL TILTF LOAD TIRE
Tilt angle Tilt angle Tire angle
Object sensor Load sensor
sensor sensor sensor
Maintenance operation examples:
1 Main controller replacement
2 SAS controller replacement
3 Tilt angle sensor removal installation or
•
replacement
4 Sensor rod length change or
replacement
5 Load sensor replacement
6 Tire angle sensor or sensor cover
replacement
7 Change to another attachment
8 Mast replacement
9 Tilt cylinder replacement
10 Tilt cylinder uneven movement
adjustment
*1: Since the forward tilt control stop position is calculated by the controller, carry out matching by holding
the mast in vertical position.
Note:
The matching value for the tilt angle sensor determines the mast stop position in fork automatic
leveling. If the fork does not stop horizontally because of the site condition (such as inclined
floor), perform matching by holding the mast in vertical position (in this case the mast stop angle
will be deviated on the horizontal floor surface).
17-32
MINI LEVER MATCHING

For lever angle sensors that is used for mini lever function, the lever neutral status signal voltage values
are stored in the controller memory in the factory before shipment, and these values are used as the basis
for control. Therefore, when equipment or parts related to these sensors are replaced, matching must be
performed (updating of the sensor signal voltage values while the vehicle is in the standard state).
Lift lever neutral Tilt lever neutral Attachment lever 1 Attachment lever 2
Content of matching
position position neutral position neutral position
Attachment lever 1 Attachment lever 2
Matching condition Lift lever neutral Tilt lever neutral
neutral neutral
Analyzer indication LIFT TILT ATT 1 ATT 2
Lift lever Tilt lever Attachment lever 1 Attachment lever 2
Object sensor
potentiometer potentiometer potentiometer potentiometer
Maintenance operation examples:
1 Main controller
replacement
2 Lift lever
potentiometer
replacement
3 Tilt lever
potentiomete
replacement
4 Attachment 1 lever
potentiometer
replacement
5 Attachment 2 lever
potentiometer
replacement
17-33
STANDARD STATE OF VEHICLE

If the surface on which matching is to be performed is slanted, error occurs to the standard state. Select a
level floor without irregularity for matching.
Note:
The finishing accuracy of the floors for factories, warehouses and buildings in general calls for the
floor inclination to be 0.5° or under. Therefore, matching on these floors is not affected. Do not
perform matching on a floor that is inclined for over 0.5° for draining purpose.
Fork stop position with automatic leveling and forward

tilting limit position
V FV⋅FSV
Set the vehicle in the following condition so as to have the tilt
angle sensor signal voltage value stored with the mast held
vertical to the floor surface: Load sensor
No-load standard load
100 mm (3.9 in)
Set the vehicle in the following condition so as to have the

load sensor signal voltage value stored under no-load
condition:
500 mm (19.7 in)

Standard:
• Raise the fork to a height of 500 mm (19.7 in) for the V
mast or raise the rear lift cylinder to a height of 100
mm (3.9 in) for the FV or FSV mast. Place a level
(goniometer) at a height of 1200 to 1500 mm (47.2 to
59.1 in) on the front or rear side of the outer mast and
set the mast in the vertical position.
• In the case of a special vehicle with a heavy
attachment (exceeding the additional weight shown in
the table below), adjust the perpendicularity of the
mast with the attachment height at 500 mm (19.7 in),
and perform relief at the topmost position.
Note:
• Keep the fork or attachment installed on the vehicle.
• Set the mast vertical from a backward tilted position
(not from the forward tilted position).
• In case of a detachable attachment, keep the attachment
installed on the vehicle.
Additional Weight Table kg (lbs)

Model 16 18 20 25 30 35 40 45 50
Lift height
mm (in) model model model model model model model model model
3000 (118) 700 800 950 950 1200 1400 1500 1800 1800
or less (1544) (1764) (2095) (2095) (2646) (3086) (3307) (3968) (3968)
3300 (130) 700 700 950 950 1200 1400 1500 1600 1600
~ 4000 (157.5) (1544) (1544) (2095) (2095) (2646) (3086) (3307) (3527) (3527)
4300 (169) 600 650 900 900 1000 1000 1500 1500 1500
~ 5000 (197) (1323) (1433) (1985) (1985) (2205) (2205) (3307) (3307) (3307)
5500 (216.5) 450 550 650 800 800 1000 1200 1500 1500
~ 6000 (236) (992) (1213) (1433) (1764) (1764) (2205) (2646) (3307) (3307)
6500 (256) 500 500
      
~ 7000 (275.5) (1103) (1103)
17-34
m
Tires in straight traveling position

Set the vehicle in the following condition so as to have the
Within 50 mm (2.0 in)

tire angle sensor signal voltage value stored with the tire in
each on the left and

straight position.
right sides
Standard:
Align the center of the vehicle to the line on the level
5m (16 ft) road surface and drive the vehicle for 5 meters (16 ft)
with the steering handle fixed. And the center of the
vehicle stays within 50 mm (2.0 in) each to the left and
the right.
17-35
CAUTIONS ON MODIFYING VEHICLES

No. Content of modification Condition Content of work
1 Single tire to double tire  Remove the lock cylinder.
2 Double tire to single tire  Install the lock cylinder.
3 Mast replacement
Replacement between single tire  Change the mast.
vehicles
4 Mast replacement
Replacement between double tire  Change the mast.
vehicles
5 Mast replacement
Installation of mast for a single tire  Change the mast.
vehicle on a double tire vehicle
6 Mast replacement
Installation of mast for a double tire  Change the mast.
vehicle on a single tire vehicle
7 Installation Removal of attachment
•
 Install or remove attachment.
8 Mast installation Install the mast.
(Mast less spec. model)  Install the lifting height switch.
Install the mast harness.
Note:
• Proceed with the alignment (matching) procedure after the above-mentioned modification.
(See page 3-51.)
• When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch,
load sensor, mast harness and other SAS related parts) simultaneously if such parts are
required.
18-1
APPENDIX
Page
SST LIST...........................................................................18-2
0
SERVICE STANDARDS ...............................................18-6
1
CONNECTOR DRAWING (16 ~ 35 MODEL) ........18-16
2
CONNECTOR DRAWING (40 ~ 50 MODEL) ........18-33
CONNECTING DIAGRAM (16 ~ 35 MODEL) ........18-51 3
CONNECTING DIAGRAM (40 ~ 50 MODEL) ........18-52 4
WIRING DIAGRAM (16 ~ 35 MODEL) ....................18-55 5
WIRING DIAGRAM (40 ~ 50 MODEL) ....................18-58 6
7
Elschema, Fram&Back omkopplare på armstöd.....18-59
8
Elschema, BOBO hytt................................................18-63 9
10
11
12
13
14
15
16
17
18
19
20
21
22
18-2
SST LIST
18
: Newly adopted SST

Section
Illustration Part No. Part Name
0 1 2 3 4 5 6 7 8 9 10 13 14 15 17
09010-20111-71 Engine unit hanger
09120-23600-71 Puller
09230-13700-71 IC check pin

Sub-harness
09231-21320-71
09232-13130-71 Sub-harness

Sub-harness
09232-21320-71
09235-13130-71 Sub-harness
09237-13130-71 Sub-harness
09238-13130-71 Sub-harness
09240-23400-71 IC clip
18-3
Section
0 1 2 3 4 5 6 7 8 9 10 13 14 15 17
Reamer bolt re-

09310-23320-71
mover
0
09316-76008-71 Transfer bearing
(09316-60011) replacer 1
2
Output shaft nee-
09319-76001-71
(09319-60020)
dle roller bearing 3
remover
4
09370-10410-71
Front axle bearing 5
replacer
6
Drive pinion bear-

7
09370-20270-71
ing replacer
8
9
Second drive shaft
09411-41800-71
dust seal replacer 10
11
09420-23001-71 Bearing remover 12
13
14
Front axle hanger
09421-30840-71
15
16
09421-33020-71 Front axle hub re-
(09950-40011) placer
17
18
09450-23320-71 Adapter 19
20
21
22
18-4
Section
0 1 2 3 4 5 6 7 8 9 10 13 14 15 17

Bolt
09460-21320-71
Cylinder cup instal-

09471-22000-71
lation tool
Brake pressure
09472-22000-71
measuring adapter
09509-76002-71 Rear wheel bear-

(09509-55020) ing nut wrench
09610-22000-71 Inner mast stopper
Cylinder cap re-

09620-10100-71
mover & replacer
09630-23600-71 Deep socket A
09630-31720-71 Deep socket C
09630-33900-71 Deep socket B
09631-22000-71 Wear scale chain

18-5
Section
0 1 2 3 4 5 6 7 8 9 10 13 14 15 17
Spring pin tool re-

09700-30200-71
mover
0
1
09810-20172-71 Joint pin remover
2
09950-76003-71
(09950-50012)
Puller C set 3
4
09950-76014-71
Puller B set
5
(09950-40011)
6
09950-76018-71
7
Replacer set
(09950-60010)
8
9
09950-76019-71
(09950-60020)
Replacer set No.2
10
11
09950-76020-71
(09950-70010)
Handle set 12
13
14
Buttery hanger
25001-21320-71
15
16
17
18
19
20
21
22
18-6
SERVICE STANDARDS
BATTERY (Reference)
Specific gravity upon full charge (at 20°C) 1.280 [20°C (68°F)]
Specific gravity upon end of discharge (at 20°C) 1.150 [20°C (68°F)]
72 V vehicle: 61
Voltage upon end of discharge V
80 V vehicle: 68
Insulation resistance MΩ 1 or more
CONTROLLER
ITEM 16 ~ 18 model 20 ~ 35 model 40 ~ 50 model
F1 (For drive) A 500 600 700
F3 (For PS) A 40 40 –
F4 (For lamps) A 10 10 10
F5 (For control circuit) A 10 10 10
F6 (For SAS & solenoid) A 10 10 10
F7 (For DC-DC comverter) A 10 10 10
The greater, the better. The insulation resist-
ance, however, depends greatly on the vehicle
Control panel insulation mΩ
operating state, place, environment and weath-
er. (Approx. 1 or more)
MB (power supply contactor) coil resistance Ω Approx. 20 (at 20°C)
C2E1 (–) – E2 (+) : ∞
C2E1-E2
C2E1 (+) – E2 (–) : Continuity shall exist.
G2 (–) – E2 (+) : ∞
TMPS (transistor for PS) kΩ G2-E2
G2 (+) – E2 (–) : ∞
C2E1 (–) – C1 (+) : Continuity shall exist.
C2E1-C1
C2E1 (+) – C1 (–) : ∞
SH (shunt) Continuity shall exist.
Drive motor input voltage difference (V) between phases 4 or less
Pump motor input voltage difference (V) between phases 4 or less
ACCELERATION POTENTIOMETER
When pedal is operated 0
Acceleration switch (SWAC) Ω
When pedal is not operated ∞
DIRECTION SWITCH
Lever position
Forward Neutral Reverse
DSF 0Ω ∞Ω ∞Ω
DSR ∞Ω ∞Ω 0Ω
DSBU ∞Ω ∞Ω 0Ω
DSFQ 0Ω ∞Ω ∞Ω
18-7
BRAKE LIMIT SWITCH

Limit switch ON dimension See page 2-42
DRIVE MOTOR
Stator ASSY insulation resistance MΩ Standard 1 or more
Speed sensor resistance Ω Standard ∞
Thermo sensor Between the connector and stator Ω Standard ∞
resistance Between both connector terminals kΩ Standard 0.5 ~ 1.0
Tightening torque N m (kgf cm) [ft lbf]
• • •
End bracket set nut Standard 45.0 ~ 55.0 (460 ~ 560) [33.3 ~ 40.5]
PUMP MOTOR
Stator ASSY insulation resistance MΩ Standard 1 or more
Speed sensor resistance Ω Standard ∞
Thermo sen- Between the connector and stator Ω Standard ∞
sor resistance Between both connector terminals kΩ Standard 0.5 ~ 1.0
Tightening torque N m (kgf cm) [ft lbf]
• • •
16 ~ 35 model Standard 39 ~ 91 (398 ~ 928) [28.8 ~ 67.1]

Pump motor set nut (bolt)
40 ~ 50 model Standard 45 ~ 55 (459 ~ 561) [33.2 ~ 40.6]
End bracket (terminal side) set nut Standard 22.5 ~ 27.5 (229 ~ 280) [16.6 ~ 20.3]
POWER STEERING MOTOR

16 ~ 35 Model
Brush spring forse N (kgf) [lbf] Limit 4.3 (0.43) [0.95]
Insulation resistance between connector
MΩ Standard 1 or more
terminal and motor body
Standard 25 (0.98)
Brush lenght mm (in)
Limit 15 (0.59)
Standard 50 (1.97)
Commutator outside diameter mm (in)
Limit 45 (1.77)
Standard 0.8 (0.031)
Under cut mm (in)
Limit 0.3 (0.012)
Commutator runout mm (in) Limit 0.03 (0.0012)
Armature coil insulation resistance MΩ Standard 1 or more
Insulation resistance between brush hold-
MΩ Standard 1 or more
er ASSY and commutator frame ASSY
18-8
DRIVE UNIT
Differential
Standard 22.00 (0.8661)
Spider outside diameter mm (in)
Limit 21.75 (0.8563)
Standard 22.12 (0.8709)
Differential pinion inside diameter mm (in)
Limit 22.22 (0.8748)
Side gear thrust washer thickness mm (in)
Limit 1.3 (0.051)
Pinion gear thrust washer thickness mm (in)
Limit 1.0 (0.039)
Tightening torque N⋅m (kgf⋅cm) [ft⋅lbf]
16 ~ 35 model Standard 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9]
Gear case set bolt
40 ~ 50 model Standard 94.5 ~ 175.5 (960 ~ 1800) [69.5 ~ 130.2]
Differential upper case set bolt Standard 43.1 ~ 53.9 (440 ~ 550) [31.8 ~ 39.8]
Drive unit gear No.3 set bolt Standard 127.5 ~ 176.5 (1300 ~ 1800) [94.1 ~ 130.2]
FRONT AXLE
16 ~ 35 Model
Front axle ASSY
Front axle shaft staring forse 16 ~ 25 model Standard 15.0 ~ 42.4 (1.5 ~ 4.3) [3.3 ~ 9.5]
N (kgf) [lbf] 30·35 model Standard 19.9 ~ 63.7 (2.0 ~ 6.5) [4.4 ~ 14.3]
Tightening torque N•m (kgf•cm) [ft•lbf]
Front axle ASSY set bolt Standard 80 ~ 120 (820 ~ 1220) [59.3 ~ 88.3]
Bearing lock nut screw Standard 2.0 ~ 3.9 (20 ~ 40) [1.45 ~ 2.89]
Front axle bracket set bolt (For frame connec-
Standard 185 ~ 344 (1900 ~ 3500) [137.5 ~ 253.2]
tion)
Front axle bracket set bolt (For gear case con-
Standard 108 ~ 137 (1100 ~ 1400) [79.5 ~ 101.3]
nection)
40 ~ 50 Model
Front axle ASSY
Standard 22.0 (0.866)
Planet gear shaft outside diameter mm (in)
Limit 21.85 (0.873)
Front axle shaft starting force N (kgf) [lbf] Standard 56 ~ 100 (5.7 ~ 10.2) [13 ~ 32]
Tightening torque Unit: N m (kgf cm) [ft lbf]
• • •
Hub bolt lock nut Standard 264.8 ~ 294.2 (2700 ~ 3000) [195.3 ~ 217.1]
Internal gear set bolt Standard 176.4 ~ 235.2 (1800 ~ 2400) [130.2 ~ 173.6]
Front axle shaft lock nut Standard 294.0 ~ 343.0 (3000 ~ 3500) [217.1 ~ 253.2]
Front axle bracket set bolt (For frame connection) Standard 235 ~ 294 (2400 ~ 3000) [173.6 ~ 217.1]
Front axle bracket set nut (For gear case connec-
Standard 221 ~ 323 (2250 ~ 3300) [162.8 ~ 238.8]
tion)
Front axle ASSY set nut Standard 221 ~ 323 (2250 ~ 3300) [162.8 ~ 238.8]
18-9
REAR AXLE
16 ~ 35 Model
Rear axle ASSY
Rear axle ASSY front to rear
mm (in) Standard 0.7 (0.028) or less
clearance
Rear axle center pin bushing
mm (in) Limit 52.0 (2.047)
inside diameter
Steering knuckle
Rear axle hub starting force
N (kgf) [lbf] Standard 15 ~ 39 (1.5 ~ 4.0) [3.3 ~ 8.5]
(at hub bolt)
King pin outside diameter mm (in) Limit 27.8 (1.094)
Steering knuckle starting force
N (kgf) [lbf] Standard 19.3 (2.0) [4.4] or less
(at front end of knuckle)
Rear axle cylinder
Rear axle cylinder piston rod
mm (in) Limit 50.0 (1.969)
outside diameter
Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.020)
Rear axle cylinder inside diameter mm (in) Limit 76.35 (3.0059)
Tightening torque Unit: N•m (kgf•cm) [ft•lbf]
Axle bracket cap set bolt Standard 128 ~ 175 (1310 ~ 1780) [94.78 ~ 128.8]
King pin lock bolt and lock nut Standard 44.1 ~ 53.9 (450 ~ 550) [32.6 ~ 39.8]
Rear axle cylinder rod guide set nut Standard 88 ~ 118 (900 ~ 1200) [65.1 ~ 86.8]
Rear axle cylinder set bolt Standard 166.7 ~ 215.8 (1700 ~ 2200) [123.0 ~ 159.1]
Steering knuekle tie rod end pin lock nut Standard 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9]
Rear axle cylinder tie rod end pin lock nut Standard 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9]
18-10
40 ~ 50 Model
Rear axle ASSY
Rear axle ASSY front to rear clearance mm (in) Standard 1.0 (0.039) or less
Rear axle center pin bushing
mm (in) Limit 67.0 (2.638)
inside diameter
Steering knuckle
Rear axle hub starting force
N (kgf) [lbf] Standard 43 ~ 72 (4.4 ~ 7.3) [9.7 ~ 16.1]
(at hub bolt)
King pin outside diameter mm (in) Limit 34.8 (1.370)
Steering knuckle starting force
N (kgf) [lbf] Standard 19.3 (2.0) [4.4] or less
(at front end of knuckle)
Rear axle cylinder
Rear axle cylinder piston rod
mm (in) Limit 55.0 (2.165)
outside diameter
Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.020)
Rear axle cylinder inside diameter mm (in) Limit 90.40 (3.5591)
Tightening torque Unit: N m (kgf cm) [ft•lbf]
• •
Axle bracket cap set bolt Standard 128 ~ 175 (1310 ~ 1780) [94.78 ~ 128.8]
King pin lock bolt and lock nut Standard 44.1 ~ 53.9 (450 ~ 550) [32.6 ~ 39.8]
Rear axle cylinder rod guide set nut Standard 117.7 ~ 137.3 (1200 ~ 1400) [86.82 ~ 101.3]
Rear axle cylinder set bolt Standard 421.7 ~ 470.7 (4300 ~ 4800) [311.1 ~ 347.3]
STEERING
Hydrostatic steering valve ASSY
Relief pressure 16 ~ 35 model Standard 8040 +490
0 (82 +50 ) [1170 +70
0 ]
kPa (kgf/cm2) [psi] 40 ~ 50 model Standard

11770 +490
0 (120 +50 ) [1710 +70
0 ]
Tightening torque N•m (kgf•cm) [ft•lbf]

Mast jacket ASSY set nut Standard 34.3 ~ 53.9 (350 ~ 550) [25.3 ~ 39.8]
Steering wheel set nut Standard 24.5 ~ 58.8 (250 ~ 600) [18.1 ~ 43.4]
Steering valve ASSY set bolt Standard 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9]
Steering valve end cap set screw Standard 24 ~ 36 (245 ~ 367) [17.7 ~ 26.6]
18-11
BRAKE
Front brake
16 ~ 35 model
Limit 5.6 (0.220)
Disc thickness mm (in)
40 ~ 50 model
Limit 5.2 (0.205)
16 ~ 35 model
Limit 2.6 (0.102)
Pressure plate thickness mm (in)
40 ~ 50 model
Limit 2.6 (0.102)
Spring warp mm (in) 16 ~ 35 model Limit 1.2 (0.047)
Standard 38 (1.50)
Spring free length mm (in) 40 ~ 50 model
Limit 34 (1.34)
Parking brake
Cone height of cone spring washer mm (in)
Limit 6.35 (0.250)
Brake disc thickness mm (in)
Limit 3.06 (0.1205)
Plate thickness mm (in)
Limit 2.26 (0.0890)
Brake valve
Standard 20 (0.79)
16 ~ 35 model
Limit 18.0 (0.709)
Compression spring free length mm (in)
Standard 21 (0.83)
40 ~ 50 model
Limit 18.9 (0.744)
Standard 20 (0.79)
16 ~ 35 model
Limit 18.0 (0.709)
Valve return spring free length mm (in)
Standard 21.9 (0.862)
40 ~ 50 model
Limit 19.7 (0.776)
Brake pedal
Brake pedal height 16 ~ 35 model Standard 143 ~ 148 (5.63 ~ 5.87)
mm (in)
(from toe board: with pad) 40 ~ 50 model Standard 135.5 ~ 140.5 (5.33 ~ 5.53)
Brake pedal play mm (in) Standard 5 ~ 9 (0.197 ~ 0.354)
Brake valve push rod play mm (in) Standard 1 (0.04)
Brake pedal depressed height 16 ~ 35 model Standard 100 (3.94) or more
mm (in)
(with pad) 40 ~ 50 model Standard 100 (3.94) or more
16 ~ 35 model Standard 46 ~ 66 (470 ~ 670) [34.0 ~ 48.5]
Piston guide set bolt
40 ~ 50 model Standard 45 ~ 60 (460 ~ 610) [33.2 ~ 44.1]
16 ~ 35 model Standard 31 ~ 45 (320 ~ 460) [23.2 ~ 33.3]
Spring set bolt
40 ~ 50 model Standard 10.5 ~ 24.5 (110 ~ 250) [7.8 ~ 18.1]
Parking brake cover set bolt Standard 51.0 ~ 64.7 (520 ~ 660) [37.6 ~ 47.8]
18-12

Natural drop test
Natural drop mm (in) Limit 45 (1.77)
Natural forward tilt test
Natural forward tilt mm (in) Standard 15 (0.59) or less
Oil leak test
16 ~ 35 model Standard 8 (0.49) or less
Lift cylinder oil leak amount (at lift port) cm3 (in3)
Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3)
MAST
Mast adjustment (V mast, 16 ~ 35 model)
Mast lift Inner mast roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
roller Outer mast roller clearance mm (in) Standard 0 ~ 0.5 (0 ~ 0.017)
Lift Middle and lower lift roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
bracket
roller Side roller clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Mast strip to inner mast clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
Mast adjustment (V mast, 40 ~ 50 model)
Mast lift Inner mast roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
roller Outer mast roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
Lower lift roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
Lift Side roller clearance mm (in) 40 45 model
•
Standard 0 ~ 0.5 (0 ~ 0.020)
bracket
roller Middle lift roller clearance mm (in) Standard 0.5 ~ 1.0 (0.020 ~ 0.039)
Side roller clearance mm (in) 50 model Standard 0 ~ 0.8 (0 ~ 0.031)
Mast strip to inner mast clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
Fork
Front end misalignment mm (in) Limit 10 (0.39)
147.1 ~ 343.2
Mast support cap set bolt Standard (1500 ~ 3500)
[108.5 ~ 253.2]
18-13
CYLINDER
Lift cylinder (V) (16 ~ 35 model)
16 18 model
•
Limit 34.92 (1.3748)
Piston rod outside
mm (in) 20 25 model
•
Limit 39.92 (1.5717)
diameter
30 35 model
•
Limit 44.92 (1.7685)
16 18 model
•
Limit 45.20 (1.7795)
20 25 model
•
Limit 50.20 (1.9764)
30 model Limit 55.35 (2.1791)
35 model Limit 60.35 (2.3760)
Piston rod bend mm (in) Limit 2.0 (0.079)
Rear lift cylinder (FV FSV) (16 ~ 35 model)
•
FV Limit 31.92 (1.2567)

16 18 model
•
FSV Limit 34.92 (1.3748)

Piston rod outside FV Limit 34.92 (1.3748)
mm (in) 20 25 model
•
diameter FSV Limit 39.92 (1.5717)

30 model FV Limit 39.92 (1.5717)
35 model FSV Limit 44.92 (1.7685)
FV Limit 45.20 (1.7795)
16 18 model
•
FSV Limit 45.20 (1.7795)

FV Limit 50.20 (1.9764)
20 25 model
•
Cylinder bore mm (in) FSV Limit 50.20 (1.9764)

FV Limit 55.35 (2.1791)
30 model
FSV Limit 55.35 (2.1791)
35 model FSV Limit 60.35 (2.3760)
Lift cylinder (V) (40 ~ 50 model)
Piston rod outside
mm (in) 40 ~ 50 model Limit 49.92 (1.9654)
diameter
40 45 model
•
Limit 65.35 (2.5728)
50 model Limit 70.35 (2.7697)
Rear lift cylinder (FV FSV) (40 ~ 50 model)
•
Piston rod outside 40 45 model FV

•
Limit 44.92 (1.7685)
mm (in)
diameter 40 ~ 50 model FSV Limit 49.92 (1.9654)
FV Limit 65.35 (2.5728)
40 45 model
•
Cylinder bore mm (in) FSV Limit 65.35 (2.5728)

50 model FSV Limit 70.35 (2.7697)
18-14
Front lift cylinder (FV⋅FSV) (16 ~ 30 model)

FV Limit 69.91 (2.7524)
16 18 model
•
FSV Limit 69.91 (2.7524)

mm (in) 20 25 model
•

FV Limit 84.90 (3.3425)
30 model
FSV Limit 84.90 (3.3425)
FV Limit 85.40 (3.3622)
16 18 model
•
FSV Limit 85.40 (3.3622)

FV Limit 90.40 (3.5591)
Cylinder bore mm (in) 20 25 model
•
FSV Limit 90.40 (3.5591)

FV Limit 105.40 (4.1496)
30 model
FSV Limit 105.40 (4.1496)
Front lift cylinder (FV⋅FSV) (35 ~ 50 model)
35 model FSV Limit 60.0 (2.362)
mm (in) 40 45 model
•

50 model FSV Limit 69.91 (2.7524)
35 model FSV Limit 90.40 (3.5591)
FV·
Cylinder bore mm (in) 40 45 model
•
Limit 95.40 (3.7559)
FSV
50 model FSV Limit 105.40 (4.1496)
Tilt cylinder
16 ~ 35 model Limit 70.35 (2.7697)
40 ~ 50 model Limit 90.40 (3.5591)
Piston rod outside 16 ~ 35 model Limit 29.92 (1.1780)
mm (in)
diameter 40 ~ 50 model Limit 39.92 (1.5717)
Tightening torque Unit: N m (kgf cm) [ft•lbf]
• •
16 ~ 35 model 260 ~ 350 (2650 ~ 3600) [192 ~ 260]

Tilt cylinder piston set nut
40 ~ 50 model 245.2 ~ 343.2 (2500 ~ 3500) [180.9 ~ 253.2]
18-15
OIL PUMP
Oil pump ASSY (16 ~ 35 model)
Bushing axial length mm (in) Limit 26.411 (1.03980)
Gear shaft outside diameter mm (in) Limit 18.935 (0.74547)
Body inside surface flaw depth mm (in) Limit 0.1 (0.004)
Oil pump ASSY (40 ~ 50 model)
Side plate (2nd) thickness mm (in) Limit 2.65 (0.1043)
Gear shaft outside diameter mm (in) Limit 21.997 (0.86602)
Gear tooth width mm (in) Limit 33.3 (1.311)
Bushing inside Front side (frange side) Limit 24.1 (0.949)
mm (in)
diameter Rear side Limit 17.1 (0.673)
Side plate (1st) thickness mm (in) Limit 2.65 (0.1043)
Body (1st) inside surface flaw depth mm (in) Limit 0.01 ~ 0.06 (0.0004 ~ 0.0024)
Tightening torque Unit: N m (kgf cm) [ft lbf]
• • •
Cover set bolt (16 ~ 35 model) Standard 46.1 ~ 48.6 (470 ~ 500) [34.0 ~ 36.2]
Body (2nd) set bolt (40 ~ 50 model) Standard 88 ~ 98 (897.4 ~ 999.3) [64.9 ~ 72.3]
OIL CONTROL VALVE

Oil control valve
16 18 model
•
16180 +490
0 (165 +50 ) [2350 +70
0 ]
Relief set pressure Lift
2 20 ~ 50 model 18140 +490
0 (185 +50 ) [2630 +70
0 ]
kPa (kgf/cm ) [psi]

Housing set nut Standard 39.2 (400) [28.9]
Lift lock unlocking bolt Standard 3.54 ~ 4.31 (36 ~ 44) [2.60 ~ 3.18]
SAS
Tire angle sensor set bolt Standard 1.0 ~ 2.0 (10 ~ 20) [0.72 ~ 1.4]
Tire angle sensor cover set bolt Standard 7.0 ~ 16.0 (71 ~ 163) [5.1 ~ 11.8]
Upper side: 10.5 ~ 24.5 (107 ~ 250) [7.74 ~ 18.1]
Swing lock cylinder pin set bolt Standard
Lower side: 16.2 ~ 37.8 (165 ~ 385) [11.9 ~ 27.9]
Tilt angle sensor set bolt Standard 6.9 ~ 16.1 (70 ~ 161) [5.0 ~ 11.6]
Load sensor Standard 35.3 ~ 43.1 (360 ~ 440) [26.0 ~ 31.8]
Fork lifting height switch ASSY set bolt Standard 14.4 ~ 33.6 (147 ~ 343) [10.6 ~ 24.8]
18-16
CONNECTOR DRAWING (16 ~ 35 MODEL)

CN1 CN8
CN9
CN3
CN12
CN4
CN13
CN5
CN14
CN6
18-17
CN15 CN26
CN17
CN29
CN31
CN18
CN34
CN19
CN38
CN23
18-18
CN41 CN51
CN42
CN52
CN53
CN43
CN49
CN55
CN50 CN56
18-19
CN57 CN78
CN79
CN70
CN80
CN82
CN77
CN85
18-20
CN86 CN92
CN87
CN94
CN88
CN95
CN90
CN97
CN91
CN98
18-21
CN101 CN103
CN104
CN102
18-22
CN110 CN115
CN126
CN111
CN135
CN136
CN112
CN141
CN113
CN114
18-23
CN142 CN151
CN148
CN152
CN150
18-24
Main harness joint
Mini lever harness joint Rear-upper harness joint

18-25
CPU Boad Connector
CN104 CN103 CN102 CN101
CN105
CN107
CN100
CN101 CN102 CN103 CN104
NO P J NO P J NO P J NO P J
1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B80V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B80V
3 65 LSB 3 – AOPT 3 147 CANGND 3 3 SOLL+
5 67 LSD 5 59 SPL 5 324 SSO+ 5 5 SOLLD
6 – – 6 20 POTL1 6 325 SSO– 6 6 SOLT+
7 – OPTO 7 21 POTL2 7 41 VBBT 7 7 SOLTF
8 72 LEDTK 8 22 POTT1 8 – CHK15V 8 8 SOLTR
9 39 FAN– 9 23 POTT2 9 – CHK5V 9 55 CPR
10 39 FAN– 10 24 POTAT11 10 16 D15V 10 55 CPR
11 63 LSAT1+ 11 25 POTAT12 11 – CHK3.3V 11 9 SOLAT1+
15 308 SMTSK 15 – AOPT+ 15 142 SDTMA 15 44 VBMB
17 62 LSTR+ 17 58 SPL+ 17 35 SOLAT2U
18 70 SWTK 18 28 POTL+ 18 36 SOLAT2L
19 90 MH1 19 29 POTT+ 19 1 MB+
20 91 MH2 – 1 20 30 POTAT1 20 2 MB–
21 92 MH2 – 2 21 31 POTAT2 21 37 SOLD+
22 68 LSAT2+ 22 51 POT– 22 N2 N2
23 61 LSTF+ 23 N2 N2
24 – LSOPT 24 39 FAN–
25 – – 25 42 KEYSTART
26 51 LS– 26 – SOLP+
27 71 SWLE 27 – SOLP–
28 – – 28 38 SOLD–
29 – –
30 73 LSPA
31 – –
32 60 LSL+
33 – –
34 51 POT–
CN100 CN105 CN107
NO P J NO P J NO P J
1 – C5V 1 39 FAN– 1 127 FANR+
2 – GNDC 2 39 FAN– 2 128 FANR–
3 – FTXD 3 39 FAN–
4 – FWE 4 130 FAN1
5 – MD1 5 131 FAN2
6 – FRES 6 132 FAN3
7 – FRXD 7 133 FAN4
8 – SELR 8 134 FAN5
9 135 FAN6
10 – FAN7
11 – CHKG
18-26
SCPU Board Connector
CN145 CN146
CN144
CN140
CN141 CN142
CN141 CN142
CN140
1 – C5V 1 – SSTXA 1 65 SLSB
2 – GNDC 2 – SXTSA 2 319 POTS
3 – FTXD 3 309 SSTMA 3 317 POTH
4 – VPP 4 307 SMTSA 4 324 SSN+
5 – MDJ 5 – SS+ 5 325 SSN–
6 – FRES 6 312 STS1 6 – –
7 – FRXD 7 313 STS2 7 – POTOPT–
8 – SELR 8 314 STSC 8 320 SPOT–
9 – SSTXK 9 – POTOPT+
10 – SXTSK 10 318 POTS+
11 310 SSTMK 11 316 POTH+
12 308 SMTSK 12 – –
13 138 SL/L–
14 137 SL/L+
15 – SS–
16 315 STS–
17 311 STS+
18 – –
CN144 CN145 CN146
1 321 SYR+ 1 340 TMPSG 1 – PS15V
2 323 SYR– 2 P24 SH+ 2 44 VBMB
3 322 SYR 3 N1 SH– 3 350 PS20V
4 351 GNDPS
5 352 SC15V
6 353 GNDSC
7 331 DRSOL+
8 332 DRSOL–
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14 – –
18-27
DC/SD Board Connector
CN147
CN148
CN147 CN145
CN148
NO P J NO P J
1 – – 1 327 SOLS+
3 350 PS20V 3 44 VBMB
4 351 GNDPS 4 – CK20V
5 352 SC15V 5 330 SOLST–
6 353 GNDSC 6 328 SOLS–
7 331 DRSOL+ 7 N2 N2
8 332 DRSOL– 8 – CK15V
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14 – CKT-G
18-28
Main Controller Connector • Component
CN104
CN103
CN102
CN101
CN126
18-29
SAS Controller Connector • Component

CN147
CN145
CN146
Yaw rate
sensor
CN144 CN140
CN141 CN142
CN148
CN51
CN141
CN142
CN51
CN148
18-30
Traveling Controller Connector • Component
P3
P7
P8
CN110
P9
N1
Material Handling Controller Connetor • Component.
P3
P14
P15
CN111
P16
N2
18-31
Contactor Panel Connector • Component
P1
F1
P3
CN135
CN134
CN136
18-32
Oil Control Valve Connector • Component
CN87
CN88
Brake Change Valve Connector • Component
Brake solenoid
CN82
18-33
CONNECTOR DRAWING (40 ~ 50 MODEL)

CN1 CN8
CN9
CN3
CN12
CN4
CN13
CN5
CN14
CN6
18-34
CN15 CN24
CN17 CN26
CN29
CN18
CN31
CN19
CN34
CN23
18-35
CN38 CN43
CN52
CN40
CN53
CN41
CN55
CN42
CN56
18-36
CN57 CN78
CN79
CN70
CN80
CN82
CN77
CN85
18-37
CN86 CN91
CN87
CN92
CN94
CN88
CN89
CN95
CN90
CN96
18-38
CN97 CN102
CN98
CN101
CN103
18-39
CN104 CN111
CN112
CN113
CN110
CN114
18-40
CN115 CN141
CN126
CN142
CN135
CN136
CN148
18-41
Main harness joint
Mini lever harness joint Rear-lower harness joint
Rear-upper harness joint Mast harness joint

18-42
CPU Boad Connector
CN104 CN103 CN102 CN101
CN105
CN107
CN100
CN101 CN102 CN103 CN104
NO P J NO P J NO P J NO P J
1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B80V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B80V
3 65 LSB 3 – AOPT 3 147 CANGND 3 3 SOLL+
5 67 LSD 5 59 SPL 5 324 SSO+ 5 5 SOLLD
6 – – 6 20 POTL1 6 325 SSO– 6 6 SOLT+
7 – OPTO 7 21 POTL2 7 41 VBBT 7 7 SOLTF
8 72 LEDTK 8 22 POTT1 8 – CHK15V 8 8 SOLTR
9 39 FAN– 9 23 POTT2 9 – CHK5V 9 55 CPR
10 39 FAN– 10 24 POTAT11 10 16 D15V 10 55 CPR
11 63 LSAT1+ 11 25 POTAT12 11 – CHK3.3V 11 9 SOLAT1+
15 308 SMTSK 15 – AOPT+ 15 142 SDTMA 15 44 VBMB
17 62 LSTR+ 17 58 SPL+ 17 35 SOLAT2U
18 70 SWTK 18 28 POTL+ 18 36 SOLAT2L
19 90 MH1 19 29 POTT+ 19 1 MB+
20 91 MH2 – 1 20 30 POTAT1 20 2 MB–
21 92 MH2 – 2 21 31 POTAT2 21 37 SOLD+
22 68 LSAT2+ 22 51 POT– 22 N2 N2
23 61 LSTF+ 23 N2 N2
24 – LSOPT 24 39 FAN–
25 – – 25 42 KEYSTART
26 51 LS– 26 12 SOLP+
27 71 SWLE 27 13 SOLP–
28 – – 28 38 SOLD–
29 – –
30 73 LSPA
31 – –
32 60 LSL+
33 – –
34 51 POT–
CN100 CN105 CN107
1 – C5V 1 39 FAN– 1 127 FANR+
2 – GNDC 2 39 FAN– 2 128 FANR–
3 – FTXD 3 39 FAN–
4 – FWE 4 130 FAN1
5 – MD1 5 131 FAN2
6 – FRES 6 132 FAN3
7 – FRXD 7 133 FAN4
8 – SELR 8 134 FAN5
9 135 FAN6
10 – FAN7
11 – CHKG
18-43
SCPU Board Connector
CN145 CN146
CN144
CN140
CN141 CN142
CN141 CN142
CN140
1 – C5V 1 – SSTXA 1 – SLSB
2 – GNDC 2 – SXTSA 2 319 POTS
3 – FTXD 3 309 SSTMA 3 317 POTH
4 – VPP 4 307 SMTSA 4 324 SSN+
5 – MDJ 5 – SS+ 5 325 SSN–
6 – FRES 6 312 STS1 6 – –
7 – FRXD 7 313 STS2 7 – POTOPT-
8 – SELR 8 314 STSC 8 320 SPOT–
9 – SSTXK 9 – POTOPT+
10 – SSTSK 10 318 POTS+
11 310 SSTMK 11 316 POTH+
12 308 SMTSK 12 – –
13 138 SL/L–
14 137 SL/L+
15 – SS-
16 315 STS–
17 311 STS+
18 – –
CN144 CN145 CN146
1 321 SYR+ 1 – TMPSG 1 – PS15V
2 323 SYR– 2 – SH+ 2 44 VBMB
3 322 SYR 3 – SH– 3 350 PS20V
4 351 GNDPS
5 352 SC15V
6 353 GNDSC
7 331 DRSOL+
8 332 DRSOL–
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14 – –
18-44
DC/SD Board Connector
CN147
CN148
CN147 CN148
NO P J NO P J
1 – – 1 327 SOLS+
3 350 PS20V 3 44 VBMB
4 351 GNDPS 4 – CK20V
5 352 SC15V 5 330 SOLST–
6 353 GNDSC 6 328 SOLS–
7 331 DRSOL+ 7 N2 N2
8 332 DRSOL– 8 – CK15V
9 333 CKSOLS
10 334 CKSOLST
11 335 SGSOLS
12 336 SGSOLST
13 337 RESOL
14 – CKT-G
18-45
Main Controller Connector • Component
CN104
CN103
CN102
CN101
CN126
18-46
SAS Controller Connector • Component
CN147
CN145
CN146
Yaw rate sensor
CN144 CN140
CN141 CN142
CN148
CN141
CN142
CN148
18-47
Traveling Controller Connector • Component
P3
P7
P8
CN110
P9
N1
Material Handling Controller Connector • Component
P3
P14
P15
CN111
P16
N2
18-48
Contactor Panel Connector • Component
P1
F1
P3
CN135
CN134
CN136
18-51
7FBMF 16-35
18-52
7FBMF 40-50
18-54 7FBMF 16-50 Symbolbeteckningar på elschemat
AM D Drivmotor MB Huvudkontaktor
AM P Pumpmotor PB CPU CPU kort, åkning och hydraulik
BZ Backlarm PB DC/SD DC/SD kort, styrning
BATT Batteri PB SCPU CPU kort, styrning
CPR Resistor SH Strömshunt, styrmotor
CU D Åkpanel SOL At1L Solenoid, Aux1 (nedre)
CU P Hydraulpanel SOL At1U Solenoid, Aux1 (övre)
CHI F Varningssignal vid körning framåt SOL At2L Solenoid, Aux2 (nedre)
CHI R Varningssignal vid körning bakåt SOL At2U Solenoid, Aux2 (övre)
DM PS Styrpumpsmotor SOL D Solenoid, P-broms
DS BU Brytare, backljus SOL LD Solenoid, sänk
DS F Brytare, fram SOL LU Solenoid, lyft
DS FO Brytare, fram (option) SOL P Solenoid, avlastningsventil (40-50)
DS R Brytare, back SOL S Stabiliseringscylinder
F1 Huvudsäkring SOL ST Shuntventil, styrning
F3 Säkring, styrmotor SOL TF Solenoid, tilt framåt
F4 Säkring, belysning SOL TR Solenoid, tilt bakåt
F5 Manöversäkring före nyckel SPL Lastsensor
F6 Säkring, SK/PS & solenoider SSD Hastighetssensor, drivmotor
F7 Säkring, DC-DC Converter SSP Hastighetssensor, pumpmotor
FAN Ex Kylfläkt, Paneler SST Rattsensor
FAN Vent Kylfläkt, Ventilation STMD Tempsensor, drivmotor
FAN Cpu Kylfläkt, Cpu-kort STMP Tempsensor, pumpmotor
FR Y Blinkrelä SW F Blinkersomkopplare
H Signal SW H Signalknapp
L BU-R Backljus, höger SW K Nyckelbrytare
L C-L Positionsljus, vänster SW L Omkopplare, belysning
L C-R Positionsljus, höger SW MH1 Brytare, lyfthöjd 1
L F-L Blinkerslampa, Vä fram SW TK Knapp på tiltspak
L F-LR Blinkerslampa, Vä bak SWAC Brytare, fartreglage (1 MS)
L F-R Blinkerslampa, Hö fram SYR G-Kraft sensor
L F-RR Blinkerslampa, Hö bak TMPS Transistor, styrpumpsmotor
L H-L Strålkastare, Vä fram VRAD Fartreglage
L H-R Strålkastare, Hö fram VRAH Potentiometer, styrhjulsvinkel
L L-L Skyltbelysning, Vä VRAT Potentiometer, tiltvinkel
L L-R Skyltbelysning, Hö VRAL 1 Potentiometer, lyft 1
LR Roterande varningsljus VRAL 2 Potentiometer, lyft 2
L ST-L Bromsljus Vä VRAT 1 Potentiometer, tilt 1
L ST-R Bromsljus Hö VRAT 2 Potentiometer, tilt 2
L T-L Bakljus Vä VRAAT 11 Potentiometer, Aux1 1
L T-R Bakljus Hö VRAAT 12 Potentiometer, Aux1 2
LW Arbetsbelysning bakåt VRAAT 21 Potentiometer, Aux2 1
LCD DISP Display VRAAT 22 Potentiometer, Aux2 2
LS B Bromsbrytare
LS D Stolsbrytare
LS PB Brytare, parkeringsbroms
LS ST Brytare, bromsljus
18-55
7FBMF 16-35
Röd P21
P21 = C1
Vit
P23 = C2E1
P24 = E2
Toyota - Kabelfärger på elschemat

B = Svart BR = Brun DG = Mörkgrå G = Grön L = Ljusblå LG = Ljusgrön
O = Orange P = Rosa PU = Lila R = Röd W = Vit Y = Gul
18-57 7FBMF 16-50 Symbolbeteckningar på elschemat
AM D Drivmotor MB Huvudkontaktor
AM P Pumpmotor PB CPU CPU kort, åkning och hydraulik
BZ Backlarm PB DC/SD DC/SD kort, styrning
BATT Batteri PB SCPU CPU kort, styrning
CPR Resistor SH Strömshunt, styrmotor
CU D Åkpanel SOL At1L Solenoid, Aux1 (nedre)
CU P Hydraulpanel SOL At1U Solenoid, Aux1 (övre)
CHI F Varningssignal vid körning framåt SOL At2L Solenoid, Aux2 (nedre)
CHI R Varningssignal vid körning bakåt SOL At2U Solenoid, Aux2 (övre)
DM PS Styrpumpsmotor SOL D Solenoid, P-broms
DS BU Brytare, backljus SOL LD Solenoid, sänk
DS F Brytare, fram SOL LU Solenoid, lyft
DS FO Brytare, fram (option) SOL P Solenoid, avlastningsventil (40-50)
DS R Brytare, back SOL S Stabiliseringscylinder
F1 Huvudsäkring SOL ST Shuntventil, styrning
F3 Säkring, styrmotor SOL TF Solenoid, tilt framåt
F4 Säkring, belysning SOL TR Solenoid, tilt bakåt
F5 Manöversäkring före nyckel SPL Lastsensor
F6 Säkring, SK/PS & solenoider SSD Hastighetssensor, drivmotor
F7 Säkring, DC-DC Converter SSP Hastighetssensor, pumpmotor
FAN Ex Kylfläkt, Paneler SST Rattsensor
FAN Vent Kylfläkt, Ventilation STMD Tempsensor, drivmotor
FAN Cpu Kylfläkt, Cpu-kort STMP Tempsensor, pumpmotor
FR Y Blinkrelä SW F Blinkersomkopplare
H Signal SW H Signalknapp
L BU-R Backljus, höger SW K Nyckelbrytare
L C-L Positionsljus, vänster SW L Omkopplare, belysning
L C-R Positionsljus, höger SW MH1 Brytare, lyfthöjd 1
L F-L Blinkerslampa, Vä fram SW TK Knapp på tiltspak
L F-LR Blinkerslampa, Vä bak SWAC Brytare, fartreglage (1 MS)
L F-R Blinkerslampa, Hö fram SYR G-Kraft sensor
L F-RR Blinkerslampa, Hö bak TMPS Transistor, styrpumpsmotor
L H-L Strålkastare, Vä fram VRAD Fartreglage
L H-R Strålkastare, Hö fram VRAH Potentiometer, styrhjulsvinkel
L L-L Skyltbelysning, Vä VRAT Potentiometer, tiltvinkel
L L-R Skyltbelysning, Hö VRAL 1 Potentiometer, lyft 1
LR Roterande varningsljus VRAL 2 Potentiometer, lyft 2
L ST-L Bromsljus Vä VRAT 1 Potentiometer, tilt 1
L ST-R Bromsljus Hö VRAT 2 Potentiometer, tilt 2
L T-L Bakljus Vä VRAAT 11 Potentiometer, Aux1 1
L T-R Bakljus Hö VRAAT 12 Potentiometer, Aux1 2
LW Arbetsbelysning bakåt VRAAT 21 Potentiometer, Aux2 1
LCD DISP Display VRAAT 22 Potentiometer, Aux2 2
LS B Bromsbrytare
LS D Stolsbrytare
LS PB Brytare, parkeringsbroms
LS ST Brytare, bromsljus
18-58
7FBMF 40-50
Toyota - Kabelfärger på elschemat

B = Svart BR = Brun DG = Mörkgrå G = Grön L = Ljusblå LG = Ljusgrön
O = Orange P = Rosa PU = Lila R = Röd W = Vit Y = Gul
Till maskin - Stift Till F&B - Hylsor
Röd Blå 51, Matning F&B
Röd-Blå (1) Orange (1) Kablage med
kopplingsplint
Gul 120, Option
Gul-Röd (2) Svart (2) till orginal
Röd Fram&Back
103, Backljus
Röd-Vit (3) Grön (3) omkopplare
Grön 46, Back på rattstam.
Grön (4) Vit-Orange (4)
7FBMF 16-50 Fram&Back på armstöd

Vit 45, Fram
Vit (5) Vit-Brun (5)
Svart-Gul (6) Svart Gul 43, Matning backljus Röd (6)
Röd
Svart
Blå
Gul
Brytare för val av
Fram&Back reglage
monterad på instr. panel.
3 2 1
Backljus Fram&Back 1 2 3
6 5 4 4 2
Kopplingsplint mellan
5 1 3
armstöd och maskin.
4 5 6
G/G
3
4
2
Numrering sett
från stiftsidan i Fram&Back brytare Numrering sett
kontaktstycket. på armstöd. från hylssidan i
kontaktstycket
Backljus Fram&Back
Växelväljare (ratt/armstöd) Fram&Back brytare
14 R5 Bl 6 2 1 3
<Vä. Hö.> Framåt
18-59
G/G 1 Sv 2 Gu 3 G/G 4
Spår för
låsbricka
Toyota 7FBMF 16-50
18-60
Fram&Back brytare på armstödet Original kopplingsplint
Brytare för val av
CN9 till F&B spak
Fram&Back reglage Kopplingsdon
AMP 6-pol (stift)
7FBMF 16-50 Fram&Back på armstöd

Kopplingsdon
AMP 6-pol (hylsor)
Kablage A22600-001
Kopplingsdon
AMP 6-pol (hylsor)
Kopplingsdon
AMP 6-pol (stift)
Kopplingsdon
AMP 6-pol (hylsor)
Original kopplingsplint
CN9 till maskin
Kablage A22600-002
F&B brytare
Kopplingsdon
AMP 6-pol (stift)
18-63

Toyota 7FBMF 16 50

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Toyota 7FBMF 16 50

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TOYOTA 7FBMF 16-50

HOW TO USE THIS MANUAL

2. How to read components figures (Example)

The number at the top right of each

HOISTING THE VEHICLE

CAUTION FOR TOWING

3. Always set the key switch to OFF and the direction

PARKING BRAKE RELEASE METHOD

1. Remove the toe board.

L 3. As shown in the figure, install the service bolt (or SST),

ATTENTIVE POINTS ON SAS

(2) Digital circuit tester

2. Difference in result of measurement with a circuit tester

3. Difference in measurement result by measurement range (analog type)

Power source: 1.5V

STANDARD BOLT & NUT TIGHTENING TORQUE

BOLT STRENGTH TYPE IDENTIFICATION METHOD

Hexagon Two protruding 5T

Hexagon Two protruding 6T

TIGHTENING TORQUE TABLE

2. Method for reuse of precoated bolts

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

WIRE ROPE SUSPENSION ANGLE LIST

60° 1.16 time 0.58 time 60°

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

RECOMMENDED LUBRICANT QUANTITY & TYPES

*) Shell Donax TD = OK/Q8 T2200

P/N: 755224-020 20 liter

Inspection I. Inspect every 8 hours (daily)

1 Chain 8 Tie rod end pin

Inspection I. Inspect every 8 hours (daily)

1 Chain 8 Tie rod end pin

I : Inspection⋅Repair or Replacement if required.

Inspection Period Every Every Every Every

Inspection Period Every Every Every Every

Inspection Period Every Every Every Every

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Pos Kontroll av: Pos Kontroll av: Pos Kontroll av:

0:0 Grupp 0 Hel maskin 3:0 Grupp 3 Bromsar/hjul 5:9 Fartreglage

6:0 Grupp 6 Hydraulik

7:0 Grupp 7 Arbetsfunktion

(*) Endast 7FBMF 16-35

BATTERY COMPARTMENT AND REQUIRED WEIGHT

7FBMF20, 25 5PzS550L 852 (33.5) ↑ ↑ 1530 (3374)

7FBMF20.25 4PzS560L 711 (28.0) ↑ ↑ 1560 (3440)

7FBMF40, 45, 50 6PzS840L 999 (39.3) ↑ ↑ 2180 (4807)

Plate corrosion Sulfation Plate warpage and active substance freeing

Damaged Crack or chipping of cell

Deposition of freed Fouled terminal or

Short circuit Electrolyte leakage and reduction Loosened or corroded connection

2. Battery electrolyte specific gravity inspection

Equation for converting specific gravity

How to use the hydrometer

3. Insulation resistance inspection

Battery control table

Material handling controller

SAS (with PS) controller

Material handling controller

SAS (with PS) Controller (16 ~ 35 model)

BEFORE STARTING REPAIR WORK

PRECAUTIONS FOR PARTS REPLACEMENT

CONNECTOR INSPECTION LIST

SST 09240-23400-71 SST 09240-23400-71