CA eyoFOREWORD This manual covers the service procedures of the TOYOTA ELECTRIC POWERED FORKLIFT 7FBMF16 to 50. Please use these manuals for providing quick, correct servicing of the corre- sponding forklift models. This manual deals with the above models as of September 2002. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News TOYOTA Material Handling Company [A vision of TOYOTA INDUSTRIES CORPORATIONSECTION INDEX NAME ‘SECTION [MOTOR CYLINDER Ea OIL PUMP0-1 GENERAL Page EXTERIOR VIEWS... on OZ VEHICLE MODELS.. FRAME NUMBER. HOW TO USE THIS MANUAL... 0-5 EXPLANATION METHOD... TERMINOLOGY. ABBREVIATIONS.. OPERATIONAL TIP: JACK-UP POINT... HOISTING THE VEHICLE CAUTION FOR TOWING... PARKING BRAKE RELEASE METHOD. ATTENTIVE POINTS ON SAS.. CIRCUIT TESTER... STANDARD BOLT & NUT TIGHTENING TORQUE... BOLT STRENGTH TYPE IDENTIFICATION METHOD.......... 0-13 TIGHTENING TORQUE TABLE. PRECOATED BOLTS . HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE... WIRE ROPE SUSPENSION ANGLE LIST... Page SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE... COMPONENTS WEIGHT RECOMMENDED LUBRICANT QUANTITY & TYPES LUBRICATION CHART PERIODIC MAINTENANCE......... 0-21 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS...40 ~ 50 Model4 VEHICLE MODELS Model code Load capacity Vehicle model Voltage 16 76 ton 7FBMFI6 Bovir2V 18 1.8 ton 7FBMF18, t 20 2.0 ton 7FBMF20 t 2 | 2.5 ton 7FEMF25 tT 30 3.0 ton 7FBMF30 te [36 3.6 ton 7FBMFS5 T 40 — 40ton 7FBMF40 t 45 45 ton TEBMF45 eee 50 5.0 ton 7FBMF5O. t FRAME NUMBER Vehicle model Punching format Frame No. punching position 7EBMF 16 Punching peston |—yeemrig | «SS 7FBMF18@ 10071 7FBMF20 Fee 7EBMEDS 7FBMF25© 10011 7FBMF30 7FBMF35 7FBMF35@ 10011 ‘7FBMF40 | 7FBMF45 | 7FBMFS0©10014 7FBMF500-5 HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operation procedure (1). The operation procedure is described in elther 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, followed by explanation of cautions and notes summarized as point operations. Example of description in pattern B DISASSEMBLY -INSPECTION-REASSEMBLY Tightening torque unit T = N-m (kgf-om) [feof] EERE 7 a] + Step Nos. are sometimes partially | omitted in illustrations. | + When a part requiring tightening torque instruction is not indicated in the illustration, the part name is, described in the illustration frame. 72464-4841 (470 ~ 490} [34.9355] Disassembly Procedure 4 Remove the cover, [Point 4] 2 Remove the bushing [Point 2] € Operation explained later 3. Remove the gear. Point Operations Explanation of key point for operation with an illustration “ [Point 1] Disassembly: Put a match mark when removing the pump cover. [Point 2] Inspection: Measure the bushing inside diameter. Limit: 19.12 mm (0.7528 in)0-6 2. How to read components figures (Example) (1), The components figure uses the illustration in the parts catalog for the vehicle model. Please refer to the catalog to check the part name The number at the top tight of each components figure indicates the Fig number in the parts catalog. __t FIG number in 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 Sociely of Automotive eral: iia Engineers (USA) Attachment ‘SAS ‘System of active stability ‘Central hydraulic CHPS sae eoare SST Special service too! | _tH ___befthand STD Standard U | Tess = Tightening torque Option OOT | Number of teeth (60) _ 7 Oversize UIs: Undersize PS: | Power steering we 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. (8) 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 (6) 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. ae Jaciup polnt & ‘Wooden block o stand setting point —_ey om Senvioe bolt ne Nut | ~Fiston washer 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. Cautio + 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 Remove the toe board. 2. Remove the plug from the center of the parking brake cover. 3. As shown in the figure, install the service bolt (or SST), nut and plate washer to the plug hole. Service bolt size’ M14 x 1.5, L= 40 mm (all screws) Note: + Ifyou do not have a service bolt, use the SST. SST 09460-21320-71 + Screw the service bolt securely into the parking brake piston.rv 2 c 4, Fix the head of the service bolt, then tighten the nut TORRES \ clockwise to fully pull in the parking brake piston. This Bot | q releases the parking brake. OW) Fix ATTENTIVE POINTS ON SAS 1 Reference should be made to separate manual "New Model Feature 7FBMF16 to 60 Pub. No.PE313" for the explanations of SAS functions and operations, Read Section 17 “SAS Precautions for Repair” on Page 17-11 in this repair manual in advance 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) 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. The SAS oil control valves have many precision valves. Since dirty or contaminated hydraulic cil 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 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.).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 itis difficult to observe the variation or movement. 4. Difference in measurernent 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: k range Analog type “| Continuity exists Forward i Rs ka [2 Paes No continuity a 28. (2) Digital circuit tester Forwarddrecion —_~Revere decten Measurement result example Tester range: MO range Digital ype No continu — Le Forward ; y Continuity exists Reverse ont pe is 2a0-12 2 Difference in result of measurement with a circuit tester The circuit tester power supply voltage depends on the tester type, 1.6 V, 3.0 V or 6.0 Vis 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. =) Forward current Forward voltage The resistance values of the same semiconductor measured with two types of circuit testers having different power supply voltages are different. This manual describes the results of measurement with a circuit tester whose power supply voltage is 3.0 V. 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. Resistor Meter a \Varebie resistor Current tow Resistor ‘Rengex Connector No. Condi Standard Remarks CNTOTAE a 7 7 z (08, suisK) | - immeasurable - cntorg jis) | = oH ~ GNiori?—ENTOMIE cag (62, LSTR#) | (61, LS) ie T Key switch OFF forkautomatciey-| yo gy cntot-18 | eNt01-16 | eling switch ON wil (70,SWTK) | (S1,LS+) | Key switch OFF, fork automatic lev- 1 eling switch OFF ne Pe CNiOTI9 01-6 |, uns i Bes) [titlowest posiion Approx. OV ‘CNIO1-20 CNTOI-I6 (91, MH2-1) : LS), |tit¥owest poston Approx. 5V Ota : nme) ; Suis) iftlowest poston ‘Approx. 8 V CNIOTE CNIS cy + (68,LSAT2) | (64,48) ant =H CNI01-23 CNiOTe Fase tee = i e@xistrs) | (61s) _[Netused 7 ‘CNIO1-24 7 cisom | Not used = onTor2s + = = = GNID-26 gris) | in | = = CNTOTAT CNIOTAE Tor uea @7,swley | (61,Ls) ot user = oni01-28 7 = | = = He | cNior2e = = =) GNTOT30 | GNOI-18 Ta co ‘ 7] (73, LSPA) 61,L8) Hee ee CNIOT-31 Se = = ONTOS GATOS |uorusea ; (60, LSL*) 61, LS) Pee ae CNt01-33 = = i Nioraa > CNTOT6 ipor) | (61, LS) peroCN102 Basic conditions (Battery plug connected, key switch ON) Connéator No esConnector No. Conditions Siandard Remarks | Key switch OFF, accelerator pedal v onioz1 | cNto222 | depressed Approx. 0 (64, SWAC) (51, POT: [icay Switch OFF accelerstorpedal J ~ 7 ~~ ~~ I I not depressed ‘Approx. V GNiaaa ~~ GNI0ZBT Jey switch OFF, accelerator pedal aya (52,POTA) =| (81, POT-) fully depressed N102-3 v aorT) | ae Not used a CNTR 1“ ENT02-33| Amount of change when tit moved Geubey (86,POTTA) | (51, POT-) from forward to backward —“suiges TT cnioe-z2 (9,SPL) 1 61,POT) 7 OSV~48V T When fevers neta Appian 1 gannes |) uence Ml sees 20, POTL 1, POT.) ge wha i aver is i ‘ ui I (81, POT) moved forward or backward O5V~22V T ‘When ke is neutral exe | enveagn(hbeTowrteutel_ | Aap SV econ Giipory | Atiount of change whan it everis 1 i moved forward or backward T When fevers neutral Bey | ereDe [Artount of haige when Ti everis| ~ on aos (22, POTT (51, POT-) am ~ ‘ a » | moved forward or backward tavaeay cnt02-9 cntozze | Wnenleverisreuiel | Aer sav bs poral i por) (Amount of change when if fevers i ero et roree moved forward or backward eave ‘When lever is neutral ‘Approx. 13 CN102-10 0N102-22 ‘Amount of change when aitach- [~~ “4 (24, POTAT 11) (51, POT-) ‘ment 1 lever is moved forward or O5V~22V backward When lever is neutral Apron 330 ento2.11 cn102.22 [amount of change whan attach 7 (25, POTATI2) (51,POT-) [iment lever is moves forward or backward When ieveris neutral ON102-42 ON102-22 [Amount of change when aitach- 2 (26, PoTAT21) (51,POT) —|iment 2 lover is moved forward or | 0.5V~22V backward (When levers neutral Approx 33V ont02-13 cN102-22 —[Ainount af charge whan attach J ~ — ~~ ~~ a (27, PoTAT22) (61,POT-) [iment levers moved forward or 2av~4v backward CNTR 14 ~CN102-22 (apotas) | (1,Por?) Approx. ABV cures | NTO ;AOPT+) | (61, POT-) late = CN102-16 (CN102-22 A (s7,portay) | 61, POT) Approx. 4.7 V oNrOa-17 CNTO2BE 8,spu) | 4, POT) ern212 (141, SMTDA) Immeasurable Gannectar No.esConnestor No. Conditions Slandard Remarks N03-78 CNTO2-2E @,potey) | 61, POT) eer GNTORTS GNTORE2 Fee eros) | 61,P0T) Lauineianaks ENIOE-20 GNTOZZ oe 20, potartsy | 1, POT) Approx. 4.5 V Ge CNTOZAZ @ipotatzy | (61, POT) Approx. 45. CNTOREZ a a a (1, POT.) “1: B.wey oll control valve *2: way oil control valve CN103 Basic conditions (Battery plug connected, key switch ON) Connecter No =Connedtor No. Condkions Standart Romane CNIOS = faa: cancaye tt - Immeasurable 7 | oniasa ait rcattae = Immmeasurable i NTO ONT0-12 Ee (147, CANGND) | (14, GNDD) per ON cnio3-4 — TcNt03-12 | Key switch OFF Aeprox OV (43, vBky) | (14, GNDD) key switch ONT ~~ Approx. 48V CHIDSS CNIS. (324, 880+) | __(14, GNDD) pear. entoa-e 1 enT08-72 (25,880) _|__(14, GNOD) eee. casT 1 ent06-73 in ss (#,veBT) | _ (44, GNDD) fered CN103-8 T CN103-12 aa (I CHKISy) | (14, eNDD) _|Notused fe CNT08-9 TT ENTO0-12 i GoHKsy) 1 (14, enpp) | Netused ca CNTOR-10 1 CNI03-12 (18,018v) | __(14, GNOD) ppmto 1b ONTOS | _ ONTOa2 CHK3.3v) | (14, NOD) _|Notused cuios-2 | (14, aNDD) a a Ge CNRS a cia siTOK) | — Immeasurable CHiOg- Ta = as sort | s immeasurable = CNIS Z = aa sony | = Immeasurable 7 CNTOS-16 |213 CN104 Basic conditions (Battery plug connected, key switch ON) 2 lever is moved backward ‘Connector No.«»Connector No, ‘Conditions ‘Standard Remarks | GROET GRIDER J vach OFF Approx 80 104-7 ui CN104-22, Be | ORE man ore wopon 80 GNioea tT eNtoaa | When fevers neutral Approx OV (3, SOLL+) : (4, SOLLU) ‘Amount of change when liftis raised] — “2V~8V - When lever is neutral ‘Approx. OV GN 104-9 HIE Hen 10a-b-Ee ete eee eCeLEL A, Peete OE (SOL!) | (SOLD) Amount Of change when fk Siow Es) red \ GNiOea CNG] Measure the resistance withthe sou) | @.80LL+) _|battor lug disconnected Aperox. 70 GNiGes CN64-3 | Measure the resistance withthe (5, SOLLD) | (SOL) _[battery plug disconnected eee When fever snout Apion OV cN104-6 =| ONT04-7 ia “Fagonia SEE peor 1 7, SOLTF) i (6, SOLT+) : (7, Se y fewae eeiee 2V~8V Wen fevers neutral Appiee OV EN 1046 HEE HCN 108 Foi of change whan im WEEE TEE asc (6, LT+) (8, SOLTR} a Ee eee eee | moved backward yee CNIOaF CNI04-6 Measure the resistance with the _ — (7,S0LTF) | (6 SOLT) _| battery plug disconnected ppp CN104-8 | ‘CN104-6 | ‘Measure the resistance with the (6 SOLTR) | _(€.SOLT+ _| battery plug disconnected poet a CN104-9| CN104-22 a PEPE Pee fee ete cere ‘Approx. 60 V CNTO-70, GNTOZE (55,cPR) | (N2, N2) ‘Approx. 80 V a When le itral x. OV CNt04-11 1 CN104-12 ee Se et Seep oa Popeater zl (@,SOLATI+) (10, SOLATiU) /Amountof change when altachment 2Vv~8V : {lever is moved backward When lev itral Ay OV CNI08-11 | CNT04-13 ee el eee eee eee f (8, SOLATIN) | (11, SOLATIL) _ [Afiountof change whan alfachment vay 1 7 4 lever is moved forward cniOaz GHIGEAT [Measure the resistance wih the : (10, SOLATIU) | (@,SOLATI#) battery plug disconnected ee i cNiod-13 1 ~ GNTOAT —|Meosire the resistance wihite | aoe 70 a (1H, SOLATHL) | _(@.SOLAT14) [battery pig dlecomected Pr CNiDe-14 CNIOEE (44,vemey | (N2, Na) Approx. 80V CN104-15° ‘CN104-22 (44,vemB) | (N2,N2) eee t Wien ever is neural paren OV cntoa1e | cntoary | Whenleverigneutat_ | Aprox OV a (24, SOLAT24) | (5, SOLAT2U)_ [AmountOFeRange when allachmant ayoay 2 lever is moved forward E mn is midwe x. OV cntosts | cntoatg — [rrenioverismeway_ | Peer (G4 SOLAT2+) | (86, SOLATaL) [Atiountofchange when altachment ta:214 Connector No Connector No. Conditions Slanderd Raman CN10417 CN104-16 | Measure the resistance with the ae « (95, SOLAT2U) | (G4, SOLAT2+) _ | battery plug disconnected caine : 7 ‘aes eS a CNI04-16 | Nieasure the resistance with the 7 | (4,SOLAT2+) _ [battery plug disconnected penton fo 7 CNi0s-19° TEN T0a20 [Set CNT04-20%6 (-) probe and (MBH) | @MB) | measure pene ‘CNI04-20-—TONT04-19 Measure the resistance with the @MB-) | __(1,MB+) _[ battery plug disconnected ae CN104-21 1 CN104-28 Set CN104-28 to (-) probe and Z (87,SOLD+) | (88, SOLD) _| measure Ee Cnoeas ss 7 a (2,N2) ison tia pseee eee e (N2,N2) an A cnio4-24 1 GNi04-22—[Whenfanstopped Aoprox 60 (23,FAN-) | (N2,N2)_— hen fan ON Approx 30 Nt04-25 1 CNt04-22 [Key switch OFF Approx. 0V" (42, KEYSTART) { (N2, N2) Key Switch ON Roprox. 80V ~ | N104-26 CN104-27 ‘Set CN104-27 to (-) probe and - (i2,soups) | (43, S0LP)__| measure eee = CNi0427 ONI0#-26 | Wleasure the roststance with the a (13, SOLP-) s (12, SOLP+) _| battery plug disconnected eae oe: ‘ CN104-28 ‘CN101-16 Measure the resistance with the o (60,Lst+) | (61, LS-)_| battery plug disconnected Mic ealeht "1: 3-way oil control valve *2; 4-way oil control valve *3: 40 ~ 50 model only2-15 CN105 Basic conditions (Battery plug connected, key switch ON) Connecter No.esCannester No. Condifons Siandard Remarks Gnios; | cNton2a | When stopped Rpprox 80V (39, FAN) (N2, N2) WhentanON Kpprox. 33 ~ cNi0g2 | cNTon22 | When fan stopped Roprox 600 — (39, FAN) (N2, N2) [WhenfanON Approx. 32V |~cniosa 1 enon z2 [When fan Stopped ‘Roprox. 800 (39, FAN) =| (NB, N2) WhentanON Approx 32V T When fan stopped “Approx. 60 V et cNt0s-4 =; ontog.g2 [RID Spee _ tA (190, FAN) (N2,N2)__|Wihei fan ON (Depending on vehi- | — Approx 1V i cle conditions.) (Approx. 32 V) T When Tan stopped ‘Approx, 80V oN1055 | CNI0a-22 ope epee (131, Fan) (N2, N2) Approx. 1V 1 (Approx. 32 V) T me CN105-6 =| CN104.22 ato 12, FANS) IN2, N2) ; sees eteetiucined (Approx. 32 V) Ieee eee ‘ | Approx. 80V | CN105-7 | CN104-22 : EE Rprron 00. (133, FAN4) (N2, Na) ‘When fan ON (Depending on vehi- Approx. 1 ' ‘ole conditions.) (Approx. 32 V) When fan stopped Approx 60 CN105-8 1 CN104-22 pee teor bepett Eee epee ech (194, FANS); (N2,N2) ‘When fan ON (Depending on vehi- Approx. 1V : : cle concitions.) (Approx. 32 V) When fan stopped Approx. 80V ae CN10622 rag TaFOH (DaSbng OSTA] ~ ReeeAY 135, FANG) IN2,N2) | When jependi ; \ (N2.N2) | ele conditions.) (Approx. 32 V) CNTOE-0 a nn = ' - Not used ~ CN107 Basic conditions (Battery plug connected, key switch ON, connector disconnected) Connector No Connector No. Condiions Sandard Remarks CNIOT-T GNTO72__|When ciroult board cover fan ON (127, FANR+) (128, FANR-} (active test 1 execution) Approx. 24 V CNIS a aa a (128, FANR.) Traveling Controller CN110 Basic conditions (Battery plug connected, key switch ON) Tannacior NoesConnector No. | Conditions landard Ramarke CN110-4 a , CUDIDO) fi pee ce ‘CNTIO-2 ce , CUDID1) af ieee A CN110-3 | oe 7 ast cana) ~ immeasurable ct CNTIO-4 (1a3,cany | - immeasurable ae2:16 Connector No.csGonnector We Conaltons Standard Raman] Excannay - Not used ee t (147, CANGND) | (447, GNDD) fmocev voneniti (2.2) _| temo a0v f ee) _ Not used = | 0.890") | (008.10) porn 12 cessso-1b) | @,980."0, Approx OV Soe | ee, an - oe era ato ' - Not used a Material Handling Controller CN111 Basic conditions (Battery plug connected, key switch ON) Connecter No. Connector No. Conaiions ee a : (etupoy | erway ppron. OV ge came ~ immeasurable a (ue CAN) | = Timmeasurabie 7 (cantro) | Not used a a ay | ae = PecusoM 7 Not used = eassey | (en sse-tP) ; room ev | ere, eS a oes = tee.s5P2) | (ar ssmtey ov= tev eee ~ immeasurable a247 SAS Controller ‘SCPU board CN140 for software write, not connected ‘Connector No.=Connector No. i Gondtions, Standard Reniarks CRT tua a Goo [fe = oo) | a a BRT Se ee - : a : ~~ - ae a 7 (CN141 Basic conditions (Battery plug connected, key switch ON) Connector No, =Connector No. ~_Condtions Slandard Romans | OT mmeasurabie = oe immeasurable : = at Inmeasuraie = oan Inmeasurble onus | ounaras — [Mhenteveina speed | OV | (324,884) | 25,58) [arcing sopvee, Batlon nig ds- y gro 9 CS) |_| mmeasuraie a Gui, i - mee, lal : SRE 1 ian i ena T aH — | immeasurable = 4 (310, 887M i - Irmmeasurable af ontat-12 (908: SHTSK) ; aa immeasurable 4 as Gansu) | Grete) Approx BV2:18 ‘Conndclar No-s0onnedtor No. Conditions ‘Standard Remarks CNt4I-14 T ONTAT-16 : | (137, SuL+) | G15, STs) PR EN “cNidi-s 1 —~GnTaew e ei (ern sts) [When traveling stopped Approx. 2.5 GNtaicig nas 6 FEEeEe EEG G15,8Ts) | (312, STS1) CNTaTAT NTIS # (811, STS+) (315, sTS1) fener ontaig Not used : CN142 Basic conditions (Battery plug connected, key switch ON) Connector No. es Connector No. Conditions Siandard Remarks eee Key Sullch OFF, accelerator pedal | rox. BV cntaza | depressed Approx. § a (65,sis8) | Key Swich OFF, accelerator pedal T ~~ 7 ~~ i nt depressed jeer oe CNTR Tena seas : (19, POTS) | GIN StSo) | When vehicles level Approx. 32 3 CNIS TNT rane 7 @i7.PoTH) | Gta Stso) | When steering wheels neutral Approx. 2.0\V “ea <= FNet used 7 oniaas I = Not used = 7 cutee = Not used te = ONTRT i ee PoToRT) | 7 [Netra ni ONES) ONTAES 5 7 (920, SPOT) (312, STS1) ‘Approx. OV ouae F ctoreersy | - Not used oe CNT onTaas [~ 7 18, POTS¥) (314, StS) pete _ CNAZAT ONTaES eee | (316, POTH+) |! (314, STSC) Miaka ones See Fe) eee "3: 40 ~ 50 model only “4: 16 ~ 35 model only2-19 CN144 Basic conditions (Battery plug connected, key switch ON) (337, RESOL) (353, GNDSC) Tonnedtor No.esConnecior No. Conations Siancard Remarks oNTaaT CHiaez (21, SYR) (223, SYR.) Approx. 5 V CHT4.2 THIS ou (223, SYR) (353, GNDSC) chides ONTAAE 382, sR) | (628, SYR) Dee eer CN145 Basic conditions (Battery plug connected, key switch ON) Conneator No.esConnecior No. Conditions Siandard Remarks Niassa - : SSE EEGHEEEECEEP EEE fe oases = Immeasurabe — 4 CHAS : ee 4 immeasurable = 4 CNI4E-3 CN148-7 [ * (yisHy | (Nt.Nt) nh 7 *4; 16 ~ 35 model only CN146 Basic conditions (Battery plug connected, key switch ON) Connector Ne ssConnedtor No. Conditions Bandara Remarks CNT467 emetic Immeasurable 7 CNT46-2 i CN146-6 (avons) | sh enbecy [Key witch OFF Approx. 80 ontaes tT ONTaBa 7 7 (950, PS20V) | _ (851, GNDPS) Approx. 24. Gniasa Pena 4 Immeasurable — CHidss TT CNTABE a (952, S15V)_| (963, GNDSC) preree 1e CNIS ONTAET ay (353, GNDSC) | (N1.N1) L 0) ra : coronas) | 7 immeasurable = cue eeu 7 immeasurable ce (392, DRSOL-) CNET oo cosrexsa.s) | 7 immeasurable [eNiae0 a aanexsorsn | - immeasurable 7 ONE —)_ONTABE a (95, S6S0Ls)_| (963, GNDSC) CNTAE-TE CNIa66 (338, seso.sr) | (983, GNDSC) Approx. 15 ‘CN146-13 CNI4ES ‘Approx. 15V CNId6-74 Notused2-20 DCISD Board CN147 Basic conditions (Battery plug connected, key switch ON) (Nt, N1) Immeasurable CNTaa8 (ck15v) immeasurable Connector No.sConnactor No. Condtions Siandara Remarks ONt47-4 Not used a CNTaFR CNIS (44, VBMB) (353, GNDSC) home on ‘Approx. 80 V GNTaTS GNTaTa 7 (350, Ps20v) | (361, GNDPS) Approx. 21.V oniara + - a esrenors) | = immeasurable a CN147-5 | t CN147-6 SEES (982, Sc15v) | (353, GNDSC) eee | CNia7-6 ONT a (353, GNDSC)_} (851, GNDPS) ONia7-7 _| (31, DRSOLY) | ~ immeasurable fH onia7-8 7] z (32, DRSOL) | - immeasurable ot CN147-9 CN147-6, H 7 +e (333, CKSOLS) (353, GNDSC) ~ “CNTTAN_ | ENTATS — (334, CKSOLST) (353, GNDSC) oa oNtaTAat | eNTATS Faro eat (935, SGSOLS) | (353, GNDSC) CNET AS ontar6 (836, SGSOLST) | (353, GNDSC) ‘ApPTOK. 15. V CN147-13 CN147-6 A (337, RESOL) : (353, GNDSC) Approx. 15.V CN147-14 — wera) | _ Not used CN148 Basic conditions (Battery plug connected, key switch ON) ‘Connedior No-=Connedior No. Conditions Standard Remarks "NIM; CNT [Rey switch ON ‘Approx, 12 7 (827, SOLS+) | (828, SOLS-) _[icey Switch OFF TY OU Appian 6 ~CNi48-2 CN148-5 (329, SOLST+) : (330, SOLST-} ener OM, Approx. 10 V ONt48-3 | ~~ GNTAB-7 aprox 600 (44, VBMB) —,—_(N4,N1) Preece envied i = — oxy) | = immeasurable ONES CNT T = (830, SOLST-) | __(N1,N1) Approx. 12.V CNTBG CNTR ae (328, SOLS-) 1 (N1, N41). CN148- 1 i - \ ICN149 Basic conditions (Battery plug connected, key switch ON) 2:21 Cannector No.=Connector No. Conalions Sandard Remarks ee 1 =H Immeasurable an (340, TMPSG) N51 Basic conditions (Battery plug connected, key switch ON) Gonnector No esConnector No. Conditions Slandard Remarks ‘CNS1-4 7 CNSt-4 (P21, VBP21) (Nt, TMPS) Approx. 80 CNS1-2 CNB 1-4 7 (P21, VeP21) (Nt, TMPS) ‘Approx. 80V CNS1-3, CN51-4 A | (P23, P23) t (Nt, TMPS) When PS motor stopped Approx, 80.V ONBT-e ONSET a aint) | (nt. TPS)2-22 MAIN CONTROLLER REMOVAL-INSTALLATION 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.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 © between P3 and N2 to discharge the capacitor. Removal Procedure 1 2 3 4 5 6 7 Open the seat stand and disconnect the battery plug Remove the controller cover. Remove the main controller. (See page 2-22) Remove the controller cover bracket. Disconnect the connectors and terminals from the traveling/material handling controller. [Point 1] Remove the short bar No.7 and No.2, Remove the traveling/material handling controller. Installation Procedure The installation procedure is the reverse of the removal procedure.224 Point Operations [Point 1] Installation: 1, Be sure to wire correctly and connect the terminal in the prescribed orientation. : 2. Tighten to the specif T= 14~ 18 Nem (143 ~ 184 kgf-em) [10.3 ~ 13.3 felbf]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 resistor at approx. 100 Q between P3 and N2 to discharge the capacitor. Removal Procedure 1 2 3 4 5 6 7 8 Open the seat stand and disconnect the battery plug Remove the controller cover. Remove the main controller. (See page 2-22.) Remove the contactor panel. (See page 2-36.) Remove the controller cover bracket. Disconnect the connectors and terminals from the traveling/material handling controller. [Point 1] Remove copper bars No.1 and No.2. Remove the traveling/material handling controller. Installation Procedure The installation procedure is the reverse of the removal procedure,2-26 Point Operations [Point 4] Installation: 1. Be sure to wire correctly and connect the terminal in the presorlbed orientation. E=0°~90° 2, Tighten to the specified torque. T= 414 ~ 18 Nem (143 ~ 184 kgf-com) [10.3 ~ 13.3 fbf]227 FAN INSPECTION Inspection Method Fan connector disconnection Material handling controller fan CN133-1 (9) - CN133-2 (10) Portion to be : las Measurement terminals Standard Tester range Traveling controller fan CN132-1 (7) - CN132-2 (8) o2 Qx1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 norinally. Drive motor input voltage measurement method Procedure 1 Open the seat stand and disconnect the battery plug. 2. Jack up the front wheels, 3 Remove the controller cover. 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 PO 12 Compare the voltages measured for P7, P8, and P9. The error should be within the standard. Standard: Within 4 V2-29 Pump Motor Input Voltage Measurement Method Procedure Open the seat stand and disconnect the battery plug. Remove the controller cover. Connect the analog voltmeter's (-) probe to the N2 terminal. Conneet the voltmeter's (+) probe to P14 (P15, P16). Connect the battery plug. Tum the key switch to ON Move the tit lever backward, read the voltage while in the relief position, and record the voltage. Also follow steps 4 to 7 for P15 and P16. Compare the voltages measured for P14, P15, and P16. The error should be within the standard. ©Cevoasens ‘Standard: Within 4V2:30 SAS (WITH PS) CONTROLLER (16 ~ 35 MODEL) REMOVAL-INSTALLATION 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 Open the seat stand and disconnect the battery plug Remove the controller cover. Remove the hood ASSY (LH). Disconnect the connector and remove the reverse buzzer. Remove the seat stand damper. [Point 1] Remove the SAS (with PS) controller set bolts. [Point 2] Lift up the SAS (with PS) controller, disconnect the connector, and remove the SAS (with PS) controller, Oakons2-34 Installation Procedure The installation procedure is the reverse of the removal procedure. Point Operations [Point 1] Removal-Installation: Secure the seat stand with a string, etc., so that it does not fall over. [Point 2] Removal: When removing the SAS (with PS) controller, be careful not to drop the rubber or collar. 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 Measurement terminals Standard Tester range C2E1 (-) be - E2 (+) oo CRETER (J probe “2 (+) probe C2E1 (+) probe - E2 (-) probe | Continuity shall exist. G2Ot > feet eat eae CO) probe - E2 Fy probe eta G2 (+) probe - E2 (-) probe wD eas C2ETC)-C1)_| Continuity shall exist C2E1 (+) - C4 (-) oo 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, OxT2:34 SAS CONTROLLER (40 ~ 50 MODEL) REMOVAL-INSTALLATION 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 1 Open the seat stand and disconnect the battery plug. 2 Remove the hood ASSY (LH). 3 Remove the SAS controller cover. 4 Disconnect the connector and remove the SAS controller. Installation Procedure The installation procedure is the reverse of the removal procedure.2-35 CONTACTOR PANEL REMOVAL INSTALLATION Removal Procedure 1 Open the seat stand and disconnect the battery plug, 2. Remove the controller cover. 3 Disconnect the connectors and terminals from the contactor panel. [Point 1] 4 Remove the contactor panel. Installation Procedure The installation procedure is the reverse of the removal procedure2:36, Point Operations [Point 1] Installation: 4. Install the terminal at the prescribed orientation A= 90° 2. Tighten to the specified torque. T= 11 ~ 15 Nem (112 ~ 153 kghem) (8.10 ~ 11.1 fbf]2:37 INSPECTION 1. MB (Power supply contactor) Inspection Method Disconnect the CN134 connector and measure the MB coil resistance, Portion to be inspected Measurement terminals Standard Tester range a H Approx. 20 2 MB Coil Both CN134 terminals (et 20°C (68 °F) Qxt 2. Fuses Inspection Method Remove the fuse and measure the resistance. Portion to be - inspected Measurement terminals Standard Tester range 7 A Both fuse terminals 08 ax42:38 INSTALLATION Contactor panel installation diagram T= Nem (kgfom) [ftibt] T=29~39(29~30) T=7.8~ 11.8 (80~ 120) 29-39 (20 ~ 40) 22-29) Tare~t18 —(80~ 120) [58~86] T=78~ 118 (60~ 120)[88~a5) Uitl a Te (130-170) (ea~ 16) (112 ~ 153) | fet0~r1.4)| T=20~30) (20~ 30) [14 ~22) Ts78-118) (60 ~ 120) [58~86) \teis~35 (15-35) (t= 28) 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 MQ or more MB contactor Inulin hootDISPLAY 2-39 If the trouble is found in the display, apply the battery voltage and measure the voltage to the connector. CN70 connector basic conditions (Battery plug on) Connector No.esConnector No, Standard NTO. 14 NTO 30 (18, D1sv) (14, GNDD) Peer eeHed2-40 DIRECTION SWITCH REMOVAL: INSTALLATION Removal Procedure 1 Open the seat stand and disconnect the battery plug. 2 Remove the steering wheel column cover. 3 Disconnect the connector and remove the meter cover Widisplay. 4 Disconnect the connector and remave the direction switch. Installation Procedure The installation procedure is the reverse of the removal procedure.2-44 DISASSEMBLY -INSPECTION-REASSEMBLY wa Removal Procedure Remove the connector cover and disconnect the connector. Remove the plate W/base and micro switch. Remove the base Wimicro switch. [Point 1] Remove the cam RONG Installation Procedure ‘The reassembly procedure is the reverse of the disassembly procedure.2-42 Point Operations [Point 1] Installation: 1. Install the micro switch in the correct position. 2. When replacing the micro switch, perform the wiring following the line colors. Inspection When the direction switch has been assembled, inspect the continuity before installing the switch Standard: Lever Position Inspection Neutral Forward | Reverse DS: eo 0a =O DSR >a =a da DSau =o oO 0a DSeo : “oo | 02 Hl oo Q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 | , When pedalis operated | 0Q Standard 2. Accelerator potentiometer installation adjustment (1) Insert 2 1.5 mm (0.0089 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) tums to ON (0.9). (3) Inspect the accelerator switch's (between 51 and 64) ON/OFF switching point. Switch status (between 51 and 64) Standare [12 +0(0.039) — OFF @ a T (Adjustment gap) mm {in} [T=2.0(0.079) | ON(09) (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.244 et For brake” Pe rere (Uf WON | 'For'stop tame S= orm (697-038 in) 38 mm vet \(a12-031 4) BRAKE SWITCH ADJUSTMENT FOOT BRAKE 4 Inspect the brake pedal play. Standard: 5 ~ 9 mm (0.20 ~ 0.35 in) If the measured value does not satisfy the standard, adjust the length of the brake pedal push rod. (See 10- 29.) 2. Operate the brake pedal and check that the stop lamp limit switch operates (ON) when the play range is 5 to 9 mm (0.20 to 0.38 in). Standard: When not operating: OFF (2 ©) When operating: ON (0 2) 3. When the brake pedal play disappears, depress the pedal deeper (3 to 8 mm (0.12 to 0.31 in)) and check to see if the brake regeneration limit switch actuates (OFF). Standard: When not operating: ON (0.0) When operating: OFF (» ) 4. If not within the standard value, adjust the switch by bending the limit switch brackets. 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 is 0.1mm (0.004 in) gap between the pedal stopper bolt and the pedal.MULTI-DISPLAY FUNCTIONS MULTIPLE DISPLAY... GENERAL... SPECIFICATIONS ...... GENERAL FUNCTIONS... DISPLAY INDICATION LIST ABBREVIATIONS DISPLAYED ON THE SCREEN. NORMAL FUNCTION SCREEN .... OPERATION PROCEDURE .. MASK FUNCTIONS .. GENERAL... PASSWORD .... ANALYZER. TUNING... OPTION SET. MATCHING WHEEL DIA... DIAGNOSIS .... DIAGNOSIS CODE LIST3-2 MULTIPLE DISPLAY GENERAL The multiple display is capabie 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 fingor. If a sharp-edged tool is used, the button may be damaged. neo W 6 & Go When the voici isin stopped state | ((1)te (hin the table vary with eae function aetation eate,) sor o @ “id © o hy [SUMED ish Trial sereon (12) Daring Pavaling ow temperature warning indicator No. Description No Desc (1) [Swing lock indicator 1 @) [Power select indicator 5 (2) [Parking brake indicator | (8) | Muitipie 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 cee (5) | Overheat warning indicator —___|(41) Power select switch a | (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 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 vehiole speed to the set level. The speed control level can be set using the travel 2nd speed control level SET UP screen, (4) Diagnostic mode indicator This indicator blinks when the diagnostic mode operates, the error code is displayed, and the buzzer sounds. Up to 3 abnormality codes are displayed at a time. When more than 3 abnormalities occur at @ 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. Ifitis on, carry out matching by raferring to the Matching section (8) Ovetheat waming indicator When the temperature of the main control controller, traveling controller, material-handling controller, drive motor, or pump motor exceeds the specified temperature, the overheat warming 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 shown on the display. (verhest warning indlcatoe Display information: CIR : Main control controller DCR: Traveling controller PCR: Material-handling controller DM : Drive motor (Traveling motor) PM : Pump motor (Material-handling motor) (Overheat postion3-4 Vehicle Operation Restriction at Overheating DIR: Main control controller overheat | se cate Sep. | Hrmode |The dy ashes as A, | P mote | 2 Peappeen poe” bse! und conimiosy TP" | mado [3 Nts tan porate DCR: Traveling controller overheat PCR: Material-handling controller overheat See | ote ‘Contont of conte, Speaton T ode ‘Content of contol, S10, | Hee] Stal Ta a TS rb, | Wabi” | arcadia ton ei fash niet, | Pree [2-Pecpseeereo bum cuntetersees | | CEE | mide |2 emp pop pny” bzz sods ene {OA | smodo [3 sues nar ete {OPH | Sec [3 Matianaaing poe sted DM: Drive motor overheat Specie Mode Goren conver rinary con ‘Secondary sonal "se a el sto 1 Giracerdipay Tass cetera 2. "Peep peep poe buzzar sounds er 5 see 8. Shee Sma "Gharavi Washes, ncaa ashes 2. Continous baer sound p4e9, peep” 5. Shs fal ot Pmede Simote "Shatin 2 "Peop poop paepbuzzee und fo 6300 2, Stes to al tote Fiche. orn) H mode 1 Charade aisny Yeah. ndetor anes 2. Peep pean peep buzzer Sounds oS 2 Sts to S moda 1. Charade dpe fashes, ncaa ake 2. Nozze sume 3. Traveling power resiced 1 Character dopey Taare dete Washes 2. Conuous buzzer sound 5809. pf" 3. Swichos tat hoe Pode Smad 7 Sharad Siiay tasks cena thes 2. "Paap peep poop” buzzer sounds for 5 soe 3. Traveling power rested 7 Sharada dpi tates cesar ashes 2. Continous buzer sound peep, peas” 4. Sweches onal rat PM: Pump motor overheat SpRRR Node Content of conrat ‘STO. Wnoae | Chart aay atonal Hashes miata, | Pode | 2 °Poep poop peer buzz sors oS sez {OPT | smoee |. matrashanting power rest(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) If traveling or material handling operation is attempted when the remaining baitery capacity drops below the setting fevel 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 material handling operation is prohibited. However, the operation is possible only once for 30 seconds by turning the key switch from OFF to ON. Mote: 3 The level can be set using TUNING FUNCTION of the MASK MENU. (See page 3-37) Low remaining battery capacity alarm Battery overclscharge alarm BomglAY The baton capsly idlator segments Al batery capaci inceatorsogmont Bink -cofresponding to the remaining capactty blink, = (7) Power select indicator (traveling and material handling) 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. 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 (8) Multiple-screen display area The date and time are normally indicated in this area. This area is also used for various purposes such as function setting and abnormality code display by the diagnosis function. (9) Travel 2nd speed control set switch Press this switch on the NORMAL FUNCTION screen to set or clear Travel 2nd speed control (10) Hour meter select switch This switch changes the screen of multi-hour-meter function (11) Power setect switch This switch selects the operating mode from S, P and H. Press this switch on the NORMAL 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 function.36 (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 tenperature postin COLD DCR: Traveling controller COLD PCR: Material-handling controller37 SPECIFICATIONS LCD Doi matrix + fixed display [Buttons Three buttons Back light LED type that comes on when the key switch is tumedtoON———~*&L 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 ieee Model Functions — pee ‘Alr-round model (optional) Easy model (standard) ° 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 | Nlaterial handling power control level setting | Travel 2nd speed control level setting Key switcl jour meter ©} Oo} Oo] Oo} oF Oo] Of Ol oo Drive (travel) or pump (material handling) motors service hour meter Drive (travel) motor service hour meter — Integrating [Bump (material handing) motor service hour meter meter Tap time meter Odometer {ip meter CalendariCiock Battery over-discharge warming Cow battery capacity warning ‘Gverheat warning /Parki ike ON warnin Weming —_|Patklna brake © ing Parking brake OFF warning Retum to neutral warning Over speed alarm Diagnostic code display I oof of oj of of of ol of of of oj ola, © Jol df alo afofofojololo fo)38 DISPLAY INDICATION LIST NORMAL FUNCTION screen + For user setting "Travel and speed ON/OFF ‘OW or OFF setting of Travel and speed control ‘Suillghing over hour meter di splay ‘Cheoking traveling or material handing system ON time Power celect Power mode selection * For user setting Traveling sped level Selting of Travel 2nd speed conirol level ‘Speed alarm Input of password “Traveling speed selting lor over-spood alarm Power control select Fine adjustment of power contral level Press switch (3) for 2 sec. Clock set ‘Agjusiment of indicated time MASK FUNCTION screen + For setting by dealer or serviceman ANALYZER DIAG MEMORY Checking past diagnosis codes stored in memory TO MONITOR? ‘Checking the temperature and vokage of each functional part WO MONTTOR? Checking iraveling-related sensors [iO MONITORS ‘Checking material handling and masl coniral saneors TO MONITORS Knob position correction control and chacking other sensors ACTIVE TEST Forced ON/OFF test of each switch TUNING —/TUNINGT Standard function adjustment TUNNG2LFTV Liftlever adjustment TUNINGS TILT Tiltover adjustment TUNINGS ATTAV] ATT fever aqjuetient OPTION SET [DEMO MODE TUNINGS ATTY) ATT 2 lever adjustment ‘Operation is possible during traveling/ Maternal-handling before Hii start Hind START PiCLOOK DESTI BLEVEL Start the hour meter count ower canirol lock selection Display information changes by delivery destination oi specified MPH CENTRES Vehicle speed display Setting Not specified BATTERY /SHOU-TORT, Not speciied ‘Auto power OFF setting selection Parking brake OFF alarm selection Hast forvard tit angie restriction selacton SWE WLOGK [Not spectied 7 TTICTF-Lit | Mast forward viol function selection B-TYPE Battery typo sslection| 7aV TAVREOV selection 2-WAY VALVE |2-way valve selection a FISHERMAN [Fishing specifcalions Sotocion MATCHING [TILT Tiievel angie To Ti forward estictee anglS TOAD NU load =p TIRE Tite angie sensor forward direction Swe "|Rot epeciiea uFT Liftiever neutal TT Tilt lever neutral suaal ATT? ‘Attachment 7 lever neutral | ArTZ ‘Avachment 2 eve" nell WHEEL DIA|WHEECDIA [Tire constant seting3-9 ABBREVIATIONS DISPLAYED ON THE SCREEN Abbreviation Weaning ‘Abbreviation Meaning ‘Ai(SOL)__[Altachment f proportional valve 88D "[Drive motor rpm ‘A2 (SOL) _[Altachment 2 proportional valve ‘SS0L ‘Swing solenoid ‘APOT ‘Analog input voltage SSP Pump motor rpm ATT ‘Attachment t ‘STS. ‘Steering angle sensor RITZ Attachment 2 ‘SWAG ‘Accelerator switch oR Conitoiier SWE ‘Swing angie sensor (Unused) DCR Traveling controller Swik Tiltknob switch BM Drive motor T (SOL) Tit proportional valve al DoF Een aiecian seth aa Travelagcanielor Gru board temps DsOL Brake change vaive solenoid output | TBP. Neceeee ee DSR Reverse direction switch TD Drive motor temperature FAN Fan output TEMP Conirat circuit board temperature aaa Tae Tuco | Waving conte an era eae DIFF [Steering angle knob positon aterental [ce |Naleralhanding controlar main crcuk KPOS ‘Sieering angle knob position TILT Tilt forward angle Fe KSOL Knob position correcting solenoid TTL Tilt level L(SOL) [Lift proportional valve TIRE Tire angle sensor TOAD Materiahandling hydraulic pressure [TP Pump motor temperature iss Brake switch Ve80 Baltery voltage tsb ‘Seat switch VBBD Traveling controller main circuit power a Tannen vege | lt enain snot an creak PIG Power control ~~ VeKs Key stant voltage i POR Material-handiing controller VBMB (M) | Voltage after MB contactor (main input) Phi Pump motor POTA ‘Accelerator potention oe “| VBMB (S) | Voltage after MB contactor (SAS input) OTT PSOL Unioad valve VeSOL | Solenoid voltage SPD Main vehicie speed YAW Yaw raie sensor voltage ee SPL Pressure sensor PPE IEEE ia3:10 NORMAL FUNCTION SCREEN OPERATION PROCEDURE Suton (4) Switch (2) NORMAL FUNCTION \ Travel 2nd speed ON/OFF setting Hour meter display selection Power eeleet mode ress Switch (3) tor2 sooons ormare, 1, aden (1) TRAVEL 2ND SPEED CONTROL LEVEL SETTING soreen ress suten(3) Lb OVERSPEED ALARM SETTING secon * This soreen is cisplayed only on the al round model The easy model does nat have this screen, Pross Suiteh (2) (| [Hl [Sian so on + Pattemn2: 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: ($F IH1SIIPI IH S| Bland 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. Swinty swengy | TRAVEL 2ND SPEED CONTROL LEVEL SETTING SCREEN NEE 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). 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 CONTROL SET UP SELECTION screen. Vehicle epeed setting for speed alarm Sitch (1) Switch (2}Switch (1) Swit (2) Soloct °YES" and Switch (3) prass switch (3) TRAVELING POWER CONTROL LEVEL SETTING serean Parner O, MATER LeveL HANDLING POWER CONTROL -TTING screen ross switch (3) > (CLOCK SET UP SELECTION screen 313 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 SELECTION screen, select "YES", and then press switch (3) to display the 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 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 (2) on the POWER CONTROL SET UP SELECTION screen, select “NO", and then press switch (3) to display the next screan (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 (A) Saitoh (By UFTING POWER CONTROL Sacn ay Spit 2) ca\a5 =) 5 ‘Shieh B) Suck By 7 Select NO" Soe VES a press switchig) NOMAL FUNCTION screen (End of cloak seting) 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 inorease 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 soreen.3-16 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 slaff 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 Lind Delivery | replace- | Others mont Used for daplaying the operation status Unon vehicle of electrical systems onboard or for Analyzer ~ — | abnormaiity accessing information on errors detected praia by the controler. Used for fine-tuning the traveling and © | As requested Tuning - 5 material handing control features. 2_| by customer : Used for changing the setups according 3 Specifications lo the avaliablity of options. *1 7 | 2 a ~~ Used for changing the setups according Avaiiabilty OF Con- 9 the availabilty of various controlfea- | — | 9. - trols 243 tures Option cing | Muilipie hour meter [Used for Staring up the mulipie hour a o : startup meter 4 Used far setting and cancaling the den Uponnow Demonstration J onstration mode. (Function prohibiting Ps ~ — | vehicle dem- mode material handing operation during travel- eee ing whichis set atthe time of delivery.) | Used for readjusting the sonsor signal - Matching voltage values associated with the star- | — | ~ daré vehicle condition, Used for improving the spesdometer aE Whee! dia. (tire constant) accuracy by updating the wheel diameter | — 7 - 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. 92) Board canon Main controller *3: Board SAS controller control board °4: Board... Multiple-sereen 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 tum the key switch to ON. 2. Operate the MASK MENU according to the password input procedure explained on page 3-17,347, 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, tum 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 sound is given off. |A short high-pitched electronic sound is given off. [X short high-pitched electronic | sound is given off. 1 | Press switches (1) and (2) at a time. 2 | Press switch (1). 3. | Press switeh (2) Simultaneously press switches (2) an longer high-pitched electronic (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. wien) Syleh @) ewich | iai6 | ODPM cereii Pros ove (and | nt) yan oan asic (2)simuitanoously gaye (4) | Sy Bhand )srnanacny for VERSION coven | tan 10 eco aie: monomer o Dane TeIMASKNEN seen in 10 Soro poss itch 2)VERSION scroen SO owien (ty gen a ANALYZER srs Press (1) (2) 0 es TUNING seroon Prost cutchoecen &P OPTION SET soveen caer op mh soe MATCHING seen KASS (aa) Press (3) or (2) 0 ‘witch sere, WHEEL DIA sereen Press (1) or(2)10 x a g 03s (1) or 2) switch sereen, oan END seveen Press switch (3) NORMAL FUNCTION screen OPERATION ON MASK MENU SCREEN Operation Procedure 1 Input the password on the NORMAL FUNCTION screen (as explained on the preceding page) to display the MASK MENU screen. Select a desired function using switches (1) and (2). Then, press switch (3) (set) to display the function screen or setting screen of the selected function. (1) ANALYZER sereen This screen indicates the electrical system status and 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 (3) OPTION SET screen Use this screen to match the controller or display control according to the set option or control. (4) MATCHING screen This screen updates the signal voltage values stored in the controller (signal voltage values from the SAS. function and the mini fever function sensors under the standard vehicle condition), (5) WHEEL DIA screen This screen rewrites the tire information in the controller for correcting the speed indication and trip meter. (6) 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 to OFF when any menu is displayed to return to the normal function screen319 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) Infout monitor function (VO 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) lO MONITOR1 Displays the temperature and analog input voltage at the respective terminal of each electrical component detected by the controller. 2) YO MONITOR2 Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control 3) #0 MONITORS Displays the material handling and mast switch ON/OFF states and analog input voltages from material handling and mast sensors. 4) JO MONITORS 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 VO MONITOR screen or ACTIVE TEST screen.