r/m 7fgu15-32 7fdu15-32 7fgcu20-32...

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 7FGU/7FDU15~32 series and 7FGCU20~32 series. Please use this manual for providingquick, correct servicing of the corresponding forklift models.

For the portion not covered herein, please refer to the repair manuals shown below.

This manual deals with the above models as of August 2005. Please understandthat disagreement can take place between the descriptions in the manual andactual vehicles due to change in design and specifications. Any change ormodifications thereafter will be informed by Toyota Industrial Equipment Parts &Service News.

(Reference)Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 7FGU/7FDU15~32, 7FGCU20~32REPAIR MANUAL (No. CU027-2)

TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINEREPAIR MANUAL (No. CE602-2)

TOYOTA INDUSTRIAL EQUIPMENT 1DZ-II ENGINEREPAIR MANUAL (No. CE618-2)

SECTION INDEXNAME SECTION

GENERAL 0OPS 1BODY 2MATERIAL HANDLING SYSTEM 3OIL CONTROL VALVE 4SAS 5APPENDIX 6

0-1

0GENERAL

Page

PERIODIC MAINTENANCE.................................0-2OPS SYSTEM.......................................................0-3SAS.......................................................................0-8

0-2

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

Item

Every 6 weeks

Every 3 months

Every 6 months

Every 12 months

Every 250 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

SAFETY DEVICES, ETC.

Seat

Loosening and damage of mounting I ← ← ←

Seatbelt damage and function I ← ← ←

Seat switch function I ← ← ←

OPS Functions I ← ← ←

0-3

0

OPS SYSTEM

GeneralThe OPS (Operator Presence Sensing) system is added as standard.

The switch mounted underneath the seat detects the operator on the seat. When there is no operator, the OPSsystem cuts off the driving power and restricts material handling operations. (Refer to page 0-6.)

The OPS system operates (to disable traveling and material handling) upon lapse of 2 seconds after the operatorleaves the seat.

When the OPS controller detects the seat switch going off, it sounds the OPS buzzer* (bleeping) for about onesecond and turns the OPS lamp on before OPS activation. Furthermore, the OPS lamp keeps lighting while the seatswitch stays off.

*: The buzzer sounds only export model.

Only export model:If the seat switch is turned on without returning the forward/reverse lever to the neutral position after drive OPSactivation, the newly added return to neutral warning function sounds the buzzer at short intervals (pip-pip) to warnthe operator of the unreleased state of the drive OPS.

When the OPS controller detects any system malfunction, the OPS lamp blinks to warn the abnormality.

Control block diagram

Forward tilt switch

Battery

Key switch

Foward reverseswitch

Bakward tilt switch

* Lower limit switch

* OPS

Controller

* OPS lamp* OPS lamp relay

* OPS buzzer(Export model)

* Plug inanalyzer

Tiltcylinder

SASController

Liftcylinder* Unload

valve

* Tiltcontrolvalve

* Liftlock

valve

* Oil control valve

Oil tank

Oilpump

EngineT/C

* Forwardinterrupt relay

Forward drivevalve

* Reverseinterrupt relay

Reverse drivevalve

* Seat switch

F

N

R

*: Parts added or changed for OPS

0-4

Name of each part　　　　

(13)

(3) (4)

(5) (6)

(16)

(15)

(14)

(1)

(2)

(7) (8) (9)(10) (11) (12)

(1) OPS controller (9) Backward tilt switch

(2) Seat switch (10) Unload valve

(3) Forward switch (11) Lift lock valve

(4) Reverse switch (12) Tilt control valve

(5) Forward interrupt relay (13) OPS lamp

(6) Reverse interrupt relay (14) OPS lamp relay

(7) Lower switch (15) OPS buzzer (Export model)

(8) Forward tilt switch (16) Plug-in analyzer

0-5

0

Function of each partInput to controller

Output from controller

Name Function

(2) Seat switch This switch mounted underneath the seat detects the operator sitting on the seat.

(3) Forward switchThis switch inputs the voltage branched from the forward drive valve power supply line to the OPS controller that detects the forward drive operation.

(4) Reverse switchThis switch inputs the voltage branched from the reverse drive valve power supply line to the OPS controller that detects the reverse drive operation.

(7) Lower switch This limit switch installed at the lift spool of the oil control valve detects the lowering operation by the lift lever.

(8) Forward tilt switch This limit switch installed at the tilt spool of the oil control valve detects the forward operation of the tilt lever.

(9) Backward tilt switch This limit switch installed at the tilt spool of the oil control valve detects the backward operation of the tilt lever.

Name Function

(5) Forward interrupt relay This relay cuts off the voltage supply to the forward drive valve in the torque converter according to the instruction from the OPS controller.

(6) Reverse interrupt relay This relay cuts off the voltage supply to the reverse drive valve in the torque converter according to the instruction from the OPS controller.

(10) Unload valve Provides a bypath to the tank circuit for the hydraulic oil supplied from the oil pump to the oil control valve.

(11) Lift lock valveThis valve cuts off the oil flow from the lift cylinder to the oil tank according to the instruction from the OPS controller to disable fork lowering.

(12) Tilt control valveThis valve changes the oil path to the tilt cylinder according to the instruction from the OPS controller to disable forward tilting and to slow down the backward tilting speed.

(13) OPS lampThis lamp lights while the seat switch is off to indicate the OPS operation. Furthermore, it blinks when the OPS controller detects any abnormality.

(14) OPS lamp relayThe OPS lamp electric circuit is opened or closed according to the instruction from the OPS controller. The lamp is kept on when there is no instruction from the OPS controller.

(15) OPS buzzer (Export model)This buzzer sounds in the predetermined pattern when the seat switch is turned off or when the forward/reverse shift lever needs returning to the neutral position (return to neutral warning).

(16) Plug-in analyzer

This new plug-in analyzer is added with the OPS analyzer functions to the service functions of the conventional SAS analyzer. It is connected to the same service connector.OPS analyzer functions• Diagnostic display (More detailed display than OPS lamp blinking frequency)• I/O monitor display (Shortening the time required for troubleshooting)• Output test (Shortening the troubleshooting time by setting each output on and off according to the instruction from the OPS controller)

0-6

Control specifications1. Drive OPS

When the OPS controller detects seat switch off state for 2 seconds, the forward/reverse interrupt relay isoperated to disconnect the driving power supply to the forward/reverse drive relay in the torque converter.This drive OPS operation is released when the seat switch is turned on and the forward/reverse shift relay isreturned to the neutral position.

2. Material handling OPS When the OPS controller detects seat switch OFF for 2 seconds, the lift lock valve and tilt control valve arecontrolled to stop fork lowering and forward tilting. Other material handling operations such as backwardtilting, fork lifting and attachment operations are stopped by interrupting the hydraulic oil supply by means ofthe unload valve. The disabled material handling operations are released upon lapse of 1 second after seatswitch ON.

Caution:• Backward tilting: If the material handling lever is operated while the OPS is functioning, the mast

may be tilted backward because of the weight of the tilted mast or the back pressure at the unloadvalve.

• Attachment: If the material handling lever is operated while the OPS is functioning, the attachmentmay move because of the own weight of the attachment or the back pressure at the unload valve.

1. OPS operation noticeWhen the OPS controller detects the seat switch off state, it sounds the OPS buzzer* (bleep) for about onesecond, and turns the OPS lamp on to warn the operator of the OPS operation.

*: The buzzer sounds only export model.

2. Return-to-neutral warning (Only export model)The OPS controller warns the driver of the failure in releasing the drive OPS by sounding the buzzer at shortintervals (pip-pip) when the seat switch is turned on without returning the forward/reverse shift lever to itsneutral position.

3. Malfunction alarmWhen the OPS controller detects any malfunction, it blinks the OPS lamp to warm the malfunction. The lampblinking frequency identifies the defective part.

SeatEvery seat has the seat switch for operator detection. When replacing seat, install a genuine TOYOTA seat designed specifically for this lift truck. (The OPS may fail tooperate unless the correct seat is used.)

Combination MeterOPS lamp

This lamp indicates OPS operation and warns an OPS error.

Note:With addition of OPS lamp, the remaining fuel warning lamp(OPT), which used to be in the combination meter, isrelocated to the instrument panel.

0-7

Oil Control Valve1. A new oil control valve is adopted for use with the added OPS system.

2. An electronic hydraulic control mechanism is incorporated in the tilt control circuit for controlling the mast tiltingoperation.

3. The additional check valve in each of the lift and tilt circuit greatly reduces natural drop and natural forward tilt.

4. The unload valve provided in the supply circuit.

Specifications

Pn1-ton series Pn2 · Cu2-ton series Pn3 · Cu3-ton series

Relief pressure settingMPa (kgf/cm2) [psi]

Lift 18.7 (191) [2720] ← ←

Tilt 15.7 (160) [2280] ← ←

Flow divider flow rate L/min 13.0 (3.43) ← Pn: 15.2 (4.01)Cu: 13.0 (3.43)

Unloading solenoid valveManual downlifting valve

Lift lock solenoid valve Tilt control solenoid valve

Open this valve toforcibly lower the fork with the enginekey turned OFF.

0-8

SAS

Hydraulic circuit diagramThe integral control valve has integrated the unload valve (unload SOL), lift lock valve (lift lock SOL) and the tiltcontrol valve (tilt control SOL) with the oil control valve in the previous model. Each solenoid valve (SOL) is normallyclosed.

R

P

OUT

C1

C2

C3

C4

C5

T1

T2

(1) Unloading valve (Unloading SOL)(2) Lift lock valve (Lift lock SOL)(3) Tilt control valve (Tilt control SOL)(4) Gage port

(1)

(2)

(3)

(4)

0-9

Hydraulic circuit controlTilt control is achieved by ON/OFF of the tilt control solenoid (SOL) valve installed on the integral control valve. Therelationships between the tilt hydraulic circuit and tilt control SOL valve is as shown in the table below. When theSOL is OFF upon backward tilting operation, the circuit is fully open. When the SOL is OFF upon neutral or tiltforward operation, tilting is stopped.

*Backward tilting operation with the tilt lever knob switch depressed.

Tilt control SOL

ON OFF

Semi-open circuit Forward tilt circuit Full open circuit for backward tilting Tilt stop circuit

• High lifting height, backward tilting speed restriction

• Low lifting-height, backward tilting speed restriction*

• Forward tilting • Low lifting height, backward tilting

• Tilt lever at neutral• Stop with forward tilting

angle restriction• Automatic leveling stop

with forward tilting

1. Tilt stop circuitThe tilt stop circuit refers to the state where the tiltingoperation is disabled as upon tilt lever setting at the neutralposition or upon stopping with forward tilting angle restrictionor fork automatic leveling. The tilt cylinder operation isstopped because the tilt control valve in the control valve isclosed.

2. Tilt semi-open circuitThe tilt semi-open circuit refers to the state where the tiltingoperation speed is restricted (slowed down).The tilting speed is slowed down because the orifice in the tiltcontrol valve is connected to reduce the oil flow to the tiltcylinder.

Tilt ControlValve

TiltLever

Tilt Cylinder

PilotLine

SOL OFF

Tilt Cylinder

Tilt ControlValve(Orifice)

TiltLever

PilotLine

SOL ON

0-10

Key-off lift lock1. The integral control valve is designed for addition of the OPS system and the lift hydraulic circuit is modified

accordingly.

2. When the engine key is turned off, the fork cannot be lowered when the lift lever is set to the down position.

3. Since the check valve was closed during no hydraulic pressure generation in the past, lowering operation wasdisabled. After the change, the lift lock solenoid valve is adopted to enable lowering when the engine isstopped so loan as the key switch is at the ON position.

3. Tilt full open circuitThe tilt full open circuit refers to the state where the tiltingspeed is not restricted. The forward/backward tilting speed atthe low lifting height becomes the normal tilting speed.The fully opened circuit in the tilting control valve results innormal tilting speed with no restriction.

Tilt Cylinder

Tilt ControlValve

TiltLever

PilotLine

RR Tilt : SOL OFFFR Tilt : SOL ON

1-1

1

OPSPage

GENERAL ............................................................1-2COMPONENTS ....................................................1-4OPS CONTROLLER ............................................1-5

REMAVAL · INSTALLATION ..................................1-5OPS PLUG-IN ANALYZER..................................1-6

SCREEN CONFIGURATION...................................1-6BASIC OPERATION..............................................1-7ANALYZER ..........................................................1-9TROUBLESHOOTING .........................................1-12

OPS TROUBLESHOOTING...............................1-14DIAGNOSIS........................................................1-14DIAGNOSIS ERROR CODE LIST..........................1-15TROUBLESHOOTING BY ERROR CODE..............1-18TROUBLESHOOTING BY PHENOMENON ............1-33

Note:See Section 5 (SAS) for the connector layout, controller sequence and connector diagram.

1-2

GENERAL

Forward tilt switch

Battery

Key switch

Foward reverse

switch

Bakward tilt switch

* Lower limit switch

* OPS

Controller

* OPS lamp

* OPS buzzer (Export model)

* Plug in

analyzer

Tilt

cylinder

SAS

Controller

Lift

cylinder* Unload

valve

* Tilt

control

valve

* Lift

lock

valve

* Oil control

valve

Oil tank

Oil

pumpEngine

T/C

* Forward

interrupt relay

Forward drive

valve

* Reverse

interrupt relay

Reverse drive

valve

* Seat switch

F

N

R

* OPS lamp relay

*: Parts added or changed for OPS

1-3

1(13)

(3) (4)

(5) (6)

(16)

(15)

(14)

(1)

(2)

(7) (8) (9)(10) (11) (12)

(1) OPS controller (9) Backward tilting switch

(2) Seat switch (10) Unload valve

(3) Forward drive switch (11) Lift lock valve

(4) Reverse drive switch (12) Tilt control valve

(5) Forward interrupt relay (13) OPS lamp

(6) Reverse interrupt relay (14) OPS lamp relay

(7) Lift lowering switch (15) OPS buzzer (Export model)

(8) Forward tilting switch (16) Plug-in analyzer

1-4

COMPONENTS1910

5701-467

4

VZ

PA

QY

WE

WG

PG

MF

LN

WE

GU

PA

QY

MF

RQ

2

3

4

RQ

GU

GH

GH

3

1

1

2

36A

PG36A

LY

VZ

LN

LN

WA

WS

WS

RQ

EP

5701

1-5

1

OPS CONTROLLERREMAVAL · INSTALLATION

Removal Procedure1 Remove the toe board.

2 Remove the lower panel.

3 Remove the instrument panel (RH).

4 Remove the OPS controller set bolts.

5 Disconnect the connector.

6 Remove the OPS controller.

Installation ProcedureThe installation procedure is the reverse of the removal procedure.

5

46

1-6

OPS PLUG-IN ANALYZERFor the maintenance and service of OPS functions, a separate type plug-in analyzer is introduced as an SST(Special Tool for Service).The plug-in analyzer is designed to read the operating state of sensors and actuators used for the OPS functionsand the error information detected by the controller. It serves to check on the operating state of OPS functions andshortens the repair time for a problem. Moreover, it is installed with save function to file data displayed on the screenin the SST.

SCREEN CONFIGURATION

SST 09240-23323-71

Menu name Content of function Reference page

Com

mun

icatio

n fu

nctio

n wi

th th

e O

PS co

ntro

ller o

n th

e ve

hicle

side

OPS

DIAG MEMORY Indication of ten error codes and sub-codes in past. 1-9

IN/OUT MONITOR Monitoring input voltage value from the sensors and the output signal, etc. to the solenoid, etc. 1-10

ACTIVE TEST Forced operation of solenoids and warning lamps. 1-11

CONTROLLER DATA Indication of OPS controller abbreviation number and version 1-11

See the SAS section.

See the SAS section.

Page

1-9

1-10

1-111-11

1-7

BASIC OPERATIONName of Sections and the Switch Functions

Caution on using:• Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections.• Operate the switch with finger tip.• Donít give it strong impact from dropping or collision.• Donít leave it under the direct rays of the sun for long time.

Name of section Position of indication Mark Function Switch

A

• Move the cursor to the above item.• Move to the preceding page.

Selectorswitch • Move the cursor to right or left.

<Blank> <No function>

B

• Select the item below.• Move to the following page. Selector

switch

<Blank> <No function>

C

Determine an item for selection.Menu switch

<Blank> • Move to MENU screen.

Connection and Operation of SST1. Turn the key switch OFF.2. Open the diagnosis connector cover of the vehicle and properly

connect the connector on the SST side.SST 09240-23323-71

Note:Since the connector has no locking device, securely connectit to prevent contact defect upon closing the engine hoodwith the connector in connected state.

3. Turn the key switch ON or start engine.4. Display of the initialization screen

After about 15 seconds of display, "LANGUAGE SET" or "MAINMENU" screen appears. The screen may be changed duringthis period by pressing the menu switch .

Connector

Main unit

Screen title A Switch

Switch mark indicatorCB

SST

Diagnosis connector

PLUG IN ANALYZER

SYSTEM PROG VER 4.00

1-8

5. "LANGUAGE SET" screenSince this screen appears only when the language isundefined, determine a language to use for display.(1) Select a display language by pressing selector switch

and .• Japanese• English

(2) Press MENU switch to determine the language setting.

Note:Once the display language is defined, "LANGUAGE SET"screen will not be displayed from the next time onward. Tochange language, go to "TESTER SET" of "MAIN MENU".

6. "MAIN MENU" screen(1) Select the menu using selector switch and and

determine by pressing menu switch .• SAS: Moves to SAS MENU screen. (See the SAS section)• OPS: Moves to OPS ANALYZER MENU Screen.• TESTER SET: Moves to TESTER SET screen. (See the SAS

section)

Removal of SST

1. Check that the screen title is for one of the MENU screens.

2. Turn the key switch OFF.

3. Disconnect the connector.

Note:To disconnect, hold the body of the connector.

4. Close the diagnosis connector cover.

1-9

ANALYZER

ANALYZER MENU Display contents and function Page

1. DIAG MEMORY Indication of error codes for 10 most recent errors 1-9

2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 1-10

3. ACTIVE TEST Forced operation signal output to the selected item 1-11

4. CONTROLLER DATA Indication of the OPS controller part number and version 1-11

Operation Procedure1. Select and enter "2OPS" on the main menu screen to display

the OPS ANALYZER MENU screen.

2. ANALYZER MENU screen

(1) Move the cursor to the desired menu by operating selectorswitch or , and enter by operating MENU switch .

(2) Select and enter "END" to return to the MAIN MENUscreen.

"1 DIAG MEMORY"This screen displays ten error codes from the most recent one.

[Explanation on display contents]

(1) Order of error occurrence

(2) Error codes

[Clear memory]

Press selector switch continuously for 2 seconds.

[End]

Press MENU switch to return to the ANALYZER MENU screen.

Note:• Only "-" appears at the end of the item involving no error

occurrence.• If reception has not been completed, only the number

appears without "-" indication.

(1) (2)

1-10

"2 IN/OUT MONITOR"[Explanation on display contents]

(1) SEAT: Seat switch input signal

(2) DIR: Direction switch input signal

FWD: Forward direction switch input signal

REV: Reverse direction switch input signal

(3) RLY: Output signal to forward/reverse interrupt relay

FWD: Output signal to forward interrupt relay

REV: Output signal to reverse interrupt relay

(4) VOLTAGE: OPS controller power supply voltage

(5) LIFT LOWER: Lift lowering switch input signal

(6) UNLOAD SOL: Output signal to unload solenoid

(7) LWR SOL: Output signal to lowering lock solenoid

(8) TILT SOL: Output signal to tilt solenoid

(9) TILT: Tilt lever switch input signal

FWD: Forward tilt switch input signal

BWD: Backward tilt switch input signal

CONT: SAS tilt control command input signal

(10) LSOPT: Reserved.

[End]


(1)(2)

(3)

(4)

(1)

(4)

(5)(6)(7)(8)

(1)(9)

*(8)

(10)(4)

*: "CONT ---" appears on the SAS-less spec. model.

1-11

"3 ACTIVE TEST"

Note:ON indication on the screen shows the controller outputstate. The operation, therefore, should be checked visually,by operating sound, etc.

1. Select the item by selector switch , and set OFF/ON byselector switch .


(1) RLY FWDSet to ON for forced output of forward interrupt relayactivating signal. (Forward traveling disabled state)

(2) RLY REVSet to ON for forced output of reverse interrupt relayactivating signal. (Reverse traveling disabled state)

(3) UNLOAD SOLSet to ON for forced output of unload solenoid activatingsignal. (Material handling disabled state)

(4) LWR SOLSet to ON for forced output of lowering lock solenoidactivating signal. (Lowering enabled state)

(5) TILT SOLSet to ON for forced output of tilt solenoid activating signal.(Forward tilting enabled state with backward tilting speedrestriction)

(6) LAMPSet to ON for forced output of OPS lamp lighting signal.(OPS lamp lighting state)

(7) BUZZER (Export model)Set to ON for forced output of OPS buzzer sounding signal.(Continuous OPS buzzer sounding)

2. After resetting all items to OFF, press MENU switch to returnto the ANALYZER MENU screen.

"4 CONTROLLER DATA"The OPC controller abbreviation No. and version No. can bedisplayed on this screen.


(1) DATAController abbreviation No.

(2) VERVersion No.

[End]


(1)(2)(3)(4)(5)(6)(7)

(1)

(2)

1-12

TROUBLESHOOTING

No display on the screen.

Related Portion

Estimated Causes:

Inspection 1:

Measure the voltage between CN44-12 and CN44-3.Key switch ON (engine in stopped state)

Standard:

Inspection 2:

Measure the voltage between analyzer CN-1 and analyzer CN-13.Key switch ON (engine in stopped state)

Standard:

Connector contact defect Analyzer harness (power supply) defect Plug-in analyzer defect

CN44-12 (+) ~ CN44-3 (-) 8 to 16 V

Analyzer CN-1(+) ~ analyzer CN-13 (-) 8 to 16 V

TAB

RE

C

RE

CTA

BR

EC

TAB

TAB

RE

C

TAB

RE

C

To IG SW

OP

S c

ontr

olle

r

CN44-12(IG, Power supply)

(E2, Main GND)Analyzer CN

Analyzer

1

13

6CN44-1CN45-1

ECU-IG

CN46-3

CN6-3

CN44-3

J2

Inspection 2: Measure the voltage between analyzer CN-1 and analyzer CN-13.

Check CN44 and analyzer connector for any disconnection. Screen check after correction.

Inspection 1: Measure the voltage between CN44-12 and CN44-3.

Plug-in analyzer defect

Harness defect on vehicle side

Analyzer harness defect

NG

OK

NG

NG

NG

OK

OK

CN44 (REC)

1

7

12

2

8

13

3

9

14

54

10

1615

6

11

17

18

2019

21 2322

Analyzer CN (REC)

1-13

No data display on data (DIAG MEMORY, voltage value, etc) display screen

Related Portion

Estimated Causes:

Inspection 1:

Check continuity between CN44-1 and CN45-1.Key switch OFF, disconnection between CN44 and CN45.

Standard:

Inspection 2:

Check continuity between analyzer CN-6 and CN44-1.Key switch OFF, disconnection between analyzer CN andCN44.

Standard:

Connector contact defective Plug-in analyzer defect Analyzer harness (communication) defect OPS controller defect

CN44-1 ~ CN45-1 Continuity

Analyzer CN-6 ~ CN44-1 Continuity

TAB

RE

C

RE

CTA

BR

EC

TAB

TAB

RE

C

TAB

RE

C

To IG SW

OP

S c

ontr

olle

r

CN44-12(IG, Power supply)

(E2, Main GND)Analyzer CN

Analyzer

1

13

6CN44-1CN45-1

ECU-IG

CN46-3

CN6-3

CN44-3

J2

Check CN44 and analyzer connector for any disconnection. Data display check after correction.

Inspection 1:Check continuity between CN44-1 and CN45-1.

Inspection 2:Check continuity between analyzer CN-6 and CN44-1.

Check data display by connecting the analyzer to another vehicle.

Harness defect on vehicle side

Analyzer harness defect

NG

OK

NG

NG

NG

OK

OK

Plug-in analyzer defectNG

OPS controller defect

OK

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN44 (REC)

1

7

12

2

8

13

3

9

14

54

10

1615

6

11

17

18

2019

21 2322

Analyzer CN (REC) CN44 (TAB)

1-14

OPS TROUBLESHOOTINGDIAGNOSISThe diagnosis function informs the operator of a trouble occurrence and the trouble position by blinking the OPSlamp on the combination meter when the OPS controller detects an abnormality. The trouble position is indicated bythe lamp blinking count.

Note:• The OPS lamp is lit for 1 second upon key switch ON for broken lamp check.• The OPS lamp comes on when the operator leaves the seat.• If multiple errors occur at a time, only the lowest error code appears. Upon correction of that error, the

next lowest error code appears.

Example:

Display example of error code 3

Break point indication Code indication

ON

OFF

2 sec.

Abnormality detection (Code 3)

0.5 sec.0.5 sec.

0.5 sec.0.5 sec.

0.5 sec.0.5 sec.

0.5 sec.

1-15

1

DIA

GN

OSI

S ER

RO

R C

OD

E LI

ST

Lam

pE

rror

co

deVe

hicl

e sp

ec.

Err

or d

escr

iptio

nM

ajor

cau

seP

heno

men

on o

n ve

hicl

e

SA

S s

pec.

mod

elS

AS

-less

spe

c. m

odel

ON

——

Dea

d la

mp

chec

k—

——

Blin

king

(one

sh

ort O

N

puls

e)1-

1A

ll sp

ecifi

catio

nsS

eat s

witc

h ab

norm

ality

Stic

king

GN

D fa

ult

No

OP

S fu

nctio

ning

No

OP

S fu

nctio

ning

Blin

king

(tw

o sh

ort O

N

cycl

es)

2-1

Oth

er th

an m

ini

leve

r mod

elLi

ft lo

wer

ing

switc

h ab

norm

ality

Stic

king

GN

D fa

ult

No

spec

ial c

hang

e fro

m n

orm

al

stat

e(E

xces

sive

leak

dur

ing

low

erin

g)

No

spec

ial c

hang

e fro

m n

orm

al

stat

e(E

xces

sive

leak

dur

ing

low

erin

g)

2-2

SA

S-le

ss*

Tilti

ng s

witc

h ab

norm

ality

Stic

king

GN

D fa

ult

—N

o sp

ecia

l cha

nge

from

nor

mal

st

ate

(Exc

essi

ve le

ak d

urin

g lo

wer

ing)

2-3

2-4

Blin

king

(thr

ee

shor

t ON

cy

cles

)

3-1

All

spec

ifica

tions

Forw

ard

inte

rrup

t rel

ay

(RY

F) a

bnor

mal

ity

Dis

cont

inui

tyFo

rwar

d tra

velin

g is

pos

sibl

e w

hile

O

PS

is o

pera

ting.

Forw

ard

trave

ling

is p

ossi

ble

whi

le

OP

S is

ope

ratin

g.

GN

D fa

ult

↑↑

+B s

horti

ngFo

rwar

d tra

velin

g is

alw

ays

disa

bled

.Fo

rwar

d tra

velin

g is

alw

ays

disa

bled

.

3-2

Rev

erse

inte

rrup

t rel

ay

(RY

R) a

bnor

mal

ity

Dis

cont

inui

tyR

ever

se tr

avel

ing

is p

ossi

ble

whi

le

OP

S is

ope

ratin

g.R

ever

se tr

avel

ing

is p

ossi

ble

whi

le

OP

S is

ope

ratin

g.

GN

D fa

ult

↑↑

+B s

horti

ngR

ever

se tr

avel

ing

is a

lway

s di

sabl

ed.

Rev

erse

trav

elin

g is

alw

ays

disa

bled

.

Blin

king

(fou

r sh

ort O

N

cycl

es)

4-1

All

spec

ifica

tions

Unl

oad

sole

noid

(SO

L1)

abno

rmal

ity

Dis

cont

inui

ty

Lift

low

erin

g an

d ba

ckw

ard

tiltin

g ar

e di

sabl

ed b

ut o

ther

mat

eria

l ha

ndlin

g op

erat

ions

are

pos

sibl

e w

hile

OP

S is

ope

ratin

g

Lift

low

erin

g an

d ba

ckw

ard

tiltin

g ar

e di

sabl

ed b

ut o

ther

mat

eria

l ha

ndlin

g op

erat

ions

are

pos

sibl

e w

hile

OP

S is

ope

ratin

g

GN

D fa

ult

↑↑

+B s

horti

ng

All

mat

eria

l han

dlin

g op

erat

ions

are

di

sabl

ed w

hile

OP

S is

ope

ratin

g.

Whi

le O

PS

is n

ot o

pera

ting,

onl

y lif

t lo

wer

ing

is p

ossi

ble

but o

ther

m

ater

ial h

andl

ing

oper

atio

ns a

re

disa

bled

.

All

mat

eria

l han

dlin

g op

erat

ions

are

di

sabl

ed w

hile

OP

S is

ope

ratin

g.

Whi

le O

PS

is n

ot o

pera

ting,

onl

y lif

t lo

wer

ing

is p

ossi

ble

but o

ther

m

ater

ial h

andl

ing

oper

atio

ns a

re

disa

bled

.

1-16

*: S

AS-

less

spe

c. m

odel

onl

y be

caus

e of

det

ectio

n by

the

SAS

con

trolle

r her

e on

the

SAS

spe

c. m

odel

s.

Blin

king

(fou

r sh

ort O

N

cycl

es)

4-2

All

spec

ifica

tions

Low

erin

g lo

ck s

olen

oid

(SO

L2) a

bnor

mal

ity

Dis

cont

inui

ty

Whi

le O

PS is

ope

ratin

g, a

ll mat

eria

l ha

ndlin

g op

erat

ions

are

disa

bled

. Whi

le

OPS

is n

ot o

pera

ting,

onl

y fo

rwar

d tilt

ing

is di

sabl

ed a

nd a

ll oth

er m

ater

ial

hand

ling

oper

atio

ns a

re p

ossib

le.

Whi

le O

PS is

ope

ratin

g, a

ll mat

eria

l ha

ndlin

g op

erat

ions

are

disa

bled

. Whi

le

OPS

is n

ot o

pera

ting,

onl

y fo

rwar

d tilt

ing

is di

sabl

ed a

nd a

ll oth

er m

ater

ial

hand

ling

oper

atio

ns a

re p

ossib

le.

GN

D fa

ult

↑↑

+B s

horti

ng

Whi

le O

PS

is o

pera

ting,

onl

y lif

t lo

wer

ing

is p

ossi

ble

and

all o

ther

m

ater

ial h

andl

ing

oper

atio

ns a

re

disa

bled

.

Whi

le O

PS

is o

pera

ting,

onl

y lif

t lo

wer

ing

is p

ossi

ble

and

all o

ther

m

ater

ial h

andl

ing

oper

atio

ns a

re

disa

bled

.

4-3

All

spec

ifica

tions

Tilt

sole

noid

(SO

L3)

abno

rmal

ity

Dis

cont

inui

ty

Whi

le O

PS is

ope

ratin

g, a

ll mat

eria

l ha

ndlin

g op

erat

ions

are

disa

bled

. Whi

le

OPS

is n

ot o

pera

ting,

onl

y fo

rwar

d tilt

ing

is di

sabl

ed a

nd a

ll oth

er m

ater

ial

hand

ling

oper

atio

ns a

re p

ossib

le.

Whi

le O

PS is

ope

ratin

g, a

ll mat

eria

l ha

ndlin

g op

erat

ions

are

disa

bled

. Whi

le

OPS

is n

ot o

pera

ting,

onl

y fo

rwar

d tilt

ing

is di

sabl

ed a

nd a

ll oth

er m

ater

ial

hand

ling

oper

atio

ns a

re p

ossib

le.

GN

D fa

ult

↑↑

+B s

horti

ngA

utom

atic

leve

ling

stop

is d

isab

led.

—

Blin

king

(fiv

e sh

ort O

N

cycl

es)

5-1

All

spec

ifica

tions

Shi

ft le

ver a

bnor

mal

ity+B

sho

rting

Whe

n O

PS

is o

pera

ting,

rele

asin

g is

dis

able

d (lo

cked

sta

te b

y re

turn

to

neu

tral f

unct

ion)

.

Whe

n O

PS

is o

pera

ting,

rele

asin

g is

dis

able

d (lo

cked

sta

te b

y re

turn

to

neu

tral f

unct

ion)

.

ON

7-1

All

spec

ifica

tions

CPU

abn

orm

ality

Con

trolle

r ab

norm

ality

Driv

e O

PS

doe

s no

t fun

ctio

n,

low

erin

g is

alw

ays

disa

bled

, and

m

ater

ial h

andl

ing

OP

S d

oes

not

func

tion.

Driv

e O

PS

doe

s no

t fun

ctio

n,

low

erin

g is

alw

ays

disa

bled

, and

m

ater

ial h

andl

ing

OP

S d

oes

not

func

tion.

7-2

CP

U a

bnor

mal

ity

7-3

CP

U a

bnor

mal

ity

Blin

king

(s

even

sho

rt O

N c

ycle

s)7-

4C

PU

abn

orm

ality

Non

e in

par

ticul

arN

one

in p

artic

ular

ON

7-5

EEPR

OM

abn

orm

ality

Driv

e O

PS

doe

s no

t fun

ctio

n,

low

erin

g is

alw

ays

disa

bled

, and

m

ater

ial h

andl

ing

OP

S d

oes

not

func

tion.

Driv

e O

PS

doe

s no

t fun

ctio

n,

low

erin

g is

alw

ays

disa

bled

, and

m

ater

ial h

andl

ing

OP

S d

oes

not

func

tion.

7-6

EE

PR

OM

abn

orm

ality

ON

—A

ll sp

ecifi

catio

nsLo

w v

olta

ge a

larm

Low

bat

tery

vo

ltage

Alar

m b

efor

e O

PS o

pera

tion,

but

driv

e/m

ater

ial h

andl

ing

OPS

doe

s no

t fu

nctio

n, lo

werin

g is

alwa

ys d

isabl

ed.

Alar

m b

efor

e O

PS o

pera

tion,

but

driv

e/m

ater

ial h

andl

ing

OPS

doe

s no

t fu

nctio

n, lo

werin

g is

alwa

ys d

isabl

ed.

ON

——

OPS

ope

ratio

nDe

partu

re fr

om s

eat

——

Lam

pE

rror

co

deVe

hicl

e sp

ec.

Err

or d

escr

iptio

nM

ajor

cau

seP

heno

men

on o

n ve

hicl

e

SA

S s

pec.

mod

elS

AS

-less

spe

c. m

odel

1-17

List of Reference Pages for Error Codes and Sub Error Codes

List of Pages to be Referenced by Phenomenon

Without analyzer (SST) With analyzer (SST)

Error code Error description Page Error code Error description Page

1 Seat switch abnormality 1-18 1-1 Seat switch abnormality 1-18

2Lowering switch abnormalityTilt switch abnormality (L/SAS spec.)

1-21

2-1 Lowering switch abnormality 1-23

2-2 Tilt lever switch simultaneous ON abnormality 1-24

2-3 Forward tilt switch 2-minute shorting abnormality 1-24

2-4 Backward tilt switch 2-minute shorting abnormality 1-24

3

Forward interrupt relay (RYF) abnormalityReverse interrupt relay (RYR) abnormality

1-263-1 Forward interrupt relay (RYF)

abnormality 1-26

3-2 Reverse interrupt relay (RYR) abnormality 1-26

4 Solenoid (SOL) abnormality 1-28

4-1 Unload solenoid (SOL1) abnormality 1-28

4-2 Lowering lock solenoid (SOL2) abnormality 1-28

4-3 Tilt solenoid (SOL3) abnormality 1-28

5 T/C shift lever abnormality 1-30 5-1 T/C shift lever abnormality 1-31

7 OPS controller abnormality —

7-1 CPU abnormality —

7-2 ROM abnormality —

7-3 RAM abnormality —

7-4 A/D conversion abnormality —

7-5 EEPROM data abnormality —

7-6 EEPROM access abnormality —

DescriptionPages to be referenced

Without analyzer With analyzer

The OPS buzzer does not sound, or keeps sounding. (Export model) 1-33 1-33

The OPS lamp does not come on. 1-37 1-37

The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled) 1-39 1-42

Cannot lower the fork. 1-45 1-48

The material handling OPS does not function (Including when lowering and forward tilting are disabled). 1-50 1-50

Material handling fails (Including when fork lowering is disabled). 1-51 1-51

The mast backward tilting speed is always slow or unrestricted. 1-52 1-52

Slow mast backward tilting speed (SAS-less spec. vehicle). 1-56 1-56

Mast does not tilt forward. 1-57 1-57

Mast does not tilt forward. (SAS-less spec. vehicle). 1-61 1-61

The drive OPS does not function. 1-63 1-63

Traveling fails (Including forward traveling only, reverse traveling only, and occasional abnormalities). 1-66 1-66

1-18

TROUBLESHOOTING BY ERROR CODE

Error Code 1 · 1-1 (Seat switch abnormality)

Related Portion

Estimated Causes:

*: After correction, check the OPS lamp indication.After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFFagain.After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display errorcode 1 with blinking.

Connector contact defect Harness defect Seat switch defect Controller defect

RE

CTA

BR

EC

TAB

RE

CTA

B

RE

CTA

B

TAB

RE

C

OP

S c

ontr

olle

r

CN45-23 (DMI, Seat SW)

CN45-17 (E03, Switch GND)J1

CN4CN50 CN60

CN65

6

1

1

2

1

2Seat switch

Check CN45, CN50, CN60, CN4 and CN65 connectors for any disconnection or internal wetting.

After correction, check the OPS lamp indication.*

Error code 1

Inspection 1:Check the seat switch individually for continuity.

Inspection 2:Check continuity between CN45-23 and CN45-17

Controller defect

Seat switch defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

1-19

Inspection 1:

Check the individual seat switch for continuity.Key switch OFF, CN 60 disconnection.

Standard:

Inspection 2:

Check continuity between CN45-23 and CN45-17.Key switch OFF, CN45 disconnection. (CN4, CN50 and CN60 must be connected.)

Standard:

*: After correction check the OPS lamp indication.After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFF again.After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display error code1 with blinking.

Seated Unseated

CN60-1 ~ CN60-2 Continuity No continuity

Seated Unseated


CN60 (TAB)

2 1

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

Check CN45, CN50, CN60, CN4 and CN65 connectors for any disconnection or internal wetting.


Error code 1-1

Inspection 1:With CN60 disconnected, check the input signal to the controller.

Inspection 2:Check continuity between CN45-23 and CN45-17

Controller defect

Seat switch defect

Harness defect

NG

OK

OK

NG

NG

NG

OK

1-20

Inspection 1:

With CN60 disconnected, check the input signal to the controller.CN60 connector disconnection, key switch OFF ⇒ ONAnalyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Inspection 2:

Check continuity between CN45-23 and CN45-17.Key switch OFF, CN45 disconnection. (CN4, CN50, CN60 and CN65 must beconnected.)

Standard:

Seated Unseated

SEAT OFF OFF

Seated Unseated


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-21

Error Code 2Error Code 2-1 (Lowering switch abnormality)Error Code 2-2 (Tilt lever switch simultaneous ON abnormality) (L/SAS Spec.)Error Code 2-3 (Forward tilt switch 2-minute shorting abnormality) (L/SAS Spec.)Error Code 2-4 (Backward tilt switch 2-minite shorting abnormality) (L/SAS Spec.)

Related Portion

Estimated Causes:

*: After correction check the OPS lamp indication.After key switch ON, operate the tilt lever forward and backward to check if the OPS lamp blinks.Or keep the tilt lever in the neutral position for 2 minutes and check if the OPS lamp blinks.Or keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.The OPS lamp must not indicate error code 2 with blinking.

Connector contact defect Forward tilt switch defect Lowering switch defect Backward tilt switch defect Harness defect Tilt switch installation defect Controller defect Lowering switch installation defect

TAB

RE

C

RE

CTA

BR

EC

TAB

OP

S c

ontr

olle

r

CN45-25 (TFI, Forward tilt switch)Forward tilt switch

CN45-24 (TRI, Backward tilt switch)Backward tilt switch

CN45-17 (E03, SW-GND)

CN45-26 (DOWN, Lowering switch)

Lowering switch

J1

CN34-3CN34-4

CN49-1

CN49-2

CN34-2CN34-1

Check the CN45, CN34, and CN49 connectors for any disconnection or internal wetting.

After correction check the OPS lamp indication.*

Error code 2

Inspection 1: Check the lift lowering switch wiring and tilt lever switch wiring for continuity.

Inspection 2:Check the lift lowering switch and tilt lever switch individually (as installed on the vehicle) for continuity.

Lever switch installation defect

Controller defect

Harness defect

NG

OK

OK

OK

NG

NG

OK

Inspection 3: Check the lift lowering lever switch and tilt lever switch individually (as removed from the vehicle) for continuity.

Switch defectNG

NG

1-22

Inspection 1:

Check the lift lower lever switch wiring and tilt lever switch wiring for continuity.Key switch OFF, CN45 disconnection.

Standard:• Lift lower switch

• Tilt switch

Inspection 2:

Check the lift lower lever switch and tilt lever switch individually (as installed on thevehicle) for continuity.Key switch OFF, CN34 and CN49 disconnection.

Standard:• Lift lower switch

• Tilt switch

Inspection 3:

Check the lift lower lever switch and tilt lever switch individually (as removed from thevehicle) for continuity.Key switch OFF, CN34 and CN49 disconnection.

Standard:• Lift lower switch (switch on the upper side when installed on the vehicle)

• Forward tilt switch (switch on the upper side when installed on the vehicle)

• Backward tilt switch (switch on the lower side when installed on the vehicle)

Lever at neutral position Lever at up position Lever at down position

CN45-26 ~ CN45-17 No continuity No continuity Continuity

Lever at neutral position Lever at forward tilt position

Lever at backward tilt position

CN45-25 ~ CN45-17 No continuity Continuity No continuity








Switch free Switch pressed






CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN34 (TAB)

1

3

2

4

CN49 (TAB)

12

CN34 (TAB)

1

3

2

4

CN49 (TAB)

12

1-23

*: After correction, check the OPS lamp indication.After key switch ON, keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.The OPS lamp must not indicate error code 2 with blinking.

Inspection 1:

Disconnect CN49 and check the switch output upon lowering operation.Key switch ON (engine in stopped state)Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:Lift lower switch

Inspection 2:

Check the lift lower lever switch individually (as installed on the vehicle) for continuity.Key switch OFF, CN49 disconnection.

Standard:Lift lower switch


LIFT LOWER OFF OFF OFF



Check CN45 and CN49 connectors for any disconnection or internal wetting.


Error code 2-1

Inspection 1:Disconnect CN49, and check the switch output upon lowering operation.

Inspection 2:Check lift lower lever switch individually (as installed on the vehicle) for continuity.


Inspection 4:Check continuity between CN45 and CN49.

Harness defect

NG

OK

NG

OK

NG

OK

OK

Inspection 3:Check the lift lower lever switch individually (as removed from the vehicle) for continuity.

Lower switch defectNG

NG

Controller defect (Error occurrence upon continuing lowering operation for 2 minutes or more, however, is normal.)

NG OK

CN49 (TAB)

12

1-24

Inspection 3:

Check the lift lower lever switch individually (as removed from the vehicle) for continuity.Key switch OFF, CN49 disconnection.

Standard:Lift lower switch (switch on the upper side when installed on the vehicle)

Inspection 4:

Check continuity between CN45 and CN49.Key switch OFF, CN45 and CN49 disconnection.

Standard:

*: After correction, check the OPS lamp indication.After key switch ON, keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.



CN45-26 ~ CN45-17 No continuity

CN49 (TAB)

12

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN49 (REC)

1 2

Inspection 3:Check the tilt lever switch individually (as removed from the vehicle) for continuity.

Check CN45 and CN34 connectors for any disconnection or internal wetting.


Error codes: 2-2, 2-3, and 2-4

Inspection 1:Disconnect CN34, and check the switch output upon tilting operation.

Inspection 2:Check the tilt lever switch individually (as installed on the vehicle) for continuity.



Harness defect

NG

OK

NG

OK

NG

OK

OK

Tilt switch defectNG

NG

Controller defect (Error occurrence upon continuing lever operation for 2 minutes or more or upon simultaneous ON during installation adjustment, however, is normal.)

NG OK

1-25

Inspection 1:

Check the switch output upon tilting operation after disconnecting CN34.Key switch ON (engine in stopped state)Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard: Tilt switch

Inspection 2:

Check the tilt lever switch individually (as installed on the vehicle) for continuity.Key switch OFF, CN34 disconnection.

Standard:Tilt switch

Inspection 3:

Check the tilt lever switch individually (as removed from the vehicle) for continuity.Key switch OFF, CN34 disconnection.

Standard: • Tilt forward switch (switch on the upper side when installed on the vehicle)

• Tilt backward switch (switch on the lower side when installed on the vehicle)

Inspection 4:


Standard:

Lever at neutral position

Lever at forward tilt

position

Lever at backward tilt

position

TILT FWD OFF OFF OFF

TILT BWD OFF OFF OFF


Lever at forward tilt position










CN34 (TAB)

1

3

2

4

CN34 (TAB)

1

3

2

4

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN34 (REC)

2

4

1

3

1-26

Error Code 3Error Code 3-1 (Forward interrupt relay (RYF) abnormality)Error Code 3-2 (Reverse interrupt relay (RYR) abnormality)

Related Portion

Estimated Causes:

*: After correction, check the OPS lamp indication.After key switch ON, place the shift lever in the forward or reverse position and leave the seat to check if the OPSlamp blinks.The OPS lamp must not display error code 3 with blinking.

Note: When the analyzer is provided, check the related portion after checking the error memory for the currenterror code. See p1-9 "1 DIAG MEMORY" for the error memory check method.

Connector contact defect Harness defect Forward interrupt relay defect Controller defect Reverse interrupt relay defect

TAB

RE

C

TAB

RE

COP

S c

ontr

olle

r

CN45-10 (RYF, Forward interrupt relay)

CN45-11 (RYR, Reverse interrupt relay)

CN45-17, (E03, SW-GND) CN46-6

T/C relay block

Forward interrupt relay

Reverse interrupt relay

2

1

1

2

Check the CN45 and CN46 connectors for disconnection or internal wetting and the relays for insertion.


Error Codes 3, 3-1, 3-2

Inspection 1:Check the forward/reverse interrupt relay individually (on the coil side) for the resistance value.

Inspection 2: Check the wiring between CN45 and the T/C relay block for continuity.

Controller defect

Interrupt relay defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

1-27

Inspection 1:

Check the forward/reverse interrupt relay (on coil side) individually.Measure the resistance between terminals of each of the forward and reverse interrupt relays.Key switch OFF, relay disconnection from T/C relay block.

Standard:

Inspection 2:

Check continuity of the wiring between CN45 and T/C relay block.Key switch OFF, CN45 disconnection, relay removal from the T/C relay block.

Standard:• Discontinuity check

• GND fault check

• +B shorting check

• IG line shorting check

Resistance

Forward interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)

Reverse interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)

CN45-10 ~ Forward interrupt relay terminal 2 Continuity

CN45-11 ~ Reverse interrupt relay terminal 2 Continuity

CN45-17 ~ Forward interrupt relay terminal 1 Continuity

CN45-17 ~ Reverse interrupt relay terminal 1 Continuity





CN45-10 ~ CN45-15,-16 No continuity


RLY

2 1

3(5) 4

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

T/C FR RLY

1 2

35

4

T/C RR RLY

1 2

35

4

1-28

Error Code 4Error Code 4-1 (Unload solenoid (SOL1) abnormality)Error Code 4-2 (Lowering lock solenoid (SOL2) abnormality)Error Code 4-3 (Tilt solenoid (SOL3) abnormality)

Related Portion

Estimated Causes:

*: After correction, check the OPS lamp indication.After starting the engine, operate lift up/down, forward/backward tilt in each of OPS activation and deactivation tocheck if the OPS lamp blinks.The OPS lamp must not display error code 4 with blinking.

Note: When the analyzer is provided, check the related portion after checking the error memory for the currenterror code. See p1-9 "1 DIAG MEMORY" for the error memory check method.

Connector contact defect Tilt solenoid defect Unload solenoid defect Controller defect Lowering lock solenoid defect Harness defect

RE

CTA

BR

EC

TAB

RE

CTA

B

RE

CTA

B

TAB

RE

C

OP

S c

ontr

olle

r

CN45-14 (SOL1, Unload SOL)

CN45-12 (SOL3, Tilt SOL)

CN45-30 (E3, SOL-GND)


CN45-13 (SOL2, Lowering lock SOL)

Unload SOL

Lowering lock SOL

Tilt SOL

CN47-1

W/SPLICE-Z

CN46-9

CN46-8CN12-2

CN12-1CN48-2

CN48-1CN47-2

(E3, Body GND)

Check the CN45, CN46, CN47, CN48 and CN12 connectors for any disconnection or internal wetting.


Error Codes 4, 4-1, 4-2, 4-3

Inspection 1:Check the solenoids (SOL1 - SOL3) individually for the resistance value.

Inspection 2: Check the wiring between CN45 and each solenoid (SOL1 - SOL3) for continuity.

Controller defect

Solenoid defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

1-29

Inspection 1:

Check the resistance of each solenoid (SOL1 to SOL 3).Key switch OFF, CN47, CN48 and CN12 disconnection.

Standard:

Inspection 2:

Check continuity of the wiring between CN45 and each of solenoids SOL1 to SOL3.Key switch OFF, CN45, CN47, CN48 and CN12 disconnection.


• GND fault check



Resistance

SOL1 CN47-1 ~ CN47-2 Approx. 9 Ω (20°C)






CN47-2 ~ Frame Continuity


















2 1

CN47 (TAB) CN48 (TAB)

2 1

CN12 (TAB)

12

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN47 (REC)

21

CN48 (REC)

21

CN12 (REC)

1 2

1-30

Error Code 5 · 5-1 (T/C shift lever abnormality)

Related Portion

Estimated causes:

*: After correction, check the OPS lamp indication.After key switch ON, operate the shift lever to forward or reverse position and check if the OPS lamp blinks.The OPS lamp must not display error code 5 with blinking.

Connector contact defect Controller defect Shift lever switch defect Fuse defect Harness defect

TAB

OP

S c

ontr

olle

r

RE

C

TAB

RE

C

RE

C

To IG1SFT

CN6-8

CN46-1 CN53-5(CN57-3)CN53-1

CN53-6

(CN57-6)

4 4

CN46-11

CN45-3 (DRF, Forward drive SW)

CN45-4 (DRR, Reverse drive SW)

T/C relay block


Reverse interrupt relay Shift

lever

RE

CTA

B

Check if the fuse (SFT) is blown. After correction, check the OPS lamp indication.*

Error Code 5

Inspection 1:Check the shift lever individually for continuity.

Inspection 2:Check the continuity of wiring between CN45 and IG SW.

Controller defect

Shift lever defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

Check connectors CN45, CN46, CN53 and CN6 for any disconnection or internal wetting.


NG

OK NG

1-31

Inspection 1:

Check the T/C shift lever individually for continuity.Key switch OFF, CN53 disconnection.

Standard:

Inspection 2:

Check the wiring between CN45 and IG SW for continuity.Key switch OFF, CN45 and IG SW connectors disconnection.(CN6, CN46 and CN53 must be connected.)

Standard:• Lever at neutral




Lever at forward traveling position

Lever at reverse traveling position

Between pins 5 and 6 on lever side No continuity Continuity No continuity

Between pins 6 and 1 on lever side No continuity No continuity Continuity

CN45-3 ~ IG SW-4 No continuity






DIRECTION SWITCH

34789

18 1716 14131215

6 5 2 1

1011

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

IG SW

243

Check if the fuse (SFT) is blown. After correction, check the OPS lamp indication.*

Error code 5-1

Inspection 1: Disconnect CN53, and check the input signal to the controller.

Inspection 2:Check the wiring between CN45 and IG SW for continuity.

Controller defect

Shift lever defect

Harness defect

NG

OK

OK

NG

NG

NG

OK

Check CN45, CN46 and CN53 connectors for any disconnection or internal wetting.


NG

OK NG

1-32

*: After correction, check the OPS lamp indication.After key switch ON, operate the shift lever to the forward or reverse position and check if the OPS lamp blinks.The OPS lamp must not indicate error code 5 with blinking.

Inspection 1:

Disconnect CN53, and check the input signal to the controller.CN53 disconnection, and key switch ON (engine in stopped state)Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Inspection 2:

Check the wiring between CN45 and IG SW for continuity.Key switch OFF, CN45 and IG SW connectors disconnection.(CN6, CN46 and CN53 must be connected.)

Standard:• Lever at neutral



Lever at neutral position Lever at forward traveling position

Lever at reverse traveling position

DIR FWD OFF OFF OFF

DIR REV OFF OFF OFF







CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

IG SW

243

1-33

TROUBLESHOOTING BY PHENOMENON

The OPS buzzer does not sound. (Export model)The OPS buzzer keeps sounding. (Export model)

Related Portion

Estimated Causes:

*: After correction, check the OPS buzzer sound.After connecting all connectors, turn the key switch ON, and leave the seat to check if the buzzer sounds.

Connector contact defect Controller defect OPS buzzer defect Fuse defect Harness defect

TAB

RE

C

RE

CTA

B

To IG SW

OP

S c

ontr

olle

r

CN45-9 (BZO, OPS buzzer) OPS buzzer

ECU-IG

CN51-1

CN51-2

Check for blown fuse (ECU-IG). After correction, check the OPS buzzer sound.*

The OPS buzzer does not sound.

Inspection 1:Check the continuity between the IG SW and CN51, and between CN45 and CN51.

Inspection 2: Check the continuity between CN51-2 and the frame.

Controller defect

Harness defect

OPS buzzer defect

NG

OK

NG

OK

NG

OK

NG

Check the CN45 and CN51 for any disconnection or internal wetting. After correction, check the OPS buzzer sound.*

NG

OK NG

1-34

Inspection 1:

Check the continuity between the IG SW and CN51, and between CN45 and CN51.Key switch OFF, CN45, CN51, IG SW connector disconnection.

Standard:

Inspection 2:

Check the continuity between CN51-2 and the frame.

• Without analyzer

Disconnect CN51 and turn the key switch to ON (engine in stopped state).

Standard:

* Normally, the buzzer sounds for 1 second upon lapse of 0.5 seconds after the operator leaves the seat.

• With analyzer

Disconnect CN51 and turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST

Standard:Forcibly turn the OPS buzzer ON and OFF, and check the continuitybetween CN51-1 and CN51-2.

IG SW-4 ~ CN51-1 Continuity


Buzzer ON Buzzer OFF

Between CN51-2 and the frame Continuity No continuity


Between CN51-2 and the frame Continuity No continuity

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN51 (REC)

1 2

IG SW

243

CN51 (REC)

1 2

CN51 (REC)

1 2

1-35

*: After correction, check the OPS buzzer sound.After connecting all connectors, turn the key switch to ON and leave the seat to check if the buzzer sounds.

Inspection 1:

Check the continuity between the IG SW and CN51, and between CN45 and CN51.Key switch OFF, CN45, CN51, IG SW connector disconnection.

Standard:



Between CN45-9 and the frame No continuity

Check CN45 and CN51 for any disconnection or internal wetting. After correction, check the OPS buzzer sound.*

The OPS buzzer keeps sounding.

Inspection 1:Check the continuity between IG SW and CN51, between CN45 and CN51, and between CN45 and the frame.

Inspection 2:Check the continuity between CN51-2 and the frame.

Controller defect

Harness defect

OPS buzzer defect

NG

OK

NG

OK

NG

OK

NG

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN51 (REC)

1 2

IG SW

243

1-36

Inspection 2:

Check the continuity between CN51-2 and the frame.


Disconnect CN51 and turn the key switch to ON (engine in stopped state).

Standard:

* Normally, buzzer sounds for 1 second upon lapse of 0.5 sec after the operator leaves the seat.

• With analyzer

Disconnect CN51 and turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST

Standard:Forcibly turn the OPS buzzer ON and OFF, and check the continuitybetween CN51-1 and CN51-2.


Between CN51-2 and frame Continuity No continuity


Between CN51-2 and frame Continuity No continuity

CN51 (REC)

1 2

CN51 (REC)

1 2

1-37

The OPS lamp does not come on.

Related Portion

Estimated Causes:

*: After correction, check OPS lamp lighting.After connecting all connectors, turn the key switch to ON (engine in stopped state) and leave the seat to see thatthe OPS lamp comes on.

Connector contact defect Harness defect OPS lamp defect Controller defect OPS lamp relay defect Fuse defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

RE

CTA

B

To IG SW

GAUGE

ECU-IG

W/SPLICE-Y

OP

S c

ontr

olle

r

CN45-8 (RYLP, OPS lamp relay)

CN5-12

CN6-3

CN58-3

CN41-12

421

3

4CN8-3

Combination meter

OPS lamp relay

SAS lamp relay

Check if the OPS lamp is burnt out. After bulb replacement, check that the OPS lamp comes on.

Check for blown fuse (GAUGE).

Check CN45, CN41, CN5, CN6, CN8 and CN58 for any disconnection or internal wetting, and check any relay disconnection.

Inspection 1:Check the continuity between fuse (ECU-IG), CN45, CN41, frame, and OPS lamp relay.

After correction, check that the OPS lamp comes on.*

After correction, check that the OPS lamp comes on.*

NG

OK

NG

NG

NG

OK

OK

NG

Controller defect

OK

NG

Harness defectNG

Inspection 2:Check the OPS lamp relay.

OK

OPS lamp relay defectNG

1-38

Inspection 1:

Check the continuity between fuse (ECU-IG), CN45, CN41, frame, and OPS lamp relay.Turn the key switch OFF, disconnect CN45 and CN41, and remove the OPS lamp relay.

Standard:

Inspection 2:

Check the OPS lamp relay.


(1)Turn the key switch OFF, remove the OPS lamp relay from the relay block, and then turn the key switch to ON (enginein stopped state). Check the continuity between OPS lamp relay pin 1 and the frame with no one on the seat.

Standard:

(2)Turn the key switch to OFF, reinstall the OPS lamp relay, and then turn the key switch to ON (engine instopped state). Measure the voltage between OPS lamp relay pins 3 and 4.

Standard:

• With analyzer

(1)Turn the key switch to OFF, remove the OPS lamp relay from the relayblock, and then turn the key switch to ON (engine in stopped state).Check the continuity between OPS lamp relay block 1 and the framewith no one on the seat.

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST

Standard:Forcibly turn the OPS lamp ON and OFF, and check the continuity.


Standard:

Between fuse (ECU-IG) and relay pin 2 Continuity

Between CN45-8 and relay pin 1 Continuity

Between frame and replay pin 3 Continuity


Between frame and relay pin 1 No continuity

Lamp ON Lamp OFF

Between relay pin 1 and frame No continuity Continuity

Lamp ON Lamp OFF

Between relay pins 3 and 4 0 V Approx. 12 V

Lamp ON signal Lamp OFF signal


Lamp ON Lamp OFF


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN41 (REC)

1 2 3 4 7 8 9 10 11 12 135 6

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

1-39

The OPS lamp keeps lighting. (Including when traveling and material handling are bothdisabled)

Related Portion

Estimated Causes: Contactor contact defect Controller defect OPS lamp defect Fuse defect OPS lamp relay defect Low battery voltage Harness defect Seat switch discontinuity

RE

CTA

B

TAB

RE

C

RE

CTA

B

RE

CTA

B

TAB

RE

C

TAB

RE

CTA

BR

EC

RE

CTA

B

TAB

RE

C

TAB

RE

C

TAB

RE

C

OP

S c

ontr

olle

r

TAB

RE

C

To IG SWGAUGE

ECU-IG CN6-3

CN58-5

CN46-5

W/SPLICE-Y

CN46-4

CN41-12

CN5-12

CN8-3

CN60CN50CN4

CN64

J1CN45-17(E03, Switch GND)

CN45-23 (DMI, Seat switch)

CN45-8 (RYLP, OPS lamp relay)

CN45-16 (IG2, IG line)CN45-15 (IG, IG line)CN45-32 (BATT, +B)

ECU-B

1

2

1

2

6

1

421

3

4

Combination meter

OPS lamp relay

SAS lamp relay

CN58-3

To battery

Seat switch

1-40

*: After correction, check that the OPS lamp goes off.After connecting all connectors, turn the key switch to ON while staying on the seat (engine in stopped state).Check that the OPS lamp goes off in 1 second.

Check for blown fuse (ECU-B). After correction, check that the OPS lamp goes off.*

Without Analyzer

Check CN45, CN46, CN4, CN5, CN6, CN8, CN41, CN50, CN58 and CN60 for any disconnection or internal wetting, and check the OPS lamp relay for connection.

After correction, check that the OPS lamp goes off.*

NG

OK

NG

NG

OK

NG

Inspection 1:Check and measure the continuity and voltage between IG SW and CN45, between battery and CN45, between IG SW and OPS lamp relay, between OPS lamp relay and CN45, and between CN60 and CN45.

Harness defectNG

OK

Inspection 2:Check the input voltage from the IG line to the controller.

Battery defect (low battery voltage)NG

OK

Inspection 3:Check the OPS lamp relay.

OPS lamp relay defectNG

OK

Inspection 4:Check the seat switch.

Seat switch defectNG

OK

Controller defect

1-41

Inspection 1:

Check and measure the continuity and voltage between IG SW and CN45, between the battery and CN45,between IG SW and OPS lamp relay, between OPS lamp relay and CN45, and between CN60 and CN45.Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamprelay.

Standard:

Inspection 2:

Check the input voltage from the IG line to the controller.Disconnect CN45 and turn the key switch to ON. (Connectors other than CN45 must be connected).

Standard:

Inspection 3:


(1)Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch toON (engine in stopped state). Check the continuity between OPS lamp relay pin 1 and frame with no one onthe seat.

Standard:


Standard:



Between IG SW-4 and relay pin 2 Continuity







CN45-32 ~ CN45-31 Approx. 12 V

CN45-15 ~ CN45-31 11 V or more

CN45-16 ~ CN45-31 11 V or more

Lamp ON Lamp OFF


Lamp ON Lamp OFF


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

IG SW

243

OPS LAMP RLY

1 2

35

4

CN60 (REC)

21

OPS LAMP RLY

1 2

35

4

1-42

Inspection 4:

Check the individual seat switch for continuity.Turn the key switch to OFF, and disconnect CN60.

Standard:

*: After correction, check that the OPS lamp comes on.After connecting all connectors, turn the key switch to ON while staying on the seat (engine in stopped state).Check that the OPS lamp goes off in 1 second.

Seated Unseated


CN60 (TAB)

2 1

Inspection 2:Check the input voltage from the IG line to the controller. Battery defect (low battery voltage)

NG

OK

Inspection 3:Check the OPS lamp relay. OPS lamp relay defect

NG

OK

Inspection 4:Check the seat switch. Seat switch defect

NG

Controller defect

OK

OK

Check for blown fuse (ECU-B). After correction, check that the OPS lamp goes off.*

With Analyzer

Check CN45, CN46, CN4, CN5, CN6, CN8, CN41, CN50, CN58 and CN60 for any disconnection or internal wetting, and the OPS lamp relay for connection.

After correction, check that the OPS lamp goes off.*

NG

OK

NG

NG

OK

NG

Inspection 1:Check and measure the continuity and voltage between the IG SW and CN45, between the battery and CN45, between the IG SW and the OPS lamp relay, and between the OPS lamp relay and CN45, and between CN60 and CN45.

Harness defectNG

OK

1-43

Inspection 1:

Check and measure the continuity and voltage between the IG SW and CN45, between the battery and CN45,between the IG SW and the OPS lamp relay, between the OPS lamp relay and CN45, and between CN60 and CN45.Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamp relay.

Standard:

Inspection 2:

Check the input voltage from the IG line to the controller.After connecting all connectors, turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Inspection 3:


(1)Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch toON (engine in stopped state). Check the continuity between OPS lamp relay pin 1 and the frame with no oneon the seat.


Standard:Forcibly turn the OPS lamp to on and off, and check the continuity.


Standard:



Between IG SW-4 and relay pin 2 Continuity







CN45-32 ~ CN45-31 Approx. 12 V

Key ON

VOLTAGE 11 V or more

Lamp ON signal Lamp OFF signal


Lamp ON Lamp OFF


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN60 (REC)

21

IG SW

243

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

1-44

Inspection 4:

Check the seat switch individually.Turn the key switch to OFF and disconnect CN60.

Standard:

Seated Unseated


CN60 (TAB)

2 1

1-45

Cannot lower the fork.

Related Portion

Estimated Causes: Connector contact defect Lowering lever switch installation defect Lowering switch defect Controller defect Control valve lowering lock valve sticking defect Harness defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r

CN45-26 (DOWN, Lowering switch)

CN45-17 (E03, SW-GND)

CN45-13 (SOL2, Lowering lock solenoid)

Lowering switch



CN46-8

CN46-9

CN49-1

CN49-2J1

CN48-1CN48-2

W/SPLICE-Z

(E3, Body ground)

Lowering lock solenoid

1-46

Caution:*: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:

Check the lift lowering lever switch wiring for continuity.Turn the key switch to OFF and disconnect CN45.

Standard:

Lever at neutral position Lever at up position Lever at lowering position


OK

Is the OPS lamp blinking to indicate an error.

Perform troubleshooting according to the error code.

Without Analyzer

Yes

No

Does the OPS lamp go off when seated. Perform troubleshooting for "The OPS Lamp keeps lighting".

No

Check CN45, CN46, CN48 and CN49 for any disconnection or internal wetting.

NG

Yes

OKNG

Inspection 1:Check the lift lowering lever switch wiring for continuity.

Inspection 2:Check the continuity between CN45 and CN49.

NGHarness defect

NG

After correction, get on the seat and check if the fork can be lowered.

Inspection 3:Check the lift lowering lever switch (as removed from the vehicle) for continuity.

Lowering switch defect

NG

OK

Lowering lever switch installation defect

OK

OK

Put a hand on the lowering lock solenoid (at the rear lower left-hand portion of the control valve) and operate for lowering the fork while seating to check the solenoid open/close sound (with the engine in stopped state and the fork in the fully lowered position).*

NGController defect

Lowering lock valve sticking

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-47

Inspection 2:

Check the continuity between CN45 and CN49.Turn the key switch OFF, and disconnect CN45 and CN49.

Standard:

Inspection 3:

Check the lift lowering lever switch individually (as removed from the vehicle) for continuity.Turn the key switch OFF, and disconnect CN49.

Standard:



Free Pressed


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN49 (REC)

1 2

CN49 (TAB)

12

1-48

Caution:*: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:

Check the switch output when operated for lowering.Turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Lever at neutral position Lever at up position Lever at lowering position

LIFT LOWER OFF OFF ON

After correction, get on the seat and check if the fork can be lowered.

OK

Is the OPS lamp blinking to indicate an error?


With Analyzer

Yes

No

Does the OPS lamp go off when seated. Perform troubleshooting for "The OPS Lamp keeps lighting."

No


NG

Yes

OKNG

Inspection 1:Check the switch output when operated for fork lowering.

Inspection 2:Check the continuity between CN45 and CN49.

NGHarness defect

NG

Inspection 3:Check the lowering lever switch individually (as removed from the vehicle) for continuity.

Lowering switch defect

NG

OK

Lowering lever switch installation defect

OK

OK

Put a hand on the lowering lock solenoid (at lower rear left-hand portion of the control valve) and operate for fork lowering on the seat to check the solenoid open/close sound (with the engine stopped and the fork in the fully lowered position).*

NGController defect

Lowering lock valve sticking

1-49

Inspection 2:

Check the continuity between CN45 and CN49.Turn the key switch to OFF, and disconnect CN45 and CN49.

Standard:

Inspection 3:

Check the lift lowering lever switch individually (as removal from the vehicle) for continuity.Turn the key switch to OFF, and disconnect CN49.

Standard:



Free Pressed


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN49 (REC)

1 2

CN49 (TAB)

12

1-50

The material handling OPS does not function (Including when lowering and forwardtilting are disabled).

Related Portion

Estimated Causes:

*1: Check if the OPS lamp is blinking.Turn the key switch to OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle as itis for 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.

*2: Check the control valve solenoid operating sound.• Turn the key switch to ON (engine in stopped state) and put a hand on the unload solenoid of the control valve

to check the solenoid open/close sound is heard in 2 seconds after leaving the seat or upon getting on theseat.

• Put a hand on the lowering lock solenoid of the control valve while seating to confirm the solenoid open/closesound is heard upon fork lowering operation.

Caution:*2:Be careful so as not to get burnt because the solenoid may be hot.

Controller defect Control valve unload valve or lowering lock valve defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r

CN45-14 (SOL1, Unload SOL)

CN45-13 (SOL2, Lowering lock SOL)



CN46-8

CN46-9 (E3, Body ground)

CN48-2

CN48-1

CN47-1

CN47-2W/SPLICEUnload SOL

Lowering lock SOL

Is the OPS lamp blinking?*1

Sticking unload valve on control valve or lowering lock valve

No


Yes

Check the operating sound of the control valve solenoid.*2

OK

Controller defectNG

1-51

Material handling fails (Including when fork lowering is disabled)

Related Portion

Estimated Causes:

*: Check the control valve solenoid operating sound.Turn the key switch to ON (engine in stopped state) and put a hand on the unload solenoid of the control valve tocheck if the solenoid open/close sound is heard in 2 seconds after leaving the seat or upon getting on the seat.

Caution:*:Be careful so as not to get burnt because the solenoid may be hot.

Sticking unload valve on control valve Controller defect

TAB

RE

C RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r CN45-14 (SOL1, Unload solenoid)



CN46-8

CN46-9

W/SPLICE-Z

CN47-1

CN47-2

Unload solenoid

(E3, Body ground)

Is the OPS lamp blinking to indicate an error?

Sticking unload valve on control valve

No


Yes

Check the unload solenoid operating sound.*

OK

Controller defectNG

Check if OPS lamp turns OFF while sitting on the seat.

Yes

Perform troubleshooting for "The OPS lamp keeps lighting".

No

1-52

The mast backward tilting speed is always slow or unrestricted.

Related Portion

Estimated Causes: Connector contact defect Sticking tilt control valve Harness defect OPS controller defect Tilt lever switch defect SAS controller defect Tilt lever switch installation defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r

CN45-25 (TFI, Forward tilt switch)

CN45-24 (TRI, Backward tilt switch)

CN45-17 (E03, SW-GND)

CN45-20 (TGND, Forward/Backward tilt GND)

CN45-22 (TFO, Forward tilt output)CN45-21 (TRO, Backward tilt output)CN45-5 (TCON, Tilt control)

6

10

CN46J1

CN3412

34

W/SPLICE-A

CN1-22CN1-23

CN1-10CN1-9

CN1-13 SA

S c

ontr

olle

r

Forward tilt lever switch

Backward tilt lever switch

After correction, check the backward tilting speed while staying on the seat.*2

Perform troubleshooting according to the error code.Is the OPS lamp blinking?*1

No

Yes


NG

Perform SAS troubleshooting (check the auto level switch and lift height switch).

OK

To be continued

NG

1-53

*1: Check if the OPS lamp is blinking.Turn the key switch to OFF → ON (2 seconds or more) → ON with no one on the seat. Leave the vehicle as it isfor 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.

*2: After correction, check the backward tilting speed while staying on the seat.After turning the key switch to ON while staying on the seat, check the mast backward tilting speed.

*3: Check the tilt solenoid operating sound.Turn the key switch to ON (engine in stopped state) and put a hand on the tilt solenoid of the control valve tocheck the solenoid open/close sound upon forward tilting operation with the unloaded fork at a height of 500 mm(20 inches).


Inspection 1:

Check the tilt lever switch signal to the OPS controller.Turn the key switch to OFF and disconnect CN45. (CN34 and CN46 must beconnected.)

Standard



CN45-25 ~ CN45-17 No continuity Continuity No continuityCN45-24 ~ CN45-17 No continuity No continuity Continuity

OK

Inspection 1:Check the tilt lever switch signal to the OPS controller.

Inspection 2:Check the tilt lever switch individually (as installed on the vehicle) for continuity.

NGHarness defect (between CN34 and CN45)

OK

Inspection 3:Check the tilt lever switch individually (as removed from the vehicle) for continuity.

Tilt lever switch defect

NG

NG

Tilt lever switch installation defect

OK

OK

Inspection 4:Check tilt lever switch signal to SAS controller.

NGInspection 5:Check the continuity between CN45 and CN1.

SAS controller defect

Continued

Harness defect (between CN45 and CN1)

NG

OKOK

Check the tilt solenoid operating sound.*3 Sticking tilt control valve

OK

Inspection 6:Check tilting control by the OPS controller.

NG

NG


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-54

Inspection 2:

Check the tilt lever switch individually (as installed on the vehicle) for continuity.Turn the key switch to OFF and disconnect CN34.

Standard:

Inspection 3:

Check the tilt lever switch individually (as removed from the vehicle) for continuity.Turn the key switch to OFF and disconnect CN34.

Standard:• Forward tilting switch (upper switch as installed on the vehicle)

• Backward tilting switch (lower switch as Installed on the vehicle)

Inspection 4:

Check the tilt lever switch signal to the SAS controller.Disconnect CN1 and turn the key switch to ON (engine in stopped state).

Standard:

Note: As the key switch is turned to ON with the connector disconnected for this inspection, the SAS lamp comeson and the error code (F1) appears.






Free Pressed


Free Pressed


Circuit tester Lever at neutral position



Digital typeCN1-10 (+) ~ CN1-23 (-) No continuity Continuity No continuity

CN1-9 (+) ~ CN1-23 (-) No continuity No continuity Continuity

Analog type CN1-10 (-) ~ CN1-23 (+) No continuity Continuity No continuity

CN1-9 (-) ~ CN1-23 (+) No continuity No continuity Continuity

CN34 (TAB)

1

3

2

4

CN34 (TAB)

1

3

2

4

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

1-55

Inspection 5:

Check the continuity between CN45 and CN1.Turn the key switch to OFF, and disconnect CN1 and CN45. (CN46 must be connected.)

Standard:

Inspection 6:

Check the tilt control by the OPS controller.Disconnect CN1 and turn the key switch to ON. (CN34 and CN46 must be connected).Operate the tilt lever to check the mast movement.

Standard:





Between CN45-22 and frame No continuity

Between CN45-21 and frame No continuity

Lever at neutral position Mast does not move.

Lever at forward tilt position Mast tilts forward.

Lever at backward tilt position Mast tilts backward at the normal speed.

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-56

Slow mast backward tilting speed (SAS-less vehicle)

Related Portion

Estimated Causes:

*1: Check if the OPS lamp is blinking.Turn the key switch to OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle as itis for 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.Furthermore, operate the tile lever to the forward position on the operator's seat, make sure that the OPS lampdoes not blink.

*2: Check the tilt solenoid operating sound.Turn the key switch to ON (engine in stopped state) while staying on the seat and put a hand on the tilt solenoidon the control valve to check if the solenoid open/close sound is heard when the tilt lever is operated to theforward tilt position.


Controller defect Sticking tilt control valve

TAB

RE

C RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r CN45-12 (SOL3, Tilt SOL)



CN46-8

CN46-9

W/SPLICE-Z

CN12-1

CN12-2Tilt SOL

(E3, Body ground)

Is the OPS lamp blinking?*1


No


Yes

Check the tilt solenoid operating sound.*2

NG

Sticking tilt control valveOK

1-57

Mast does not tilt forward.

Related Portion

Estimated Causes: Connector contact defect Sticking tilt control valve Harness defect OPS controller defect Forward tilt lever switch defect SAS controller defect Forward tilt lever switch installation defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r


CN45-17 (E03, SW-GND)

CN45-20 (TGND, Forward/reverse tilt GND)

CN45-22 (TFO, Forward tilt output)CN45-5 (TCON, Tilt control)

CN466

10

W/SPLICE-A

CN34

J1

1

2


SA

S c

ontr

olle

rCN1-22CN1-23

CN1-10CN1-13

Check if the OPS/SAS lamp blinks to indicate an error.

Get on the seat and check if the fork can be lifted.



Perform troubleshooting for Disabled Material Handling error.

Yes

No

No

Yes

After repair, get on the seat and check forward tilting operation.*1

NG

To be continued

NG

1-58

*1: Get on the seat and check forward tilting operation:Stay on the seat and turn the key switch to ON. Operate the tilt lever with the unloaded fork at a height of 500mm (20 inches) to check if the mast can be tilted forward.

*2: Check for tilt solenoid operating sound:Stay on the seat and turn the key switch to ON (with the engine in stopped state). Put a hand on the tilt solenoidof the control valve with the unloaded fork at a height of 500 mm (20 inches) to check for solenoid operatingsound.

Caution:*2: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:

Check the forward tilt lever switch signal to the OPS controller.Key switch OFF, CN45 disconnection. (CN34 and CN46 must be connected.)

Standard:

Lever at neutral position Lever at forward position Lever at backward position


Check the tilt solenoid operating sound.*2

Inspection 1:Check the forward tilt lever switch signal to the OPS controller.

Inspection 2:Check the forward tilt lever switch individually (as installed on the vehicle) for continuity.

OK

Harness defect (between CN34 and CN45)

NG

OKNG

Continued


Inspection 3:Check the forward tilt lever switch individually (as removed from the vehicle) for continuity.

Forward tilt lever switch defect

OK

NG

Forward tilt lever switch installation defect

Inspection 4:Check the forward tilt lever switch signal to the SAS controller.


OK

Harness defect (between CN45 and CN1)OK

NGNG

Sticking tilt control valve

NG

OK

Inspection 6:Check tilt control by the OPS controller. OPS controller defect

OK

NG

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-59

Inspection 2:

Check the forward tilt lever switch individually (as installed on the vehicle) for continuity.Key switch OFF, CN34 disconnection.

Standard:

Inspection 3:

Check the forward tilt lever switch individually (as removed from the vehicle) for continuity.Key switch OFF, CN34 disconnection

Standard:Tilt forward switch (upper switch when installed on the vehicle)

Inspection 4:

Check the forward tilt lever switch signal to the SAS controller.CN1 disconnection, key switch ON (with the engine in stopped state)

Standard:


Inspection 5:

Check continuity between CN45 and CN1.Key switch OFF, CN1 and CN45 disconnection. (CN46 must be connected.)

Standard:





Free Pressed





Digital type CN1-10(+) ~ CN1-23(-) No continuity Continuity No continuity

Analog type CN1-10(-) ~ CN1-23(+) No continuity Continuity No continuity



CN34 (TAB)

1

3

2

4

CN34 (TAB)

1

3

2

4

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-60

Inspection 6:

Check tilt control by the OPS controller.CN1 disconnection, key switch ON. (CN34 and CN46 must be connected.)Operate the tilt lever and check the mast movement.

Standard:


Lever at neutral position Mast does not move.

Lever at forward tilt position Mast tilts forward.

Lever at backward tilt position Mast tilts backward at the normal speed.

1-61

Mast does not tilt forward. (SAS-less spec. vehicle)

Related Portion

Estimated Causes: Connector contact defect Forward tilt lever switch defect Harness defect Forward tilt lever switch installation defect OPS controller defect Sticking tilt control valve

TAB

RE

C

TAB

OP

S c

ontr

olle

r

RE

C

RE

CTA

B


CN45-17 (E03, SW-GND)

6CN46

J1

CN341

2


Stay on the seat and check if the fork can be lifted.

Check if the OPS lamp blinks to indicate an error.

Inspection 1:Check the forward tilt lever switch signal to the OPS controller.


Perform troubleshooting for Disabled Material Handling error.

Yes

No

No

Yes

Check CN34, CN45 and CN46 for any disconnection or internal wetting.

After correction, check forward tilting operation while sitting on the seat.*1

NG

NG

Inspection 2:Check the forward tilt lever switch individually (as installed on the vehicle) for continuity.

OK

Harness defect

NG

OKNG

Inspection 3:Check the forward tilt lever switch individually (as removed from the vehicle) for continuity.

Forward tilt lever switch defect

OK

NG

Forward tilt lever switch installation defect

Check the tilt solenoid operating sound*2 Sticking tilt control valveOK


NG

OK

1-62

*1: Stay on the seat and check the forward tilting operation.After turning the key switch to ON, operate the tilt lever to check if the mast can be tilted forward.

*2: Check the tilt solenoid operating sound.Stay on the seat and turn the key switch to ON (with the engine in stopped state), put a hand on the tilt solenoidto hear the solenoid operating sound generated when the tilt lever is operated forward.

Caution:*2: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:

Check the forward tilt lever switch signal to the OPS controller.Key switch OFF, CN45 disconnection. (CN34 and CN46 must be connected).

Standard:

Inspection 2:

Check the forward tilt lever switch individually (as installed on the vehicle) for continuity.Key switch OFF, CN34 disconnection.

Standard:

Inspection 3:

Check the forward tilt lever switch individually (as removed from the vehicle) for continuity.Key switch OFF, CN34 disconnection.

Standard:Forward tilt switch (switch on the upper side as installed on the vehicle)







Free Pressed


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN34 (TAB)

1

3

2

4

CN34 (TAB)

1

3

2

4

1-63

The drive OPS does not function.

Related portion

Estimated Causes: Connector interrupt defect Harness defect Forward interrupt relay defect Controller defect Reverse interrupt relay defect

RE

C

TAB

OP

S c

ontr

olle

r

RE

C

REC

TABREC

TAB

RE

CTA

BR

EC

RE

CTA

B

To IG SW


CN45-4 (DRR, Reverse drive switch) CN46-11

CN46-1

CN46-6

CN6-8 CN53-6CN53-5

CN53-1

CN52

CN541 2

5 7

1 3

2 4

2 3

1 4

SFT

CN45-3 (DRF, Forward drive switch)


CN45-17 (E03, SW-GND)

T/C relay block


Shift lever


Shift SOL

1-64

*1: Check if the OPS lamp blinks to indicate an error.Without getting on the seat, turn the key switch to OFF → ON (2 seconds or more) → OFF. Leave the vehicle asit is for at least 15 minutes. Then turn the key switch to ON again and make sure that the OPS lamp does notblink.

*2: After correction, check if the drive OPS functions normally.Turn the key switch ON, set the shift lever to either forward or reverse and leave the seat. Check if the drive OPSis activated.

Inspection 1:

Check continuity of the wiring between CN53 and T/C relay block, and the wiring betweenCN54 and T/C relay block.Turn the key switch OFF, disconnect CN53 and CN54, and remove the relays from the T/Crelay block.

Standard:

Between CN53-5 and pin 4 of forward interrupt relay Continuity

Between CN53-1 and pin 4 of reverse interrupt relay Continuity



CN53-6 ~ IG SW-4 Continuity

Check if the OPS lamp blinks to indicate an error.*1

Inspection 1:Check continuity of the wiring between CN53 and T/C relay block, and the wiring between CN54 and T/C relay block.

Harness defectNG


Yes

No

Check CN45, CN46, CN54, CN6, CN52 and CN53 for any disconnection or internal wetting, and any relay disconnection.

After correction, check if the OPS functions normally.*2

NG

NGOK

Inspection 2:Check the forward/reverse interrupt relay. Interrupt relay defect

NG

OK

Controller defect

OK

CN53 (REC)

76321

10 11 12 14 15 1614

4 5 8 9

1817

CN54 (REC)

1 2

IG SW

243

1-65

Inspection 2:

Check the forward/reverse interrupt relay individually.

(1)Turn the key switch to OFF and disconnect the relays from the T/C relay block. Measure theresistances between the specified pins of the forward/reverse interrupt relay.

Standard:

(2) Install the relay and disconnect CN53 and CN54. Leave the seat unseated, and turn the keyswitch to ON (with the engine in stopped state).


Standard:

• With analyzer

Forcibly set forward and reverse interrupt relays to ON and OFF and check continuity in each state.


Standard:• Forward interrupt relay (RLY FWD)

• Reverse interrupt relay (RLY REV)

Resistance

Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Unseated Seated

CN53-5 ~ CN54-1 No continuity Continuity


Relay ON Relay OFF


Relay ON Relay OFF


RLY

2 1

3(5) 4

CN53 (REC)

76321

10 11 12 14 15 1614

4 5 8 9

1817

CN54 (REC)

1 2

1-66

Traveling fails (Including forward traveling only, reverse traveling only, and occasionalabnormalities)

Related Portion

Estimated Causes: Connector contact defect Controller defect Forward interrupt relay defect Shift lever switch defect Reverse interrupt relay defect Fuse defect Harness defect

RE

C

TAB

OP

S c

ontr

olle

r

RE

C

REC

TABREC

TAB

RE

CTA

BR

EC

RE

CTA

B

To IG SW


CN45-4 (DRR, Reverse drive switch) CN46-11

CN46-1

CN46-6

CN6-8 CN53-6CN53-5

CN53-1

CN52

CN541 2

5 7

1 3

2 4

2 3

1 4

SFT

CN45-3 (DRF, Forward drive switch)


CN45-17 (E03, SW-GND)

T/C relay block


Shift lever


Shift SOL

Check if the fuse (SFT) is blown. After correction, check if the OPS functions normally.*

NG

OK

Check if the OPS lamp blinks to indicate an error. Perform troubleshooting according to the error code.

Yes

No

Stay on the seat and check if the OPS lamp goes off. Perform troubleshooting for "OPS lamp keeps lighting".

No

NG

Yes

Check CN6, CN45, CN46, CN52, CN53 and CN54 for any disconnection or internal wetting.

After correction, check if the OPS functions normally.*

NG

OK

To be continued

1-67

* After correction, check if the OPS functions normally. Check that forward traveling is disabled if operator leaves the seat with key switch ON to activate the OPS, setsthe shift lever to forward and then sits on the seat again. Next, check that forward traveling is enabled if the shift lever is set to neutral once and then to forward again.

Inspection 1:

Check the T/C shift lever unit individually for continuity.Key switch OFF, CN53 disconnection.

Standard:

Inspection 2:

Check the wiring between CN53/CN54 and T/C relay block and between CN45 and CN53 for continuity.Turn the key switch to OFF, disconnect CN53, CN54 and CN45, and disconnect relays from the T/C relay block.

Standard:

Lever at neutral Lever at forward Lever at reverse

Between pins 6 and 5 on lever side No continuity Continuity No continuity

Between pins 6 and 1 on lever side No continuity No continuity Continuity





CN53-6 ~ IG SW-4 Continuity



Inspection 3:Check the forward/reverse interrupt relay. Interrupt relay defect

NG

OK

Inspection 1: Check the shift lever unit individually for continuity. Shift lever defect

NG

OK

Inspection 2:Check the wirings between CN53/CN54 and the T/C relay block, and between CN45 and CN53 for continuity.

Harness defectNG

OK

Controller defect

Continued

DIRECTION SWITCH

34789

18 1716 14131215

6 5 2 1

1011

CN53 (REC)

76321

10 11 12 14 15 1614

4 5 8 9

1817

CN54 (REC)

1 2

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-68

Inspection 3:

Check the forward/reverse interrupt relay individually.

(1)Turn the key switch OFF and remove the relays from the T/C relay block. Measure the resistancebetween pins of each of forward and reverse interrupt relays.

Standard:

(2) Install the relays and disconnect CN53 and CN54. Turn the key switch to ON (with the engine in stoppedstate) after leaving the seat.


Standard:

• With analyzer

Forcibly turn each of the forward and reverse interrupt relays ON and OFF, and check the continuity in each state.


Standard:• RLY FWD

• RLY REV

Resistance

Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Unseated Seated



Relay ON Relay OFF


Relay ON Relay OFF


RLY

2 1

3(5) 4

CN53 (REC)

76321

10 11 12 14 15 1614

4 5 8 9

1817

CN54 (REC)

1 2

2-1

2

BODYPage

COMPONENTS ....................................................2-2RELAY BLOCK....................................................2-3

RELAY INSPECTION ............................................2-3PORTIONS PROTECTED BY FUSES......................2-4

SEAT SWITCH .....................................................2-5INSPECTION ........................................................2-5

2-2

COMPONENTS

5701-467

4

VZ

PA

QY

WE

WG

PG

MF

LN

WE

GU

PA

QY

MF

RQ

2

3

4

RQ

GU

GH

GH

3

1

1

2

36A

PG36A

LY

VZ

LN

LN

WA

WS

WS

RQ

EP

5701STD

5701-468

4

VZ

PA

QY

WE

LN

GU

PA

QY

MF

PG

RQ

2

3

4

RQ

KZ

3

1

1

2

36A

WG

PG

MF

36A

WE

LYWT

GU

RQ

KZ

TZ

LY

EP

LN

LN

WS

36KK

PN

FS

VZ

WS

VZ

TY

EP

5701UL spec.

2-3

2

RELAY BLOCK

RELAY INSPECTIONIndividual Relay Continuity Inspection

Measurement state Measurement positions Standard

Head/tail relay

Normal state1-2 Continuity

3-5 No continuity

When the battery voltage is applied to terminals 1 and 2: 3-5 Continuity

Glow/ST relay

Normal state1-2 No continuity

3-4 Continuity

When the battery voltage is applied to terminals 3 and 4: 1-2 Continuity

SAS-LAMP relay, OPS lamp relay, T/C FR relay, T/C RR relay

Normal state 1-2, 3-4 Continuity

When the battery voltage is applied to terminals 1 and 2: 3-4 No continuity

LayoutFront

GOV

OPSLAMP

OPS lamp relay

Front

T/C relay

T/CFR

T/CRR

Head/tail relay

ST relay

SAS-Lamp relay, OPS lamp relay, T/C FR relay, T/C RR relay

2-4

PORTIONS PROTECTED BY FUSES

Including options

Fusible links

NO Name Capacity Main protected portions

– – –

TWC 7.5A TWC (3-way catalytic) system

ST (Starting motor) 7.5A Starting motor relay (IG) and glow plug timer (IG)

SFT (Shift) 7.5A Electric shift T/C

ECU-IG 7.5A SAS controller and SAS lamp relay

IGN (Ignition) 7.5A Alternator, glow plug timer, ignition coil, LPG solenoid, fuel cut and vehicle speed control system

TURN (Turn) 7.5A Turn signal lamp and flasher relay

GAUGE (Meter) 10A

Hour meter, water temperature gauge, fuel gauge, warning lamps (charge, engine oil pressure, air cleaner, lock indicator, sedimenter, glow indicator, fuel, brake, cooling water and battery), back-up buzzer, T/C oil thermometer, strobo, back-up lamp and SAS buzzer

EFI 15A EFI injector, EFI fuel pump

GOV 15A Governor ECU, EFI ECU, Electronic throttle body

HORN (Horn) 7.5A Horn

ALT-S (Alternator sending) 5A Alternator sending

HEAD (Headlamp) 15A Headlamp

CHARGE (Charge) 7.5A Charge lamp, choke and glow plug timer

TAIL (Tail) 7.5A Tail lamp, clearance lamp and meter illumination

ECU-B 7.5A OPS controller

STOP (Stop lamp) 7.5A Stop lamp

NO. Name Capacity Type

FL GOV 30A

FL AM1 40A

FL HEAD 40A

FL GLOW 60A

FL ALT 80A

Cartridge type

Screw-fastened type

2-5

2

SEAT SWITCHINSPECTIONPush on the seat cushion and check continuity of the seat switch.

Measurement terminals:Seat switch connector terminals CN50-1 and CN50-2

Standards:Not pressed: OFF (∞ Ω)Pressed: ON (0 Ω)

3-1

3

MATERIAL HANDLING SYSTEMPage

COMPONENTS ....................................................3-2NATURAL DROP TEST.......................................3-3

NATURAL FORWARD TILT TEST ..........................3-3OIL LEAK TEST...................................................3-4

LIFT CYLINDER....................................................3-4TILT CYLINDER....................................................3-4

3-2

COMPONENTS6801

3-3

3

NATURAL DROP TEST1. 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 stop theengine.

2. Draw datum lines on the inner and outer masts, andmeasure the drop in 15 minutes.

Limit:W/SAS, L/SAS 45 mm (1.77 in)

NATURAL FORWARD TILT TEST1. Set the mast in the vertical position with standard load on the

fork. Lift the fork by about 50 cm (19.7 in) and stop theengine.

2. Measure the tilt cylinder rod extension in 15 minutes.

Vehicle modelNatural forward tilt amount

mm (in)

W/SAS, L/SAS

Pn1 ton series W/SAS, L/SAS: 15 (0.59) or lessPn · Cu2 ton series W/SAS, L/SAS: 20 (0.79) or lessPn · Cu3 ton series W/SAS, L/SAS: 25 (0.98) or less

3-4

OIL LEAK TESTLIFT CYLINDER1. 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. Slowly tilt the mast fully forward, and stop the engine. After 5minutes, disconnect the oil control valve to oil tank hose.Place a measuring cylinder under the elbow and measurethe amount of oil leaking in one minute.

Standard (at lift port):W/SAS, L/SAS 8 cm3 (0.49 in3) or less

Note:If the natural drop is great even though the oil leakamount is within the standard, the lift cylinder packing isdefective.

TILT CYLINDER1. Set the mast in the vertical position with standard load on the

fork. Lift the fork by about 50 cm (19.7 in) and stop theengine.

2. After waiting for 5 minutes, disconnect the oil control valve tooil tank hose. Place a measuring cylinder under the elbowand measure the amount of oil leaking in one minute.

Standard (total for lift and tilt):W/SAS, L/SAS 16 cm3 (0.98 in3) or less

3. The leak amount at the tilt port is the total leak amount lessthe leak amount from the lift port.

Note:If the natural forward tilt is great even though the oil leakamount is within the standard, either the tilt lock valve orthe tilt cylinder packing is defective.

4-1

4

OIL CONTROL VALVEPage

GENERAL (W/SAS AND L/SAS).........................4-2SPECIFICATIONS................................................4-7COMPONENTS ....................................................4-7OIL CONTROL VALVE ASSY .............................4-8

REMOVAL · INSTALLATION..................................4-8DISASSEMBLY · INSPECTION · REASSEMBLY ......4-9

RELIEF PRESSURE ADJUSTMENT.................4-14LIFT LOCK RELEASE BOLT ............................4-16

4-2

GENERAL (W/SAS AND L/SAS)

T2

R PX1

C1

X2 X3

C3

X4C5

C4C2X4X3X2

X1

OUT

T1

4-3

4

X1-X1

X2-X2

Flow divider valve

Relief valve

Unloading SOL

Lift lock SOL

Lower limit switch

Lift spool

Manual down valve

4-4

X3-X3

X4-X4

Tilt control SOL

Tilt spool

Backward tilt limit switch Forward tilt limit switch

Attachment spool

4-5

4

Solenoid Connector

Lift limit switch connector

Lift lock solenoid connector

Unload solenoid connector

Tilt control solenoid connector

Tilt limit switch connector

4-6

Hydraulic Circuit Diagram

(1)

(2)

(3)

(1) Unloading SOL

(2) Lift lock SOL

(3) Tilt control SOL

R: Gauge port

T2 R

P

OUT

C1

C2

C3

C4

C5

T1

4-7

SPECIFICATIONS

COMPONENTS

Vehicle modelItem

Pn 1 · 2 ton series Cu 2 · 3 ton series Pn 3 ton series

Type Add-on type

Relief set pressure Lift 18.7 (191)[2720] ←

MPa (kgf/cm2 [psi]) Tilt 15.7 (160)[2280] ←

Flow divider valve frow ratel/min (US gal/min) 13.0 (3.43) Pn 15.2 (4.02)

Others Built-in frow divider valve ←

6705

4-8

OIL CONTROL VALVE ASSYREMOVAL · INSTALLATION

T=N·m (kgf·cm) [ft·lbf]

Removal Procedure1 Remove the toe board.2 Remove the lower panel. 3 Remove the instrument panel RH. 4 Disconnect the lever rod.5 Disconnect the piping.6 Disconnect the connector.7 Remove the oil control valve W/bracket.

(Carefully operate so as not to damage the limit switch under the oil control valve.)8 Remove the oil control valve.9 Remove the fitting.

Installation ProcedureThe installation procedure is the reverse of the removal procedure.

Note: After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.

6

5

75

T=61 (620) [44.9]

5

4-9

DISASSEMBLY · INSPECTION · REASSEMBLY

Note: • Select a clean location for operation.• Since each part is finished with high precision, carefully operate so as not to damage it.

T=N·m (kgf·cm) [ft·lbf]

Disassembly Procedure1 Remove the lift solenoid. [Point 1]2 Remove the lift limit switch and spring cover. [Point 2]3 Remove the lift spool. [Point 3]4 Remove the tilt solenoid. [Point 4]5 Remove the tilt limit switch and spring cover. [Point 5]6 Remove the tilt spool. [Point 6]7 Remove the unload solenoid. [Point 7]8 Remove the flow divider valve. [Point 8]9 Remove the relief valve. [Point 9]10 Remove the attachment valve.11 Remove the rod bolt and the housing.

Reassembly ProcedureThe assembly procedure is the reverse of the disassembly procedure.

Note: Thoroughly wash each part, remove dirt by blowing compressed air, and apply hydraulic oil beforeassembly.

2

2

1

3

44

4

5

5

5

6

7

9

8

9

8

10

10

11

11

T=39.2 (400) [28.9]

4-10

Point Operations[Point 1]

Disassembly: Provide a match marks on each solenoid to ensure installationin the correct position.

Inspection:Check the lift solenoid for continuity.

Inspection:Check the filter for any clogging and clean it if clogged.

Inspection:Check the orifice for any clogging and clean it if clogged.

Reassembly: Assemble while checking match marks. Carefully preventincorrect installation of each solenoid spool.

[Point 2]

Inspection:Check the lift limit switch for continuity.

4-11

[Point 3]

Disassembly-assembly:Remove the compression spring from the lift spool.

SST 09610-10161-71Use the SST with a washer.

[Point 4]

Inspection:Check the tilt solenoid for continuity.

Inspection:Check the filter for any clogging, and clean it if clogged.

Inspection:Check the orifice for any clogging, and clean it if clogged.

Reassembly: Carefully prevent incorrect installation of each solenoid spool.

[Point 5]Inspection:

Check the tilt limit switch for continuity.Forward tilting side (between terminals 1 and 2): No continuity when the switch is pressed.

Backward tilting side (between terminals 3 and 4): No continuity when the switch is pressed.

Reassembly:Carefully prevent confusion between forward and backward tiltlimit switches.

Washer

SST

4-12

[Point 6]

Disassembly-assembly:Remove the compression spring from the tilt spool.

SST 09610-10161-71Use the SST with a washer.

[Point 7]

Inspection:Check the unload solenoid for continuity.

Inspection:Check the filter for any clogging and clean it if clogged.

[Point 8]

Inspection:Check the orifice for any clogging and clean it if clogged.

[Point 9]

Inspection:Check the filter for any clogging, and clean it if clogged.

Washer

SST

4-13

Reassembly:When the relief valve is disassembled, temporarily install it aftersetting the nuts as illustrated.

a = 27.0 mm (0.62 in)a

4-14

RELIEF PRESSURE ADJUSTMENTNote: • Since the relief valve is structured in two stages, always adjust the relief pressure in the correct order: the

lift (high pressure) side first and the tilt (low pressure) side later. (If the lift side is normal and the tilt sideis abnormal as the result of relief pressure inspection, it is allowed to adjust only the tilt side pressure.)

• Always adjust the relief pressure as described below. Thoughtless adjustment may give rise to a highpressure, possible damaging the hydraulic equipment such as the oil pump.

• Make sure that the no-load maximum speed is as specified before the adjustment operation.1. Install an oil pressure gauge.

Remove the oil pressure detection port plug installed on the leftside of the oil control valve, and install the oil pressure gauge.

Plug size: 9/16-18UNFFitting size: 9/16-18UNF PF1/4Fitting: 90407-13469-71

2. Set adjusting screw A and adjusting sleeve B of the reliefvalve as follows:

(1) Loosen lock nut 1 and fully tighten adjusting screw A.Then loosen it by one to two turns.

(2) Loosen lock nut 2, and position adjusting sleeve B tosatisfy the following dimension:

a = 27 mm (0.62 in)

3. Start the engine and check for any oil leak or abnormal noise.4. Adjust the lift side relief pressure.

(1) Turn the seat switch to ON. (Operate by two persons withone on the operator's seat)

(2) Operate the lift lever to raise the fork to the uppermostposition.

(3) With the engine running at the maximum speed, operatethe lift lever to the lift side. Gradually tighten adjustingsleeve B to adjust the oil pressure in the relief state tosatisfy the standard below for adjustment, and fix it byturning lock nut 2.

5. Adjust the tilt side relief pressure.(1) Turn the seat switch to ON. (Operate by two persons with

one on the operator's seat.)(2) Operate the tilt lever to tilt the mast fully backward.(3) With engine running at the maximum speed, operate the

tilt lever to the backward side. Gradually tighten adjustingscrew A to adjust the oil pressure in the relief state tosatisfy the standard below. Then fix the position bytightening lock nut 1.

6. Turn the key switch to OFF.7. Remove the oil pressure gauge and tighten the plug.

Fitting

9/16-18UNF

a

Adjusting screw A

Adjusting sleeve B

Lock nut 2

Lock nut 1

4-15

StandardsUnit: MPa (kgf/cm2) [psi]

Standards All models

Lift side relief pressure 18.7 (191 )[2720 ]

Tilt side relief pressure 15.7 (160 )[2280 ]

+1.70

+170

+2400

+1.70

+170

+2400

4-16

LIFT LOCK RELEASE BOLTT=N·m (kgf·cm) [ft·lbf]

When the forks do not descend, due to a malfunction or other cause, loosen the lift lock unlocking bolt to lower theforks in emergencies.

After the repair, tighten it appropriately.

Lift lockunlocking boltT = 28.8~35.2 (294~359) [21.3~26.0]

5-1

5

SASPage

TROUBLESHOOTING .........................................5-2TROUBLESHOOTING BY ERROR CODE................5-3TROUBLESHOOTING BY PHENOMENON ..............5-7

CONNECTOR LAYOUT (SAS, OPS).................5-12CONTROLLER SEQUENCE (SAS, OPS) .........5-13CONNECTOR DIAGRAMS (SAS, OPS)............5-14

5-2

TROUBLESHOOTINGTroubleshooting is described only for the portion changed by adoption of the OPS.

List of Reference Pages for Error Codes and Sub Error Codes

List of Pages to be Referenced by Phenomenon

Without analyzer (SST) With analyzer (SST)

Error code Error description Page Error code Error description Page

63 Tilt lever switch abnormality 5-3

63-1 Tilt lever switch simultaneous ON 5-3

63-2 Forward tilt switch short circuit for 2 minutes 5-3

63-3 Backward tilt switch short circuit for 2 minutes 5-3

64 Tilt solenoid abnormality 5-5 64-1 Tilt solenoid abnormality 5-5

DescriptionPage to be referenced

Without analyzer With analyzer

Act

ive

mas

t fu

nctio

n co

ntro

ller The active mast rear tilt speed control is not regulated, or the

backward tilting speed is always slow. 5-7 5-10

The mast does not perform front tilt. See "The mast does not tilt forward" section in OPS Troubleshooting.

5-3

5

TROUBLESHOOTING BY ERROR CODEError code 63 (Tilt lever switch abnormality)Error code 63-1 (Both tilt lever switches ON at the same time)Error code 63-2 (Forward tilt switch 2-minute short circuit)Error code 63-3 (Backward tilt switch 2-minute short circuit)

Related Portion

Estimated Causes:

* After the ignition switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward. Makesure that the 2-minute waiting OPS lamp blinks when the tilt lever is on the neutral position.

Connector contact defect Backward tilt switch defect Harness defect Tilt switch installation defect Forward tilt switch defect Controller defect

TAB

RE

C

TAB

RE

C

RE

CTA

B

RE

CTA

B

SA

S c

ontr

olle

r

CN1-10 (MF, Forward tilt switch)

CN1-9 (MR, Backward tilt switch)

CN1-23 (E02, SW-GND)

CN46-10

J1

CN45-22CN45-21

CN45-20

CN45-17

CN45-24

CN45-25

CN34-1CN34-2

CN34-3

CN34-4

OP

S c

ontr

olle

r

Forward tilt switch

Backward tilt switch

Check CN1, CN45 and CN46 for any disconnection or internal wetting.

After correction, check the indication by the SAS lamp. *

Error code 63


Perform troubleshooting for error code 2 for the OPS controller. For this defect, the SAS lamp blinks instead of the OPS lamp.

Harness defect

NG

OK

NG

OK

Inspection 1:Check the wiring between the tilt lever switch and the OPS controller for continuity.

SAS controller defectOK

NG

5-4

Inspection 1:

Check continuity through the tilt lever switch wiring.Turn the ignition switch OFF and disconnect CN1.

Standard:

Inspection 2:

Check continuity between CN1 and CN45.Turn the key switch OFF and disconnect CN1 and CN45.

Standard:CN1-10 ~ CN1-9 : No continuityCN1-10 ~ CN1-23 : No continuityCN1-9 ~ CN1-23 : No continuityBetween CN1-10 and frame : No continuityBetween CN1-9 and frame : No continuity




Digital typeCN1-10 (+) ~ CN1-23 (-) No continuity Continuity No continuity

CN1-9 (+) ~ CN1-23 (-) No continuity No continuity Continuity

Analog type CN1-10 (-) ~ CN1-23 (+) No continuity Continuity No continuity

CN1-9 (-) ~ CN1-23 (+) No continuity No continuity Continuity

CN1 (REC)

CN1 (REC)

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

5-5

5

Error Code 64 · 64-1 (Tilt solenoid abnormality)

Related Portion

Estimated Causes:

* After correction, check the indication by the SAS lamp.

Start the engine and operate for forward/backward tilting to check if the SAS lamp blinks. The SAS lamp must not blink.

Connector contact defect SAS controller defect Harness defect OPS controller defect

RE

CTA

B

RE

CTA

B

RE

CTA

B

TAB

RE

C

SA

S c

ontr

olle

r

CN1-13 (TILT, Tilt solenoid)

CN1-24 (E1, main GND) CN46-8

CN46-9

(E3, body ground)

CN12-2

CN12-1

CN45-5

CN45-29CN45-30

CN45-12

OP

S c

ontr

olle

r

Tilt solenoid

Check CN1, CN45 and CN46 for any disconnection or internal wetting, and disconnected the body ground.

After correction, check the indication by the SAS lamp.*

Inspection 2:Measure the resistance between input pins of OPS controller.



NG

OK

NG

NG

OK

Inspection 1:Check continuity between CN1 and CN45. Harness defectNG

OK

5-6

Inspection 1:

Check continuity between CN1 and CN45.Key switch OFF, CN1 and CN45 disconnection.(Keep CN46 connected and also keep the body ground connected to the frame.)


CN1-13 ~ CN45-5: ContinuityCN1-24 ~ CN45-29: ContinuityCN1-24 ~ CN45-30: Continuity

• GND fault checkCN1-13 ~ CN1-24: No continuity

• +B shorting checkCN45-5 ~ CN45-32: No continuity

• Ignition line shorting checkCN1-13 ~ CN1-11: No continuity

Inspection 2:

Measure the resistance between input pins of the OPS controller.Key switch OFF, CN45 disconnection.

Standard:CN45-4 ~ CN45-31: Approx. 800Ω (at 20°C)

CN1 (REC)

13 12111098765432114 15 16 17 18 2625242322212019

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN45 (TAB)

32 31 26 23 17

16 11 10 8 1345912131415

30 29 25 24 22 21 20

267

28 27 19 18

5-7

TROUBLESHOOTING BY PHENOMENON

The mast backward tilting speed is always slow or unrestrected.

Related Portion

Active fork leveling switch

Con

trol

ler

(MN Tilt knob SW)

Act

ive

fork

leve

ling

switc

h

(E02 SW-GND)

Lifting height switch

Con

trol

ler (MH1, Lifting

height sensor 1)

(MH21, Liftingheight sensor 21)

Lifti

ng h

eigh

t sw

itch(E02, SW-GND)

5-8

OK

Stopping with automatic leveling occurs upon automatic leveling switch operation when the fork is raised to approx. 500 mm (19.6 in) without a load.

Without analyzer

Check connectors CN1 and CN33 for disconnection or internal wetting.

Inspection1Check the automatic leveling switch wiring for continuity.

Inspection 2Check continuity of the automatic leveling switch alone.

Inspection 3Check continuity between CN1 and CN33.

CN33 connector defect.

Fork height switch abnormality.

Check if the backward tilting speed is normal after the repair.

Controller defect.

Automatic leveling switch defect.

Harness defect.

OK

OK

OK

OK

NG

NG

NG

NGNG

NG

NO YES

NG

OKPerform troubleshooting for "The mast backward tilting speed is always slow or unrestricted". (P. 1-52).

Stopping with automatic leveling occurs when tilted forward (without pressing the automatic leveling switch) when the fork is raised to approx. 500 mm (19.6 in) without a load.

Inspection 4Check continuity of the fork height switch alone.

5-9

Inspection 1:

Check continuity of the active fork leveling switch wiring.Key switch OFF, CN1 disconnection.

Standard:

Inspection 2:

Check continuity of the active fork leveling switch only.Switch OFF, CN33 disconnection.

Standard:

Inspection 3:

Check continuity between CN1 and CN33.Turn the key switch OFF and disconnect CN1 and CN33.

Standard:CN1-8 ~ CN33-1: ContinuityCN1-23 ~ CN33-2: Continuity

Inspection 4:

Check continuity of the lifting height switch only.Key switch OFF, CN31 disconnection.

Standard:

Active fork leveling switch free Active fork leveling switch depressed


Active fork leveling switch free

Active fork leveling switch depressed


Low lifting height High lifting height



CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)

CN31 (REC)

5-10

Inspection 1

Check the output signal of the active fork leveling switch.Turn the key switch ON (with the engine in stopped state).Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA

Standard:



KNOB OFF ON

OK

With analyzer

Inspection 1Check the output signal of the active fork leveling switch.

Check for slip off of the CN1 and CN33 connectors.

Inspection 2Check continuity of the active fork leveling switch wiring.

Inspection 3Check continuity of the individual active fork leveling switch.

Inspection 4Check continuity between CN1 and CN33.

CN33 connector defect.

Inspection 5Check the output signal of the lifting height switch.

Inspection 6Check continuity of the individual lifting height switch.

After correction, check the backward tilting speed.

CN1 connector or controller defect

Active fork leveling switch defect

Harness defect

OK

OK

OK

OK

NG

NG

NG

NG

NG

NG

NG

Controller defect.

OK

Lifting height switch defectNG

Perform troubleshooting for "The mast backward tilting speed is always slow or unrestricted". (P. 1-52).

OK

5-11

Inspection 2:

Check continuity of the active fork leveling switch wiring.Key switch OFF, CN1 disconnection.

Standard:

Inspection 3:

Check continuity of the active fork leveling switch only.Key switch OFF, CN33 disconnection.

Standard:

Inspection 4:


Standard:CN1-8 ~ CN33-1: Continuity

CN1-23 ~ CN33-2: Continuity

Inspection 5:

Check the output signal of the lifting height switch.Turn the key switch ON (start the engine).Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA

Standard:When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SW1: ONSW21:OFFSW22:OFF

Inspection 6:

Check continuity of the lifting height switch only.Key switch OFF, CN31 disconnection.

Standard:







Low lifting height High lifting height



CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)

CN31 (REC)

5-12

CONNECTOR LAYOUT (SAS, OPS)

TABREC

TABREC

RECTAB

TABREC

TABREC

TAB

RE

C

TABREC

RECTAB

RECTAB

RECTAB

RECTAB

TABREC

TABREC

TABREC

TABREC

PRES SSR

CN26TABREC

RECTAB CN3

CN22CN41 CN42 CN43

SPD SSR

TABREC CN47

UNLORDSOL

TABREC CN51

OPS BZR(Export model)

TABREC CN54

SFT SOL

TABREC CN55

DIODE A

FPC

SAS BZR

COMB METHOUR METSAS LPSWN LOCP LP

SASCONTROLLER

CN1 CN2

TABREC

OPSCONTROLLER

CN45

CN48 CN12 CN34

NTRLTILT SW

CN33

OPS-LAMPRLY

(OPS R/B)

CN27

CN31

MAST SW1

DOWNLOCKSOL

RECTAB

CN49

LIFTSW

TILTSOL

TILT SW1TILT SW2

CN37

HOURMET CNN

TABREC

CN46

CN35

SAS RE-SETTINGCN

CN44

CN4 RECTAB

CN65

CN5

DIAG SW(CHKR)

FR W/H

E/G W/H

TILT AGLSSR

CN6

SAS-LAMP RLY(R/B)

SIDEW/H

RE

CTA

B

RR LWRW/H

CN7 SWN SOL

CN11

FR

W/H

SID

E W

/H

TABREC CN8 TAB

REC CN9

BODY EARTH03

RE

CTA

B

SIDEW/H

TAB

RE

C

HOODW/H

CN50

EZ R/SFT RLY

EZ F/SFT RLY

TAB

RE

C

CN52

T/C FR RLYT/C RR RLY(T/C R/B)

TAB

RE

C

CN57

SEAT SW

CN60RECTAB

W/H: Wire harness

5-13

CONTROLLER SEQUENCE (SAS, OPS)

5

43

10

7CN525

29

8

63

7

8

5

2

4

111

CN63

+-

OPS CONTROLLER

EZ MAINRELAY

STARTERRELAY

PARKINGSWITCH

DIRECTIONSWITCH RR

DIRECTIONSWITCH FR

EZ RR SFTRELAY

EZ FR SFTRELAY

DR

R

RY

R

DR

F

RY

F

SH

IFT

SO

LEN

OID

RB

T/C RRRELAY

SH

IFT

SO

LEN

OID

FB

T/C FRRELAY

TO E03

DIODE A

JOINT4 JOINT3

CN

68

6C

N6

CN

610

5C

N6

JOIN

T2

JOINT1

DIODE A

JOINT3JOINT4

W/SPLICE-A

W/S

PLI

CE

-Y

W/SPLICE-Z

W/S

PLI

CE

-C

SFT (7.5A)

BU

S B

AR

BZ

O

OPS BUZZER(EXPORT MODEL)

SO

L3

DM

I

DG

ND

DM

O

RY

F

E03

E2

DR

F

RY

R

DR

R

E3

SIL

IG

RY

LP

SO

L2

DO

WN

E3

IG

SO

L1

TF

I

TR

I

TC

ON

TF

O

TR

O

TG

ND

SP

I1

BATTBCON

BCIN

SP

I2

OPS CONTROLLER

SILP

LUG

-IN

AN

ALY

ZE

R

IG

E0

TRG

CHKR

SAS-LAMPRELAY

OPS-LAMPRELAY

EZ PEDAL

ECU-B(7.5A)

SAS SYSTEM

UN

LOA

DS

OLE

NO

ID

LIF

T S

WIT

CH

DO

WN

LO

CK

SO

LEN

OID

E1

RLY

HR

M2

SIL

IG

HR

M3

HR

M1

E02

YAW RATESENSOR

+-

SW

2D

IAG

CO

NN

EC

TO

R

See Table1.

MN

NE

UT

RA

LT

ILT

SW

ITC

H

T/C FRRELAY

T/C RRRELAY

SO

LEN

OID

RB

OU

T1

SO

LEN

OID

FB

SHIFT LEVER

SAS CONTROLLER

MH

22

MH

21

MH

1

SA

S R

E-S

ET

TIN

GC

ON

NE

CT

OR

SW

1

MF

MR

TIL

T S

WIT

CH

FB

SE

AT

SW

ITC

H

TIL

T

ST

RG

SW

N

TIL

TS

OLE

NO

ID

SWINGSOLENOID

SPEEDSENSOR

SPEEDCONTROLLER

YB

1

TR

G

TIL

T A

NG

LES

EN

SO

R

COMBINATION METER

L

OPS LAMP

L

LOCKINDICATOR

SASWARNINGLAMP

L

SP

D

SP

DF

SP

D+

SP

D-

ECU-IG (7.5A)

GAUGE (10A)

FL AM1(40A)

IG1

E01

MA

ST

SW

ITC

H

TIL

T S

WIT

CH

RB

5TT

5MA

MA

5SA

SA

5PR

S

PR

ES

SS

2

SS

C

SS

1

- +

PRESSSENSOR

5CN4

1CN3

2CN3

4CN37

CN3

10C

N5

11C

N5

1

CN4661

14 2

118

3

CN52

CN

65

CN

50

CN50

CN46

CN52

CN46CN46W/SPLICE-F

CN

46

CN

46C

N46

CN46

CN46 CN46 CN

46

CN52

CN52

CN52 CN52

CN52

CN57CN57

W/SPLICE-F

CN46 CN46

CN

58

(MH1)

(MH21)

(MH22)

(E02)

ATable 1

SAS spec.

(MH1)

(MH21)

(MH22)

SAS less spec.

(E02)

5-14

CONNECTOR DIAGRAMS (SAS, OPS)

CN2

8 7 6 5 4 3 2 113 12 11 10 9141516

TABNo. JC1 RLY2 -3 HRM14 SPD+5 SPD-6 SS17 SS28 5SA9 OUT110 SPDF11 HRM312 HRM213 SPD14 SSC15 YB116 TRG

13 121110987654321

14 15 16

RECNo. JC1 CN5-11L-W2 --3 CN41-4V-G4 CN22-1G-B5 CN22-2G-R6 --7 --8 --9 CN42-9L-O10 CN6-5P-B11 CN42-12P-L12 CN41-3V-R13 G-B14 --15 --16 CN44-14L-B

CN1

13 12 11 10 9 8 7 6 5 4 3 2 1

141516171826 25 24 23 22 21 2019

TABNo. JC1 5PRS2 SIL3 MH14 MH215 MH226 SW27 SW18 MN9 MR10 MF11 IG12 TLT213 TLT114 5MA15 5T16 YR17 MA18 PRES19 -20 T21 SA22 E0123 E0224 E125 SWN26 STRG

13 12111098765432114 15 16 17 18 2625242322212019

RECNo. C1 G-2 V3 L-4 L-B56 LG-B7 LG8 P-G9 Y-B10 Y11 B-R12 -13 L-14 G-R15 -16 -

Y-GG-Y

---

BR-BR-W-BL-B

-

17181920212223242526

JCN3-1

CN46-3CN3-7CN3-4

CN44-23CN35-1CN33-1

CN45-21CN45-22

W/SPLICE-Y(IG)-

CN45-5CN27-1

--

CN27-2CN3-2

---

W/SPLICE-AW/SPLICE-A

BODY EARTH05CN4-7

-

L-W CN3-5

*

5-15

Note:*: Terminal not related to SAS and OPS.

CN5

TABNo. JC1 *R-L2 *R-B3 *R-W4 *G-Y5 *R-G6 *W7 *LG-B8 BODY EARTH 05G9 CN45-32G-W10 CN41-1P-G11 CN2-1L-W

12BODY EARTH 02 or

W-B or B

5678

1234

9101112

RECNo. JC1 *R-L2 *R-B3 *R-W4 *G-Y5 *R-Y6 *W7 *LG8 *-9 *-10 SAS-LAMP RLY(B)P-G11 SAS-LAMP RLY(+S)L-W12 ST RYL(-S) or SAS-LAMP RLY(L)W-B

8765

4321

1211109

8

4

7 6 5

3 2 1

CN3

RECNo. JC1 CN26-3G2 CN26-2G-Y3 CN31-1BR-W4 CN31-3L-B

5 CN26-1BR

6 --7 CN31-2L8 --

1 2 3

5 6 7

4

8

TABNo. JC1 CN1-1G2 CN1-18G-Y3 W/SPLICE-A(E)BR4 CN1-4L-B

5 W/SPLICE-A(E)BR

6 --7 CN1-3L8 --

CN4

RECNo. JC1 *Y-B2 *Y3 *Y-G4 *B-L5 *L-B6 CN45-23G-W

1 2

TABNo. JC1 --2 *Y3 *Y-G4 *B-L5 CN7-1L-B6 CN50-1G-W

5

2 1

L-W CN1-5 L-W *

6

3

544

3

6

DIODE STBODY EARTH 04 or

5-16

CN7

2 1

TABNo. JC1 CN4-5L-B2 BODY EARTH 03W-B

21

RECNo. JC1 CN11-1L-B2 CN11-2W-B

TABNo. JC1 *B-2 *B-W3 W/SPLICE-Y (IG)B-R4 *B-W5 *R6 *B-Y7 *LG-R8 *L9 --10 *W-L11 --

123

4

7

910

65

8

11

RECNo. JC1 *B-2 *B-W3 F=ECU-IG (L) B-R4 *B-W5 --6 *B-Y7 --8 *L9 --

10 *W-L11 --

1 2 3

4

7

9 10

65

8

11

CN6

TABNo. JC1 Phorting: (+)-2 Phorting: (-)-

12

RECNo. JC1 CN7-1L-B2 CN7-2W-B

1 2

CN11

TABNo. JC1 Phorting: (+)R2 Phorting: (-)B

12

RECNo. JC1 CN45-12GR-R2 W/ SPLICE-Z (E)W-B

1 2

CN12

TABNo. JC1 +S2 -S

12

RECNo. JC1 CN2-4G-B2 CN2-5G-R

1 2

CN22

CN8

RECNo. JC1 *P2 --3 SAS LAMP RLY(L)W-B4 *Y-B5 *L6 --

1 2

TABNo. JC1 *P-B2 *R-W3 OPS LAMP RLY(L)W-B4 *Y-B5 *G-B6 --

5

2 1

6

3

544

3

6

5-17

CN26

123

TABNo. JC123

---

GND (Ground) Vout (output)

Vcc power supply

321

RECNo. C1 BR2 G-Y3 G

JCN3-5CN3-2CN3-1

CN27

123

TABNo. JC123

---

Power supplySensor output

GND

321

RECNo. C1 G2 Y-G3 BR

JCN1-14CN1-17

W/SPLICE-A

CN31

123

TABNo. JC123

BR-WL

L-B

CN3-3CN3-7CN3-4

321

RECNo. C1 BR2 W3 R

JCOMNCNO

CN34

1

3

2

4

TABNo. JC123

RBRR

4 B

Forward tilt side (+)Forward tilt side (-)

Backward tilt side (+)Backward tilt side (-)

2

4

1

3

RECNo. C1 P-G2 BR-W3 P-L

JCN45-25JOINT 1CN45-24

4 BR-W JOINT 1

CN33

12

TABNo. JC12

BRBR

5V or GNDGND or 5V

21

RECNo. C1 P-G2 BR

JCN1-8

W/SPLICE-A

CN35

1

TABNo. JC1 BR-

1

RECNo. C1 LG-

JCN1-7

5-18

CN42

1 2 3 4 7 8 9 10 11 12 135 6

RECNo. JC1 *V-G2 *LG-B3 BODY EARTH02W-B4 *R-W5 --6 *R-G7 *Y-B8 *R-9 CN2-9L-O10 --11 *R-L12 CN2-11P-L13 BODY EARTH02W-B

CN41

1 2 3 4 7 8 9 10 11 12 135 6

RECNo. JC1 CN5-10P-G2 *Y-R3 CN12-2V-R4 CN2-3V-G5 *-6 CN37-2Y-B7 BODY EARTH02W-B8 *V-9 --10 *LG-R11 *Y-G12 OPS-LAMP RLY (B)G13 *Y-

CN37

2 1

TABNo. JC1 CN5-10P-G2 BODY EARTH02W-B

1 2

RECNo. JC1 CN43-1L-W2 CN41-6Y-B

CN44

1

7

12

2

8

13

3

9

14

54

10

1615

6

11

17

18

2019

21 2322

RECNo. J1 JOINT 2 or CN46-32 *3 W/SPLICE-B(E):::::

12 W/ SPLICE-Y (IG) 13 *14 CN2-16::

22 W/ SPLICE-A (E)23 CN1-6

CV-

BR-W

B-R

L-B

BRLG-B

SAS Lamp relay (Base side)

3(B)

5

1 4 2(+S) (L) (-S)

No. JC1 CN5-11L-W2 F=ECU-IGB-R3 CN5-10P-G4 CN5-12,CN8-3W-B5 --

CN43

2 1

TABNo. JC1 GNDB2 Power supplyR

21

RECNo. JC1 SAS relayL-W2 FuseR-G

5-19

CN45

32 31 26 23 17

16 11 10 8 1345912131415

30 29 25 24 22 21 20

267

28 27 19 18

TABNo.1234567891011121314151617181920212223242526

JCSIL

-DRFDRR

TCON--

RYLPBZORYFRYRSOL3SOL2SOL1

IGIG2E03

--

TGNDTROTFODMITRITFI

DOWN27 -28 -29 E330 E331 E232 BATT

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

RECNo.1234567891011121314151617181920212223242526

JCN46-3

-CN46-1CN46-11CN1-13

--

OPS-LAMP RLY (-S)CN51-2

T/C FR RLY (+S)T/C RR RLY (+S)

CN12-1CN48-1CN47-1CN46-5CN46-4CN46-6

--

CN46-10CN1-9

CN1-10CN4-6

CN34-3CN34-1CN49-1

CV-

G-RRL--O

W-GG

Y-RGR-RGR-LGR-GB-RB-R

BR-W--

BRY-BY

G-WP-LP-GP-B

27 --28 --29 CN46-9W-B30 CN46-8W-B31 CN46-2W-B32 CN58-9W-R

CN46

1 2 4

11106

3

8 9

5

7

RECNo.1234567891011

JT/C FR RLY (B)

BODY EARTH10CN1-2 or CN44-1W/SPLICE-Y (IG)W/SPLICE-Y (IG)T/C RR RLY (-S)

-W/SPLICE-Z (E)W/SPLICE-Z (E)W/SPLICE-A (E)T/C RR RLY (B)

CG-RW-B

VB-RB-R

BR-W-

W-BW-BBRR

11 10 6

4 2 135

89 7

TABNo.1234567891011

JCG-RW-B

VB-RB-R

BR-W-

W-BW-BBRR

CN45-3CN45-31CN45-1

CN45-16CN45-15CN45-17

-CN45-30CN45-29CN45-20CN45-4

5-20

CN54

21

REC

No. C1 L-W2 L-R

JCN52-5CN52-7

2 1

TAB

No.12

JC--

No. C12

JFBRB

CN52

1 2 3

5 6 7

4

8

REC

*

No. C1 Y-R2 G3 R-Y4 G-W5 L-W6 -7 L-R8 W-B

J**

BODY EARTH02T/C RR RLY (L)

-T/C FR RLY (L)

*

8

4

7 6 5

3 2 1

TAB

*

No. C1 Y-R2 G3 L-B4 L5 L-W6 -7 L-R8 W-B

J**

W/SPLICE-F (E)CN54-2

-CN54-1

*

CN53

76321

10 11 12 14 15 1613

4 5 8 9

1817

1718

9 8 5 4

1316 15 14 12 11 10

12367

(RH SHIFT LEVER)

(LH SHIFT LEVER)

RECNo.12345678910111213141516

CR

R-YB/B-Y

-G-R

LB-WR-G

----------

1718

JT/C RR RLY (B)

**-

T/C FR RLY (B)CN6-8

**----------

CN48

21

RECNo. C1 GR-L2 W-B

JCN45-13

W/ SPLICE-Z (E)

2 1

TABNo.12

JCWW

No. C12

J--

CN49

1 2

RECNo. C1 P-B2 BR-W

JCN45-26JOINT1

12

TABNo.12

JCRB

No. C12

J--

CN50

1 2

RECNo. C1 G-W2 BR

JCN60-1CN60-2

12

TABNo.12

JCG-WBR

No. C12

JCN4-6

CN65-14

CN47

21

RECNo. C1 GR-G2 W-B

JCN45-14

W/ SPLICE-Z (E)

2 1

TABNo.12

JCWW

No. C12

J--

CN51

1 2

RECNo. C1 B-R2 W-G

JW/SPLICE-Y (IG)

CN45-9

12

TABNo.12

JC--

No. C12

J--

5-21

CN57

123

456

TABNo. C1 R-W2 B3 G-R4 R-G5 B-W

J**

SFT SOL RLY (FR) (NO)**

6 R SFT SOL RLY (RR) (NO)

654

321

RECNo. C1 R-W2 B3 G-R4 R-G5 B-W

J**

T/C FR RLY (B)**

6 R T/C RR RLY (B)

CN60

2 1

TABNo.1 G-W2 BR

JCN50-1CN50-2

C

21

RECNo. C1-2-

J+-

CN58

TAB

*

No. C1 B-L2 B-O3 V-G4 B5 W-R6 B-Y7 G8 W-B

J**

***

CN45-32*

1234

5678

REC

*

No. C1 B-L2 B-O3 V-G4 B5 W-R6 B-Y7 G8 W-B

J**

***

F=ECU-B*

4321

8765

CN65

RECNo. JC1 *B-O2 *G3 *G-R4 *G-W5 *G-O6 *G-Y7 *G-B8 *B-Y9 *R-Y10 *V11 *V-W12 *B13 R-G14 JOINT 1BR

*

1314

1 2 3 4 5 6

8 9 10 11127

TABNo. JC1 *2 *3 *4 *5 *6 *7 *8 *9 *10 *11 *12 *13 *14 CN50-2

8 7

6 5 4 3 2 1

13 12 1110 914

B-OG

G-RG-WG-OG-YG-BB-YR-YV

V-WB

R-GBR

OPS-LAMP RLY (Base side)

RECNo. C1 O2 B-R3 W-B4 G5 -

JCN45-8

W/SPLICE-Y (IG)CN8-3

CN41-12-

1 2

3

5

4

T/C FR RLY (Base side)

RECNo. C1 BR-W2 G3 L-W

4 G-R

JT/C RR RLY (-S)

CN45-10CN52-5CN46-1,

CN53-5 or CN57-35 - -

1 2

3

5

4

T/C RR RLY (Base side)

No. C1 BR-W2 Y-R3 L-R

4 R

JT/C FR RLY (-S),CN46-6

CN45-11CN52-7

CN46-11,CN53-1 or CN57-6

5 - -

REC

1 2

3

5

4

1

4

2 3

5

EZ FR SFT RLY

RECNo. C1 W-L2 L-B3 G-R4 W-B5 G-W

J**

CN57-3**

1

4

2 3

5

EZ RR SFT RLY

RECNo. C1 W-G2 L-B3 R4 W-B5 G-W

J**

CN57-6**

CN55

1 2 3

REC

3 L-R JOINT3

No. C1 L-W2 W-B

JJOINT4

W/SPLICE-F (E)

123

TABJ

--

No. C12

J+-

3 - +

6-1

6

APPENDIXPage

SST LIST ..............................................................6-2SERVICE STANDARDS LIST..............................6-3WIRING DIAGRAM ..............................................6-4

6-2

SST LIST : Newly adopted SST

Illust. Part number Part nameSection

1 4

09240-23323-71 Plug-in analyzer

09610-10161-71 Oil control valve spring remover and replacer

6-3

6

SERVICE STANDARDS LIST

METERIAL HANDLING SYSTEM

OIL CONTROL VALVE

Natural drop test

Natural drop mm (in) Limit W/SAS, L/SAS: 45 (1.77)

Natural forward tilt test

Natural forward tilt mm (in)

Pn1 ton series Standard W/SAS, L/SAS: 15 (0.59) or less

Pn ⋅ Cu2 ton series Standard W/SAS, L/SAS: 20 (0.79) or less

Pn ⋅ Cu3 ton series Standard W/SAS, L/SAS: 25 (0.98) or less

Oil leak test

Lift cylinder oil leak amount cm3 (in3) Standard W/SAS, L/SAS: 8 (0.49) or less

Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3) Standard W/SAS, L/SAS: 16 (0.98) or less

OIL CONTROL VALVE

Relief set pressureMPa (kgf/cm2)[psi]

Lift Standard 18 .7 (191 )[2720 ]

TiltPn1 ⋅ Pn 2ton series and Cu2 ⋅ Cu 3ton series Standard 15 .7 (160 )[2280 ]

Pn3ton series Standard 14 .7 (150 )[2130 ]

+1.70

+170

+2400

+1.70

+170

+2400

+1.70

+170

+2400

6-4

WIRING DIAGRAM

Note: This manual shows only the wiring diagrams revised in August 2005. As for wiring diagrams not shownherein, refer to 7FGU/7FDU15-32 and 7FGCU20-32 Repair Manuals (Pub. Nos. CU027, CU027-1 and CU027-2) and Parts & Service News, Ref. No. CB-4006 (issued in February 2004).

NAME G D LP G/LP GS DS LPS Page

BATTERY, RELAY BOX 6-5

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: 3-WAY CATALYTIC SYSTEM)

— — 6-6

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: LESS 3-WAY CATALYTIC SYSTEM)

— — 6-7

ELECTRIC SHIFT T/C, STARTING, GLOW, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (DIESEL ENGINE)

— — — — — 6-8

SAS AND OPS CONTROLLER 5-13

COMBINATION METER 6-9

COMBINATION METER (EZ PEDAL) — — — 6-10

3-WAY CATALYTIC SYSTEM (G, GS) — — — — — 6-11

3-WAY CATALYTIC SYSTEM (LP, LPS) — — — — — 6-12

3-WAY CATALYTIC SYSTEM (4Y-ECS, LP) — — — — — — 6-13

3-WAY CATALYTIC SYSTEM (G/LP) — — — — — — 6-14

6-5

6

BATTERY, RELAY BOX

SA

S W

AR

NIN

GLA

MP

RE

LAY

B-Y

BATTERY

W

W W V

US BAR

FL

HE

AD

40A

FL

AM

140

A

40A

FL

ALT

80A

W-L

BUS BAR

W-L

L-B

W-L

HE

AD

15A

TAIL

7.5A

STO

P7.

5A

R W

HE

AD

LP

RLY

TAIL

LP

RLY

R-L

GR-B

R-W

W B

B

W-L

G-Y

R-G

R-Y

G-W

L-W

B-R

W-L

AM

1

IG1

ST

1

IG S

W

FU

SE

ALT

-S

FU

SE

IGN

ALT

BS

IGL

B-Y

B-Y

B-Y

STA

RT

ER

RLY

GLO

W R

LY

DO

UB

LE

DO

UB

LE

DO

UB

LE

HO

RN

7.5

A

ALT

-S 5

A

GA

UG

E 1

0A

TU

RN

7.5

A

IGN

7.5

A

EC

U-I

G 7

.5A

SF

T 7

.5A

ST

7.5

A

B-Y

B-W

L B-W

B-R

HE

AD

LA

MP,

ME

TE

R IL

LUM

INAT

ION

TAIL

LA

MP

(O

PT

), C

LEA

RA

NC

E L

AM

P (

OP

T)

STO

P L

AM

P (

OP

T)

STA

RT

ER

ALT

ER

NAT

OR

SE

NS

ING

HO

RN

HO

UR

ME

TE

R, W

ATE

R T

EM

P IN

D, F

UE

L IN

DB

AC

K B

UZ

ZE

R (

OP

T),

BA

CK

UP

LA

MP

(O

PT

)

T/C

OIL

TE

MP

ER

ATU

RE

IND

ICAT

OR

(O

PT

)

TU

RN

SIG

NA

L LA

MP

(O

PT

)

ALT

ER

NAT

OR

, GLO

W P

LUG

TIM

ER

FU

EL

CU

T S

OL,

GA

SO

LIN

E S

OL,

LP

G S

OL

IGN

ITIO

N C

OIL

, VS

CS

EC

U (

OP

T)

SA

S E

CU

ELE

CT

RIC

SH

IFT

T/C

STA

RT

ER

RE

LAY

(C

OIL

)

EC

U-B

7.5

A

TW

C 7

.5A

W-R

L-O

OP

S C

ON

TR

OLL

ER

FL

GLO

W

B-R

GLO

W P

LUG

(U

L-D

, DS

)

TH

RE

E W

AY C

ATA

LYT

IC S

YS

TE

M

W-L

W

B-Y

B-W

B-O

RE

LAY

BO

X

DISCONNECT SW(L-GS,DS,LPS)

(UL-G,LP,G/LP)

6-6

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: 3-WAY CATALYTIC SYSTEM)

VF

2S

TV

RR

aV

F

F1

IG2

IG1

F2 N

Rr

R Ra

N

B-R

SOLENOID

BODY EARTH

W-B

Y

W-B

L-R

W-B

R BODY EARTH

SOLENOID

W-B

R-Y

R-W

BZR W-B

MOTION ALARM (OPT)

W-BR-Y

R-G

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W

B-W

B-W

ST7.5A

GAUGE10A

B

B-YSTARTER RELAY

STA

RT

ER

B

W-B

B-Y

B-LB-RB

B

B

W-B

B-Y

B-L

RLY2

LFC

STA

BO

DY

EA

RT

H

B-R

B

STARTER KEEPRELAY

SLOW SOLENOIDKEEP RELAY

T/C RRRELAY

T/C FRRELAY

W-B

PARKING BRAKE LAMP (OPT)

LOCK

RELEASE

L-R

L-W

R

G-R L-W

SH

IFT (LP,

LP

S)

CO

NT

RO

L S

W

RE

LAY

BO

X

RE

LAY

BO

X

B-Y

LL

R-G

W

W-L

B-Y

TW

C C

ON

TR

OLL

ER

W-L

B-Y

FL

HE

AD

40A

IG S

W

FL

ALT

80A

SFT7.5A

AM

1S

T1

IG1

FL

AM

140

A

B-R

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W B-W

ST7.5A

B-W B-R

B

B-W

L

RE

LAY

BO

X EZ

MA

IN R

ELA

Y

STA

RT

ER

RE

LAY

(+S

)

PK

B S

WIT

CH

EZ

PE

DA

L

B-Y

B-W

B-Y

IG S

W

SFT7.5A

AM

1S

T1

IG1

STARTER SUBRELAY

B-R

B

A

B

See pages 6-12 ,13 ,14.

6-7

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: LESS 3-WAY CATALYTIC SYSTEM)

B-R

SOLENOID

BODY EARTH

W-B

Y

W-B

W-B

R BODY EARTH

SOLENOID

W-B

R-WW-B

BZR

R L-R

MOTION ALARM (OPT)

W-BW-BR-Y

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W

B-W

ST7.5A

B

W-L

STARTER RELAY

STA

RT

ER

B

W-BW-B

BO

DY

EA

RT

H

B-R

B

R-G


R-Y

B

RE

LAY

BO

X

RE

LAY

BO

X

B-Y

L-W

L-W

L-R

LL

W

W-L

B-Y

B-W

B-W

B-W

W-L

B-Y

FL

HE

AD

40A

IG S

W

FL

ALT

80A

SFT7.5A

GAUGE10A

AM

1S

T1

IG1

FL

AM

140

A

LOCK

RELEASE

R-G

VF

2V

F

F1

ST

VR

Ra

IG2

IG1

F2 N

R Ra

Rr

N

G-R

SH

IFT

CO

NT

RO

L S

W

T/C RR RELAY

T/C FR RELAY

6-8

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (DIESEL ENGINE)

VF

2S

TV

RR

aV

F

F1

IG2

IG1

F2 N

Rr

R Ra

N

B-R

SOLENOID

BODY EARTH

W-B

Y

W-B

L-R

W-B

R

W-B

B

W-B

BODY EARTH

SOLENOID

W-B

R-Y

R-W

BZR W-B

MOTION ALARM (OPT)

W-BR-Y

R-G

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W

B-W

B-W

ST7.5A

GAUGE10A

B

W-L

STARTER RELAY

STA

RT

ER

B

BG

-R

W-BW-B

W-BW-B

BO

DY

EA

RT

H

B-R

B

T/C RRRELAY

T/C FRRELAY

GLOW RELAYMAIN

GLOW PLUG

W-B

R-G

B-O

R

GLOW

R

Y


LOCK

RELEASE

L-R

L-W

R

G-R L-W

SH

IFT

CO

NT

RO

L S

W

RE

LAY

BO

X

RE

LAY

BO

X

B-Y

LL

R-G

W

W-L

B-Y

GLO

W P

LUG

TIM

ER

RE

LAY

BO

X

ALT

(L)

IG S

W(I

G1)

W-L

B-Y

FL

HE

AD

FL

GLO

W

GAUGE10A

40A

60A

IGN7.5A

IG S

W

FL

ALT

80A

SFT7.5A

AM

1S

T1

IG1

FL

AM

140

A

LG-B

WATER TEMPSENSOR

R-G

6-9

COMBINATION METER

(UL-D,DS)

(UL-G,LP,G/LP)(UL-G,LP,G/LP)

LEVEL SW (SEDIMENTER)

B-Y

FL

AM

140

AW

-L

GA

UG

E10

A

RE

LAY

BO

X

W-B

AM

1

IG1

ST

1

IG S

W

FU

EL

SE

ND

ER

B-Y

OUT1

HRM1

HRM2

HRM3 E1

SA

S E

CU

RE

LAY

BO

X

CO

MB

INAT

ION

ME

TE

R

SAS WARNING

DISCONNECT SW

LOCK IND

HOUR METER

OPS

FUEL

WATER TEMP

CHARGE

AIR CLEANER

RADIATOR(OPT)

OIL

BRAKE (OPT)

OVER HEAT (OPT)

SAS WARNINGLAMP RELAY

P-G

L-O

V-GV-RP-L

Y-B

W-B

W-B

V-W L-Y

V V Y-G W-B W-B

W-B

WATER TEMP SENDER

LGLG-B

W-B

BODYEARTH

YYBODYEARTH

ALTERNATOR

VACCUM SW(AIR CLEANER)

LEVEL SW (OPT)(RADIATOR RESERVOIR TANK)

OIL PRESSURE SW

WATER TEMP SW (OPT)

Y-RY-R

Y-G Y-G B

W-BW-B

W-BB

LG-R LG-R BODY EARTH

BODY EARTHV-GV-G

R-G

B-Y

P-G W-B

W-B

OPS-LAMPRELAY

G W-B

L

SEDIMENTER

Y-B Y-B W-BWW-B

(UL-D,DS)

TWC(STD:2004.1 TWC ECU

W-BW-BY-BY-BCHECK (4Y-ECS) (OPT) 4Y-ECS ECU (OPT)

W-B

GLOW GLOW TIMER

W-BW-B

RR

R R

(UL-G,LP,G/LP,D)(UL-D)CHECK (VSCS) (OPT) VSCS ECU (OPT)

W-BW-BR R

LPG WARNING (OPT) LPG PRESSURE SW (OPT)

W-BW-BV-W

UL

-G, D

, G/L

PU

L-G

S, D

S

W

W WLW

W-L

B

LEVEL WARNING SW (OPT)

PARKING BRAKE SW (OPS)

W-BR-W

R-W

R-W

R-W

W-B

R

W-BG-W

V-W W-B

R-G

(UL-G,D,LP,G/LP)

(UL-G,DS,LPS)

6-10

COMBINATION METER (EZ PEDAL)

(UL-D)

(UL-G, LP, G/LP)

LEVEL SW(SEDIMENTER)

B-Y

FL

AM

140

AW

-L

GA

UG

E10

A

RE

LAY

BO

X

W-B

AM

1

IG1

ST

1

IG S

W

FU

EL

SE

ND

ER

B-Y

OUT1

HRM1

HRM2

HRM3 E1

SA

S E

CU

RE

LAY

BO

X

CO

MB

INA

TIO

N M

ET

ER

SAS WARNING

LOCK IND

HOUR METER

OPS

FUEL

WATER TEMP

CHARGE

AIR CLEANER

RADIATOR(OPT)

OIL

BRAKE (OPT)

OVER HEAT (OPT)

SAS WARNINGLAMP RELAY

P-G

L-O

V-G

V-R

P-L

Y-B

W-B

W-B

V-W L-Y

V V Y-G W-B W-B

W-B

WATER TEMP SENDERLGLG-B

W-B

BODYEARTH

YYBODYEARTH

ALTERNATOR

VACCUM SW(AIR CLEANER)

LEVEL SW (OPT)(RADIATOR RESERVOIR TANK)

OIL PRESSURE SW

WATER TEMP SW (OPT)

Y-RY-R

Y-G Y-G B

W-BW-B

W-BB

LG-R LG-R BODY EARTH

BODY EARTHV-GV-G

R-G

BATTERY

B-Y

P-G W-B

W-B

OPS-LAMP RELAY

G W-B

L

SEDIMENTER

Y-B Y-B W-BWW-B

(UL-D)

TWC(STD:2004.1 TWC ECU

W-BW-BY-BY-BCHECK (4Y-ECS) (OPT) 4Y-ECS ECU (OPT)

W-B

GLOW GLOW TIMER

W-BW-B

RR

R R

LPG WARNING (OPT) LPG PRESSURE SW (OPT)

W-BW-BV-W

UL

-G, D

, G/L

P

W

W-L

W-B

LEVEL WARNING SW (OPT)

PARKING BRAKE SW

W-BR-W R-W

R-W

B-RW-B

G-W

BSTARTERRELAYEZ PEDALRELAY

B-R

LOCK

RELEASE

G-R

R

L

V-W W-B

UL

-G, D

, LP,

G/L

P

R-G

6-11

3-WAY CATALYTIC SYSTEM (G, GS)DISCONNECT SW

FL

AM

1

FL WW (GS) W

BB

EZ PEDAL

B

L-O

L-B

L-B

B-O

BODYEARTH

W-B

BU

S B

AR

RE

LAY

BO

X

B-W

B-W

B-W

B-W

B-W

B-Y

B-Y

B-Y

B-Y

SHIFTCONTROL SW

B-O

W-L

R-G

R-G

Y-B Y-B

FCM4

GAS RLY

B

BR

W-B

W-B

W-B

OXYGENSENSOR

R

G

SH

-LD

R-Y

W-B

W-G

W-G

W-G

W-G

B

SH

-LD

B-W

L-BL-B

L-BL-B

L-OL-O

L-O

G-R

W-B

L-O

W

L-W

V-G

B-Y

SEL1

FCM3

FCM1

E1

OXM

TE2

IGB2

BATT1

E01

E02

VA

CU

UM

SE

NS

OR

VCC

PIM

E2

AIR

BLE

ED

CO

NT

RO

L V

ALV

E

L-B

R-B

R-G

R

GFUL

OXM G-Y

WATER TEMPSENSOR

FUEL CUTSOLENOID

THW

B-O

L-O

W-B

TWC RLY

STARTER SUB RLY

TW

C7.

5A

STA

IG-

R-WFCM2

B-O

E1

W-B

G-B

G-W

BATT2

W

IGB

TE2

TE1

VF

OX

E2

VF

TE1

COMBINATION METER (TWC LAMP)

TW

C E

CU

IIA

CH

EC

KC

ON

NE

CTO

R

G

GA

UG

E10

A

ST

7.5A

RE

LAY

BO

X

IGN

7.5A

IG1

ST

1A

M1

IG S

W

W-L

40A

FL

HE

AD

40A

W (G) B-Y

6-12

3-WAY CATALYTIC SYSTEM (LP, LPS)

L-O

W-B

B-O

B

BU

S B

AR

RE

LAY

BO

X

B-W

B-W

B-W

B-W

B-W

B-Y

B-Y

B-Y

B-Y

SHIFT CONTROL SW

B-L (LP)B-O (LPS)

B-L (LP)B-O (LPS)

B-L (LP)B-O (LPS)

W-L

R-G

R-G Y-B

Y-B

L-B

LPG RLY

L

B

BR

W-B

OXYGENSENSOR

R

G

SH

-LD

R-Y

W-B

W-G

W-G

W-G

W-G

B

SH

-LD

B-W

L

L-BL-B

L-BL-B

L-OL-O

L-O

B-LA

B

W-B

L-O

V-W

W

L-W

B-O

V-G

B B

B

W-B

RLY2

RLY1

E1

OXM

TE2

IGB2

BATT1

E01

E02

VA

CU

UM

SE

NS

OR

VCC

PIM

E2

LFC

LFUL

OXM G-Y

WATER TEMPSENSOR

LPG SLOW SOLENOID

LPG MAIN SOLENOID

THW

B-O

L-O

W-BTWC RLY

TW

C7.

5A

STAB

IG-

B-O

E1

L-R

L

W-B

G-B

G-W

BATT2

W

RESISTER

LPG INJECTOR

IGB

INJ

RES

TE2

TE1

VF

OX

E2

VF

TE1


TW

C E

CU

IIA

CH

EC

KC

ON

NE

CTO

R

G

GA

UG

E10

A

ST

7.5A

RE

LAY

BO

X

IGN

7.5A

IG1

ST

1A

M1

IG S

W

W-L

FL

AM

140

A

FL

HE

AD

40A

W (LP) B-Y

DISCONNECT SWFL W

W (LPS) W

EZ PEDAL

B

STARTER SUB RLY

See page 6-6.

6-13

3-WAY CATALYTIC SYSTEM (4Y-ECS, LP)

L-O

B

Y

B-O

B-O

L-B

W-B

B-O

B

TWC

R-G

R-G

B-O

MOTOR RLY

TH

RO

TT

LE B

OD

Y

IDLE

VO

LUM

EA

CC

ELE

RAT

OR

SE

NS

OR

ALT

MEMORYCLEAR

L

IIA

GO

VE

RN

OR

EC

U

COMBINATION METER

CHECK (ECS)

CHARGE

ENGREVVSVRLY

MTR RLY

IG(MTR)

IG1

IG2

IG RLY

DIAG

CHKR

CHECKLP

ALT

GND1

GND2

M+

M-

VC2

TPS1SINTPS2SINSENSORGND2

M+

M-

VC

VTA1

VTA2

E2

ACCEL

IDL

ID

MEMCLR

G/LPCHG

MAIN RLY

CHECKER

IGNITION RLY

EZ PEDAL &E/G SHUT DOWN RLY

G-O

W

R

B

B

R

W

G

W

B

R

B

W

R

W-B

W-BLG-R

LGL-W

L-WL-W

L-W

L-W

L-W

B-R

L-W

L-R

V-W

B

SH-LD

W-B

B-O

R

Y

L-B

B-O

W-B

L-W

SH

-LD

SH-LD

SH-LD

W-B

B

SH-LD

VC3

SENSORGND1

VC1

VSV SOLENOID

IN

VC

ID

E2

SH-LDVSV RLY

W-BB-L

L-W

SH-LD

INT

ER

NA

L W

IRIN

G O

F C

OM

BI M

ET

ER

IG-B B-W

B-O

B

V

W-B

L-B

FL

GO

V40

AG

OV

15A

B B-LB-L B-L

LFULV-W

B-O

SH

-LD

W-B

W-B

RE

LAY

BO

X

B-W

B-W

B-W

B-W

B-Y

B-Y

B-Y

B-Y

SHIFT CONTROL SW

B-O

W-L

Y-B Y-B

L-B

LPG RLY

L

B

BR BR

BR

BR

W-B

OXYGENSENSOR

R

G

R-Y

W-B

W-G

W-G

W-G

W-G

L

L-BL-B

L-BL-B

L-OL-O

L-O

B

W-BL-O

W

L-W

V-G

B B W-B

SEL1

SEL2

E1

OXM

TE2

IGB2

BATT1

E01

E02

VA

CU

UM

SE

NS

OR

VCC

PIM

E2

LFC

OXM G-Y

WATER TEMPSENSOR

LPG SLOW SOLENOIDLPG MAIN SOLENOID

THW

B-O

L-O

W-B

TWC RLY

TW

C7.

5A

STAB

B-O

E1

G

L-R

L

W-B

G-B

G-W

BATT2

W

RESISTER

LPG INJECTOR

IGB

INJ

RES

TE2

TE1

VF

OX

E2

VF

TE1

COMBINATION METER

TW

C E

CU

CH

EC

KC

ON

NE

CTO

R

GA

UG

E10

A

ST

7.5A

RE

LAY

BO

X

IGN

7.5A

IG1

ST

1A

M1

IG S

W

W-L

FL

AM

140

A

FL

HE

AD

40A

W B-Y

IG RLY

B-LASee page 6-6.

B-W

EZ PEDAL

B

STARTER SUB RLY

6-14

3-WAY CATALYTIC SYSTEM (G/LP)

L-O

BODYEARTH

B-L

W-B

L-B

L-B

B

R

LB B

-Y

B-R

B-Y

BU

S B

AR

RE

LAY

BO

X

B-W

B-W

B-W

B-W

B-Y

B-Y

B-Y

B-Y

SHIFT CONTROL SW

B-L B-L

B-YB-Y

B-R

B-O

W-L

R-G

R-G

Y-B Y-B

FCM4

L-B

GAS RLY

LPG RLY

L

B

B-R

B-Y

BR BR

BR

BR

W-B

OXYGENSENSOR

R

G

SH

-LD

R-Y

W-B

W-G

W-G

W-G

W-G

B

SH

-LD

B-W

L

L-BL-B

L-BL-B

L-OL-O

L-O

G-R

B

W-B

L-O

B-Y

B-R

V-W

W

L-W

B-R

V-G

B

B-OB-O B-O

B-O

W-B

B

B

W-B

GAS

LPG

SEL2FCM3

FCM1

E1

OXM

TE2

IGB2

BATT1

E01

E02

VA

CU

UM

SE

NS

OR

VCC

PIM

E2

AIR

BLE

ED

CO

NT

RO

L V

ALV

E

L-B

R-B

R-G

R

LFC

LFUL

GFUL

OXM G-Y

WATER TEMPSENSOR

FUEL CUT SOLENOID

GAS SOLENOID

LPG SLOW SOLENOID

LPG MAIN SOLENOID

GAS

LPG

FUEL CHANGE SW

THW

B-O

L-O

W-B

TWC RLY

TW

C7.

5A

STAB

IG-

R-WFCM2

B-O

E1

L-R

L

W-B

G-B

G-W

BATT2

W

RESISTER

LPG INJECTOR

IGB

INJ

RES

TE2

TE1

VF

OX

E2

VF

TE1


TW

C E

CU

IIA

CH

EC

KC

ON

NE

CTO

R

G

GA

UG

E10

A

ST

7.5A

RE

LAY

BO

X

IGN

7.5A

IG1

ST

1A

M1

IG S

W

W-L

FL

AM

140

A

FL

HE

AD

40A

W B-Y

B-LA See page 6-6.

B-W

EZ PEDAL

B

STARTER SUB RLY

C

Published by

A

1st Printing: Oct. 2005

Pub. No. CU040

Printed in Japan

r/m 7fgu15-32 7fdu15-32 7fgcu20-32...

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