You are on page 1of 185

< Tillbaka till Servicemanual 7FBEF 15-20

Index

FOREWORD
This manual mainly describes the development objectives of new Toyota forklift
7FBEF15 to 20 models, outlines of main component units, structures and functions of
new mechanisms and other technical features.

Please read it carefully for sales and service activities.


This manual has been edited for the vehicles launched into the market in May
2003.
Any later change shall be informed through Toyota Industrial Equipment Parts &
Service News.
Please refer to the repair manual and parts catalog for the matters necessary
for servicing.

TOYOTA Material Handling Company


A Division of TOYOTA INDUSTRIES CORPORATION

SECTION INDEX
NAME

SECTION

GENERAL

DEVELOPMENT OBJECTIVE

ELECTRICAL SYSTEM

POWER TRAIN

TRAVELING, STEERING AND BRAKE SYSTEMS

INSTRUMENTS

FRAME AND AUXILIARY EQUIPMENT

MATERIAL HANDLING AND HYDRAULIC SYSTEM

SAS CONTROL SYSTEM

OUTLINE OF MAJOR OPTIONS

APPENDIX

10

0-1

GENERAL
Page

VEHICLE EXTERIOR VIEWS ...................................... 0-2


MODEL LINEUP .............................................................. 0-3

2
3
0
3

0-2

VEHICLE EXTERIOR VIEWS

Vehicle exterior views

Front View

Rear View

0-3

MODEL LINEUP
Vehicle model lineup
Payload
(L.C. 500 mm)

New model

Previous model

Voltage

1.5 ton

7FBEF15

5FBE15

48V

1.6 ton

7FBEF16

48V

1.8 ton

7FBEF18

5FBE18

48V

2.0 ton

7FBEF20

48V

L.C.: Load center

2
3
0
3

0-4

1-1

DEVELOPMENT OBJECTIVE
Page

DEVELOPMENT OBJECTIVE ..................................... 1-2

2
3

FEATURES (SELLING POINTS) ................................ 1-3


MAJOR DIFFERENCES BETWEEN NEW AND
PREVIOUS MODELS ................................................. 1-9

1-2

DEVELOPMENT OBJECTIVE
Development objective
Toyota 5FBE series, 1,500-kg to 1,800-kg three-wheel, counter battery type forklift have favorably been
accepted by a large number of customers thanks to their ease of use and reliability since the model
change in 1993.
After the model changes by competitors in later years, however, disparities in specifications and
equipment compared to 7FB series and 7FBR series have been pointed out.
Growing environmental concerns in the market, on the other hand, has been adding to the importance of
battery vehicles.

Development concepts
1

Optimum material handling operation matching each customer's needs by making the most of
the features of AC-motor drive system.

Adoption of the SAS (mast control and steering synchronizer) developed in the 7 series and
highly evaluated in the market for realization of high stability comparable with that of the 7
series.

Easier ingress and egress by adoption of the open step, small-diameter steering wheel and tilt
steering with memory.

Addition of 1,600- and 2,000-kgf models to the 1,500- and 1,800-kgf models in the previous
series.

The AC drive system, especially was implemented in 1999 ahead of other companies by consolidation of
our time-tested technologies. Its features have fully been utilized not only in performances but also in
operating feel.
We propose these models as three-wheel counter battery forklift trucks without an equal in performance
and operating feel.

1-3

FEATURES (SELLING POINTS)


Major selling points
The greatest feature of the new models is adoption of the AC motor drive system. New features of the 7FB
series have also been adopted in many places.
1. Adoption of AC Motor Drive System
What is AC motor drive system?
The conventional DC motor drive system uses a controller for battery current chopping (ON and OFF)
to control the motor power by changing the chopping ratio to realize from inching at the time of starting
up to the maximum power.
The controller in the AC motor drive system converts the battery current to a three-phase alternate
current, whose sine wave form (frequency and waveform height) varies to control the motor power.
The table below compares the motor voltage, motor structure and the controller between the AC
system and DC system.
Comparison between the DC and AC systems
Motor voltage

Motor structure

Controller
Motor

Mean voltage

Commutator

Brush

Battery

ON

DC
system

ON ON

Controller

Battery voltage

Microcomputer
control

Motor voltage
Contactor

Conversion from battery DC


voltage into the mean voltage by the chopper

Sine wave

Need of brush and commutator maintenance


Complicated structure

Relatively easy by mean DC


voltage control
Need of contactor for rotating direction change
Motor

Stator core

Stator coil

Controller

Battery

AC
system

Battery voltage

1 Phase
Motor voltage

Conversion from battery DC


voltage into the AC voltage
by the controller

No brush and commutator


(maintenance-free)
Compact and lightweight

Microcomputer
control

Conversion from DC into


three-phase AC by the module
No need of contactor for
rotating direction change

2
3
1

1-4
Features of AC motor drive system
The table below shows three major features of the AC motor drive system. The AC motor drive system
has already been adopted in the industrial world by making the most of these features.
System feature

Product feature

Simple, compact motor structure

Realization of higher performance in the same


product size

Realization of new control by three-phase


AC control

Realization of new performance and feel thanks


to wider motor control range

No motor brush and contactor

Reduction of maintenance cost for motor brush


and contactor

It has been known to worldwide forklift engineers that the AC motor drive system, as stated above, is a
very excellent system for battery forklift trucks.
Selling points of the new models fully utilizing these features are explained below.
2. Power Select Function
The performance best matching the operator can be selected by single switch operation.
The traveling performance in loaded state is improved in new models by making the most of the
simple, compact structure of the AC motor. One switch selects any of the following modes.
Mobility-preference mode featuring the shortest cycle time (H mode)
Efficiency-preference mode for short cycle time and long working hours (P mode)
Operation-hour-preference mode featuring the longest operation hours with the performance
equivalent to that of previous models (S mode)
To satisfy individual customer requirements, a power control select function is provided for setting the
traveling mode by selection from six modes including H, P and S.
The operation efficiency is greatly improved by selection of the optimum performance for each
customer need like H mode selection for a job requiring the power and performance or S mode
selection for continuous operation for many hours.
Power select function

[7FBEF15]
Cycle time
(sec/cycle)

:Fixed mode

[H mode]

85
[P mode]
90
Previous model
[S mode]
95

180min 220min 260min 300min

Operation time
(DIN 4PzS 440L)

1-5
Especially, the loaded traveling and material handling performances in the H mode have been
improved over 30%. As a result, our 30-m operation cycle time has been shortened by about 10% or
more.

2
3

1.5 ton
Lifting speed
mm/sec
NL610

65%UP
600

540
480

FL430

480

420

350
280

260
NL: No load
FL: Full load

H mode

P mode

S mode

5FBE15

STILL

Traveling speed
Km/h
NL16.5 30%UP
FL15.0

16.0

15.0
14.0

14.0

13.5
12.5 12.5
11.5

NL: No load
FL: Full load
H mode

P mode

S mode

Cycle time
(TOYOTA 30m operation cycles)
sec/cycle

11%UP

95

5FBE15

STILL R20

Operation time
(DIN 4PzS 440L, TOYOTA 30m operation cycles)
95

270

min
240

230

85
185

91

H mode

P mode

S mode

5FBE15

H mode P mode S mode

5FBE15

1-6
3. Improved Efficient Operation Hour
The accelerator-off regeneration system is added to the AC drive system for longer operation
compared to the previous models. The power up function is also adopted for longer efficiency
operation hours.
Power keep function
(Setting to the P mode at the Efficiency-preference and the S mode for Operation-hour-preference)
The power keep function has been developed as the new control in new models for maintaining the
discharged battery performance by making use of the wider motor control range of the AC motor drive
system.
The efficiency operation hours allowing operation without feeling performance degradation
is improved by 40% by adoption of the power keep function and extension of the operation
hours.
The number of operation cycles without feeling performance degradation is also improved by
40%.
This new function actually improves the operation efficiency at each customer greatly.
Low remaining battery charge warning

Full load performance


1.1

New model
Battery usage
limit range

Decrease in
performance

0.9
Previous model

0.8

Lift interruption
25%UP

0.7
0%

20%
40%
Previous model (1.5t)
Efficiency operation hour:2H20m
(440AH/5hr)

60%

80%

100%
Battery discharge level (%)

40%UP
Previous model (1.5t:S mode)
Efficiency operation hour:3H20m
(440AH/5hr)

However, note that efficient operation becomes hard when the battery level indicated by the battery
charge indicator becomes one bar (battery discharge to about 90%).

1.5 ton

min
350

52% UP

270

17% UP
230

7FBEF15 7FBEF15
5FBE15
S mode
S mode
(DIN 5PzS550L) (DIN 4PzS440L)

1-7
4. Easy Ingress/Egress and Dwelling Ability
Easy Ingress/Egress
An open step is provided for easy ingress/egress.
The tilt steering is also provided with a memory as on the 7FB series to allow full forward tilting of the
steering column to ensure smoother ingress/egress.
Step height
Step height
430mm
(16.9in)

Step height
545mm
(21.5in)

New model Previous model

Dwelling Ability
Compared to previous models, the head clearance is increased by 25 mm (0.98 in) to 1,025 mm (40.4
in).
5. Maintenance Cost Reduction
Maintenance items specific to battery vehicles are as follows:
1) Addition of distilled water for battery
2) Pump motor brush replacement
3) Pump contactor replacement in controller
4) Drive motor brush replacement
5) Drive contactor replacement in controller
Since the AC motor has no brush and contactor as explained earlier, brush replacements are
unnecessary. Depending on the operating conditions at each customer, the annual maintenance cost
can be reduced as much as 80%.
The newly adopted acceleration-off regeneration system regenerates the electrical braking energy
upon accelerator pedal release during traveling in the battery by making the most of the wider motor
control range of the AC motor drive system. This accelerator-off regeneration system not only extends
the operation hours and improves the running stability by electrical braking but also reduces the brake
load and lining wear for less brake maintenance cost.

1-8
6. Safety Functions
The new models are installed with the SAS safety functions adopted on the 7FB series to ensure
equivalent safety. Though the safety functions are summarized below, refer to the SAS Control
Equipment section for further details.
Safety Function List
Safety control

Mast
control

Functional outline

Active mast front tilt angle control

Decreases the front tilt angle at a high fork height


or under a heavy load, and increases it at a low
fork height or under a low load.

Active mast backward tilt speed control

Retards the backward tilting speed at a high fork


height, and increases it at a low fork height.

Key-lift interlock

If the key switch is in the OFF position, the lift


operation is disabled even when the material handling lever is operated.

Automatic fork leveling control

Forward tilting by pressing the button causes the


mast to be stopped automatically when the fork is
leveled.
The steering knob is not shifted during full
hydraulic power steering.

Steering synchronizer (EHPS)

EHPS: ELECTRONICALLY CONTROLLED FULLY-HYDRAULIC POWER STEERING


On three-wheel battery counter vehicles, the automatic control rear stabilizer is not provided because
of no rear wheel swing mechanism.
7. Anti-rollback
A function for easy starting on a slope (reduction of rollback on a slope) is provided.
8. Model Series
The 1.6- and 2.0-ton models have been developed anew to enrich the model line-up.
The 1.0- and 1.25-ton models have been discontinued.

Capacity (kgf)
1000

1250

1500

1600

1800

2000

7FBE
5FBE
: Continuation

: New

9. Maximum battery capacity


The battery compartment length in the longitudinal direction has been widened by 87 mm on the 1.5ton model and 193 mm on the 1.8-ton model to accept the same DIN-size batteries for the STILL R20
on all series models.

Capacity (kgf)
1500

1600

1800

2000

7FBE

5PzS550L

6PzS660L

6PzS660L

6PzS660L

5FBE

4PzS440L

4PzS440L

1-9

MAJOR DIFFERENCES BETWEEN NEW AND PREVIOUS MODELS


:Not applicable
New models
Item

Applicable
models

Motor

Controller

Traveling system

1.5 ton

1295 mm

All models

1490 mm

1.6 to 2.0 ton

1070 mm

1.5 to 1.8 ton

1075 mm

All models

1125 mm

2.0 ton

Overall height

1980mm

All models

1950mm

All models

Drive motor

AC: 4.9 kW 2

All models

DC: 3.3 kW 2

All models

Pump motor

AC: 9.2 kW

All models

DC: 8 kW

All models

PS motor

DC: 0.75 kW

All models

Main controller

Traveling, material
handling and steering control

All models

Traveling/material
handling control

All models

Steering controller

All models

Contactor type

All models

Steering system

Steering synchronizer, EHPS system

All models

FHPS system

All models

Parking brake lever

Parking brake lever


ratchet type

All models

Parking brake lever


ratchet type

All models

18 78

1.5 to 1.8 ton

18 78-14PR

1.5 ton

18 78-16PR

1.8 ton

16 6-8-10PR(dual)

All models

Overall width

Front tire

200/50-10

2.0 ton

15 4.1/2-8(dual)

1.5 to 1.8 ton

16 6-8(dual)

2.0 ton

Mast control
Active mast front
tilt angle control
Mast backward
tilt angle control
Automatic fork
leveling control
Key-lift interlock

All models

Steering synchronizer EHPS

All models

1025mm

All models

1000mm

All models

Step height

430mm

All models

Rear combination
lamp

High-mount embedded type

All models

Add-on type

All models

Tires
Rear tire

SAS equipment

Frame
Auxiliary
equipment

Applicable
models

1385 mm

Wheel base
General

Previous models

SAS specifications

Head clearance

1-10

2-1

ELECTRICAL SYSTEM
Page

BATTERY .......................................................................... 2-2


MOTORS ........................................................................... 2-4

2
3

MAIN CONTROLLER .................................................... 2-10

2-2

BATTERY
General
1. Battery Compartment and Necessary Weight
When purchasing the battery locally, always adjust the weight to satisfy the minimum weight shown in
the table below.
Compartment dimensions mm (in)

Vehicle model

Length X
STD
R/O

Width Y

Height Z

830 (32.7) 627 (24.7)

Minimum required battery


weight (with case) Kg (lb)

7FBEF15

630 (24.8)

7FBEF16 to 20

738 (29.1)

985 (2172)

7FBEF15

630 (24.8)

830 (1830)

7FBEF16 to 20

738 (29.1)

985 (2172)

R/O: Battery roll-out specifications

th

ng

Z
Height

Le

Y
Width

830 (1830)

Remarks

2-3
2. Battery Specifications
No batteries are provided.
Please use the batteries conforming to DIN 43 531A.
Use 320A connectors.

2
3

RIGHT

LEFT

180
(7.1)
-+

250
(9.8)

2
FRONT

320A
CONNECTOR

3. Battery List
The table below shows recommended batteries.
Refer to the general description for batteries with regard to the minimum required weight.
DIN 43 531A
Installed battery
Vehicle models

Voltage

Supplier
VARTA

7FBEF15

48

OLDHAM
CHLORIDE
VARTA

7FBEF16 to 20

48

OLDHAM
CHLORIDE

Battery case
Dimensions mm (in)

Model

Capacity
[AH/5HR]

5PzS550L

550

5PzS600Hx

600

24CYQ5

500

24CYH5

550

5PzS500

500

627 (24.7)

5PzS550H

550

6PzS660L

660

6PzS720Hx

720

24CYQ6

600

24CYH6

660

6PzS600

600

735 (28.9)

6PzS660H

660

length

width

height

630 (24.8) 830 (32.7) 627 (24.7)

738 (29.1) 830 (32.7) 627 (24.7)

2-4

MOTORS
Drive motor
General
1. A compact, high-performance, maintenance-free AC induction motor optimum for battery forklift trucks
has been newly developed as the drive motor.
2. The motor is maintenance-free because it has no brush.

Specifications
Vehicle model

Voltage
(V)

Rated output
(kW)
(60-min rating)

7FBEF15 to 20

48

4.9

Type

Size
Diameter Length
mm (in)

Mass
kg (lb)

3-phase AC

180 (7.1) 227 (8.9)

37 (82)

Drive motor features


The induction motor (see the figure below) developed for the new models this time has the following
features:
The drive unit is integrated with the motor (built-in structure) to attain a compact size.
The iron core shape and winding are optimized for motor efficiency improvement.
A high-precision rpm sensor for direct detection of the motor speed is adopted to realize elaborate
functions such as power select and power keep.
A motor temperature sensor is adopted to ensure stabilized output and to prevent burning due to
overloaded use.

Caution
Depending on the use at each customer (continuous heavy-load operation for example), the vehicle
performance may temporarily be dropped to protect the controller and motor from overheating. This is due
to restriction of the current to the motor as a result of specified temperature detection by the temperature
sensor built in the controller or the motor. This is not an abnormality. Since the respective warning appears
on the monitoring display, stop the operation and restart after the warning indication disappears.
Length
Field core

Drive unit

Field winding

Rpm sensor bearing

Diameter

Rotor

2-5

Structure and principle of AC induction motor


The AC induction motor has no brush and commutator unlike the conventional DC motor, so there is no
sliding part. It, therefore, has the following features:
1. The motor size can be reduced by dimension L for the brush and commutator if the output is the same.
2. In the size is same, the core size can be increased by dimension L for the brush and commutator,
resulting in a higher output.
3. Because of less number of parts and no sliding part, it features high reliability and efficiency. For new
models, a new AC induction motor best suitable for forklift trucks has been developed and adopted.
AC motor (for new models)

2
3

DC motor (for previous models)


Field core

Field winding

Field core

Field winding

Commutator

Brush

Rotor

Rotor

The rotor consists of the core made up of piled thin electromagnetic steel plates through the grooves in
which aluminum conductor bars pass. Both ends of conductor bars are shorted by end rings on both sides
of the core as illustrated in (b) below. When the bars and end rings are taken off, the shape is like a cage
for a squirrel or mouse as shown in (c) below. It is therefore called a cage rotor.
(a) Core

End ring
(b) Rotor ASSY

Conductor bar
(aluminum conductor bar)
End ring
(c) Cage rotor

2-6

Motor operation principle


Right-hand screw rule and Fleming's rule are to be explained here before explanation on the motor
operation principle.
1. Right-hand screw rule
Direction of
Raise the thumb of the right hand with other fingers
current
folded. When the thumb is placed in the current
flowing direction in this state, the magnetic field is
Magnetic
generated vertically to the thumb or in the direction of
field
Magnetic
the folded fingers.
field

Direction of
current

2. Fleming's right-hand rule


Place a linear substance in freely movable state on a
fixed material as shown at right. If the linear
substance is moved in the illustrated direction when
the magnetic field is generated as illustrated, an emf
current is generated in the illustrated direction.

Magnetic
field

Direction of
Magnetic field

Direction of
motion
Direction of
current
Magnetic field

Direction of
current

3. Fleming's left-hand rule


Place a linear substance in freely movable state on a
fixed material as shown at right. If a current flows in
the fixed material when the magnetic field is
generated as illustrated, a force is applied to the linear
substance in the illustrated direction.

Direction of
motion

Direction of force
Direction of
Magnetic
Magnetic field
field

Magnetic field
Direction of
force
Direction of
current

Direction of
current

2-7
Operation principle
1. When a current flows in a fixed direction in the field winding as shown below, magnetic field is
generated around the field winding as illustrated according to the right-hand screw rule and magnetic
poles (N and S poles) are generated.
2. Clockwise rotation of the magnetic poles here is the same as counterclockwise rotation of rotor bars.
3. A current is induced in each rotor bar in the illustrated direction according to Fleming's right-hand rule.
4. The induced current in each rotor bar generates a clockwise force according to Fleming's left-hand
rule.
5. A rotating torque is generated by the electromagnetic force as explained above. The rotating speed of
the rotor is slightly less than that of the filed poles.
6. Actually, the outer field winding does not move. The sine wave of each phase of the three-phase
alternate current generates a rotational magnetic field to generate a rotating torque of the rotor.

Field winding

Rotational
direction
magnetic
of pole
N pole

Rotational
direction
magnetic
of pole

Field winding
Magnetic field
Direction
of current

Direction of
current induced
in the bar

Direction
of force
Magnetic
field
Direction
of force

Rotational
direction of
cage rotor
Direction
of current

S pole
Current flow from the rear to the front

Magnetic field

Current flow from the front to the rear


Rotational direction
magnetic of pole

Rotor (Field winding)

2-8
7. The rotational magnetic field is as explained below.
(1) Assume that three coils are placed on the outer side the rotor. When these three coils (a1-a2, b1-b2
and c1-c2) are connected and a three phase alternate current flows, the magnetic flux varies as
shown in the figure below to generate a 2-pole rotational magnetic field. The rotating magnetic field
makes one turn in one cycle of the three-phase AC. Since the field rotates once in one cycle of the
three-phase AC, the inner rotor also makes one turn.
t1
ia

Current (i)
ic
c1

t2

t3
ib

t4
ic

b2

a2

a1
ia

b1

Time (t)

c2

ib

S
N

N
S

(2) See the internal structure of the motor. Six coils in three pairs are placed on the outer side of the
rotor. When the six coils (a1a1' - a2a2', b1b1'-b2-b2' and c1c1'-c2c2') are connected in three
phases to receive a three-phase alternate current, the magnetic flux varies as shown in the figure
below to generate a four-pole rotational magnetic field. In this case, the rotational magnetic field
makes a 1/2 turn in one cycle of the three-phase AC. In a motor with three phases of magnetic field
(using six coils in three pairs), the inner rotor can generate twice as much torque as was in the case
of a single-phase motor (using three coils).
Current (i)

t1

t2
ia

c2 b1
a1
b2

b2

c1

t4
ic

ia
c1
b1

c2
a2

a1

t3
ib

Time (t)

a2
ib

ic

S S

S
S

S
S

2-9

Pump motor
General
1. An AC induction motor most suitable for compact, high-performance, maintenance-free battery forklift
trucks is adopted newly as the pump motor just like the drive motor.
2. The motor output is increased by making use of the induction motor to improve the performance both
in loaded and unloaded states.
3. The motor is maintenance-free because of no brush.

Length

Diameter
Field winding

Field core

Rpm sensor
bearing
Rotor

Specifications
Vehicle model

Voltage
(V)

Rated output
(kW)
(5-min rating)

Type

Size
DiameterLength
mm (in)

Mass
kg (lb)

7FBEF15 to 20

48

9.2

3-phase AC

180 (7.1) 290 (11.4)

31 (68)

2-10

MAIN CONTROLLER
General
AC System
This controller is multi-functional making use of most advanced electronic technologies such as inverter
control using a microcomputer, the function for CAN communication between the main controller and the
drive/pump motor driver, and the function for communication with multi-screen display.
The power select and power keep functions have been realized by making use of the AC motor drive
system features.
Power select function

The traveling/material handling performance can be selected from H, P and


S modes by operating the buttons.
The operating performance is maintained even when the battery discharge

Power keep function

proceeds for longer, efficiency operation (only when the P or S mode is


selected).

AC motor maximum output


AC power system output
characteristics
DC power system output
characteristics
(DC motor maximum output)

Rpm

Torque

Torque

AC and DC power system output


characteristics with fully charged battery
AC power system output
characteristics with discharged battery
DC power system output
characteristics with
discharged battery

Rpm

The AC motor realized greater output than the DC motor in the same size.
The AC motor drive system output characteristics are determined by the combination of the alternate
current and frequency output from the controller.
Optimum combinations for multiple characteristics are mapped and stored in the controller for power
selection by map switchover.
The output characteristics of the DC motor drive system, on the other hand, are determined by the
controller output voltage itself. The characteristic of the motor itself when the battery voltage is applied
(chopper duty: 100%) is the maximum output. The performance, therefore, drops as the battery voltage
decreases.
On the other hand, the AC motor drive system maintains the performance by changing the AC current and
frequency combination according to the battery discharge level. The power keep function is thus realized.

2-11

Controller configuration
Traveling/Material Handling Controller System Configuration

Drive
AC
motor

Traveling
AC driver

Drive
AC
motor

Traveling
AC driver

Drive motor thermo-sensor


Drive rpm sensor

Drive motor thermo-sensor


Drive motor rpm sensor
Direction switch
Traveling accelerator potentiometer

Battery

Brake switch
Main
controller

Pump
AC motor

Tire angle sensor


Material handling switch

Material
handling
AC driver

Solenoid valve
Display
Pump motor thermo-sensor
Pump motor rpm sensor

Traveling/material handling controller

2-12
Internal Configuration of Traveling/Material Handling Controller
Battery
Traveling/material handling controller
Main controller
CPU board

Power supply
contactor

Cooling fan
CPU

Sensors and
switches

RAM

I
/
O

Traveling AC driver

Drive
AC
motor

Traveling AC driver

Drive
AC
motor

ROM
I
/
O

CAN
I/O
EEPROM

Material handling
AC driver
Solenoid
drive
circuit

Display

Pump
AC motor

Lift solenoid valve


Tilt solenoid valve
Steering synchronizer
solenoid valve

Comfortable operability is
realized by making fine
control using microcomputer.

CANBus
Controller Area Network
Bus

CPU
(Central Processing Unit)

Central processing unit

ROM
(Read-only Memory)

Read-only memory (Contains the control program.)

RAM
(Random Access Memory)

Memory allowing reading and writing (The contents are


erased when the power is turned off.)

EEPROM
(Electrically Erasable, Programmable
Read-only Memory)

Electrically programmable memory (Contains the data


required for control and error codes.)

I/O
(Input/Output)

Input/output interface

CANI/O
(Controller Area Network Input/Output
interface)

CAN input/output interface

2-13

Major controller functions


1. Two traveling motor control
Two independent AC drive systems are adopted for controlling the motors for front wheels LH and RH.
The outputs from motors LH and RH are controlled according to the steering angle for smooth
operation.
2. Accelerator-off regeneration braking
Regeneration braking is provided to regenerate the electrical braking energy into the battery when the
accelerator pedal is released during traveling. This will extend the operable hours, lengthen the brake
lining life and realizes easy, stable traveling with engine-brake-like feel. This function is active even
when the direction switch is in the neutral position.
3. Brake Pedal Regeneration Braking
Regeneration braking also functions upon ordinary braking to extend the operable hours and lengthen
the brake lining life. This function is active even when the direction switch is in the neutral position.
4. Switch-back regeneration braking
Regenerating braking also functions at the time of switch-back operation.
Smoother operation feel is obtained than on previous models.
5. Power keep function
The performance is maintained even when battery discharge proceeds for longer efficiency operation
hours. (Only when the P or S mode is selected.)
6. Power select function
The traveling/material handling mode is selectable from H, P and S by button operation on the multiscreen display.
7. Power control select function
The traveling/material handling performance mode setting and performance setting to other than H, P
and S are possible by operation on the multi-screen display.
8. Auto-off function
If the vehicle is left with the key switch kept at the ON position, the controller forcibly turn the key
switch off for power saving. To use the vehicle again, turn the key switch to OFF and ON.
9. Deadman Switch Function
Traveling is disabled while the operator is not on the seat.
10. Anti-rollback function
The anti-rollback function is provided for easier starting on a slope.
11. Traveling speed limiter
The traveling speed is limited to the maximum level set with the multi-screen display.
12. Thermal protector
The temperature sensor installed in each controller/motor informs the operator of temperature rise to
the specified level by indication on the multi-screen display and restricts the controller output for
protection.
13. Remaining battery charge calculating function
The battery voltage drop by discharge is detected and calculated by the controller for indication of the
remaining charge on the multi-screen display.
14. Diagnosis function
Any abnormality in the operating systems like the motor driver and accelerator or any sensor
abnormality is detected for indication by respective code on the multi-screen display, and a necessary
action is taken.
15. Analyzer function
When the multi-screen display is in the analyzer mode, defective part detection and functional check of
each operating system and motor driver are possible.
16. Over-discharge warning function
When the remaining battery charge drops below the specified level, it warns on the multi-screen
display and material handling during traveling is disabled. This function protects the battery and inform
the operator of the need to charge the battery.

2-14
17. Return-to-neutral function
When the direction lever is in the forward or reverse position or when the key switch is turned on while
the accelerator pedal is depressed, traveling is disabled unless the direction lever and accelerator
pedal are returned to their neutral positions.
18. Parking brake ON alarm
An alarm tone sounds when traveling is attempted without releasing the parking brake.
19. Parking Brake OFF Warning
Warning alarm sounds if the operator leaves the seat without applying the parking brake.

3-1

POWER TRAIN
Page

DRIVE UNIT...................................................................... 3-2

2
3

3-2

DRIVE UNIT
Difference from previous models
The drive unit size has been reduced by changing the train of gears from that on previous models, and the
motors LH and RH are arranged transversely on the same axis.

General
1. The drive unit adopted for new models has transversely installed traveling motors similarly as on
previous models.
2. Changing the gear train from the previous 4-axis, 3-stage to the 2-axis, 2-stage reduction mechanism
with semi-built-in traveling motors has reduced the drive unit size.
3. Hypoid gear oil (API: GL-4, SAE: 75W-85W) is adopted as the common lubricant for all models (same
as for previous models).

Structure
Gears
First-stage reduction adopts the helical gear featuring high transmission efficiency.
Second-stage reduction adopts the planetary gear featuring high space efficiency.
Reduction ratio

New models

Previous models

All models

27.040

17.482

Drive unit structural drawing


First axis
(Motor input shaft)

Drive motor

Helical gear

Planetary gear
Second axis
(Front axle shaft)

4-1

TRAVELING, STEERING AND BRAKE SYSTEMS


Page

ACCELERATOR .............................................................. 4-2


REAR AXLE ..................................................................... 4-3

2
3

TIRES ................................................................................. 4-4


STEERING ........................................................................ 4-6
BRAKE .............................................................................. 4-10

4-2

ACCELERATOR
Standard Pedal
The accelerator is mounted on the front protector bracket.
A plastic pedal is adopted as on the conventional models for smooth start in depression.
The pedal effort is decreased from 1.5 kg to 0.7 kg by revising the accelerator structure.

D2 pedal (option)
The accelerator pedal and the direction switch are integrated.
This pedal allows quick, smooth control of the vehicle speed and changeover between forward and
reverse traveling directions. The traveling direction can be changed without freeing one hand from the
steering wheel.

4-3

REAR AXLE
General
Double tires are installed as the standard feature for rear wheels of all vehicle models for longer tire life.

2
3

4-4

TIRES
General
1. Pneumatic shaped cushion (PSC) tires are adopted as standard tires.
The table below shows standard tires.
2. Pneumatic tires are adopted optionally for the 1.5- to 1.8-ton models.
3. See the OPTION LIST for details of the optional tires.
Standard Tire Setting List
Front tire
Vehicle
model

Type

Tire size

Rim size

Tire pressure
kPa(kgf/cm2)[psi]

7FBEF15

PSC

187-8/4.33 SOLID

4.33R-8

7FBEF16

PSC

187-8/4.33 SOLID

4.33R-8

7FBEF18

PSC

187-8/4.33 SOLID

4.33R-8

7FBEF20

PSC

200/50-10/6.50 SOLID

6.50F-10

Rear tire
Vehicle
model

Type

Tire size

Rim size

Tire pressure
kPa(kgf/cm2)[psi]

7FBEF15

PSC

1541/2-8/3.00 SOLID

3.00D-8

7FBEF16

PSC

1541/2-8/3.00 SOLID

3.00D-8

7FBEF18

PSC

1541/2-8/3.00 SOLID

3.00D-8

7FBEF20

PSC

166-8/4.33 SOLID

4.33R-8

Notes
Wheels of new models are not interchangeable with those of previous models.
The allowable load may vary when the tire type is changed. See the load table for details.
When color tires are adopted, install tire bands because static electricity is likely to be generated in the
vehicle by the use on resin-coated floor or roads with high friction.

4-5

Option list
Front Tire
Model
Tire name

Pneumatic
shaped cushion

Tire
specification

Wheel
size

FR

U-LUG
Tire

1878/4.33

Sidering

4.33R-8

FR

U-LUG
Tire

200/50-10/
6.50

Sidering

6.50F-10

FR

J-LUG
Tire

1878/4.33

Sidering

4.33R-8

FR

J-LUG
Tire

200/50-10/
6.50

Sidering

6.50F-10

FR

J-LUG
Tire

187814PR

Sidering

4.33R-8

FR

J-LUG
Tire

187816PR

Sidering

4.33R-8

FR

U-LUG
Tire

1878/4.33

Sidering

4.33R-8

FR

U-LUG
Tire

200/50-10/
6.50

Sidering

6.50F-10

Tire size

Wheel
specification

Wheel
size

Pneumatic

Pneumatic
shaped cushion
nonmarking
white

Tire size

Wheel
specification

7FBEF15 7FBEF16 7FBEF18 7FBEF20


STD

STD

STD

WATTS
STD

F01B

F01B

F01B

WATTS

F01J

WATTS
WATTS

F01J

F01J

WATTS

F01K

F01K

WATTS
F01K

WATTS

Rear Tire
Model
Tire name

Tire
specification

7FBEF15 7FBEF16 7FBEF18 7FBEF20

Tire
brand

RR

U-LUG
Tire

154.1/28/
3.00

Sidering

3.00D-8

RR

U-LUG
Tire

1668/4.33

Sidering

4.33R-8

RR

J-LUG
Tire

154.1/28/
3.00

Sidering

3.00D-8

RR

J-LUG
Tire

1668/4.33

Sidering

4.33R-8

Pneumatic

RR

J-LUG
Tire

154.1/2812PR

Sidering

3.00D-8

F41J

F41J

F41J

WATTS

Pneumatic
shaped cushion
nonmarking
white

RR

U-LUG
Tire

154.1/28/
3.00

Sidering

3.00D-8

F41K

F41K

F41K

WATTS

RR

U-LUG
Tire

1668/4.33

Sidering

4.33R-8

Pneumatic
shaped cushion

STD

STD

STD

WATTS
STD

F41A

2
3

WATTS
F01B

F01K

Tire
brand

F41A

F41A

WATTS
WATTS

F41A

F41K

WATTS

WATTS

4-6

STEERING
Steering system
General
Power Steering System
Full hydraulic steering system is adopted as the standard as on the previous models.
The power steering system on the previous models has used an exclusive motor pump to supply hydraulic
oil to the power steering system.
On the new models, the hydraulic oil from the oil pump is shunted by the priority valve to supply hydraulic
oil at an appropriate pressure to each power system.

Solenoid valve
Steering valve
Oil control valve
Oil pump

Priority valve
Rear axle cylinder

Rear axle

Oil tank

4-7

Priority valve
Operation
When the key switch is OFF
The spool in the priority valve is located to the left of the control spring.
P (Oil pump)

Spool
Control spring

When no steering operation is performed


Hydraulic oil flows from the pump through the spool to PP and LS pilot line.
As the CF line in the steering valve is shut and the pilot line is drained, internal pressure of CF goes
through inside the spool to PP and to the LH chamber, pushing the spool to the right side of the figure.

4-8
As the spool is pushed to the right side, the EF line circuit opens, allowing almost all the pump discharge to
flow from the EF line to the control valve.

When steering operation is performed


Turning the steering wheel opens the control orifice in the steering valve and opens the CF line.
The lower side pressure of the control orifice goes through the LS pilot line to the RH chamber, generating
the pressure difference with the LH chamber in which the pressure is equal to that of the upper control
orifice. The pressure difference differs depending on the opening of the control orifice (steering speed).
The spool is operated by this pressure difference to divide some pressure from the pump and supply
adequate hydraulic oil to the steering valve.

4-9

Steering system
General
The rack and pinion of the turning drive portion in the full hydraulic power steering system are made
compact with integration. Removal and installation of the rear axle including the rack and pinion have
become easier.

Previous
Pinion
PS cylinder

New model

PS cylinder

Pinion

Steering wheel
General
1. The steering wheel outside diameter is changed from 380 mm (15.0 in) to 360 mm (14.2 in) for easier
operation.
2. Tilt steering with memory is adopted.
3. Since the steering tilt angle is memorized when the steering column is raised and returned to the
original position, no re-setting is necessary.
4. The steering wheel adjustable angle is widened from 6 on the previous models to 9.

4-10

BRAKE
Brake pedal
General
1. The brake structure is changed from the hydraulic to the mechanical type on all models.
2. The pendant pedal link structure is adopted as on the previous models.

The regenerative brake


The regenerative brake sensor use a limit switch not only to improve the sensor system reliability but also
to facilitate maintenance when readjustment of the regenerative brake becomes necessary.

Sensor for regenerative brake

Brake pedal

4-11

Front brake
General
Hydraulic parts such as the master cylinder are discontinued by adoption of mechanical disc brake that
has excellent maintainability.

Brake specifocations
Type

Foot brake

Mechanical disc brake

Parking brake

Mechanical disc brake

Brake disc outside diameter mm (in)

203 (8.0)

Brake effective diameter mm (in)

165 (6.5)

Material
Brake pad

Dimension mm (in)
Area mm2 (in2)

Semi-metallic phenol resin


Outside diameter: R100 (3.94) Inside diameter:
R65 (2.56) Thickness: 6(0.24)
3528 (5.47) 2 2

Brake ASSY

Motor & Drive unit


Brake disc

4-12

Parking brake
General
The lever type (ratchet type) is adopted as on previous models. The grip portion is shaped for easy
gripping.

Previous model

New model

Structure
When the brake lever is pulled from position A to position B in the figure below, the disc brake is
mechanically applied through a wire cable.

Operation method
1. Grip the knob and pull the lever from position A to
position B to apply the parking brake.
2. For releasing, throw the lever from position B to
position A while pressing the release button in the
illustration.

Release button
Position A
Position B

Lever operating force


Lever operating force

N(kgf)

100~200 (10.2~20.4)

* The figure above is maximized at the position when the lever is pulled about 35 from position A above.

5-1

INSTRUMENTS
Page

MULTIPLE DISPLAY ...................................................... 5-2


GENERAL FUNCTIONS ............................................... 5-10
DIAGNOSIS ...................................................................... 5-15

2
3

MASK FUNCTIONS ....................................................... 5-21

5-2

MULTIPLE DISPLAY
General
The multiple display indicates various types of vehicle information by switching the screen according to
need.
Display and Buttons

Initial screen upon key switch on

SAS

TOYOT A
EQU I P P ED
S P H

S P H
MENU

(1) (2)

3 0 /

(3)

AM

(4)

(8) (9)

11: 00
S P H

S P H
MENU

(5) (7)

(6)

During traveling

(10)

Upon error occurrence

10Km / h 1 1 : 0 0
S P H

A1
S P H

A1

2 A1
3
1 2 3 4 5 . Oh
S P H

MENU

S P H
MENU

(1)

Parking brake ON indicator

(6)

Power select indicator

(2)

2-speed travel speed set indicator

(7)

Multiple display area

(3)

Diagnosis ON indicator

(8)

2-speed travel speed control

(4)

Overheat warning indicator

(9)

Hour meter selector button

(5)

Battery charge indicator

(10) Power select button

5-3
(1) Parking brake ON indicator
This indicator comes on when the parking brake is activated. If the accelerator pedal is depressed with
the direction lever in the forward or reverse position, beeps sound to warn the operator.
(2) 2-speed travel speed set indicator
Each time the button is pressed, the indicator comes on or goes out. When this indicator is on, 2-speed
travel speed is on to limit the maximum vehicle speed to the set level.
(3) Diagnosis ON indicator
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same
time, the corresponding error code is displayed and buzzer sounds to warn the operator.
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to
six error codes are displayed with alternation at intervals of 2 seconds.
On a SAS model vehicle without matching performed for the SAS function, this indicator comes on to
warn the service person. Perform matching by referring to the MATCHING section.
(4) Overheat warning indicator
If the temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or
pump motor rises beyond the specified level, the overheat warning indicator blinks. At the same time,
a buzzer sounds to warn the operator.
When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks.
Display Information

2
3

Overheat warning indicator

3 0 /

AM

Display information

Overheat section

C/R

Main controller

DCR

Traveling AC driver

PCR

Material handling AC driver

DM

Drive motor

PM

Pump motor

11 : 00
S P H

S P H

MENU

Overheat section

Vehicle Operation Restriction when Overheated


Overheat
section

SpecificaMode
tion

STD
Main
Fisherman
controller
spec (OPT)

STD
Traveling
Fisherman
AC driver
spec (OPT)

Material
STD
handling Fisherman
AC driver spec (OPT)

P
S
P
S
P
S

Description of control
Primary control

Secondary control

1. Character indication and indicator blink


2. Buzzer for 5 seconds
3. Change to half throttle
1. Character indication and indicator blink
2. Buzzer for 5 seconds
3. Change to half throttle
1. Character indication and indicator blink
2. Buzzer for 5 seconds
3. Restrict material handling output

Tertiary control

5-4
Overheat
section

SpecificaMode
tion

STD
P

S
Drive
motor
H
Fisherman
spec (OPT)

S
H
STD

P
S

Primary control

Secondary control

Tertiary control

1. Character indication 1. Character indication


and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
seconds
3. Change to half
3. Change to S mode
throttle

1. Character indication
and indicator blink
2. Buzzer continues
3. Change to half
throttle

1. Character indication
1. Character indication
1. Character indication
and indicator blink
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
2. No buzzer
seconds
3. Change to half
3. Restrict drive output
3. Change to S mode
throttle
1. Character indication
1. Character indication
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
seconds
3. Change to half
3. Restrict drive
throttle
output

1. Character indication and indicator blink


2. Buzzer continues
3. Restrict material handling output

1. Character indication
1. Character indication
1. Character indication
and indicator blink
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
2. No buzzer
seconds
3. Restrict material
3. Change to S mode
3. Change to P mode
handling output

1. Character indication 1. Character indication


and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
seconds
3. Restrict material
3. Change to S mode
handling output

1. Character indication
and indicator blink
2. Buzzer continues
3. Restrict material
handling output

Pump
motor
Fisherman
spec (OPT)

Description of control

5-5
(5) Battery charge indicator
This indicator indicates the remaining battery charge in 10 stages.
A: Low remaining battery charge warning
The battery charge indicator blinks when the remaining battery charge drops to the set level or below.
When the key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to warn the
operator.
B: Battery overdischarge warning (lift interrupt function)
When the battery charge decreases further below the set level after the remaining battery charge
warning, any attempt at traveling or material handling operation will cause all charge indicator
segments to blink and the alarm to sound to warn the operator. In this case, material handling during
traveling cannot be performed.
Note:
The level can be set using TUNING function of the mask function. (See page 5-45.)
Low remaining battery charge warning

3 0 /

AM

S P H

Battery overdischarge warning

3 0 /

11 : 00
S P H
MENU

Number of segments corresponding to


the remaining battery charge.

2
3

AM

11 : 00
S P H

S P H
MENU

All battery charge indicator segments blink.

(6) Power select Indicator (traveling and material handling)


A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by
pressing the power select button on the GENERAL screen.
If all symbols are enclosed, control is performed in the original mode (level set on the POWER
CONTROL LEVEL SETTING screen).
(7) Multiple display area
The date and time are normally displayed in this area. This area is also used for various function
settings and error code displays of the diagnosis function.
(8) 2-speed travel speed control
Press this button on the GENERAL screen to set the 2-speed travel speed on and off.
(9) Hour meter selector button
This button changes displayed items of multi-hour meter function. The built-in function is different on
the easy model (standard vehicle) and the all-round model (OPT). (See page 5-9.)
(10) Power select button
The button selects S, P or H mode. The selected mode can be changed each time the power select
button is pressed on the GENERAL screen.
Press the button and hold it for 2 seconds to set the level of each function.

5-6
(11) Low temperature warning indicator
Warn the low temperature of the traveling and material handling AC drivers. When the material
handling AC driver temperature becomes low, a buzzer sounds to warn the operator for 5 seconds. At
the same time, it restricts the material handling output.
The low temperature section indication blinks.
Display information

COL D
DCR

AM

Display information

Low temperature section

COLD DCR

Traveling AC driver

COLD PCR

Material handling AC driver

11 : 00
S P H

S P H
MENU

Low temperature section

(12) Wheel indicator


The turning direction is displayed by | on the
multiple display area.
Note:
Display setting can be set by option setting of mask
function.
Speedometer can not be displayed when wheel
indicator is set to be displayed.

3 0 /

AM
|

1 1 : 0 0

S P H

S P H
MENU

Wheel indicator
In straight traveling state
3 0 /

AM
|

1 1 : 0 0

During left turn


3 0 /

9
AM
|

1 1 : 0 0

During right turn


3 0 /

AM 1 1 : 0 0
|

Specifications
LCD

Dot matrix + Fixed display

Buttons

Three buttons

Back light

LED type that comes on when the key switch is turned to ON

Heater

Temperature detection type (provided only on the cold-storage model)

5-7

Display indication list


Press button (3) for 2 sec. or more

Enter password

GENERAL screen
To be selected by the user
2-speed travel speed ON/OFF
Switching to hour meter display
Power select
To be set by the user
Traveling speed level
Speed alarm
Power control select
Clock set

ON or OFF setting of 2-speed travel speed


Checking traveling or material handling system operation time
Power mode selection
Setting of 2-speed travel speed level
Traveling speed setting for overspeed alarm
Fine adjustment of each of traveling and material handling power
control levels
Adjustment of indicated time

MASK FUNCTION screen


To be set by dealer or serviceman
DIAG MEMORY Checking past diagnosis error codes stored in memory
I/O MONITOR1
Checking the temperature and voltage of each functional part
Checking traveling-related sensors
I/O MONITOR2
ANALYZER
Checking material handling and mast control sensors
I/O MONITOR3
Checking steering knob synchronizer and other sensors
I/O MONITOR4
Forced ON/OFF test of each switch
ACTIVE TEST
Standard function adjustment
TUNING1
TUNING2 LIFTV Lift lever adjustment
TUNING
TUNING3 TILTV Tilt lever adjustment
TUNING4 ATT1V ATT 1 lever adjustment
TUNING5 ATT2V ATT 2 lever adjustment
DEMO MODE
Enabling simultaneous traveling and material handling before H/M start
H/M START
Starting the hour meter count
P/C LOCK
Power control lock selection
DESTI
Changing display for each destination
B LEVEL
Setting the traveling speed display
MPH
C/CNT RES
Setting the calculation constant for battery charge indicator
BATTERY
SHOU-TOKU
Setting the operation of the Auto-OFF function in relation to the seat switch
SEAT P-OFF
PARKING ERR
Setting the parking brake OFF warning
OPTION SET
TILT CONT
Setting the mast forward tilt angle restriction
KNOB CONT
TILT F-LIM
Setting the mast forward tilt/level function
B-TYPE
Setting the battery type
36V
2-WAY VALVE
Setting the specification of 2-way mini lever models
4-WAY VALVE
Setting the specification of 4-way mini lever models
USA
Setting the wheel indicator indication
WHEEL IND
SAS
Setting the SAS function
FISHERMAN
TILTL
Matching of the tilt/level angle
TILTF
Matching of the tilt forward restricted angle
LOAD
Matching of the NL load
TIRE
Matching of the tire angle sensor forward direction
MATCHING
LIFT
Matching of the lift lever neutral position
TILT
Matching of the tilt lever neutral position
ATT1
Matching of the ATT1 lever neutral position
ATT2
Matching of the ATT2 lever neutral position
Setting the tire constant
WHEEL DIA
WHEEL DIA

5-8

Abbreviations display on the screen


Abbreviation

Meaning

Abbreviation

Meaning

A1

Attachment switch 1

SSD2

Drive motor 2 rpm sensor

A2

Attachment switch 2

SSP

Pump motor rpm sensor

C/R

Controller

STS

Steering angle sensor

DCR

Traveling AC driver

STS1

Steering angle sensor 1

DM

Drive motor

STS2

Steering angle sensor 2

DSF

Forward direction switch

STSC

Steering angle sensor for straight


traveling

DSR

Backward direction switch

SWAC

Accelerator switch

FAN

Cooling fan

SWTK

Tilt knob switch

H/M

Hour meter

Forward and backward tilt switch

K-DIFF

Deviation of steering angle knob


position

TBD

Traveling AC driver control board


surface temperature

K-POS

Steering angle knob position

TBP

Material handling AC driver control


board surface temperature

KSOL

Steering synchronizer solenoid

TD

Drive motor temperature

LOAD

Material handling hydraulic pressure

TEMP

CPU board surface temperature

Lift switch

THCD

Main drive circuit temperature

LSB

Brake switch

THCP

Main pump circuit temperature

LSD

Seat switch

TILTF

Forward tilt restriction position

MH

Lifting height switch

TILTL

Tilt level position

P/C

Power control

TIRE

Tire angle sensor voltage

PCR

Material handling AC driver

TP

Pump motor temperature

PM

Pump motor

VB48

Battery voltage

POTA

Accelerator potentiometer

VBBD

Traveling AC driver power source


voltage

POTT

Tilt angle potentiometer

VBBP

Material handling AC driver power


source voltage

SPD

Main traveling speed

VBKS

Voltage after key switch

SPL

Load sensor

VBMB

Main controller input voltage

SSD1

Drive motor 1 rpm sensor

VBSOL

Solenoid power source voltage

5-9

General functions
1. General functions can generally been used or seen by the user.
2. Two types of multiple displays are available: the easy model (the standard specification), and the allround model (OPT). The display contents vary as follows:

Functions

Status display
function

Level setting
function

Multi-hour
meter
function

Warning function

{: General function :Not provided


Model
Easy model
All-round model
(standard)
(option)

Battery charge indicator

Speedometer

2-speed travel speed set indicator

Parking brake ON indicator

Power select indicator

Wheel indicator

Power select

Traveling power control level setting

Material handling power control level setting

2-speed travel speed level setting

Key ON hour meter

Traveling hour meter

Material handling hour meter

Traveling or Material handling hour meter

Odometer

Lap time meter

Trip meter

Calendar clock

Battery overdischarge warning

Low remaining battery charge warning

Overheat warning

Low temperature warning

Parking brake ON warning

Parking brake OFF warning

Return to neutral warning

{*1

{*1

Overspeed alarm

Diagnosis display

Material handling operation lock

*1: Provided on the vehicle with mini lever (OPT).

5-10

GENERAL FUNCTIONS
Changing Display
Button (1)

GENERAL screen

3 0 /

AM

Button (2)
2-speed travel speed
ON/OFF setting
Hour meter display
selection
Power control selection

11 : 00
S P H

S P H
MENU

Button (3)
Press button (3)
for 2 seconds or more.

2-SPEED TRAVEL SPEED


LEVEL SETTING screen

S P E E D 1
L E V E L

8
S P H

S P H
MENU

Press button (3)

OVERSPEED ALARM
SETTING screen (OPT)

S P E E D
A L A RM

10Km / h
S P H

S P H

* This screen is displayed


only on the all-round model.
The easy model does not
have this screen.

MENU

Press button (3)

POWER CONTROL
FUNCTION SELECTION
screen

P O WE R

S E L E CT
Y E S / NO
S P H

S P H
MENU

Press button (3)

CLOCK SET FUNCTION


SELECTION screen

CL OCK

S E T
YES / NO
S P H

S P H
MENU

Press button (3)


(To GENERAL screen)

*1: OVERSPEED ALARM SETTING screen is displayed only on the all-round model (OPT).
This screen is skipped on the easy model (standard).
*2: Upon returning to the GENERAL screen after moving to each function setting screen, the power select
mode is set to S. If necessary, select the desired mode.
If necessary, select the desired mode.

5-11

Operating procedure of function setting


GENERAL screen
1. 2-speed travel speed on/off selection
Press button (1) for 2-speed travel speed control on/
off. The 2-speed travel speed is on if the indicator
comes on.

2-speed travel speed indicator


Button (1)

3 0 /

AM

11 : 00
S P H

S P H

MENU

2. Hour meter display selection


Press button (2) to select the hour-meter display.
The differences between the displayed contents of the easy model (standard setting) and the all-round
model (optional setting) are as follows:
Easy model (standard)
Button (2)

GENERAL screen

3 0 /

AM

G Trip meter

T R I P
RE S E T

11 : 00
S P H

1 2 3 4 5. 0
SW
2 S E C

S P H
MENU

S P H

Press
button (2)

S P H
MENU

Button (3)
Press button (2)

Press button (3)


Easy model

Press button (2)

A Key ON hour meter

K E Y

F Lap time meter

ON

L A P

0 . 0 h
S P H

S P H

1 2 3 4 5. 0
SW
2
S P H

MENU

S P H
MENU

Press button (2)


All-round model

Press button (2)

B:Traveling hour meter


C:Material handling hour meter

D:Traveling or material handling hour meter


E:Odometer

0 . 0 h
0 . 0 h
S P H

ODO
S P H
MENU

0 . 0 h
0 . 0
S P H

Press
button (2)

S P H
MENU

The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.
Press button (3) on each screen to return to the GENERAL screen.

5-12
Model
Function

Easy
model

All-round
model

Description

Key ON hour meter

Indicates the total key ON time

Traveling hour meter

Traveling operation time

Material handling hour meter

Material handling operation time

Traveling/material handling
hour meter

Total time of traveling and material handling


operation (when both operations occur at the
same time, only operation time of either
operation)

Odometer

Total distance traveled

Lap time meter

Lap time upon key ON

Trip meter

Trip distance

3. Power select mode switching (S, P or H)


Press button (3) on the GENERAL screen to change
the travel/material handling power select mode. When
all of S, P and H are highlighted by squares, the
control is performed in the mode set on the Power
Control Level SETTING screen.
S: Standard mode
P: Power mode
H: High power mode

3 0 /

AM

11 : 00
S P H

S P H
MENU

Button (3)
Power select indicator

2-SPEED TRAVEL SPEED LEVEL SETTING screen


The 2-speed travel speed level is set on this screen.
Press button (3) on the general screen for 2 seconds or
more to display the 2-SPEED TRAVEL SPEED LEVEL
SETTING screen.
1. Press button (1) to decrease the 2-speed travel speed
level.
2. Press button (2) to increase the 2-speed travel speed
level.
3. Press button (3) to display the next screen.

Blinks upon 2-speed travel Button (1)


speed level setting.
Button (2)

8
S P H

S P H
MENU

2-speed travel speed level

Button (3)

OVERSPEED ALARM SETTING screen (OPT)


The traveling speed level for the overspeed alarm is set on this screen.
Press button (3) on the 2-SPEED TRAVEL SPEED
LEVEL SETTING screen to display the OVERSPEED
ALARM SETTING screen.
1. Press button (1) to decrease the traveling speed
setting.
2. Press button (2) to increase the traveling speed
setting.
3. Press button (3) to display the next screen.

Button (1) Button (2)

10Km / h
S P H

Traveling speed setting


for overspeed alarm

S P H
MENU

Button (3)

5-13
POWER CONTROL FUNCTION SELECTION screen
The travel and material handling power control levels can be set independently using this screen.
1. Press button (1) on the POWER CONTROL
Button (1) Button (2)
FUNCTION SELECTION screen, select YES and
press button (3) to display the TRAVEL POWER
CONTROL LEVEL SETTING screen.
(1) TRAVELING POWER CONTROL LEVEL
P OWE R
S E L E C T
Y E S / NO
SETTING screen
S P H
S P H
1) Press button (1) to select the lower level.
2) Press button (2) to select the higher level.
3) Press button (3) to display MATERIAL
Button (3)
HANDLING POWER CONTROL LEVEL
Select "YES" and
SETTING screen.
press button (3)
(2) MATERIAL HANDLING POWER CONTROL
TRAVELING POWER CONTROL
LEVEL SETTING screen
LEVEL SETTING screen
1) Press button (1) to select the lower level.
2) Press button (1) to select the higher level.
3) Press button (3) to display the next screen.
S P H
2. To display the next screen, press button (2) on the
S P H
S P H
POWER CONTROL FUNCTION SELECTION screen,
select NO and press button (3); alternatively, press
button (3) on the MATERIAL HANDLING POWER
Press button (3)
CONTROL LEVEL SETTING screen.
MENU

MENU

MATERIAL HANDLING POWER


CONTROL LEVEL SETTING screen

S PH

S P H

S P H
MENU

Press button (3)

CLOCK SET FUNCTION


SELECTION screen

5-14

CLOCK SET FUNCTION SELECTION screen


The year, month, day, day of week, time and 12/24-hour display can be set independently.
Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select NO, and press
button (3), or press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING
screen to display the CLOCK SET FUNCTION SELECTION screen.
Button (1)

P OWE R

Button (2)

S E L EC T
Y E S / NO

Button (3)
Select "NO" and press button (3)

C L OCK

S E T
Y E S / NO

Press button (3)

C L OCK

S E T
Y E S / NO

Press button (3)

Press button (3)

Each press of button (3) will shift


the selection item in this order:
month, day, ... and minute.

End of clock setting

Press button (3)

1. Press button (1) on the CLOCK DISPLAY FUNCTION SELECTION screen, select YES and press
button (3) to display the CLOCK SET screen.
CLOCK SET screen
1) Press button (1) to decrease the selected (blinking) value.
2) Press button (2) to increase the selected (blinking) value.
3) Press button (3) to enter the selected (blinking) value and proceed to the next item.
4) Press button (3) when MINUTES is selected on the CLOCK SET FUNCTION SELECTION
screen to display the next screen (GENERAL screen).
2. Press button (3) when NO is selected on the CLOCK SET FUNCTION SELECTION screen to display
the next screen (GENERAL screen).

5-15

DIAGNOSIS
1. When diagnosis is activated, the diagnosis ON
indicator comes on and blinks on the screen and a
beep sounds to warn the operator that some
abnormality has occurred on the vehicle.
2. Also, up to three diagnosis error codes are displayed
on the screen. When the number of error codes
exceeds three, up to six are displayed on screens.
3. In order to enable battery level checking, battery
charge indicator is displayed during diagnosis error
codes display.

Wrench symbol

A1

A1

2 A1
3
1 2 3 4 5 . Oh
S P H

S P H
MENU

Diagnosis codes
Abnormality detection time
(Key ON hour meter)

Diagnosis code list


Displayed code: Code indicated on the display when an abnormality occurs in the vehicle
Diag memory code: Code indicated on the display when mask function DIAG MEMORY is in use P5-30
C/R: Main controller, DCR_LH: Traveling AC driver 1, DCR_RH: Traveling AC driver 2,
PCR: Material handling AC driver
Diag
Displayed
memory
code
code

Faulty

Phenomenon on vehicle

Detection
controller

DCR: Low temperature

Display only

DCR_LH,
DCR_RH

PCR: Low temperature

Restricted material
handling output

PCR

30-1

30-1

DCR_LH: Low voltage

30-2

30-2

DCR_RH: Low voltage

30-3

30-3

PCR: Low voltage

Material handling and


power steering stop

PCR

31-1
31-2

31-1
31-2

DCR_LH: Low starting voltage


DCR_RH: Low starting voltage

Traveling disabled

DCR_LH
DCR_RH

31-3

31-3

PCR: Low starting voltage

Material handling and


power steering stop

PCR

32-1
32-2
32-3

32-1
32-2
32-3

DCR_LH: EEPROM abnormality


DCR_RH: EEPROM abnormality
PCR: EEPROM abnormality

DCR_LH
Operate under the default DCR_RH
PCR

33-1

33-1

Communication abnormality from C/R to


DCR_LH

33-2

33-2

33-3

33-3

61-1

61-1

Communication abnormality from C/R to


DCR_RH
Communication abnormality from C/R to
PCR
Load sensor: Open

61-2

61-2

Load sensor: Short circuit

62-1
62-2

62-1
62-2

Tilt angle sensor: Open


Tilt angle sensor: Short circuit

Traveling disabled

DCR_LH
DCR_RH

DCR_LH
Traveling disabled
DCR_RH
Material handling and
PCR
power steering stop
No NL control and forward tilt restriction
C/R
No automatic leveling
No forward tilt restriction
C/R
No automatic leveling

5-16
Diag
Displayed
memory
code
code

Faulty

Phenomenon on vehicle

Detection
controller

63-1

63-1

63-2

63-2

63-3

63-3

64-1
64-2
64-3
65-1
65-2
65-3

64-1
64-2
64-3
65-1
65-2
65-3

Forward and backward tilt SWs:


simultaneously on
Forward tilt SW: Short circuit for more than 2
minutes
Backward tilt SW: Short circuit for more than
2 minutes
Lift solenoid: Open
Lift solenoid: Short circuit
Lift solenoid: Drive circuit abnormality
Tilt solenoid: Open
Tilt solenoid: Short circuit
Tilt solenoid: Drive circuit abnormality

66-1

66-1

Tilt matching abnormality

67-1

67-1

Lifting height switch abnormality

71-1
71-2
72-1
72-2
72-3
72-4
73-1

71-1
71-2
72-1
72-2
72-3
72-4
73-1

73-2

73-2

73-3

73-3

Tire angle sensor: Open


Tire angle sensor: Short circuit
Steering angle sensor: STS1 abnormality
Steering angle sensor: STS2 abnormality
Steering angle sensor: STSC abnormality
Steering angle sensor: Open
Steering knob synchronizer solenoid: Open
Steering knob synchronizer solenoid: Short
circuit
Steering knob synchronizer solenoid:
Drive circuit abnormality

74-1

74-1

Tire angle sensor matching abnormality

Traveling restriction,
C/R
no steering synchronizer

A0-1

DCR main drive circuit overheat

Restricted traveling output

DCR_LH,
DCR_RH

A0-2

PCR main drive circuit overheat

Restricted material
handling output

PCR

C/R

No forward tilt restriction


No automatic leveling
C/R
(Forward tilt disabled)

Interruption of lift solenoid output

C/R

Interruption of tilt solenoid output

C/R

No forward tilt restriction


C/R
No automatic leveling
No low lift restriction and
forward tilt restriction
C/R
No automatic leveling
Traveling stop, no steerC/R
ing knob synchronizer
No steering knob synchronizer

C/R

Steering knob synchroC/R


nizer solenoid output stop

A1-1

A1-1

C/R: High voltage

Traveling disabled
Material handling and
power steering disabled
(solenoid off)

A1-2
A1-3

A1-2
A1-3

DCR_LH: High voltage


DCR_RH: High voltage

Traveling disabled

DCR_LH
DCR_RH

A1-4

A1-4

PCR: High voltage

Material handling and


power steering disabled

PCR

5-17
Diag
Displayed
memory
code
code

Faulty

Phenomenon on vehicle

Detection
controller

A2-1

CPU board overheat

Restricted traveling output

C/R

A2-2

DCR_LH or DCR_RH board overheat

Restricted traveling output

DCR_LH,
DCR_RH

A2-3

PCR board overheat

Restricted material handling output

PCR

A3

A3

Incorrect battery connection

A4
A6-1
A6-3
A6-5
AA-1
AA-2
AA-3

A4
A6-1
A6-3
A6-5
AA-1
AA-2
AA-3

Accelerator switch abnormality


Lift switch abnormality
Tilt switch abnormality
Attachment switch 1 abnormality
CPU board thermo-sensor abnormality
DCR_L board thermo-sensor abnormality
DCR_R board thermo-sensor abnormality

AA-4

AA-4

PCR board thermo-sensor abnormality

AC

AC

AD-1

AD-1

AD-2

AD-2

AD-3

AD-3

AD-4

AD-4

AD-5

AD-5

AD-6

AD-6

Semiconductor switch abnormality

Traveling disabled
Material handling and
power steering disabled
MB not turned on
Traveling disabled

C/R
C/R

Material handling disabled

C/R

Restricted traveling output

C/R
DCR_LH
DCR_RH

Restricted material handling output


Traveling disabled
Material handling and
power steering disabled
MB not turned on

Communication abnormality from DCR_L to


Traveling disabled
C/R (1)
Traveling disabled
Communication abnormality from DCR_L to (when AD-4 and AD-6
C/R (2)
occur at the same time,
MB not turned on)
Communication abnormality from DCR_R to
Traveling disabled
C/R (1)
Traveling disabled
Communication abnormality from DCR_R to (when AD-2 and AD-6
C/R (2)
occur at the same time,
MB not turned on)
Communication abnormality from PCR to
Material handling and
C/R (1)
power steering disabled
Material handling and
power steering disabled
Communication abnormality from PCR to
(when AD-2 and AD-4
C/R (2)
occur at the same time,
MB not turned on)

PCR

C/R

C/R

C/R

C/R

C/R

C/R

C/R

5-18
Diag
Displayed
memory
code
code
AF-1
AF-1
AF-2
AF-2
AF-3
AF-3
AF-4
AF-4
C1-1
C1-1
C1-2
C1-2
C1-3
C1-3
C1-4
C1-4

Faulty
CPU abnormality (1)
CPU abnormality (2)
CPU abnormality (3)
CPU abnormality (4)
DCR_LH current sensor offset abnormality
DCR_LH: Overcurrent
DCR_RH current sensor offset abnormality
DCR_RH: Overcurrent

C2-1

Drive motor overheat

C2-2
C2-3

C2-2
C2-3

C3-1

C3-1

C3-2

C3-2

C4-1
C4-2
C4-3
C4-4
C7
C8-1
C8-2

C4-1
C4-2
C4-3
C4-4
C7
C8-1
C8-2

Drive motor 1 thermo-sensor abnormality


Drive motor 2 thermo-sensor abnormality
DCR_LH main drive circuit thermo-sensor
abnormality
DCR_RH main drive circuit thermo-sensor
abnormality
Accelerator potentiometer abnormality (1)
Accelerator potentiometer abnormality (2)
Accelerator potentiometer abnormality (3)
Accelerator potentiometer abnormality (4)
Direction switch abnormality
Drive motor 1 rpm sensor abnormality
Drive motor 2 rpm sensor abnormality

CB-1

CB-1

MB contactor abnormality

CB-2
E1-1
E1-2

CB-2
E1-1
E1-2

MB contactor fused
PCR current sensor offset abnormality
PCR: Overcurrent

E2-1

Pump motor overheat

E2-2

E2-2

E3

E3

Pump motor thermo-sensor abnormality


PCR main drive circuit thermo-sensor
abnormality

E8

E8

EE-1

EE-1

EE-2

EE-2

EE-3

EE-3

Pump motor rpm sensor abnormality

Phenomenon on vehicle

Detection
controller

Traveling disabled
Material handling disC/R
abled
Power steering disabled
DCR_LH
Traveling disabled
DCR_RH

Restricted traveling output

Restricted traveling output

Traveling disabled
Display only
Traveling disabled
Restricted traveling output
Traveling disabled
Material handling and
power steering disabled
(solenoid off)
Display only
Material handling and
power steering disabled
Restricted material
handling output
Restricted material
handling output
Material handling disabled

DCR_LH
DCR_RH
DCR_LH
DCR_RH
DCR_LH
DCR_RH

C/R
C/R
DCR_LH
DCR_RH
C/R
C/R
PCR

PCR

PCR
PCR

Communication abnormality from display to


C/R (1)
Display only
C/R
Communication abnormality from display to
C/R (2)
Communication abnormality from display to
Operate under the default C/R
C/R (3)

5-19
Diag
Displayed
memory
code
code
EF-1
EF-1
EF-2
EF-2
EF-3
EF-3
EF-4
EF-1

Faulty

F1-1

F1-1

F1-2

F1-2

FF
H1-1 *1
H1-2 *1
H1-3 *1
H1-4 *1
H1-5 *1
H2-1 *1
H2-2 *1
H2-3 *1
H2-4 *1
H2-5 *1
H3-1 *1
H3-2 *1
H3-3 *1

FF
H1-1
H1-2
H1-3
H1-4
H1-5
H2-1
H2-2
H2-3
H2-4
H2-5
H3-1
H3-2
H3-3

H3-4 *1

H3-4

H3-5 *1

H3-5

H4-1 *1
H4-2 *1
H4-3 *1

H4-1
H4-2
H4-3

H4-4 *1

H4-4

H4-5 *1

H4-5

H5-1 *1

H5-1

EEPROM abnormality (1)


EEPROM abnormality (2)
CPU abnormality
EEPROM abnormality (3)
Communication abnormality from C/R to display (1)
Communication abnormality from C/R to display (2)
D15V overcurrent
Lift potentiometer abnormality (1)
Lift potentiometer abnormality (2)
Lift potentiometer abnormality (3)
Lift potentiometer neutral abnormality
Lift potentiometer matching abnormality
Tilt potentiometer abnormality (1)
Tilt potentiometer abnormality(2)
Tilt potentiometer abnormality (3)
Tilt potentiometer neutral abnormality
Tilt potentiometer matching abnormality
Attachment 1 potentiometer abnormality (1)
Attachment 1 potentiometer abnormality (2)
Attachment 1 potentiometer abnormality (3)
Attachment 1 potentiometer neutral abnormality
Attachment 1 potentiometer matching
abnormality
Attachment 2 potentiometer abnormality (1)
Attachment 2 potentiometer abnormality (2)
Attachment 2 potentiometer abnormality (3)
Attachment 2 potentiometer neutral abnormality
Attachment 2 potentiometer matching
abnormality
Lift b1 (UP) solenoid abnormality (1)

H5-2 *1

H5-2

Lift b1 (UP) solenoid abnormality (2)

H5-3 *1

H5-3

Lift a1 (DOWN) solenoid abnormality (1)

H5-4 *1

H5-4

Lift a1 (DOWN) solenoid abnormality (2)

H5-5 *1

H5-5

Lift solenoid drive circuit abnormality

Phenomenon on vehicle

Detection
controller

Operate under the default


Operate under the default
C/R
Display only
Operate under the default
Display only

Display

Display off

C/R

Lift operation stop

C/R

Tilt operation stop

C/R

Attachment 1 operation
stop

C/R

Attachment 2 operation
stop

C/R

Lift operation stop


Material handling disabled
Lift operation stop
Material handling disabled
Material handling disabled

C/R

5-20
Diag
Displayed
memory
Faulty
code
code
H6-1 *1
H6-1 Tilt a2 (FRONT) solenoid abnormality (1)
H6-2 *1

H6-2

Tilt a2 (FRONT) solenoid abnormality (2)

H6-3 *1

H6-3

Tilt b2 (REAR) solenoid abnormality (1)

H6-4 *1

H6-4

Tilt b2 (REAR) solenoid abnormality (2)

H6-5 *1

H6-5

Tilt solenoid drive circuit abnormality

H7-1 *1

H7-1

Attachment 1 a3 solenoid abnormality (1)

H7-2 *1

H7-2

Attachment 1 a3 solenoid abnormality (2)

H7-3 *1

H7-3

Attachment 1 b3 solenoid abnormality (1)

H7-4 *1

H7-4

Attachment 1 b3 solenoid abnormality (2)

H7-5 *1

H7-5

Attachment 1 solenoid drive circuit abnormality

H8-1 *1

H8-1

Attachment 2 a4 solenoid abnormality (1)

H8-2 *1

H8-2

Attachment 2 a4 solenoid abnormality (2)

H8-3 *1

H8-3

Attachment 2 b4 solenoid abnormality (1)

H8-4 *1

H8-4

Attachment 2 b4 solenoid abnormality (2)

H8-5 *1

H8-5

H9-1 *1
H9-2 *1

H9-1
H9-2

H9-3 *1

H9-3

Attachment 2 solenoid drive circuit abnormality


Unload valve solenoid open
Unload valve solenoid short
Unload valve solenoid drive circuit abnormality

*1: Only on the vehicle with the mini lever (OPT).

Phenomenon on vehicle
Tilt operation stop
Material handling disabled
Tilt operation stop
Material handling disabled
Material handling disabled
Attachment 1 operation
stop
Material handling disabled
Attachment 1 operation
stop
Material handling disabled
Material handling disabled
Attachment 2 operation
stop
Material handling disabled
Attachment 2 operation
stop
Material handling disabled
Material handling disabled
Material handling disabled

Detection
controller

C/R

C/R

C/R

C/R

5-21

MASK FUNCTIONS
General
In addition to the functions described in the instruction manual for use by general users, the multiple
display provides the following mask functions for use by the service staff for vehicle maintenance and
specification setting.
The mask functions are protected by password to prevent damage of the data by unintentional operation
by users.
Mask function list
When used

Option
set

Vehicle
delivery

Board
replacement

Others

Analyzer

Displays the vehicles electrical


system operating status and reads
the error information detected by
controllers.

Upon vehicle
abnormality
detection

Tuning

Makes fine adjustment of traveling


and material handling functions.

{
*2

As requested by
customer

Specification
setting

Sets each vehicle option and other


specifications. *1

{
*2 *3

Each control
function
enable/disable

Enables or disables each control


function.

{
*2 *3

Hour meter
start

Starts the hour meter count.

{
*3

Demo mode

Enables or disables the demo


mode. (Material handling prohibition during traveling for vehicle
delivery)

Upon new
vehicle
demonstration

Updates voltage values of sensor


signals under the standard vehicle
condition.

{
*2

Makes the speedometer reading


appropriate.

{
*2

Function

Description

Matching
Tire constant set

*1: This matches the controller and screen control according to the installed options and control functions
equipped on the vehicle; note that this function does not enable or disable the option or control function
itself.
*2: Board: Main controller
*3: Board: Multiple display control board

5-22
Preparation for the MASK MENU screen
Caution:
When going to the MASK MENU screen from the
general screen, always jack up the vehicle until the
drive wheels (front tires) leave the ground, and
support the vehicle with wooden blocks under the
front frames.
Be sure to fully lower the fork.
1. Check that the battery plug is connected securely and
turn the key switch to ON.
2. Operate mask functions according to Password Input
Procedure. (See page 5-23.)

5-23

Password
Notes on password input
1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button
may be damaged.
2. If a mistake is made part of the way through, turn the key switch to OFF and begin again. If the MASK
MENU screen does not appear after several attempts, the system may be faulty.
Password input procedure
Button (1)

3 0 / 9

AM

Button (2)

11 : 00
S P H

S P H
MENU

MASK MENU screen

1. Press buttons (1) and (2) at the same time.

Button (1)

3 0 / 9

AM

Ve
D* . *
T L * . * TR* . *

11 : 00
S P H

S P H

C* .
P * .
S P H

MENU

MENU

2. Within 10 seconds, press button (1)

5. The VERSION screen is displayed for


about 3 seconds.
Button (2)
Button (3)

Button (2)

3 0 / 9

AM

3 0 / 9

11 : 00
S P H

AM

S P H

11 : 00
S P H

MENU

S P H
MENU

4. Within 10 seconds, press buttons (2) and (3)


at the same time for more than 2 seconds.

3. Within 10 seconds, press button (2)

Procedure

S P H

Operation

Response from the vehicle

Press buttons (1) and (2) at the same time.

A short beep sounds.

Press button (1) (in 10 seconds after pressing button (1) and
(2))

A short beep sounds.

Press button (2) (in 10 seconds after pressing button (1))

A short beep sounds.

Press buttons (2) and (3) at the same time and hold for 2
seconds or more. (in 10 seconds after pressing button (2), End A short beep sounds.
of password input)

The VERSION screen is displayed automatically.

After displaying the VERSION screen for 3 seconds, the MASK MENU screen appears automatically.

5-24
Operation on MASK MENU screen
Caution:
Unlike the analyzer function selection on of previous models, display of test screen does not
prohibit the vehicles ordinary operation.
1. Input the password on the general screen (see page 5-23) to display the MASK MENU screen.
2. Press button (1) or (2) to select the desired menu item, and press button (3) (enter) to display the
menu or setting screen for each function.
(1) ANALYZER screen
This screen displays the vehicles electrical system operating status and the error code detected by
the controller.
(2) TUNING screen
Performs fine adjustment of traveling and material handling control.
(3) OPTION SET screen
Matches the controller or display control according to the set option or control.
(4) MATCHING screen
This screen is for updating the sensor output voltage stored in the controller (output voltage values
from the SAS function and mini lever function sensors in the standard vehicle condition).
(5) WHEEL DIA screen
Updates the tire information in the controller to correct the speed and trip meter display.
(6) END screen
GENERAL screen can displayed from this screen.
Press button (3) on this screen to display the GENERAL screen.
As an alternative method, turn the key switch to OFF when any screen is displayed to display the
general screen.

Version screen

Button (2)

GENERAL screen

Button (1)

Press Button (3)

= ME NU=
6 . END

= ME NU=
1 . ANAL YZ ER
S P H

S P H

S P H

S P H
MENU

MENU

Button (3)
Press Button (1) or
(2) to switch screen.

Press Button (1) or


(2) to switch screen.

= ME NU=
5 . WH E E L

= ME NU=
2 . T U N I NG
S P H

D I A

S P H

S P H

Press Button (1) or


(2) to switch screen.

= ME NU=
3 . OP T I ON

Press Button (1) or


(2) to switch screen.

= ME NU=
4 . MA T C H I N G

SE T
S P H

S P H
MENU

MENU

S P H
MENU

S P H

Press Button (1) or


(2) to switch screen.

S P H
MENU

5-25

Analyzer
General
1. The analyzer supports inspection and troubleshooting of the control system using the communication
function between the traveling/material handling controller and the display.
2. Setting the display into the ANALYZER screen makes it possible to inspect and detect abnormality in
functions of the operating system and sensors, such as main traveling, material handling, EHPS, SAS
circuits and the accelerator.
3. Utilization of the analyzer functions enables quick, easy servicing.
4. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes detected in the electrical system in the past. The
diagnosis memory function displays these error codes.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/Out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors in the traveling, material
handling, EHPS and SAS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(a) I/O MONITOR1
Displays the temperature of each electrical functional part and the analog input voltage
detected by each controller.
(b) I/O MONITOR2
Displays the ON/OFF states of traveling-related switches and the analog input voltage from
related sensors.
(c)
I/O MONITOR3
Displays ON/OFF of switches related to traveling and mast control and the analog input
voltage values from related sensors.
(d) I/O MONITOR4
Displays the ON/OFF states of steering knob synchronizer-related and other switches and
the analog input voltage values from related sensors.
(3) Active test function (ACTIVE TEST)
The controller outputs an operation signal (ON or OFF signal) to the selected item in order to permit
operation check of that function.
(4) One error code at the time is displayed in the upper right-hand portion on both the I/O MONITOR
and ACTIVE TEST screens.

5-26
Analyzer menu screen list
*Values shown in the 2nd column are display examples and not the standard values.
ANALYZER MENU
screen
1

DIAG MEMORY

I/O MONITOR1
(Voltage/
temperature)

I/O MONITOR2
(Traveling
system)

Display
1st column

Meaning

2nd column

DIAG-1 to
DIAG-10

Error code and


detection time

Error display

I/O 1-1

THCD: +25/+25

Main drive circuit 1 temperature (heat sink): C


Main drive circuit 2 temperature (heat sink): C

I/O 1-2

THCP: +25

Main pump circuit temperature (heat sink): C

I/O 1-3

TD: +25/+25

Drive motor 1 temperature: C


Drive motor 2 temperature: C

I/O 1-4

TP: +25

Pump motor temperature: C

I/O 1-5

TBD: +25/+25

Traveling AC driver 1 board temperature: C


Traveling AC driver 2 board temperature: C

I/O 1-6

TBP: +25

material handling AC driver board temperature: C

I/O 1-7

TEMP: +25.0

CPU board temperature: C

I/O 1-8

VB48: 50.0

Battery voltage: V

I/O 1-9

VBKS: 50.0

Key start voltage: V

I/O 1-10

VBSOL: 50

Solenoid voltage: V

I/O 1-11

VBMB: 50

Voltage after MB contactor: V

I/O 1-12

VBBD: 50/50

Traveling AC driver 1 DC_BUS voltage: V


Traveling AC driver 2 DC_BUS voltage: V

I/O 1-13

VBBP: 50

Material handling AC driver DC_BUS voltage:


V

I/O 2-1

POTA: 0.71
SWAC: 0

Accelerator potentiometer voltage: V


Acceleration switch: 0 (OFF), 1 (ON)

I/O 2-2

DSF: 0
DSR: 0

Forward switch: 0 (OFF), 1 (ON)


Reverse switch: 0 (OFF), 1 (ON)

I/O 2-3

LSB: 1
LSD: 1

Brake switch: 0 (OFF), 1 (ON)


Seat switch: 0 (OFF), 1 (ON)

I/O 2-4

SSD1: 3000
[3000]

Drove motor 1 rpm: rpm


[Main controller instruction rpm: rpm]

I/O 2-5

SSD2: 3000
[3000]

Drove motor 2 rpm: rpm


[Main controller instruction rpm: rpm]

I/O 2-6

SPD: 10.0

Main traveling speed: mph or km/h

5-27
ANALYZER MENU
screen

Display
1st column

I/O 3-1

I/O 3-2

I/O 3-3

I/O 3-4

I/O MONITOR3
(material handling
system and mast
control)

Meaning

2nd column
L: . . 1

Lift switch: 0 (OFF), 1 (ON)

*1
L:0.90 3.50 10

Lift lever angle 1 sensor voltage: V


Lift lever angle 2 sensor voltage: V
Lift raise switch: 0 (OFF), 1 (ON)
Lift lower switch: 0 (OFF), 1 (ON)

L (SOL):.

Unused

*1
L (SOL):0.35

Lift proportional valve current: A

T:. . 10

Forward tilt switch: 0 (OFF), 1 (ON)


Backward tilt switch: 0 (OFF), 1 (ON)

*1
T:0.90 3.50 10

Tilt lever angle 1 sensor voltage: V


Tilt lever angle 2 sensor voltage: V
Forward tilt switch: 0 (OFF), 1 (ON)
Backward tilt switch: 0 (OFF), 1 (ON)

T (SOL):.

Unused

*1
T (SOL):0.35

Tilt proportional valve current: A

A1: . . 1 Attachment 1 switch: 0 (OFF), 1 (ON)


I/O 3-5

I/O 3-6

I/O 3-7

*2
A1:0.90 3.50 01

Attachment 1 lever angle 1 sensor voltage: V


Attachment 1 lever angle 2 sensor voltage: V
Attachment 1 raise switch: 0 (OFF), 1 (ON)
Attachment 1 lower switch: 0 (OFF), 1 (ON)

A1 (SOL):.

Unused

*2
A1 (SOL):0.35

Attachment 1 proportional valve current: A

A2:. .

Unused

*3
A2:0.90 3.50 01

Attachment 2 lever angle 1 sensor voltage: V


Attachment 2 lever angle 2 sensor voltage: V
Attachment 2 raise switch: 0 (OFF), 1 (ON)
Attachment 2 lower switch: 0 (OFF), 1 (ON)

A2 (SOL):.

Unused

I/O 3-8

*3
A2 (SOL):0.35

Attachment 2 proportional valve current: A

I/O 3-9

SWTK:0

Tilt knob switch: 0 (OFF), 1 (ON)

I/O 3-10

SSP:2000
[2000]

Pump motor rpm: rpm


[Main controller instruction rpm: rpm]

I/O 3-11

MH:10

Lifting height switch: 0 (OFF), 1 (ON)

I/O 3-12

POTT:2.50

Tilt angle sensor voltage: V

I/O 3-13

SPL:0.84 (1.7)

Load sensor voltage: V (MPa display)

5-28
ANALYZER MENU
screen

I/O MONITOR4
(Steering
control)

ACTIVE TEST
(operation test)

Display
1st column

Meaning

2nd column

I/O 4-1

STS:001

Steering angle sensor pulse: 0 (OFF), 1 (ON)

I/O 4-2

K-POS:159
(150)

Steering angle knob position: Actual (target)

I/O 4-3

K-DIFF:100
SOL:0

Deviation of steering angle knob position


Steering knob synchronizer solenoid:
0 (OFF), 1 (ON)

I/O 4-4

TIRE:2.40

Tire angle sensor voltage: V

ACT-1

FAN: ON/OFF
(48)

Fan output
Fan voltage: V

KSOL: ON/OFF
(0)

Steering knob synchronizer solenoid output


Steering knob synchronizer solenoid check
signal:
0 (normal), 1 (error)

ACT-2

PSOL:/ () Unused
ACT-3

*1
PSOL:
ON/OFF (0)

*1: Mini lever models (OPT)


*2: 3-way and 4-way mini lever models (OPT)
*3: 4-way mini lever models (OPT)

Unload valve output


Unload valve check signal: 0 (normal), 1 (error)

5-29
Operation procedure
1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Check that 1. ANALYZER is displayed on the MASK MENU screen and press button (3) (enter) to
display the ANALYZER MENU screen.
3. Select the menu item using buttons (1) and (2) and then press button (3) (enter) to display the set
screen.
Button (1): To the previous menu item screen
Button (2): To the next menu item screen
Button (3): Enter (to the selected menu item screen)
If you select 7. END on the MENU screen of the analyzer and press button (3), the MASK MENU screen
is displayed.
Button (1) Button (2)

MASK MENU screen

Press button (3)

= ME N U =
1 . A NA L Y Z ER
S P H

S P H

7. END screen

MENU

Button (3)
Press button (3)

= AN L ME NU=
7 . END
S P H

S P H

1. DIAG MEMORYscreen

MENU

Press button (1) or


(2) to switch screen.

= AN L ME NU=
1 . D I AG ME MOR Y
S P H

S P H

MENU

Press button (1) or


(2) to switch screen.

Press button (1) or


(2) to switch screen.

6. ACTIVE TEST screen

= AN L ME NU=
6 . A C T I V E T E S T
S P H

S P H

2. I/O MONITORI screen

MENU

Press button (1) or


(2) to switch screen.

= AN L ME NU=
2 . I / O MON I T OR 1

5. I/O MONITOR4 screen

S P H

S P H

MENU

Press button (1) or


(2) to switch screen.

= AN L MENU =
5 . I / O MON I T OR 4
S P H

S P H

3. I/O MONITOR2 screen

MENU

Press button (1) or


(2) to switch screen.

= AN L ME NU=
3 . I / O MON I T OR 2
S P H

S P H

4. I/O MONITOR3 screen

MENU

= AN L ME NU=
4 . I / O MON I T OR 3

Press button (1) or


(2) to switch screen.

S P H

S P H
MENU

5-30
Diagnosis Memory Function (DIAG MEMORY)
The controller stores up to 10 of the most recent errors. The DIAG MEMORY screen displays these
diagnosis error codes together with their detection time (as key ON hour meter reading).
The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to
DIAG-10.
Operation Procedure
1. Display the ANALYZE MENU screen.
Button (1)
2. Check that 1. DIAG MEMORY is displayed and
ANALYZER MENU screen Button (2)
press button (3) (enter). Past diagnosis codes are
displayed sequentially starting with the newest one.
3. Functions of buttons on the 1. DIAG MEMORY screen
= AN L ME NU=
are as follows:
1 . D I AG ME MOR Y
S P H
S P H
Button (1): Unused
Button (2): Unused
Button (3): Displays past diagnosis codes
Button (3)
*:
Press
button (3)
Press button (3) on the DIAG-10 screen to display the
ANALYZER MENU screen.
When no error codes are displayed on the screen and
the hour meter time is 0.0h, it indicates that no error
I A
1
A1
1
1 2 3 4 5 . 6 h
codes are stored in the memory.
S P H
S P H
Other screen cannot be displayed from DIAG
MEMORY screen. Display ANALYZER MENU screen
to display other screen.
Key ON hour meter
*: For the details of diagnosis error codes, see
Press button (3)
DIAGNOSIS CODE LIST on P5-15.
MENU

MENU

A1

I A
2

2
1 2 3 4 5 . 6 h
S P H

S P H

MENU

Press button (3)

I A

3
0 . 0 h
S P H

S P H

MENU

No error occurrence
is indicated

I A

Press button (3)

1 0
0 . 0 h
S P H

S P H
MENU

Press button (3)


ANALYZER MENU screen

5-31
Vehicle Abnormalities Not Stored in Diagnosis Memory
Some abnormalities are not stored in diag memory even when the controller detects it and warn the
operator.
Warning indicators

Warning method

Displayed code

Parking brake ON warning:


Warns if the direction switch is turned to the forward or reverse position and the vehicle travels
when the parking brake is on.

Indication
Parking brake ON
warning indicator
blinks
Beep
Short beeps

Parking brake OFF warning (OPT):


Warns if the operator vacates the seat without
pulling the parking brake lever. (Warns even when
the key switch is OFF)

Beep
Short beeps

Overdischarge warning (lift interrupt):


Warns if the battery discharge exceeds the level
set by the tuning function. (see page 5-45.)
When the warning is activated, material handling
operation while traveling is disabled.

Indication
Battery charge indicator blinks
Beep
Short beeps

Return to neutral warning:


Warns if the key switch is turned to ON when the
direction switch is in the forward or reverse position.

Beep
Short beeps

No display

Material handling lock (OPT):


When the operator leaves the seat while operating the mini lever and then sits down again, a
buzzer sounds to warn the operator and the material handling operation will be disabled.

Beep
Short beeps

No display

Incomplete matching warning:


(1) Tilt angle sensor at fork in the level position
(2) Tilt angle sensor at the forward tilt restriction
angle
(3) Pressure sensor at no-load state
(4) Tire angle sensor at straight travel position
(5) Lift lever angle sensor at lift lever neutral
position (OPT)
(6) Tilt lever angle sensor at tilt lever neutral
position (OPT)
(7) Attachment 1 lever angle sensor at
attachment 1 lever neutral position (OPT)
(8) Attachment 2 lever angle sensor at
attachment 2 lever neutral position (OPT)

Indication
Wrench symbol

No display

5-32

I/O monitor
This function displays the analog input voltage from each
of traveling, material handling and SAS sensors.
Monitoring the displayed values enables the quality of
each circuit/sensor to be judged.
When any abnormality is detected, it is displayed as an
error code on the screen.

Detected error code


at present

Activated
function No

< I / O1
T HCD :

1 >
+ 2 5 /

+ 2 5
S P H

S P H

MENU

Description of activated function

I/O monitor 1
This function displays the temperature of each electrical functional part and the voltage at the respective
terminal.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press button (2).
3. Check that 2. I/O MONITOR1 is displayed and press
button (3) (enter). I/O monitor function (1) is activated
and I/O 1-1 to I/O 1-13 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR1 screen
are as follows:
Button (1): Unused
Button (2): Unused
Button (3): Displays I/O 1-1 to I/O 1-13 screens
sequentially
*: Press button (3) on the I/O 1-13 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from I/O MONITOR1
screen.
Display ANALYZER MENU screen to display other
screen.
(1) I/O 1-1 screen
THCD: Main drive circuit (1) (2) temperature (C)
Temperatures of the main drive circuit element (1) (2)
are displayed
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(2) I/O 1-2 screen
THCP: Main pump circuit temperature (C)
Temperature of the main pump circuit element is
displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.

Button (1)
ANALYZER MENU screen Button (2)

= AN L ME NU=
2 . I / O MON I T OR 1
S P H

S P H
MENU

Button (3)
Press button (3)

(1) I/O 1-1 screen

I / O1
T HCD

1
+ 2 5 /

+ 2 5
S P H

S P H
MENU

Press button (3)

(2) I/O 1-2 screen

I / O1
T HCP

2
+ 2 5
S P H

S P H
MENU

Press button (3)

I/O 1-3 screen

5-33
(3) I/O 1-3 screen
TD: Drive motor (1) (2) temperature (C)
Temperatures of the drive motor (1) (2) is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(4) I/O 1-4 screen
TP: Pump motor temperature (C)
Temperature of the pump motor is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(5) I/O 1-5 screen
TBD:
Traveling AC driver 1/2 board surface temperature
(C)
Surface temperatures of the traveling AC driver 1/2
board are displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.

I/O 1-2 screen

(3) I/O 1-3 screen

I / O1
T D

3
+ 2 5 /

Button (2)
Button (1)

+ 2 5
S P H

S P H
MENU

Button (3)
Press button (3)

(4) I/O 1-4 screen

I / O 1
T P :

4
+ 2 5
S P H

S P H
MENU

Press button (3)

(5) I/O 1-5 screen

I / O1
T B D :

5
+ 2 5 /

+ 2 5
S P H

S P H
MENU

(6) I/O 1-6 screen


TBP:
Material handling AC driver board surface
temperature (C)
Surface temperature of the material handling AC
driver board is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(7) I/O 1-7 screen
TEMP: CPU board temperature (C)
The surface temperature of the main controller CPU
board is displayed.
Checks if the temperature measurement function is
functioning properly.
The temperatures at the time of measurement are
displayed.
(8) I/O 1-8 screen
VB48: Battery voltage (V)
The battery voltage is displayed.
Standard: 48 V

Press button (3)

(6) I/O 1-6 screen

I / O1
T B P

6
+ 2 5
S P H

S P H
MENU

Press button (3)

(7) I/O 1-7 screen

I / O1
T E MP

7
+ 2 5 . 0
S P H

S P H
MENU

Press button (3)

(8) I/O 1-8 screen

I / O1
V B 4 8

8
5 0 . 0
S P H

S P H
MENU

Press button (3)

I/O 1-9 screen

5-34
(9) I/O 1-9 screen
VBKS: Key start voltage (V)
Power source voltage of traveling and material
handling AC drivers are displayed.
Standard: 48 V
(10) I/O 1-10 screen
VBSOL: Solenoid power supply voltage (V)
Solenoid power source voltage is displayed.
Standard: 48 V

I/O 1-8 screen


Button (2)
Button (1)

(9) I/O 1-9 screen

I / O1
VBK S

9
5 0 . 0
S P H

S P H
MENU

(11) I/O 1-11 screen


VBMB: Main battery voltage input (V)
Main controller input voltage after the MB contactor is
displayed.
Standard: 48 V
(12) I/O 1-12 screen
VBBD: Main drive motor circuit (1) (2) voltage (V)
Voltages of the main drive motor circuit (1) (2) are
displayed.
Standard: 48 V
(13) I/O 1-13 screen
VBBP: Main pump motor circuit voltage (V)
Voltage of the main pump motor circuit is displayed.
Standard: 48 V

Button (3)
Press button (3)

(10) I/O 1-10 screen

I / O 1
V BSOL

1 0
5 0
S P H

S P H
MENU

Press button (3)

(11) I/O 1-11 screen

I / O 1
V BMB

1 1
5 0
S P H

S P H
MENU

Press button (3)

(12) I/O 1-12 screen

I / O 1
V B BD

1 2
5 0 /

5 0
S P H

S P H
MENU

Press button (3)

(13) I/O 1-13 screen

I / O 1
V B BP

1 3
5 0
S P H

S P H
MENU

Press button (3)

ANALYZER MENU screen

5-35
I/O monitor 2
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing
control.
Operation procedure
1. Display the ANALYZER MENU screen.
2. Press button (2) twice.
3. Check that 3. I/O MONITOR2 is displayed and press
button (3) (enter). I/O monitor function (2) is activated
and I/O 2-1 to I/O 2-6 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR2 screen
are as follows:
Button (1)
Button (1): Unused
ANALYZER MENU screen Button (2)
Button (2): Unused
Button (3): Displays I/O 2-1 to I/O 2-6 screens
sequentially
= AN L ME NU=
*:Press button (3) on the I/O 2-6 screen to display the
3 . I / O MON I TOR 2
S P H
S P H
ANALYZER MENU screen.
Other screen cannot be displayed from I/O MONITOR2
screen.
Button (3)
Display ANALYZER MENU screen to display other
Press
button (3)
screen
(1)
I/O
2-1
screen
(1) I/O 2-1 screen
POTA: Accelerator potentiometer voltage (V)
A: When the accelerator pedal is released
< I / 0 2
1 >
(SWAC: OFF)
P O T A 0 . 7 1 S WA C 0
S P H
Standard: 0.3 to 2.4 V
S P H
B: Standard voltage when the accelerator pedal is
depressed to its stroke end
Standard: 1.7 to 4.7 V
Press button (3)
B - A = 1.4 V or above
SWAC: Accelerator switch
I/O 2-2 screen
When the accelerator pedal is released
SWAC: 0 = OFF
Standard voltage when the accelerator pedal is
depressed to its stroke end
SWAC: 1 = ON
Operate the accelerator pedal to judge switch ON/
OFF quality.
MENU

MENU

5-36
(2) I/O 2-2 screen
Direction switch inspection.
DSF: Forward traveling switch
DSR: Reverse traveling switch
Operation

I/O 2-1screen
Indication

DSF

DSR

Forward traveling

1 (=ON)

0 (=OFF)

Neutral

0 (=OFF)

0 (=OFF)

Reverse traveling

0 (=OFF)

1 (=ON)

Button (1)

(2) I/O 2-2 screen

< I / 0 2
0
DS F

2 >
DSR

1
S P H

S P H

MENU

Operate the direction lever to judge switch ON/OFF


quality.
(3) I/O 2-3 screen
LSB: Brake switch inspection
When the brake pedal is released
LSB: 1 = ON
When the brake pedal is depressed
LSB: 0 = OFF
Operate the brake pedal to judge switch ON/OFF
quality.
LSD: Deadman seat check
When the seat is occupied
LSD: 1 = ON
When the seat is not occupied
LSD: 0 = OFF
Take or leave a seat to judge switch ON/OFF
quality.

Button (3)
Press button (3)

(3) I/O 2-3 screen

< I / 0 2
L S B 1

3 >
L SD

1
S P H

S P H

MENU

Press button (3)

(4) I/O 2-4 screen

< I / 0 2
4 >
SS D1
3 0 0 0 [ 3 0 0 0 ]
S P H

S P H

(4) I/O 2-4 screen


SSD1: Drive motor 1 rpm [target rpm]
Inspect the rpm sensor while the vehicle is
traveling.The rpm of the drive motor increases
according to the speed increase.
(5) I/O 2-5 screen
SSD2: Drive motor 2 rpm [target rpm]
Inspect the rpm sensor while the vehicle is traveling.
The rpm of the drive motor increases according to the
speed increase.
(6) I/O 2-6 screen
SPD: Traveling speed (km/h)
Check the traveling speed while the vehicle is jacked
up. Gradually depress the accelerator pedal. Check
that the traveling speed increase is almost at the
same rate of the depression of the accelerator pedal
to judge the quality.

Button (2)

MENU

Press button (3)

(5) I/O 2-5 screen

< I / 0 2
5 >
SS D2
3 0 0 0 [ 3 0 0 0 ]
S P H

S P H
MENU

Press button (3)

(6) I/O 2-6 screen

< I / 0 2
S P D

6 >
1 0 . 0
S P H

S P H
MENU

Press button (3)

ANALYZER MENU screen

5-37
I/O monitor 3
This function displays the ON/OFF status of material handling and mast control switches and analog input
voltages from sensors.
Operation procedure
1. Display the ANALYZER MENU screen.
2. Press button (3) three times.
3. Check that 4. I/O MONITOR3 is displayed and press
Button (1)
Button (2)
button (3) (enter). I/O monitor function (3) is activated
ANALYZER MENU screen
and I/O 3-1 to I/O 3-13 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR3 screen
= A N L
ME NU=
4 . I / O MON I T OR 3
are as follows:
S P H
S P H
Button (1): Unused.
Button (2): Unused.
Button (3): Displays I/O 3-1 to I/O 3-13 screens
Button (3)
sequentially
Press button (3)
*: Press button (3) on the I/O 3-13 screen to display the
(1) I/O 3-1 screen
ANALYZER MENU screen.
Standard models
Other screen cannot be displayed from I/O MONITOR3
screen.
Display ANALYZER MENU screen to display other
< I / O3
1 >
L :
.
.
1
screen
S P H
MENU

S P H

(1) I/O 3-1 screen


Standard models
L: Lift switch inspection
When the lift lever is in the UP position
L: . . 1 = ON
When the lift lever is in the neutral or DOWN position
L: . . 0 = OFF
Operate the lift lever to judge ON/OFF quality.
Mini lever models (OPT)
L: Lift lever angle 1 sensor voltage (V)
Lift lever angle 2 sensor voltage (V)
Lift raise switch (0=OFF, 1=ON)
Lift lower switch (0=OFF, 1=ON)
Judge the raise and lower input quality by lift lever
operation.
Lift lever angle 1
sensor voltage

Lift lever angle 2


sensor voltage

Raising

1.1 to 2.3 V

2.2 to 3.5 V

Lowering

0.4 to 1.6 V

2.9 to 4.2 V

(2) I/O 3-2 screen


Standard models
L (SOL): Unused
Mini lever models (OPT)
L (SOL): Lift proportional valve solenoid current (A)
Judge the output quality to lift proportional valve
solenoid by lift lever operation.
Standard: 0.3 to 0.85 A (Lever operated)

MENU

Mini lever models (OPT)

< I / O3
1 >
L :
1 . 0 0 3 . 0 0

1 0
S P H

S P H

MENU

Press button (3)


(2) I/O 3-2 screen
Standard models

< I / O3
2 >
L ( SO L ) :

.
S P H

S P H

MENU

Mini lever models (OPT)

< I / O3
2 >
L ( SO L ) :

0 . 3 5
S P H

S P H

MENU

Press button (3)


I/O 3-3 screen

5-38
(3) I/O 3-3 screen
Standard models
T: Forward and backward tilt switch inspection
Operation

Display

Forward
tilt switch

Backward
tilt switch

Forward tilt

T: . . 10

1 (=ON)

0 (=OFF)

Neutral

T: . . 00

0 (=OFF)

0 (=OFF)

Backward tilt

T: . . 01

0 (=OFF)

1 (=ON)

Operate the tilt lever to judge ON/OFF quality.


Mini lever models (OPT)
T: Tilt lever angle 1 sensor voltage (V)
Tilt lever angle 2 sensor voltage (V)
Forward tilt switch (0=OFF, 1=ON)
Backward tilt switch (0=OFF, 1=ON)
Judge the forward and backward tilt input quality by lift
lever operation.
Tilt lever angle 1
sensor voltage

Tilt lever angle 2


sensor voltage

Forward tilt

1.1 to 2.3 V

2.2 to 3.5 V

Backward tilt

0.4 to 1.6 V

2.9 to 4.2 V

(4) I/O 3-4 screen


Standard models
T (SOL): Unused
Mini lever models (OPT)
T (SOL): Tilt proportional valve solenoid current (A)
Judge the output quality to the tilt proportional valve
solenoid by tilt lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
(5) I/O 3-5 screen
Standard models
A1: Attachment 1 lever inspection
When the attachment 1 lever is ON
A1: , , 1 = ON
When the attachment 1 lever is in the neutral position
A1: , , 0 = OFF
Operate the attachment 1 lever to judge ON/OFF
quality.
3-way and 4-way mini lever models (OPT)
A1: Attachment 1 lever angle 1 sensor voltage (V)
Attachment 1 lever angle 2 sensor voltage (V)
Attachment 1 raise switch (0=OFF, 1=ON)
Attachment 1 lower switch (0=OFF, 1=ON)
Judge the input quality by attachment 1 lever
operation.
Attachment 1 lever
angle 1 sensor voltage

Attachment 1 lever
angle 2 sensor voltage

Raising

1.1 to 2.3 V

2.2 to 3.5 V

Lowering

0.4 to 1.6 V

2.9 to 4.2 V

I/O 3-2 screen


Button (2)
(3) I/O 3-3 screen Button (1)
Standard models

< I / O3
T :
.

3 >
.

1 0
S P H

S P H

MENU

Mini lever models (OPT) Button (3)

< I / O3
3 >
T :
1 . 0 0
3 . 0 0

1 0
S P H

S P H

MENU

Press button (3)


(4) I/O 3-4 screen
Standard models

< I / O3
4 >
T ( SO L ) :

.
S P H

S P H

MENU

Mini lever models (OPT)

< I / O3
4 >
T ( SO L ) :

0 . 3 5
S P H

S P H

MENU

Press button (3)


(5) I/O 3-5 screen
Standard models

< I / O3
A1 :
.

5 >
.

1
S P H

S P H

MENU

3-way and 4-way mini lever models (OPT)

< I / O3
5 >
A1 : 1 . 0 0 3 . 0 0

1 0

S P H

S P H
MENU

Press button (3)


I/O 3-6 screen

5-39
(6) I/O 3-6 screen
Standard models
A1(SOL): Unused
3-way and 4-way mini lever models (OPT)
A1 (SOL): Attachment 1 proportional valve solenoid
current (A)
Judge the output quality to attachment (1) proportional
valve solenoid by attachment 1 lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
(7) I/O 3-7 screen
Standard models, 2-way and 3-way mini lever
models (OPT)
A2: Unused
4-way mini lever models (OPT)
A2: Attachment 2 lever angle 1 sensor voltage
Attachment 2 lever angle 2 sensor voltage
Attachment 2 raise switch (0=OFF, 1=ON)
Attachment 2 lower switch (0=OFF, 1=ON)
Judge the forward and backward tilt input quality by tilt
lever operation.
Attachment 2 lever
angle 2 sensor
voltage

Attachment 2 lever
angle 2 sensor
voltage

Raising

1.1 to 2.3 V

2.2 to 3.5 V

Lowering

0.4 to 1.6 V

2.9 to 4.2 V

(8) I/O 3-8 screen


Standard models, 2-way and 3-way mini lever
models (OPT)
A2 (SOL): Unused
4-way mini lever models (OPT)
A2 (SOL): Attachment 2 proportional valve solenoid
current (A)
Judge the output quality to attachment 2 proportional
valve solenoid by attachment 2 lever operation.
Standard: 0.3 to 0.85 A (Lever operated)

I/O 3-5 screen


Button (2)
(6) I/O 3-6 screen Button (1)
Standard models

< I / O3
6 >
A 1 ( S OL ) :

.
S P H

S P H

MENU

Button (3)
3-way and 4-way mini lever models (OPT)

< I / O3
6 >
A 1 ( S OL ) :

0 . 3 5
S P H

S P H

MENU

Press button (3)


(7) I/O 3-7 screen
Standard models
2-way and 3-way mini lever models (OPT)

< I / O3
A 2 :
.

7 >
.
S P H

S P H

MENU

4-way mini lever models (OPT)

< I / O3
7 >
A 2 : 1 . 0 0 3 . 0 0

1 0

S P H

S P H
MENU

Press button (3)


(8) I/O 3-8 screen
Standard models
2-way and 3-way mini lever models (OPT)

< I / O3
8 >
A 2 ( S OL ) :

.
S P H

S P H
MENU

4-way mini lever models (OPT)

< I / O3
8 >
A 2 ( S OL ) :

0 . 3 5
S P H

S P H
MENU

Press button (3)


I/O 3-9 screen

5-40
(9) I/O 3-9 screen
SWTK: Automatic fork leveling cancel switch
inspection
0 = OFF
1 = ON
Operate the tilt knob switch to judge ON/OFF quality.
(10) I/O 3-10 screen
SSP: Pump motor rpm [target rpm]
Inspect the rpm sensor during the actual material
handling operation. Check that the pump motor rpm
increases according to the material handling speed
increase.
(11) I/O 3-11 screen
MH: Lifting height switch inspection
Combination of lifting height switch ON/OFF
Lifting
height

Indication

MH1
switch

MH2-1
switch

Low lifting
height

10

1 (=ON)

0 (=OFF)

High lifting
height

01

0 (=OFF)

1 (=ON)

Change the lifting height to judge ON/OFF quality.


(12) I/O 3-12 screen
POTT: Tilt angle sensor voltage (V)
Check the input voltage of tilt angle sensor controller
Standard when the mast is in the vertical position:
Approx. 1.3 V
When operating the mast forward from the vertical
position: Input voltage decrease
When operating the mast backward from the vertical
position: Input voltage increase
(13) I/O 3-13 screen
SPL: Load sensor voltage (V) (MPa display)
Check the input voltage of load sensor controller.
Standard without load: Approx. 0.8 V
Input voltage increases according to the load increase

I/O 3-8 screen


Button (2)
Button (1)

(9) I/O 3-9 screen

< I / O3
S WT K : 0

9 >
S P H

S P H
MENU

Button (3)
Press button (3)
(10) I/O 3-10 screen

< I / O3
1 0 >
SS P :
2 0 0 0 [ 2 0 0 0 ]
S P H

S P H
MENU

Press button (3)


(11) I/O 3-11 screen

< I / O3
1 1 >
MH :
1 0
S P H

S P H
MENU

Press button (3)


(12) I/O 3-12 screen

< I / O3
POT T :

1 2 >
2 . 5 0
S P H

S P H
MENU

Press button (3)


(13) I/O 3-13 screen

< I / O3
1 3 >
S P L :V 0 . 8 4 (

1 . 7 )
S P H

S P H
MENU

Press button (3)


ANALYZER MENU screen

5-41
I/O monitor 4
ON/OFF state of knob steering synchronizer and other switches and the analog input value from each
sensor are indicated.
Operation procedure
1. Display the ANALYZER MENU screen.
Button (1)
2. Press button (2) four times.
ANALYZER MENU screen Button (2)
3. Check that 5. I/O MONITOR4 is displayed and press
button (3) (enter). I/O monitor function (4) is activated
and I/O 4-1 to I/O 4-4 are displayed sequential every
= A N L ME N U =
time button (3) is pressed.
5 . I / O MO N I T OR 4
S P H
4. Functions of buttons on the I/O MONITOR4 screen
S P H
are as follows:
Button (1): Unused
Button (3)
Button (2): Unused
Press button (3)
Button (3): Displays I/O 4-1 to I/O 4-4 screens
(1)
I/O
4-1
screen
sequentially.
*:Press button (3) on the I/O 4-4 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from I/O MONITOR4
< I / O4
1 >
ST S :
0 1 0
screen.
S P H
S P H
Display ANALYZER MENU screen to display other
screen.
MENU

MENU

Press button (3)

I/O 4-2 screen


(1) I/O 4-1 screen
STS: Steering angle sensor inspection
0 = OFF
1 = ON

< I / O4
1 >
ST S :
0 1 0
S
STS1 STS2 STSC

Turning the steering wheel one round will turn STS1


and STS2 ON, OFF and then ON. STSC turns on only
when the steering wheel is in the standard position.
STSC sensor turns on when the actual value is 80 on
the I/O 4-2 screen.

159
0
1
80

5-42
(2) I/O 4-2 screen
K-POS: Actual value of knob position (target)
Actual value:
Knob position computed by the controller from the
steering angle sensor signal.
Target value:
Knob position computed by the controller from the tire
angle sensor signal.

I/O 4-1 screen

(2) I/O 4-2 screen

2 >
1 5 9

< I / O4
K POS

Button (2)
Button (1)

1 5 0
S P H

S P H

MENU

Button (3)
Press button (3)

I/O 4-3 screen


Assuming the steering wheel is divided into 160 (0 to
159), the knob position of 80 is as indicated in the
illustration to the left. This value increases when
turning the steering wheel clockwise and decreases
when turning it counterclockwise.

159
0
1
80

(3) I/O 4-3 screen


K-DIFF: Deviation of steering angle knob position
Difference between target and actual values at I/O
4-2.
SOL: Steering synchronizer solenoid
0 = OFF
1 = ON
Operate the steering wheel to check that the steering
synchronizer solenoid turns on when there is
deviation of steering angle knob position.
(4) I/O 4-4 screen
TIRE: Tire angle sensor voltage (V)
Operate the steering wheel to check the variation in
voltage.
Standard at tire straight travel position:
Approx. 2.40 V

I/O 4-2 screen

(3) I/O 4-3 screen

< I / O4
K D I FF

Button (2)
Button (1)

3 >
1 0 0 SOL
S P H

0
S P H
MENU

Button (3)
Press button (3)

(4) I/O 4-4 screen

< I / O4
T I RE :

4 >
2 . 40
S P H

S P H
MENU

Press button (3)

ANALYZER MENU screen

5-43
Active test
This function outputs ON/OFF signals to each switch related to the electrical system and compares
controller input signals with those signals.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press button (2) five twice.
3. Check that 6. ACTIVE TEST is displayed and press
Button (1)
button (3) (enter). ACTIVE TEST function is activated
and ACT-1 to ACT-3 are displayed sequential every
ANALYZER MENU screen Button (2)
time button (3) is pressed.
4. Functions of buttons on the ACTIVE TEST screen are
as follows:
= AN L ME NU=
6 . ACT I VE TE ST
Button (1): Forced ON
S P H
S P H
Button (2): Forced OFF
Button (3): Displays ACT-1 and ACT-3 sequentially
*:Press button (3) on ACT-3 screen to display the
Button (3)
ANALYZER MENU screen.
Press button (3)
Other screen cannot be displayed from ACTIVE TEST
(1) ACT-1 screen
screen.
Display ANALYZER MENU screen to display other
screen.
< ACT
1 >
MENU

(1) ACT-1 screen


FAN: Fan (Fan voltage (V))
Forcibly output the ON/OFF signal to check the fan
operation and display visually.v
Press button (1) to select ON.
Fan rotates and fan voltage is displayed.
Press button (2) to select OFF.
Fan stops rotating and fan voltage is displayed.
Note:
Be sure to open the battery hood and remove the side
cover to check the fan operation.
(2) ACT-2 screen
KSOL: Steering knob synchronizer solenoid
1: Signal check line ON (error)
0: Signal check line OFF (normal)
Turn the steering wheel slowly to check the deviation
in the rear tire movement.
ON (bypass open) selected: Tires rarely move
OFF (bypass close) selected: Tires normally move

F AN : ON / O F F

( 4 8 )
S P H

S P H

MENU

Press button (3)

(2) ACT-2 screen

< ACT
2 >
K S OL : ON / O F F

( 0 )
S P H

S P H

MENU

Press button (3)

ACT-3 screen

5-44
(3) ACT-3 screen
Standard models
PSOL: Unused
Mini lever models (OPT)
PSOL: Unload valve solenoid
1: Signal check line ON (error)
0: Signal check line OFF (normal)
Turn the key switch to ON and operate the material
handling lever.
If the unload valve turns on normally, material
handling operation is possible.If the unload
valve stays off, material handling operation is
disabled.
Turn the key switch to OFF and operate the material
handling lever.
If the unload valve turns off normally, material
handling operation is disabled.If the unload
valve stays on, material handling operation is
possible.

ACT-2 screen
Button (1)

(3) ACT-3 screen


Standard models

< ACT
P SOL :

Button (2)

3 >
(

)
S P H

S P H

MENU

Mini lever models (OPT)

< ACT
3 >
P S O L : O N / OF F

Button (3)

( 0 )
S P H

S P H
MENU

Press button (3)


ANALYZER MENU screen

5-45
Tuning
General
This function performs fine adjustment of traveling and material handling controls.
When the use requests to limit the maximum speed or weaken the regenerative braking force, each setting
can be performed on the TUNING screen in the procedures same as power control level setting.
59 tuning items are prepared including spares.
Tuning items list
Tuning
No.

Level (

Item

: Initial setting position)

Switchback regenerative breaking torque:


Changes the regenerative braking torque at
switchback.

Weak

Strong

Acceleration OFF regenerative breaking torque:


Changes regenerative breaking torque when
acceleration is OFF.

Weak

Strong

Battery warning setting level:


Changes the activation timings of low remaining
battery charge warning and battery
overdischarge warning. (See page 5-50.)

Fast

Battery charge indicator correction:


Corrects decreasing rate of battery charge
indicator.

Traveling speed limiter:


Adjust the maximum traveling speed.

Low
speed

High
speed None

Attachment power control No.1:


Changes the pump motor output for when
attachment switch No.1 is ON.

Low
speed

High
speed

Tilt power control:


Changes the pump motor output for when
the tilt switch is ON.
(The SAS function mast control speed is not limited.)

Low
speed

High
speed

Attachment power control No.2: *1


Changes the pump motor output for when
attachment switch No.2 is ON.

Low
speed

High
speed

Auto-off function activation time:


Sets the time for activating auto-off function.

Short

10

Spare

11

Spare

12

Spare

*1: 4-way mini lever models (OPT)

Slow

Slow
decrease

Disabled

Fast
decrease

Long

None

5-46
Tuning
No.

Level (

Item

: Initial setting position)

20

Lift lowering adjustment (1):


Adjusts solenoid output current at the beginning
of lift lowering operation.

Small

Large

21

Lift lowering adjustment (2):


Adjusts inching speed during lift lowering operation.

Slow

Fast

22

Lift lowering adjustment (3):


Adjusts the maximum solenoid output current during
lift lowering operation.

Small

Large

23

Lift lowering adjustment (4):


Adjusts acceleration during lift lowering operation.

Weak

Strong

24

Lift lowering adjustment (5):


Adjusts deceleration during lift lowering operation.

Weak

Strong

25

Lift raising adjustment (1):


Adjusts solenoid output current at the beginning of
lift raising operation.

Small

Large

26

Lift raising adjustment (2):


Adjusts inching speed during lift raising operation.

Slow

Fast

27

Lift raising adjustment (3):


Adjusts the maximum solenoid output current during
lift raising operation.

Small

Large

28

Lift raising adjustment (4):


Adjusts acceleration during lift raising operation.

Weak

Strong

29

Lift raising adjustment (5):


Adjusts deceleration during lift raising operation.

Weak

Strong

30

Forward tilt adjustment (1):


Adjusts solenoid output current at the beginning of
forward tilt operation.

Small

Large

31

Forward tilt adjustment (2):


Adjusts inching speed during forward tilt operation.

Slow

Fast

32

Forward tilt adjustment (3):


Adjusts the maximum solenoid output current during
forward tilt operation.

Small

Large

33

Forward tilt adjustment (4):


Adjusts acceleration during forward tilt operation.

Weak

Strong

34

Forward tilt adjustment (5):


Adjusts deceleration during forward tilt operation.

Weak

Strong

35

Backward tilt adjustment (1):


Adjusts solenoid output current at the beginning of
backward tilt operation.

Small

Large

5-47
Level (

: Initial setting position)

Tuning
No.

Item

36

Backward tilt adjustment (2):


Adjusts inching speed during backward tilt operation.

Slow

Fast

37

Backward tilt adjustment (3):


Adjusts the maximum solenoid output current during
backward tilt operation.

Small

Large

38

Backward tilt adjustment (4):


Adjusts acceleration during backward tilt operation.

Weak

Strong

39

Backward tilt adjustment (5):


Adjusts deceleration during backward tilt operation.

Weak

Strong

40

Attachment 1 lowering adjustment (1):


Adjusts solenoid output current at the beginning of
lowering operation of attachment 1.

Small

Large

41

Attachment 1 lowering adjustment (2):


Adjusts inching speed during lowering operation of
attachment 1.

Slow

Fast

42

Attachment 1 lowering adjustment (3):


Adjusts the maximum solenoid output current during
lowering operation of attachment 1.

Small

Large

43

Attachment 1 lowering adjustment (4):


Adjusts acceleration during lowering operation of
attachment 1.

Weak

Strong

44

Attachment 1 lowering adjustment (5):


Adjusts deceleration during lowering operation of
attachment 1.

Weak

Strong

45

Attachment 1 raising adjustment (1):


Adjusts solenoid output current at the beginning of
raising operation of attachment 1.

Small

Large

46

Attachment 1 raising adjustment (2):


Adjusts inching speed during raising operation of
attachment 1.

Slow

Fast

47

Attachment 1 raising adjustment (3):


Adjusts the maximum solenoid output current during
raising operation of attachment 1.

Small

Large

48

Attachment 1 raising adjustment (4):


Adjusts acceleration during raising operation of
attachment 1.

Weak

Strong

49

Attachment 1 raising adjustment (5):


Adjusts deceleration during raising operation of
attachment 1.

Weak

Strong

50

Attachment 2 lowering adjustment (1):


Adjusts solenoid output current at the beginning of
raising operation of attachment 2.

Small

Large

51

Attachment 2 lowering adjustment (2):


Adjusts inching speed during lowering operation of
attachment 2.

Slow

Fast

5-48
Level (

: Initial setting position)

Tuning
No.

Item

52

Attachment 2 lowering adjustment (3):


Adjusts the maximum solenoid output current during
lowering operation of attachment 2.

Small

Large

53

Attachment 2 lowering adjustment (4):


Adjusts acceleration during lowering operation of
attachment 2.

Weak

Strong

54

Attachment 2 lowering adjustment (5):


Adjusts deceleration during lowering operation of
attachment 2.

Weak

Strong

55

Attachment 2 raising adjustment (1):


Adjusts solenoid output current at the beginning of
raising operation of attachment 2.

Small

Large

56

Attachment 2 raising adjustment (2):


Adjusts inching speed during raising operation of
attachment 2.

Slow

Fast

57

Attachment 2 raising adjustment (3):


Adjusts the maximum solenoid output current during
raising operation of attachment 2.

Small

Large

58

Attachment 2 raising adjustment (4):


Adjusts acceleration during raising operation of
attachment 2.

Weak

Strong

59

Attachment 2 raising adjustment (5):


Adjusts deceleration during raising operation of
attachment 2.

Weak

Strong

5-49

TUNING Screen Operating Procedure


1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Press button (2) to display 2. TUNING and press button (3) (enter) to display the TUNING MENU
screen.
3. Press button (1) or (2) to display the tuning item desired to be set. Press button (3) (enter) to display
the TUNING screen of the selected item.
Button (1): Display the previous tuning item
Button (2): Display the next tuning item
Button (3): Enter (display the selected tuning item)
* Press button (3) on the TUNING MENU screen, select 6. END and press (3) to display MASK MENU
screen.
2.TUNING2 LIFTV to 5.TUNING5 ATT2V (tuning No.20 to 59) are not used on the standard models.
They are only used on the mini lever models (OPT).

MASK MENU screen

Button (1) Button (2)

=ME NU =
2 . T UN I NG
S P H

S P H

MENU

Button (3)
Press button (3)

= T UN MENU=
1 . T UN I NG1

Press button (3)

= T UN MENU=
6 . END
S P H

S P H

MENU

S P H

Press button (1) or


(2) to switch screen

MENU

Press button (1) or


(2) to switch screen

Press button (1) or


(2) to switch screen

= T UN MENU=
2 . T UN I NG2
L I F. T V

= T UN MENU=
5 . T UN I NG5
AT T 2 V
S P H

S P H

S P H

MENU

S P H
MENU

Press button (1) or


(2) to switch screen

= T UN MENU=
3 . T UN I NG3
T I L T V
S P H

S P H

Press button (1) or


(2) to switch screen

= T UN MENU=
4 . T UN I NG4
A T T 1V
S P H
MENU

S P H

Press button (1) or


(2) to switch screen

S P H
MENU

5-50
TUNING 1

Button (1) Button (2)

This function sets the tuning level of the standard


functions.

TUNING MENU screen

Operation procedure
1. Display the TUNING MENU screen.
2. Check that 1. TUNING1 is displayed and press
button (3) (enter) to display TUNING level setting
screen.
3. Press button (3) to display the tuning item desired to
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.12 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
setting screen of TUNING1. Display TUNING MENU
screen to display other screen.

= T U N ME N U =
1 . T UN I NG 1
S P H

S P H

MENU

Button (3)
Press button (3)

< T UN >
1
NO .

8
S P H

S P H

MENU

Press button (3)

< T UN >
2
NO .

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 1 2

8
S P H

S P H

MENU

Press button (3)

TUNING MENU screen

Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels (TUNING No.3)
*: The default is level 7.
Discharge
level

TUNING setting levels

50 to 59%
60 to 69%
70 to 79%
80%

Low remaining battery


charge warning
Battery charge indicator blinks

81 to 89%
90%
91 to 99%
100%

Overdischarge warning
Ten segments of battery
charge indicator blink
NO
warning

5-51

TUNING 2 LIFTV
This function changes the tuning level of the lift lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display 2.TUNING2 LIFTV
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.29 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
setting screen of TUNING2 LIFTV. Display TUNING
MENU screen to display other screen.

Button (1)
Button (2)
TUNING MENU screen

= T U N ME N U =
2 . T UN I NG 2 L I F T V
S P H

S P H

MENU

Button (3)
Press button (3)

< T UN >
NO . 2 0

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 2 1

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 2 9

5
S P H

8
S P H
MENU

Press button (3)


TUNING MENU screen

5-52

TUNING 3 TILTV
This function changes the tuning level of the tilt lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display 3.TUNING3 TILTV
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.39 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
setting screen of TUNING3 TILTV. Display TUNING
MENU screen to display other screen.

Button (1)
Button (2)
TUNING MENU screen

= T U N ME N U =
3 . T UN I NG 3 T I L T V
S P H

S P H

MENU

Button (3)
Press button (3)

< T UN >
NO . 3 0

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 3 1

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 3 9

5
S P H

8
S P H
MENU

Press button (3)


TUNING MENU screen

5-53

TUNING 4 ATT1V
This function changes the tuning level of the attachment 1 lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display 4.TUNING4 ATT1V
Button (1)
and press button (3) (enter) to display TUNING level
Button (2)
TUNING MENU screen
setting screen.
3. Press button (3) to display the tuning item desired to
be set.
= T U N ME N U =
4 . T UN I NG 4 A T T 1 V
4. Functions of buttons on the TUNING level setting
S P H
S P H
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3)
Button (3): Enter (to the next item screen)
Press button (3)
*: Press button (3) on the TUNING No.49 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
< T UN >
1
5
8
NO . 4 0
setting screen of TUNING4 ATT1V. Display TUNING
S P H
S P H
MENU screen to display other screen.
MENU

MENU

Press button (3)

< T UN >
NO . 4 1

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 4 9

5
S P H

8
S P H
MENU

Press button (3)


TUNING MENU screen

5-54

TUNING 5 ATT2V
This function changes the tuning level of the attachment 2 lever.
Operation procedure
1. Display the TUNING MENU screen.
Button (1)
2. Press button (1) or (2) to display 5.TUNING5 ATT2V
Button (2)
TUNING MENU screen
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to
= T U N ME N U =
be set.
5 . T UN I NG 5 A T T 2 V
S P H
4. Functions of buttons on the TUNING level setting
S P H
screen are as follows:
Button (1): Tuning level down
Button (3)
Button (2): Tuning level up
Press
button (3)
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.59 setting screen to
display the TUNING MENU screen.
< T UN >
1
5
8
Other screen cannot be displayed from each level
NO . 5 0
S P H
setting screen of TUNING5 ATT2V. Display TUNING
S P H
MENU screen to display other screen.
MENU

MENU

Press button (3)

< T UN >
NO . 5 1

8
S P H

S P H

MENU

Press button (3)

< T UN >
NO . 5 9

5
S P H

8
S P H
MENU

Press button (3)


TUNING MENU screen

5-55

Option set
Option set menu list
No.

Indication

Description

Selection
IndiIndiMeaning
Meaning
cation
cation

OPT-1 DEMO MODE

Enables simultaneous operation of


traveling and material handling before
starting the hour meter.

Enable

Disable

OPT-2 H/M START

Starts hour meter count.

Counting

No
counting

OPT-3 P/C LOCK

Disables level setting of traveling/material


handling power control, 2-speed travel
speed and overspeed alarm (OPT).

Lock

Unlock

OPT-4 DESTI *

Sets the data according to the destination. Changes the display.

Japan

OPT-5

Not used.

OPT-6 MPH *

Changes the traveling speed unit to mph.

OPT-7

OPT-8

Not used
Adjust the charge indicator calculation
BATTERY *
constant.

Not used
Enables/disables operation of the auto
SEAT P-OFF
power-off function in relation to the seat
switch.
Enables/disables parking brake OFF
PARKING ERR
warning.
Enables/disables the active mast front tilt
TILT CONT
angle limit

Not used
Enables/disables the mast forward tilt
TILT F-LIM
speed limit control.
B-TYPE *
Battery type

Not used

Set to
mph

Feature
A

Other
than
Japan

Set to
km/h

Feature
B

Enable

Disable

Enable

Disable

Enable

Disable

Enable

Disable

TYPE1

TYPE2

Other
than
2-way
Other
than
4-way

Nondisplay
Disable

OPT-9
OPT-10
OPT-11
OPT-12
OPT-13
OPT-14
OPT-15
OPT-16

OPT-17 2-WAY VALVE *

Sets specification of 2-way mini lever


models

2-way

OPT-18 4-WAY VALVE *

Sets specification of 4-way mini lever


models

4-way

Display

Enable

OPT-19
OPT-20 WHEEL IND
OPT-21 SAS *
OPT-22

Not used
Sets the wheel indicator of the all-round
model (OPT) to display/non-display.
Enables/disables SAS function
Not used

*: The specification of the vehicle is selected at the time of vehicle shipment.

5-56
Caution:
These functions are used to adjust the controller
and display control according to the options
installed on the vehicle; they do not enable or
disable the actual function of the options.
When the controller board is replaced, it is
necessary to reset it according to the vehicle
specifications.
When OPT-12 TILT CONT and OPT-21 SAS are
disabled by option setting, the disabled status is
indicated for 5 seconds on the display upon key
switch ON.
Meaning of indication
T-OFF:
TILT CONT (active mast front tilt angle
control) is disabled.
SAS-OFF: SAS (SAS control) is disabled.

OF F

AM

11 : 00
S P H

S P H
MENU

Indication when disable

30/ 9
S AS

AM

OF F

11 : 00
S P H

S P H
MENU

Operation procedure for OPTION SET screen


1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Press button (2) twice to display 3. OPTION SET and press button (3) (enter) to display the OPTION
SET MENU screen.
3. Press button (3) to display the desired option item to be set on the screen.
4. Functions of buttons on the OPTION SET screen are as follows:
Button (1): N Y
Button (2): Y N
Button (3): Enter (to the next item screen)
*: Press button (3) on OPT-22 OPTION SET screen to display the MASK MENU screen.

OPT-4 screen
MASK MENU screen

= ME N U =
3 . OP T I ON

Button (1)
Button (2)

Press button (3)

<OPT
3>
P / C L OCK

S ET
S P H

S P H

Y / N
S P H

MENU

S P H
MENU

Button (3)
Press button (3)

<OP T
D EMO

1>
MOD E

Press button (3)

<OP T
2>
H / M ST ART

Y / N
S P H

S P H
MENU

Press
button (3)

Y / N
S P H

S P H
MENU

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


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

5-57
OPT-3 screen

OPT-16 screen

Button (1) Button (2)

<OP T
DES T I

Press button (3)

<OP T 1 5 >
B T YPE

4 >
J / I
S P H

S P H

1 / 2
S P H

S P H

MENU

MENU

Button (3)

Press button (3)

Press button (3)

Not used

<OPT
5 >
B L EVEL

<OPT
T I L T

Y / N

1 4 >
F L I M

S P H

S P H

Y / N
S P H

S P H

MENU

MENU

Press button (3)

<OPT
MPH

Press button (3)

Not used

<OPT
K NOB

6 >
Y / N

1 3 >
CONT

S P H

S P H

Y / N
S P H

S P H

MENU

MENU

Press button (3)

Not used

<OPT
C / CN T

7 >
RE S

Press button (3)

<OPT
T I L T

Y / N

1 2 >
C ON T

S P H

S P H

Y / N
S P H

S P H

MENU

MENU

Press button (3)

<OPT
8 >
B ATT ERY

Press button (3)

<OPT
1 1 >
P A RK I NG E R R

A / B
S P H

S P H

Y / N
S P H

S P H

MENU

MENU

Press button (3)

Press button (3)

Not used

< OP T
S HOU

9 >
T OK U

< OP T
S EAT

Y / N
S P H

S P H
MENU

10 >
P OF F

Y / N
S P H

Press button (3)

S P H
MENU

5-58
OPT-15 screen
Button (2)
Button (1)

Not used

<OP T
3 6 V

1 6 >
Y / N
S P H

S P H

MENU

Button (3)
Press button (3)

<OPT
1 7 >
2 WA Y V A L V E

Y / N
S P H

S P H

MENU

Press button (3)

<OPT
1 8 >
WA Y V A L V E
4

Y / N
S P H

S P H

MENU

Press button (3)

Not used

<OPT
U SA

1 9 >
Y / N
S P H

S P H

MENU

Press button (3)

< OP T
20 >
WH E E L
I ND

Y / N
S P H

S P H

MENU

MASK MENU screen


Press button (3)

Press button (3)

Not used

< OP T
S AS

<OPT
2 2 >
F I SH ERMA N

2 1 >
Y / N
S P H

S P H
MENU

Press
button (3)

Y / N
S P H

S P H
MENU

5-59

Matching
General
Of the sensors used for SAS, the signal voltage values of the tilt angle, load and tire angle sensors in the
mast vertical position, no load state, and tire straight travel position respectively are stored in the controller
at the time of vehicle shipment to be used as the bases for control. Therefore, if maintenance or parts
replacement related to these sensors is performed, matching (updating sensor signal voltage values of the
vehicle in the vehicle standard state) becomes necessary.
Matching of the tilt angle sensor is also necessary when the vehicle posture is remarkably changed.
Matching of the load sensor is also necessary when the load in the no load state is changed including
removal and addition of attachments.
Each lever angle sensor for mini lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment.Therefore, when maintenance or
parts replacement related to these sensors is required, matching needs to be performed.
SAS Matching Items and Conditions
No. Indication
1

TILTL

TILTF

LOAD

TIRE

Description

Condition
*1 *2 *3 *6
Tilt angle sensor output in the fork level position is stored in the controller.
*7 *8
Tilt angle sensor output of forward tilt control in the mast vertical position *1 *2 *3 *6
is stored in the controller.
*7 *8
Load sensor output in the no load state is stored in the controller.
*1 *4 *6 *7
Tire angle sensor output in the straight travel position is stored in the con*1 *5
troller.

Mini lever Matching Items and Conditions (OPT)


No. Indication
5

LIFT

TILT

ATT1

ATT2

Description
Lift lever angle sensor output in the lift lever neutral position is stored in
the controller.
Tilt lever angle sensor output in the tilt lever neutral position is stored in
the controller.
Attachment 1 lever angle sensor output in the attachment 1 lever neutral
position is stored in the controller.
Attachment 2 lever angle sensor output in the attachment 2 lever neutral
position is stored in the controller.

Meaning of Conditions
*1: When the main controller is replaced
*2: When the tilt angle sensor is replaced
*3: When the tilt angle sensor rod is replaced or its length is changed
*4: When the load sensor is replaced
*5: When the tire angle sensor and sensor cover is removed/installed/replaced
*6: When an attachment is changed
*7: When the mast is replaced
*8: When the tilt cylinder is replaced
*9: When the lift lever angle sensor is replaced
*10: When the tilt lever angle sensor is replaced
*11: When the attachment 1 lever angle sensor is replaced
*12: When the attachment 2 lever angle sensor is replaced

Condition
*1 *9
*1 *10
*1 *11
*1 *12

5-60
Before matching

4. Tire straight travel position check


Signal voltage of the tire angle sensor in tire straight
travel position is stored. Tire straight travel position is
the condition in which driving the vehicle 5 meters (16
ft) with the steering wheel fixed causes the center of
the vehicle to stay within 50 mm (2.0 in) to the left and
right of the line.
5 m (16 ft)

100mm
(3.9 in)

Within 50 mm (2.0in)
each on the left and
right sides

Vehicle should be in the Standard state for matching.


Standard state means the vehicle satisfies the following conditions:
1. Tire pressure check
Make sure that the tire pressure is at the specified
V mast
level. Low pressure and deviation of tire pressure
among the tires may hinder accurate matching.
2. Surface levelness check
Matching on the unleveled or inclined surface may
cause deviation of the standard. Perform matching on
a level surface (inclination below 0.5).
3. No-load vertical condition check
500 mm
Signal voltage of the load sensor in no-load state is
(19.7 in)
stored. Make sure that the following conditions are
FVFSV mast
met.
Raise the fork of the V mast to approx. 500 mm
(19.7 in). Make sure that the mast is in the vertical
position by checking with an angle gauge.
The rear cylinder rod extension of the FV and FSV
mast should be approx. 100 mm (3.9 in).
Make sure that the mast is in the vertical position by
checking with an angle gauge.
Tilt the mast from backward tilt position to forward
until it becomes vertical.

Operation procedure for MATCHING screen


1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Press button (2) three times to display 4. MATCHING and press button (3) (enter) to display the
MATCHING setting screen.
3. Press button (3) to display the desired matching item.
4. Functions of buttons on the MATCHING setting screen are as follows:
Button (1): Unused
Button (2): Starts matching for the selected item
Button (3): Display the next item

5-61
*: Press button (3) on the ATT2 matching set screen to display the MASK MENU screen.
OK on the display is indicated only after matching (by pressing button (2)).
The value in parentheses is the one stored at present.
The value outside parentheses is the one under the present vehicle condition.
Note:
Matching is necessary when the two values, inside and outside the parentheses are different in the
vehicle standard condition.
Button (1)

Button (2)

MASK MENU screen

= ME N U =
4 . MA T CH I NG
S P H

S P H

MENU

Button (3)

Press button (3)

Press button (3)

< MA T CH I NG >
OK
T I L T L ( 2 . 0 0 ) 2 . 0 0

< MA T CH I NG >
AT T 2
(
.
)
S P H

S P H

.
S P H

MENU

MENU

Press button (3)

Press button (3)

< MA T CH I NG >
OK
T I L T F ( 2 . 0 0 ) 2 . 0 0

< MA T CH I NG >
AT T
(
.
)
S P H

S P H

.
S P H

MENU

Press button (3)

< MA T CH I NG >
OK
L OAD
( 0 . 7 0 ) 0 . 7 0

< MA T CH I NG >
T I L T
(
.
)
S P H

.
S P H

MENU

Press button (3)

< MA T CH I NG >
OK
T I RE
( 2 . 4 0 ) 2 . 4 0

< MA T CH I NG >
L I F T
(
.
)
S P H
MENU

S P H
MENU

Press button (3)

S P H

S P H
MENU

Press button (3)

S P H

S P H

.
S P H

Press button (3)

S P H
MENU

5-62

Tire constant set


General
In order to optimize the speed meter, tire constant that matches the tire outside diameter needs to be input
in the controller.
Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire
size is changed or the tires are worn excessively to a degree affecting the speedometer function.
Operation procedure for tire constant setting
1. Input the password on the general screen (see page
5-23) to display the MASK MENU screen.
2. Press button (2) four times to display 5. WHEEL DIA
and press button (3) (enter) to display the tire constant
setting screen.
3. Press button (1) or (2) to set the desired tire constant
and press button (3) (enter) to display the MASK
MENU screen.
4. Functions of buttons on the tire constant setting
screen are as follows:
Button (1): Decreases the tire constant.
Button (2): Increases the tire constant.
Button (3): Enter and display MASK MENU screen

Button (1) Button (2)

MASK MENU screen

= ME N U =
5 . WH E E L

D I A
S P H

S P H

MENU

Button (3)
Press button (3)

WH E E L

D I A
2 2
S P H

S P H
MENU

Tire constant

Tire constant list


Tire type

Pneumatic shaped
cushion

Pneumatic

Tire size

Applicable model

U lug
J lug

18 7-8

7FBEF15 16 18

White

18 7-8

7FBEF15 16 18

U lug
J lug
White

200/50-10

7FBEF20

18 7-8-14

7FBEF15

18 7-8-16

7FBEF16 18

J lug

Tire constant
24

25

20

6-1

FRAME AND AUXILIARY EQUIPMENT


Page

BODY FRAME ................................................................. 6-2


INSTRUMENT PANEL AND
ADJACENT PORTION ............................................... 6-8

2
3

AUXILIARY EQUIPMENT ............................................. 6-10


FUSES ............................................................................... 6-13

6-2

BODY FRAME
Frame
General

(1)

(4)

(3)

(2)

(1)

Round-type front stay

(3)

Cautions for jacking up

(2)

Side cover

(4)

Cautions for hoisting the vehicle

1. Round-type front stay


The newly adopted round-type front stay facilitates
ingress/egress.

2. Elimination of side covers


Side covers on previous vehicles are eliminated and replaced with structural members to strengthen
the lower portion of the frame.

6-3
3. Cautions for jacking up
A jack-up point is provided at the bottom of the
frame to the rear of the front tire.
The jack-up point is provided within a range of 150
mm (5.9 in) from the fender. Jack up the vehicle at
the specified jack-up point.
Do not attempt to perform service work when the
vehicle is jacked up. Always place wood blocks, etc.
under the vehicle before starting the work.
For jacking up the rear side, see the WEIGHT
section.

2
3
150 mm
(5.9 in)

4. Cautions for hoisting the vehicle


Hoist the front of the vehicle at the mast and the
rear at the head guard similarly as for previous
models.

6
Weight
General
1. Compared with previous models, each new model vehicle has a weight of novel design.
2. Jack up the vehicle at the points illustrated below:

6-4

Battery hood
General
1. A press-integrated hood wholly covers the top of the battery. This hood opens up fully for the ease of
battery maintenance and replacement.
2. Use the notch of the head guard to replace the battery from the right-hand side of the vehicle.

Battery hood opening/closing procedure


Caution:
When opening/closing the battery hood, hold the handle on the right-hand side of the hood.
(1) Set the mast in vertical position.
(2) Pull the lock release lever.
(3) Tilt the steering post forward.
(4) Open the battery hood.

(1)

(3)
Lock release
lever
(2)

(4)

6-5

Battery hood locking device


To fix the battery hood securely for operation, a locking device and a catch are provided on the front end
of the hood.
The locking device automatically locks the hood when closed as a fail safe locking mechanism. The
catch prevents looseness of the hood by means of cushion rubber.

2
3

Catch

Locking device

Damper stay
1. Damper stay is adopted as a standard part to reduce the hood opening/closing force.
2. When fully open, the stay is automatically locked. To close the hood, release the lock with a finger.

Push this and


release the lock

Side hoods
1. Stamped side hoods are adopted to create a simple and clean product image.
2. Simply open the battery hood only for daily inspection and battery fluid addition.
3. For battery replacement, the side hoods on both sides can be removed or installed in one-touch action
without using a tool.

6-6

Step
1. An open step is adopted for the new model. The step height is much reduced compared to previous
models for easier ingress/egress.
2. The top surface of the step is designed for both slip-resistance and easier cleaning.

Step height

mm (in)
H1

H2
545 (21.5)

Previous model
430 (16.9)

545 (21.5)

H2
H1

New model

Toe board
1.
2.
3.
4.

Toe board is divided into the front and rear sections.


The front toe board is attached with the accelerator pedal and fixed onto the frame with bolts.
The rear toe board allows one-touch installation/removal using a positioning pin.
For hydraulic oil and other daily inspection, simply remove the rear toe board.
Accel pedal

FR Toe boad

RR Toe boad

Positioning pin

6-7

Floor mat
The new model is provided with a floor mat on top of the toe board.

Seat
General
A seat switch function is added to the Grammar seat favorably accepted on the 7FGF25 series.
A fabric seat (Grammar) is adopted optionally.

Major Features
1. ORS function
Operator protection system: Decreases critical damage to the upper body of the operator in case of
unexpected rollover of the vehicle.
2. Side wings with holes
Restrain the operator in an emergency.
Assist grip function for ingress
3. Seatbelt installation as standard equipment
ELR (emergency lock retractor) type
4. Reclining function
Tilting range: 5 each in the forward and backward directions
5. Dial type operator's weight adjustment mechanism
Knob position on the front side of the seat
Operators weight adjustment function: 50 to 130 kg
6. Built-in seat switch
7. Bull mark

6-8

INSTRUMENT PANEL AND ADJACENT PORTION


Layout near operators seat

(1)

(2)
(7)
(9) (10) (11) (12)

(8)

F
N
R

(13)

(14)

(4)

(3)

(6)
(5)
(17)

Center of vehicle

Center of steering

Pattern of shift

(16)

(18)

Layout of Pedal
(15)

D2 Pedal (OPT)

No.

Name

No.

Name

(1)

Parking lever

(10) Control lever (for tilting)

(2)

Horn SW

(11)

(3)

Direction lever

(12) Control lever (for attachment) (optional)

(4)

Turn signal SW

(13) Brake pedal

(5)

Key SW

(14) Accelerator pedal

(6)

Lamp SW

(15) D2 pedal (optional)

(7)

Steering wheel

(16) Tilt steering lock lever

(8)

Seat

(17) Rear work light SW (optional)

(9)

Control lever (for lifting)

(18) Tilt steering lock release lever

* SW: Switch

Control lever (for attachment)

6-9

Instrument panel
General
1. Novel design is realized with resin molding.
2. The instrument panel consists of 2 halves using sturdy and environmentally friendly polypropylene as
the material.
3. The downsized instrument panel improves the ease of ingress/egress.

LH Instrument panel

RH Instrument panel

6-10

AUXILIARY EQUIPMENT
Direction switch
1. Difference from previous models
The direction switch is the same as that installed on the 7FGF25 series.
2. Direction lever
(1) The direction switch is of the lever type easily operable with fingers as on the 7FGF25 series.
(2) The direction switch is positioned on the left-hand side as a standard component.
(3) Since the D2 pedal (OPT) has a built-in switch, no direction lever is provided.

Direction switch

Forward

Fr

Neutral

N
R

Backward Rr

6-11

Lights
1. List of lights
Type of light

Specifications

Bulb

(1)

Head light

OPT Same as on the previous model

40W

(2)

Front combination light

OPT Same as on the previous model

10W(Clearance, upper)
25W(Flasher, lower)

(3)

Rear combination light

High-mount, transverse rear combination lights are installed as stanOPT dard components for improved
visibility, damage prevention and
design.

25W(Flasher, outer)
25W/10W
(Stop/tail, center)
25W(Reverse, RH only
inside)

(4)

Rear working light

The rear working light is of a large


OPT square type.
(red pilot lamp provided)

40W

The new model operates on 48 V and not compatible with engine-driven forklifts.

(2)

(1)

(3)

(4)

6-12
2. Light switch
Light switch is positioned on the right-hand side of the steering column for improved operability.
Two-stage light switch turns the side clearance lights and taillights ON and OFF in the first stage and
the headlights, side clearance lights and tail lights ON and OFF, in the second stage.

Turn signal switch

Light switch

Switch for rear working


light (OPT)

Turn signal switch (W/ auto return function)


T

R
Neutral

N
L

OFF

OFF

Light switch

6-13

FUSES
Installed positions
Fuses F1 and F4 to F6 are installed in the controller box located under the rear right-hand section of the
vehicle. F1 is of the module type while F4 to F6 are of the blade type. Previously independent F1 for
traveling and F2 for material handling are integrated as F1 fuse for traveling and material handling.

F1

A view

F4

F5

F6

A view

Name (Applicable function) and capacity


7FBEF15 to 20
F1

For traveling/material handling

500A

F4

For lights

10A

F5

For control circuit

10A

F6

SAS, for solenoid

10A

Cautions for fuse replacement


When replacing any fuse, always be sure to disconnect the battery plugs and discharge overall
capacitor by applying a resistance of approx. 100 to between P3 and N2.

6-14

7-1

MATERIAL HANDLING AND HYDRAULIC SYSTEM


Page

V MAST ............................................................................. 7-2


FV MAST ........................................................................... 7-3

2
3

FSV MAST ........................................................................ 7-4


MATERIAL HANDLING SPEED.................................. 7-5
LOAD BACKREST & FORK ........................................ 7-6
TILT CYLINDER .............................................................. 7-7
OIL PUMP ......................................................................... 7-8
OIL TANK .......................................................................... 7-9
OIL CONTROL VALVE .................................................. 7-10
MATERIAL HANDLING LEVER .................................. 7-19
HYDRAULIC CIRCUIT ................................................... 7-20
MAST INTERCHANGEABILITY.................................. 7-21
A4 PIPING......................................................................... 7-22

7-2

V MAST
General
1. The vehicle is installed with the V mast as the standard component.
2. The mast installation method is changed from that for the previous models to reduce the lost load
center (distance from the front axle center to the fork front).
3. A mast for 2.0 tons is newly provided.

Major improvements
1. Improved mast durability
Mast durability has been improved by reducing the torsional force applied to the mast rails by changing
the tilt bracket construction. In addition, the outer middle beam is discontinued to reduce the lost load
center while retaining sufficient mast durability.

2. Front visibility
Unique front visibility vision is retained by using the mast rail and finger bars similarly as on previous
models.
3. Chain
The mast chain size for the 1.5- to 1.8-t masts remains unchanged. The size for the 2.0-t mast is the
same (BL634) as on the 7FBMF 20 and 25 models.
4. Lift cylinder
The lift cylinder for the 1.5- to 1.8-t masts is the same as that for the 7FBMF16 and 18. The lift cylinder
for the 2.0-t mast is the same as that for the 7FBMF20 and 25.
5. Lift cylinder piping
The basic structure of the piping for the 1.5- to 1.8-t masts remains unchanged. The safety down valve
is of the same inline type as on the Previous models except for an additional fitting for the pressure
sensor.
The basic structure of the lift cylinder for the 2.0-t mast is the same as that for the 1.5- to 1.8-t masts.
6. Lift roller
The mast rollers for the 1.5- to 1.8-t masts are the same as those for the 7FBMF16 and 18.
The mast rollers for the 2.0-t mast are the same as those for the 7BMF20 and 25.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity
New model
Previous model

1.0 ton

1.3 ton

1.5 to 1.8 ton

2.0 ton

355(14.0)

370(14.6)

380(15.0)

385(15.2)

385(15.2)

7-3

FV MAST
General
1. The FV mast is optionally available.
2. The mast installation method is changed from that on previous models to reduce the lost load center
(distance from the front axle center to the fork front).
3. A mast for 2.0 tons is not provided.

2
3

Major improvements
1. High mast durability
Same as that of the V mast.
2. Front visibility
Unique front visibility vision is retained by using the mast rail and finger bars similarly as on previous
models.
3. Chain
Same as that for the V mast.
4. Lift cylinder
The lift cylinder remains unchanged from that for the 7FBMF16 and 18.
5. Lift cylinder piping
The basic lift cylinder piping is the same as that for previous models.
The same in-line type safety down valve as that for the previous models is used except for an addition
of the fitting for a pressure sensor.
6. Lift roller
Same as for the V mast.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity
New model
Previous model

1.0 ton

1.3 ton

1.5 to 1.8 ton

2.0 ton

355(14.0)

370(14.6)

380(15.0)

385(15.2)

385(15.2)

7-4

FSV MAST
General
1. The FSV mast is optionally available.
2. The mast installation method is changed from that for the previous model to reduce the lost load center
(distance from the front axle center to the fork front).
3. A mast for 2.0 tons is newly provided.

Major improvements
1. High mast durability
Same as for the V mast.
2. Front visibility
Unique front visibility is retained by using the mast rail and finger bars similar to those on previous
models.
3. Chain
The mast chain for the 7FBEF15 to 18 is the same in size as that for previous models. The chain
(BL634) for the 7FBEF20 is the same in size with that for the 7FBMF20,25.
4. Lift cylinder
The mast lift cylinder for the 1.5- to 1.8-t models remains unchanged from that for the 7FBMF16 and
18. The mast lift cylinder for the 7FBEF20 is the same as that for the 7FBMF20,25.
5. Lift cylinder piping
The basic piping structure remains unchanged for the 1.5- to 1.8-t models. The flow regulator position
has been changed to shorten the lost load center (distance between the center of the front axle to the
front edge of the fork).
The pressure sensor piping is connected to the piping between RR cylinders.
The basic lift cylinder piping structure for the 2.0-t model is the same as that for the 1.0- to 1.8-t
models.
6. Lift roller
Same as that for the V mast.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity
New model
Previous model

1.0 ton

1.3 ton

1.5 to 1.8 ton

2.0 ton

395(15.6)

415(16.3)

410(16.1)

415(16.3)

415(16.3)

7-5

MATERIAL HANDLING SPEED


List of material handling speeds
mm/s (fpm)
V-mast

Vehicle model

7FBEF15

Lift

Lift

Load

No load

Load

No load

Load

610 (120)

430 (85)

560 (110)

400 (79)

560 (110)

400 (79)

540 (106)

350 (69)

490 (96)

330 (65)

490 (96)

330 (65)

480 (94)

280 (55)

430 (85)

270 (53)

430 (85)

270 (53)

550 (108)

500 (98)

450 (89)

480 (94)

420 (83)

480 (95)

610 (120)

420 (83)

560 (110)

390 (77)

560 (110)

390 (77)

540 (106)

340 (67)

490 (96)

320 (63)

490 (96)

320 (63)

480 (94)

260 (51)

430 (85)

250 (49)

430 (85)

260 (51)

550 (108)

500 (98)

450 (89)

480 (94)

420 (83)

480 (94)

610 (120)

390 (77)

560 (110)

380 (75)

560 (110)

380 (75)

540 (106)

320 (63)

490 (96)

310 (61)

490 (96)

310 (61)

480 (94)

250 (49)

430 (85)

240 (47)

430 (85)

240 (47)

550 (108)

500 (98)

450 (89)

480 (94)

420 (83)

480 (94)

500 (98)

340 (67)

470 (93)

320 (63)

450 (89)

280 (55)

420 (83)

270 (53)

400 (79)

220 (43)

360 (71)

210 (41)

500 (98)

500 (98)

450 (89)

480 (94)

Lower ALL

7FBEF18

Lift

Lower ALL

7FBEF20

Lift

FV-mast

No load

Lower ALL

7FBEF16

FSV-mast

Lower ALL

2
3

7-6

LOAD BACKREST & FORK


LOAD BACKREST
General
1. The backrest is installed as standard equipment.
2. The same flat steel type backrest as on the 7FBMF25 series is adopted.
3. The backrest-less option is selectable for all masts.
7FBEF15 to 18
Outside width of load backrest

mm (in)

970 (42.1)

1070 (42.1)

1220 (48.0)

1520 (59.8)

Forkbar width

mm (in)

920 (36.2)

1020 (40.2)

1170 (46.1)

1470 (57.9)

STD

Height of
load backrest
mm (in)

1220 (48.0)

STD: Standard, : Not available


7FBEF20
Outside width of load backrest

mm (in)

970 (42.1)

1070 (42.1)

1220 (48.0)

1520 (59.8)

Forkbar width

mm (in)

920 (36.2)

1020 (40.2)

1170 (46.1)

1470 (57.9)

STD

Height of
load backrest
mm (in)

1220 (48.0)

STD: Standard, : Available as option, : Not available

FORK
General
1. The fork is the same as that for the 7FBMF25 series.
2. The standard fork color is black. Orange color is provided optionally.
3. The forkless option is provided for all masts as on the Previous models.
Fork width
mm (in)

Fork thickness
mm (in)

7FBEF15 to 18

80 (3.2)

7FBEF20

100 (3.9)

Vehicle model

Fork length mm (in)


800
(31.5)

1000
(39.4)

1100
(43.3)

1200
(47.2)

1400
(55.1)

40 (1.6)

STD

40 (1.6)

STD

STD: Standard, : Available as option, : Not available

7-7

TILT CYLINDER
General
1. The tilt cylinder is newly provided for the 7FBEF series.
2. The screw type front joint is changed to a welded rod type.
3. The front pin for fixing the mast to the tilt cylinder is changed to an eccentric pin. It allows fine
adjustment of the backward tilt angle and uneven lifting.
4. FR and RR installation points use clevis structure.
5. The internal structure is the same as that for the 7FBMF25 series.

7-8

OIL PUMP
General
1. The external gear pump is the same in basic structure as that on previous models.
2. The conventional double gear pump is replaced with a single gear pump for noise reduction.
3. To improve the lifting speed, the pump capacity has been increased.

Vehicle model

7FBEF15 to 20

Oil pump name

Single gear pump

Oil pump type

TMG1A21A3H5-L (Shimadzu)

Drive system

Direct motor drive

Delivery
(at a pumping rate of 1,500 rpm)
Theoretical delivery

l (US gal) /min

30.8 (8.14)

cm3 (in3) /rev

21.9 (1.34)

7-9

OIL TANK
General
1.
2.
3.
4.

An independent resin tank is separately bolted on to the frame.


It is installed on the front frame.
The oil injection and level can be checked easily by removing the toe board.
The return filter is located under the front toe board.

Breather

Level gauge & cap

Return filter

Oil tank

Other hydraulic parts


1. Oil tank cap
A rubber male-female type cap is adopted.
A separate breather is adopted for downsizing.
Check the oil level by holding the cap end in contact with the retainer opening as illustrated.
Retainer

2. Breather
To ensure prevention of oil leakage from the breather, an off-cap structure is adopted. (40- mesh)

7-10

OIL CONTROL VALVE


General
Mast control valves are provided anew.
They are as follows:
A check valve and a solenoid valve are installed in the tilt circuit to control mast tilting operation.
A check valve and a solenoid valve are installed in the lift circuit, and a key-lift interlock function is
added to prevent the fork from lowering when the lift lever is erroneously moved to the down side while
the key is in the OFF position.
The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt.

Appearance

Forward tilt switch

Backward tilt switch

Lift look release bolt


Tilt solenoid
Lift solenoid

The newly installed check valve for locking the lift circuit enables lowering when unlocked at key
ON. The tilt circuit locking check valve is unlocked to enable tilting only when the tilt lever is
operated in the forward tilt direction with the key switch in the ON position.

Specifications
Unit: MPa (kgf/cm2) [psi]
Relief pressure

Lift

17.2 (175) [246]

Tilt

13.7 (140) [195]

7-11

Functional description
General
1. This vehicle is equipped with the key-off lift lock function using a solenoid valve provided in the lift
circuit similarly as on the 7FB10-J35 series.
2. Since tilt lock is electrically controlled by the solenoid valve installed in the forward tilt circuit, the
conventional tilt lock valve has been discontinued.
3. Since the flow is controlled by pump motor revolution similarly as on the 7FB10-J35 series, no solenoid
valve is provided on the control valve side.

Lift circuit
1. During lifting (lift solenoid valve: ON)
(1) When the lift lever is operated in the lifting direction, the lift spool moves to the left in the figure.
Then, the pump pressure compresses the spring at the lift load check valve to open the valve.
(2) The pump pressure is led to the lift logic valve. The pressure compresses the spring at the lift logic
valve to open it.
(3) As the result, the pump pressure is led to the C1 port to extend the lift cylinder and raise the fork.
Check valve
Solenoid valve

C1

Logic valve

Lift spool
Lift cylinder

Pump port

Lift load check valve

7-12
2. During lowering (lift solenoid valve: ON)
(1) When the key switch is turned ON, the lift solenoid valve is turned on. The poppet moves to the
right side in the figure to open the check valve. Then the hydraulic oil at the lower portion of the lift
cylinder flows through the C1 port to the lower side of the logic valve and the solenoid valve, and to
the upper side of the logic valve and the lift spool.
(2) Therefore, the relation of the pressures when the spool is stationary with the key switch ON will be
as follows: C1 pressure = Logic valve upper side pressure = Logic valve lower side pressure.
(3) Then operating the lift lever to the lowering side pushes the lift spool to the right in the figure and
opens the circuit between the C1 and tank ports. Since part A of the logic valve has an orifice, the
hydraulic oil between the lower side of the logic valve and the spool flows to the tank port.
Meanwhile, the hydraulic oil at the C1 port does not flow down quickly because it is choked by the
logic valve orifice.
Part A

Logic valve upper side

Check valve

Orifice

Poppet
Solenoid valve

C1

Logic valve
Logic valve lower side
Tank port
Lift spool
Lift cylinder

Pump port

Lift load check valve

7-13
(4) From the result of (2), differential pressure relations stand as follows when the lift lever is operated:
C1 pressure > Logic valve upper side pressure = Logic valve lower side pressure.
(5) Then the C1 port pressure acts on the logic valve to move it downward in the figure because of the
difference in area between a and b of logic valve part A. The pressure opens the logic valve and the
main circuit of the C1 port and the tank port to cause the fork to be lowered.
Part A

a
b

Logic valve upper side

Check valve
Solenoid valve

C1

Logic valve

Tank port
Lift spool
Lift cylinder

Pump port

Lift load check valve

7-14
3. Lowering operation with key-OFF (key-off lift lock)
Operating the lift lever to the lowering side when the key is turned OFF, the lift spool moves to the right
side. Since the solenoid valve is OFF then, the hydraulic oil in the lower part of the logic valve does not
flow to the tank port because of the check valve in the solenoid valve. Thus no pressure difference is
generated between the C1 port and the lower part of the logic valve. Consequently, the logic valve
remains closed. Since the C1 port and the tank port circuits are cut off, the fork does not go down even
when the lift lever is operated in the downward direction when the key switch is turned OFF.
Check valve
Solenoid valve

C1

Logic valve

Tank port
Lift spool
Lift cylinder

Pump port

7-15
4. Emergency circuit (emergency lowering circuit)
(1) The emergency circuit is provided in consideration of a circumstance where for some electrical
reason the solenoid valve fails to function. This refers to bypassing the hydraulic circuit that links
the lift logic valve lower side to the lift spool. This bypass circuit is provided with a needle valve,
which is normally shut off with the needle pushed in with a bolt. This bolt is locked with a lock nut.
(2) The lowering operation is as follows:
1) Loosen the lock nut.
2) Turn the hexagonal bolt to loosen it. (A turn is sufficient.)
3) Operate the lift lever toward the lowering side to lower the fork. The lowering speed is set at
approximately the same rate as for normal lowering.
4) When the lowering is completed, tighten the bolt and the nut according to the instructions given
in the repair manual.
(3) When the lift is manually lowered, hydraulic oil in the lower part of the cylinder, which is led to the
lower side of the lift logic valve, is also led to the needle valve on the emergency circuit. When the
lowering is manually operated, the hydraulic oil led to the needle valve is now led to the tank port,
generating a differential pressure between C1 port and the logic valve lower side same as in
normal circumstance. This causes the logic valve to open. It also opens the main circuit from C1 to
the tank port, allowing the hydraulic oil in the lower part of the cylinder to flow to the tank port.

Bolt

Solenoid valve

Nut

C1

Needle valve
Logic valve
Emergency circuit

Tank port
Lift spool
Lift cylinder

Pump port

7-16
Tilt circuit
1. Mast backward tilting (Solenoid valve: OFF)
(1) When the key switch is turned ON and the tilt lever is operated to the backward tilting direction, the
tilt spool is pulled and moves to the left side in the figure.
(2) Then the hydraulic oil in the pump port flows through the spool and compresses the tilt logic valve
spring to open the valve.
(3) As the result of (2), the circuit connecting the pump port and the C3 port is opened. Since the C3
port is connected to the RH chamber of the tilt cylinder, the pump pressure is applied to contract the
tilt cylinder.
(4) On the other hand, when the tilt spool moves to the left side in the figure, the circuit connecting the
C2 port and the tank port opens. C2 port is jointed to the LH chamber of the tilt cylinder.
(5) The action in step (3) applies the pump pressure to the RH chamber of the tilt cylinder.
Consequently, the hydraulic oil in the LH chamber of the tilt cylinder is led from the C2 port to the
tank port through the control valve spool as if pushed by the piston inside the tilt cylinder.
Tilt cylinder

C2

C3
Check valve

Tilt spool
Solenoid valve
Tank port

Tilt logic valve


Pump port

7-17
2. Mast forward tilting (solenoid valve: ON)
(1) When the key switch is turned ON and the tilt lever is operated in the forward tilting direction, the tilt
spool is pushed and moves to the right side in the figure.
(2) Then, the circuit connecting the pump port to the C2 port opens. Since the C2 port is connected to
the LH chamber of the tilt cylinder, the pump pressure is applied to the LH chamber of the tilt
cylinder through the C2 port.
(3) Meanwhile, the tilt solenoid valve is turned ON when operated for forward tilting. The poppet in the
solenoid valve moves to the right side in the figure to open the check valve. Then the hydraulic oil in
the RH chamber of the tilt cylinder flows through the C3 port, right side of the logic valve, the
solenoid valve, the left side of the logic valve and the tilt spool to the tank port.
(4) Then, part A of the logic valve forms an orifice. Therefore, the hydraulic oil is led from the right side
of the logic valve to the spool and then to the tank port, and the hydraulic oil at the C3 port flows
gradually to the right side of the logic valve because of restriction by the orifice at logic valve part A.

Tilt cylinder
Part A

Logic valve right side


C2

C3

Check valve
Poppet

Orifice
Tilt spool

Logic valve right


side
Solenoid valve

Tilt logic valve


Tank port

Pump port

Tilt spool constriction

7-18
(5) As the result of (4) above, differential pressure relations stand as follows when the tilt lever is
operated for forward tilting: C3 pressure > Logic valve left side pressure = Logic valve right side
pressure.
(6) Here, because of the difference in area between a and b of the logic valve, the pressure at the C3
port generates a greater force that pushes the tilt logic valve to the right side in the figure. It opens
the logic valve and the main circuit is connected from the C3 port to the tank port.
(7) The choke valve at the tilt spool prevents abrupt forward tilting caused by a load to the mast
forward tilting side when the tilt lever is operated.
Tilt cylinder

Part A

C2

C3

Logic valve right side


Check valve

Poppet

Logic valve right


side

Tilt spool

Solenoid valve

Tilt logic valve


Tank port
Pump port

3. Forward tilt operation at key-OFF (key-OFF tilt lock)


Operating the tilt lever to the forward tilting side when the key switch is turned OFF, the tilt spool moves
to the right in the figure. The hydraulic oil at the C3 port is led to the right side of the tilt logic valve, but
it is cut off by the check valve in the solenoid valve ahead because the tilt solenoid valve is OFF.
Therefore, no pressure difference is generated between the C3 port and the right side of the logic
valve. Consequently, the logic valve does not open. Thus the mast does not tilt forward if it is
attempted while the key switch is OFF because the circuit between the C3 port and the tank port is
closed.
Tilt cylinder

Logic valve right side


C2

Tilt spool

C3

Check valve

Logic valve right


side
Solenoid valve

Tilt spool constriction


Tank port
Pump port

7-19

MATERIAL HANDLING LEVER


Differences from previous models
1. To improve serviceability, cotter pins are replaced with pins for installing the control valve lever rods,
control levers and the control valve spool.
2. Tilt knob switch is arranged on the knob of the tilt lever.

4th

Automatic fork leveling switch

3rd
Tilt
Lift

-pin

7-20

HYDRAULIC CIRCUIT
Hydraulic circuit
1. Resin tank is adopted to reduce contamination, and the standard adoption of the return filter promotes
protection of hydraulic devices.
2. The return filter is arranged under the front toe board.
3. The following figure shows the function of the hydraulic circuit:

7-21

MAST INTERCHANGEABILITY
Mast interchangeability by vehicle model
1. Interchangeability within new model series
Vehicle model

Mast type
V

FSV

FV

7FBEF15 to 18

7FBEF20

: Mast interchangeable between respective model groups


: Not available
2. Interchangeability with previous models
No interchangeability
3. Interchangeability with 7FBMF25 series
No interchangeability

7-22

A4 PIPING
A4 Piping setting list
Mast
Type of
piping

Oil control valve

Piping number

7FBEF15 to 18

7FBEF20

FSV

FV

FSV

A405

Four valves

A410

Three valves

A430

Four valves

A450

Four valves

: Available
: Not available
FV mast is not available for the 7FBEF20.

A4 Piping layout
1.

Following the discontinuation of outer mast middle beam, the piping for the outer mast portion has
been modified.
2. The piping of inner and middle masts remains basically unchanged from 7FBMF25 series.

Free lift
The free lift of the FV mast without backrest decreases as indicated in the table when the A4 piping is
installed. This is because the pulley for the A4 piping is installed on the front cylinder.
mm (in)
Vehicle model

Mast
FV

7FBEF15 to 18

7FBEF20

-125 (-4.9)

Termination Types
The termination and piping at the lift bracket are the same as on the 7FBMF25 series.
Piping type
A405
A410
A430
A450

7FBEF15 to 18

7FBEF20

Mast

Mast

FSV

FV

FSV

STD

NONE

NONE

NONE

NONE

NONE

STD

CTR

RH SIDE

RH SIDE

CTR

RH SIDE

OPT

CTR

CTR

CTR

STD

CTR

RH SIDE

RH SIDE

CTR

RH SIDE

OPT

CTR

CTR

CTR

STD

CTR

RH & LH SIDE

RH & LH SIDE

CTR

RH & LH SIDE

OPT

CTR & LH SIDE

CTR & LH SIDE

CTR & LH SIDE

CTR: center termination


RH SIDE: right-hand side termination
CTR & LH SIDE: center and left -hand termination
RH & LH SIDE: right-hand and left-hand side termination
: nonavailable

8-1

SAS CONTROL SYSTEM


Page

SAS CONFIGURATION ................................................. 8-2


MAST CONTROL............................................................ 8-5

2
3

STEERING SYNCHRONIZER FHPS ......................... 8-8

8-2

SAS CONFIGURATION
General
The SAS (System of Active Stability) has been developed with the following concepts:
(1) To develop forklift trucks that can be clearly distinguished by customers from other makes in
respect to both safety and engineering.
(2) To pursue carefree material handling.

Targets of sas control


Active Mast Function Controller

(1) Longitudinal stability is improved by adopting


the mast forward tilt angle control.
(2) Mast backward tilt angle speed control is
adopted to prevent load from falling.
(3) Automatic fork leveling control is adopted to
improve operating efficiency.
(4) Key-lift interlock is adopted.

Active Steering Synchronizer


with FHPS

Characteristics of turning and straight traveling is


improved by developing FHPS
FHPS:Full Hydraulic Power Steering

SAS System configuration


Sensors are installed in various places on the vehicle to detect the vehicle movement and send signals to
the controller. Signals are controlled by the controller and output to respective actuators for action.
Input
control
T

Lifting height switch

Integral control valve

Steering synchronizer
solenoid

TK

LCD display
Diagnosis

Backward tilt limit switch


Tilt knob switch
Load sensor
Traveling speed sensor
Steering angle sensor
Tire angle sensor
T:Active mast function controller
K:Active steering Synchronizer

Controller

Tilt angle sensor


Forward tilt limit switch

Output
Actuator

8-3

Names and functions of respective parts


1. Names of parts

2
3

(1)
(5)

(2)
(10)

(3) (4)
(11)

(12)

(13)

(6)

(8)

(7)

8
(9)

(1)

Lifting height switch

(8)

Tire angle sensor

(2)

Tilt angle sensor

(9)

Integral control valve

(3)

Forward tilt switch

(10)

LCD display
diagnosis

(4)

Backward tilt switch

(11)

Steering angle sensor

(5)

Tilt knob switch

(12)

Steering synchronizing solenoid valve

(6)

Load sensor

(13)

Main controller

(7)

Traveling speed sensor

8-4
2. Functions of respective parts
Input side (to the controller)
Name
(1)

Lifting height switch

(2)

Tilt angle sensor

(3)

Forward tilt switch

(4)

Backward tilt switch

(5)

Tilt knob switch

(6)

Load sensor

(7)

Traveling speed sensor

(8)

Tire angle sensor

(11)

Steering angle sensor

Functions
Detects whether the signal is for low or high lifting height. The limit
switch provided on the outer mast side detects the height of inner
mast.
Detects the mast tilt angle. This sensor at the front protector on the
upper side of RH tilt cylinder detects the mast tilt angle from the tilt
cylinder that rotates around the rear pin as the axis of rotation.
Detects the forward tilt operation of the tilt lever. The limit switch
provided to the tilt spool of the oil control valve detects forward tilting
movement when the tilt lever is operated.
Detects the backward tilt operation of the tilt lever. The limit switch
provided to the tilt spool of the oil control valve detects backward tilting movement when the tilt lever is operated.
A switch for automatically leveling the fork when it stops and for
slowing down the backward tilt speed at a low lift.
Detects the load with a pressure sensor provided to the lift cylinder
hydraulic circuit.
Detects the traveling speed from the motor revolution with a sensor
provided to the drive motor.
Detects the tire angle based on the center shaft turning angle with
the sensor at the top of the rear axle center shaft.
Detects the steering wheel position with the sensor provided under
the steering wheel.

Output side (of the controller)


Name

(9)

Integral control valve

(10)

LCD display

(12)

Steering synchronizing
solenoid valve

Functions
Two solenoids are provided to the integral control valve.
The heck valve and the solenoid valve installed to the tilt circuit
control the tilting action of the mast.
The check valve and the solenoid valve on the lift circuit add the
key-off lift lock function to prevent the fork from lowering if the lift
lever for lowering is actuated by mistake while the key is turned
OFF.
If SAS function has any error, wrench symbol mark on the display
blinks, simultaneously buzzing alarm. In addition, an error code indicates abnormal point.
SAS system always requires an initialization (matching) when an
SAS function-related service is provided. In this case, initialize the
system using the display. (See the section for the display)
The solenoid valve is installed to the correcting valve. The solenoid
valve is actuated by a command sent from the controller to open/
close the correcting valve. Opening-closing of the correcting valve
adjusts the hydraulic oil flow rate to the rear axle cylinder to correct
offset of the knob position.

8-5

MAST CONTROL
General
Mast control includes the following functions:
1. Mast forward tilt angle control
Mast forward tilt angle control automatically controls the possible forward tilt angle of the mast
according to the state of the load and lifting height. It reduces the hazards of falling cargo or vehicle tipover if the tilt lever is carelessly operated for forward tilting.
2. Mast backward tilting speed control
Automatically reduces the mast backward tilting speed to prevent the load from breaking loose when
the lifting height is high [about 2 m (6.6 ft) or above.] For low lifting height, tilting speed can be reduced
by tilting the mast backward while keeping the tilt lever knob switch pressed.
3. Automatic fork leveling control
When operated for forward tilting with the tilt lever knob switch pressed, the fork automatically stops in
level position (with the mast in vertical position). This function is convenient for connecting/
disconnecting fork during cargo loading/unloading.
4. Key-off lift lock
The fork does not lower if operated for lift lowering (the lift lever is operated to the lowering side) when
the key switch is turned OFF. This function sharply reduces natural drop or forward tilting.

2
3

Schematic diagram of control block


Lift lever
Key-switch

Lifting height switch

Tilt konb switch

Tilt angle
sensor
Tilt limit switch
Oil control valve
Tilt cylinder
Tilt solenoid
Load sensor

PS

Lift solenoid

Controller

Pump motor

8-6

Descriptions of activation
Mast forward tilt control (forward tilt angle control)
(1) Possible forward tilting angle varies as shown in the figure below according to the lifting height and
load:

Possible forward tilt angle

Light load (no load)

High lift height

Intermediate load

Heavy load

No restriction for
forward tilt angle

Low lift height

No restriction for front tilt angle

Low lift height


Maximum
Forward tilt
angle 5

High lift height

Forward tilt
(Approx 1)
Mast vertical
Load

Heavy

(2) If cargo is raised tilted forward for low lifting height, the stop position may come to the forward tilt
side than the control angle. Do not raise the cargo with the mast tilted forward same as previous
model.
(3) When the low load cargo is at the fully raised position, residual pressure from relief stop is detected
by the pressure sensor as high load, subsequently controlling the forward tilt angle. To enable
further forward tilting, lower the cargo slightly from the fully raised position and relief the pressure.
(4) When installing a heavy attachment to a specialty model, etc., the mast forward tilt control may not
be provided.
Caution:
Dont place overconfidence with the mast forward tilt control function.
Although the forward tilt angle is reduced according to the load and lifting height, this does not
guarantee that the cargo does not fall or vehicle does not tip over under any conditions.
Never tilt the mast forward from the vertical position with the cargo raised same as previous
model. Or the longitudinal stability will be degraded to cause the hazard of falling even under
allowable load.
Never use the forward tilt control for any work.

Backward tilting speed control


(1) Controls (delays) backward tilting speed for high lifting irrespective of the load. In addition,
controlled speed continues if the cargo reaches the low lifting height from the high lifting height
while backward tilting is actuated.
(2) For low lifting height, the tilting is in full speed without any control irrespective of the load. Actuating
backward tilt with the tilt lever knob switch pressed controls (delays) the backward tilting speed as
long as the switch is pressed.
(3) When the lifting height enters low level from high level during backward tilting, the tilting speed is
controlled (delayed) as long as the tilt knob switch is pressed. Tilting reaches full speed (no speed
limit) when the tilt knob switch is not pressed.

8-7
Automatic fork leveling control
Operating the fork for forward tilting from the backward tilt position with the tilt lever knob switch pressed
stops the fork automatically in level position (with the mast in vertical position). The conditions vary as
follows depending on the lifting height and the load.
Actuation will be as indicated below when the mast is operated for forward tilting from the backward tilted
position with the tilt lever knob switch pressed:
Not loaded

Loaded

High lifting height (Approx. 2m or


more)

Stops with the mast held in


vertical position

Does not tilt forward

Low lifting height (Less than approx.


2m)

Stops with the mast held in


vertical position

Stops with the mast held vertical or tilted backward by about


1 degree depending on the
load.

Pressing the tilt lever knob switch during forward tilting with high lifting height and load stops
forward tilting, but the hazard of falling is present depending on the conditions of the road
surfaces, etc. Never use this function for the purpose of any work.
In the case of a vehicle with attachment, automatic fork leveling control poses a hazard if the
lever stroke is set to maximum during high lifting.
In the case of a specialty model installed with heavy attachment, etc., the automatic fork leveling
control may not be provided.

Key-off lift lock


1. Integral control valve has been newly designed for mast control, and the lift hydraulic circuit is modified
accordingly.
2. Lowering is disabled if the lever is operated for lowering when the key switch is turned OFF.
3. Since the lift lock solenoid valve is provided to the lift hydraulic circuit, the solenoid valve remains
closed while the key switch is turned OFF, preventing the lowering if the lift lever is operated for
lowering. To lower the fork, turn the key switch ON and operate the lever for lowering.

Possible vehicle weight for installing the mast control


When installing a heavy attachment, etc. to a specialty model, the mast forward tilt angle is set to approx.
1 degree. No automatic fork leveling control is provided for high lifting height.
Upper limit of additional ATT weight (kg)
Vehicle model

Lifting height
3000 mm or
below

Lifting height
3300 to 4000
mm

Lifting height
4300 to 5000
mm

Lifting height
5500 to 6000
mm

7FBEF15

700

550

500

400

7FBEF16

700

550

500

400

7FBEF18

700

550

500

450

7FBEF20

800

700

600

500

8-8

STEERING SYNCHRONIZER FHPS


General
1. The steering angle sensor located at the lower side of the steering wheel and the tire angle sensor
provided to the upper part of the center shaft turning detect the steering angle and the tire angle
respectively and correct offset relation, if any, of both angles by opening the solenoid valve.
2. To correct the offset relation, the controller sends command to the solenoid valve to form a bypass
circuit to return part of hydraulic oil to be supplied to the PS cylinder to the tank. This system retains
relation between the steering knob position and the tire angle at a prescribed level.
3. Correction may not be made for safety reason depending on the traveling speed and other conditions.
4. If the knob position should be offset after maintenance service, etc., the steering position will be
automatically corrected by turning the key switch ON and turning the steering wheel to lock-to-lock.

Schematic diagram of control block

Steering knob

Vehicle speed sensor


Steering wheel angle sensor
DM
P

DM

Solenoid valve
Main controller

Tire angle sensor

9-1

OUTLINE OF MAJOR OPTIONS


Page

FISHERMAN SPECIFICATION ................................... 9-2


MASTLESS ...................................................................... 9-3

2
3

ATTACHMENT LIST ....................................................... 9-4


DRIVE-IN RACK SPECIFICATION ............................. 9-8
MINI LEVERS................................................................... 9-9
BATTERY ROLL-OUT SPECIFICATION .................. 9-23

9-2

FISHERMAN SPECIFICATION
General
1. The fisherman specification improved in rust prevention as compared with standard vehicles is
provided anew. Please recommend it for such cases shown below.
For use in marine product industry
For frequent use on wet ground
For use in a humid environment
For transportation of salty or other water tanks involving water splashing onto the vehicle
For use in an environment where ground surface is constantly wet with salty water
For use in an environment involving splashing of oxidizing fluid (such as hydrogen peroxide or
sodium hypochlorite)
For use in an environment where a snow-melting agent such as calcium chloride is used
2. Since the fisherman specification has poorer heat radiation because of the waterproof structures of the
drive and pump motors, the rate of operation should be kept at about 60% compared to standard
vehicles.
Depending on the type of operation (such as continuous heavily loaded operation), the vehicle
performances may be temporarily reduced for protecting the controllers and motors from overheating.
The motor current limiting function that is activated upon detection of the specified temperature by the
sensor built in each controller or motor causes this. This is not an abnormality. Since an alarm
indication is given on the monitoring display, suspend operation for some time and restart after
disappearance of the alarm indication.

Items and contents


The following items have been changed from those on the standard vehicles.
Item

Content

Drive/Pump motor

Waterproof type

Brake switch

Waterproof type

Covers

Under the Front-Protector cover


Tilt cylinder hole cover

Mast

Anti-rust roller
Fully oil charged lift cylinder

Tilt cylinder

Tilt cylinder boot

Bolt

Rust preventive treatment


(Covers, Tilt pin)

9-3

MASTLESS
General
Mastless vehicles are available optionally.
These are without the mast ASSY, lift bracket, backrest and fork.
The high-pressure hose from the mast to the control valve is not provided. The control valve fitting is
attached with a blind plug.
The tilt cylinder is for the FSV mast. The pin for fixing the tilt cylinder on the mast is not provided.
The name plate punched with the model, frame No., manufacturing year, front tread, tire size, tire
pressure, voltage, battery weight and rated load is riveted in the same position as on the standard
model.
A spare nameplate punched with the model, frame No., manufacturing year, voltage, battery weight and
rated load is supplied with the vehicle.
Note:
Always install the 7FBEF series mast for SAS manufactured by Toyota as described on the
repair manual.
SAS matching is a must after mast installation.
Refer to the table in the mast specification section for the allowable load to be punched on the
nameplate (except when the side shifter is installed).

2
3

9-4

ATTACHMENT LIST
SIDESHIFTER
ATT
NAME

E811

E811A

E811B

E911

E911A

E911B

OPT
CODE

D910

D911

D912

D900

D902

D903

INTEGRATED

INTEGRATED
+A430

INTEGRATED
+A450

HOOKED ON

HOOKED ON
+A430

HOOKED ON
+A450

7FBEF15

7FBEF16

7FBEF18

7FBEF20

MODEL

: Provided
Note:
The sideshifter includes center termination.

Hooked on sideshifter (CASCADE)


General

A detachable sideshifter (Cascade) is provided.


The basic structure remains unchanged from that for previous models.
It can be installed on the V, FSV and FV (1-t series) masts.
The shifter fork bar width is the same as the fork bar width on the vehicle.

Front view of detachable sideshifter

9-5

Specifications
STD: Standard : Available as option

7FBEF15 to 18
Fork bar width

mm (in)

Catalog No.
Assembly weight

920 (36.2)

kg (lb)

50.3 (111)

Effective thickness mm (in)

59.0 (2.32)

Max. sideshift

200 (7.87)

mm (in)

Series

STD
STD: Standard : Available as option

7FBEF20
Fork bar width

2
3

55F-SS-A890

mm (in)

1020 (40.2)

1170 (46.1)

1470 (57.9)

55F-SS-A891

55F-SS-A930

55F-SS-A932

53.5 (2.11)

59.0 (2.32)

88.3 (3.48)

Effective thickness mm (in)

59.0 (2.32)

Max. sideshift

200 (7.87)

STD

Catalog No.
Assembly weight

Series

kg (lb)

mm (in)

Others
1. Fork & Backrest
The fork and backrest are the same as those of the standard vehicles. Series options can be used as
they are.
2. A4 Piping
The E9 attachment includes the A4 piping as shown in the table below.
E9-code

A4-type

E911

A410

E911A

A430

E911B

A450

3. Control Lever Layout


The control lever layout remains unchanged. The operating directions are also the same.

9-6

Integral sideshifter
General

The sideshifter integrated with the lift bracket is provided.


The basic structure remains unchanged from that for previous models.
It can be installed on V, FSV and FV (1-t series) masts.
The allowable load and load center are the same as those on standard vehicles.

Rear view of integral sideshifter

Stroke

Stroke

Fork bar width

Specifications
7FBEF15 to 18

STD: Standard

Fork bar width

mm (in)

920 (36.2)

Max. sideshift

mm (in)

200 (7.87)

Series

STD
STD: Standard : Available as option

7FBEF20
Fork bar width

mm (in)

1020 (40.2)

1170 (46.1)

1470 (57.9)

Max. sideshift

mm (in)

200 (7.87)

STD

Series

9-7

Others
1. Fork & Backrest
The fork and backrest are the same as those of the standard vehicles. Series options can be used as
they are.
2. A4 Piping
The E8 attachment includes the A4 piping as shown in the table below.
E8-code

A4-type

E811

A410

E811A

A430

E811B

A450

3. Tire chain installation


There is no optional tire chain installation structure.
4. Control lever layout
The control lever layout and operating directions are the same as on previous models.

9-8

DRIVE-IN RACK SPECIFICATION


Structure (Differences from Standard Model)
The head guard, front stay and rear pillar shapes are different, and the seat position is moved by 36 mm
toward the center of the vehicle.

LOAD

mm (in)
A

780 (30.7)

1156 (45.5)

1883 (74.1)

780 (30.7)

Unallowable Optional Attachments


Lights (FRRR combination lamps, etc.)
4-way control valve, piping, etc.

Others
The assist grip and headlamps are not installed.
The mast backward tilting angle is up to 5.

9-9

MINI LEVERS
General
The electromagnetic oil control valves for mast control with mini levers are newly provided as options.
They are as follows:
A check valve and an electromagnetic proportional valve are installed in the tilt circuit to control the mast
tilting operation.
A check valve and an electromagnetic proportional valve are installed in the lift circuit for key-off lift
interlock to prevent the fork from lowering in case the down lift lever is touched erroneously while the
key is OFF.
The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt.

Appearance
Connection with actual machine components
Port P

Hydraulic pump
(hydraulic fluid supply source)

Port C2

Tilt cylinder bottom side

Port T1

Tank

Port C3

Tilt cylinder rod side

Port T2

Tank

Port C4

Actuator

Port C1

Lift cylinder bottom side

Port C5

Actuator

G2

Pressure reducing valve static


pressure detection port

Pressure detection port


Port P static pressure detection
port

G1

C1
G2
C3
P

C5
C2

C4
T1
G1
T2

Specifications
Unit: MPa (kgf/cm2) [psi]
Mini rever
Relief pressure

Lift

17.2 (175) [246]

Tilt

9-10

Explanation of Operation
Material handling valve
1. Pressure compensation mechanism
When pressure compensation mechanism is ON
When solenoid C1 is euergized and non-leak valve is closed, the pressure compensation mechanism
operates as follows:
Pressure oil flowing from port P flows from chamber (a) through orifice A to chamber (b), then flows
through orifice B to chamber (c).
The opening aperture of oil passage E is determined by the equilibrium of chamber (b), chamber (c)
and spring 1.
This controls the oil pressure of chamber (a) at a fixed pressure higher than the oil pressure in
chamber (c).
Pressure oil that has flowed through the pressure reducing valve flows to chamber (f), then flows
through orifice D to chamber (e).
The pressure oil in chamber (c) flows into chamber (d) and the pressure compensation valve is
operated by the equilibrium of chamber (c), chamber (d) and spring 2.
This controls the oil pressure of chamber (d) at a fixed pressure higher than the oil pressure in
chamber (e).
Chamber (d) and chamber (c) are connected by orifice C, so they have the same oil pressure, and the
pressure differential between chamber (a) and chamber (f) is kept constant by operation of the unload
valve and the pressure compensation valve.
This pressure differential is detertimed by spring 1 and spring 2.
When the oil pressure in chamber (a) becomes high, the oil drains from the pilot relief valve of the
unload valve.
Accordingly, the maximum oil pressure of chamber (a) is detertimed by the installation load of spring 3.
Pressure compensating function (sectional view of inlet section)
Main flow/excess flow
Pilot flow
Unload valve
Port T1

Spring 1
E

A (a)

B
Port P
(c)
When the pilot relief valve is opened

(b)

When the pilot relief valve is closed

(f)
Spring 3

(e)
C

Solenoid C1

(d)
Non-leak valve
Pressure compensation valve
Spring 2

9-11
When pressure compensation mechanism OFF
When solenoid C1 is not energized and the non-leak valve is open, the pressure oil from chamber (c)
flows through orifice Q, then returns to the tank via chamber (g). Now chamber (c) has the same
pressure as the tank, so all the pressure oil from port P returns to the tank via part E.
When the pressure compensating mechanism is inactive (sectional view of inlet section)
Main flow/excess flow
Pilot flow
E
Port T1

Port P
(c)

(g)

Solenoid c1

Non-leak valve

9-12
2. When material handling is not operated (spool in the neutral position)
When a pressure is applied from the port P
The pressure compensating mechanism is inactive because solenoid c1 is not activated.
When the pressure compensating mechanism is inactive (sectional view of inlet section)
Main flow/excess flow
Pilot flow
E
Port T1

Port P
(c)

(g)

Solenoid c1

Non-leak valve

9-13
Backpressure leak reduction mechanism
Port C1 of the lift cylinder is connected to the bottom of the lift cylinder, and port C3 of the tilt cylinder is
connected to the rod side of the tilt cylinder.
When load pressure from port C1 and port C3 is applied, leakage to chamber (i) and chamber (j) is
controlled by H and I on the seat.
Leakage of pressure oil that flowed to the lift lock check valve and pressure oil that flowed to the tilt
lock check valve is controlled by land part J and land part K respectively.
This reduces natural drop and natural forward tilt.
Backpressure leak reduction mechanism (sectional view of lift section)
Pilot flow

H
Port C1

(i)

Tilt lock check valve

Backpressure leak reduction mechanism (sectional view of tilt section)


I

Pilot flow
Port C3

K
(j)
Tilt lock check valve

9-14
3. Hydraulic pressure mechanism for solenoid proportional valve
The pressure oil that has had its pressure reduced by the pressure reducing valve flows to chamber
(h), then flows through passage 4 and the filter to become the pilot pressure to each solenoid.
The pressure of the oil is determined by the set load on spring 4.
Hydraulic pressure mechanism for solenoid proportional valve
Pilot flow

Electromagnetic proportional valve

Electromagnetic proportional valve


Tilt section

Lift section

Filter
(h)
Inlet section
Spring 4

Reducing valve

9-15
4. Load sensing mechanism
The pressure compensation valve, unload valve and sensing circuit are part of pressure compensation
operation.
When the spool strokes, chamber 7 connects to each cylinder port.
Sensing pressure is the cylinder pressure, which gives feedback to the pressure compensation valve.
When sensing pressure + pressure of spring (2) = pressure of chamber (d) and chamber (c), the
pressure compensation valve moves to the equilibrium position.
The pressure differential between the sensing pressure and chamber (d) and chamber (c) becomes
the pressure of spring (2).
The pressure of chamber (d) and chamber (c) is applied to the unload valve, then the unload valve
moves to the equilibrium position, when pressure of chamber (e) and chamber (c) + pressure of spring
(1) = P port pressure.
The pressure differential between chamber (d) and chamber (c) and P port pressure becomes the
pressure of spring (1).
The force of spring (1) and spring (2) is now constant, so the pressure differential is constant, and
sensing pressure + force of spring (1) +force of spring (2) = P port pressure.
Load sensing mechanism
Main flow/excess flow
Pilot flow
Lift spool

Tilt section (2nd spool)

Lift section (1st spool)

Tilt spool
Attachment section (3rd spool)

Inlet section

Attachment spool

LS check valve

9-16
5. Lift UP operation
When the lift lever is pushed to the UP side, solenoid b1 is energized and the solenoid proportional
valve moves to the right. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (k) on the left side, and the lift spool moves to the right side.
The volume of oil that flows to chamber (k) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check, then flows
through part L and chamber 7 to move the lift lock check valve, and then flows to the port C1 and the
bottom of the lift cylinder.
The select valve does not operate at this time, so the select valve becomes simply a check valve.
The pressure differential between chamber (a) and chamber 7 is kept constant by the pressure
compensation mechanism and the load sensing mechanism, so the volume of pressure oil supplied to
port C1 is determined by the opening aperture of part L irrespective of the load.
Lift UP operation (lift section)
Main flow/excess flow
Pilot flow

Inlet section
Load check

Lift logic valve

Tilt section
(a)

Section S-S

Port C1

L
Lift spool
(k)

Logic selection valve


S

Spring 5

Solenoid b1
Electromagnetic proportional valve

Solenoid a1
7

10

Electromagnetic proportional valve

9-17
6. Lift DOWN operation
When the lift lever is pushed to the DOWN side, solenoid a1 is energized and the solenoid proportional
valve moves to the left. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (m) on the right side, and the lift spool moves to the left side.
The volume of oil that flows to chamber (m) is proportional to the distance the lever is operated.
The pressure oil from chamber (m) flows through 11 into chamber (o) and shifts the select valve to the
left.
Then the pressure oil operating on port C1 flows through orifice F and enters the select valve.
The circuit is configured with the select valve and chamber (u) connected, so the pressure oil of the
select valve flows through part M and then flows from chamber (g) to the tank.
Accordingly, C1 holding pressure opens the lift lock check valve and the oil flows from C1 to the tank.
Lift DOWN operation (lift section)
Main flow/excess flow
Pilot flow

Lift logic valve


M

Port C1

Lift spool
5
Logic selection valve

Spring 6

(o)
11
(m)

(g)
Solenoid a1

Solenoid b1
Electromagnetic proportional valve

Electromagnetic proportional valve

If, due to a malfunction, you want to lower the mast without moving the lift spool, opening the
emergency DOWN valve will configure the circuit as shown in the diagram and the mast will descend.
Lift emergency down (lift section)
Main flow/excess flow

Port C1

Emergency down valve

(g)

9-18
7. FORWARD tilt operation
When the tilt lever is pushed to the FORWARD side, solenoid a2 is energized and the solenoid
proportional valve moves to the left. Then the pressure oil controlled by the pressure reducing valve
flows to chamber (p) on the right side, and the tilt spool moves to the left side.
The volume of oil that flows to chamber (p) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check, then flows from
port C2 to the bottom of the tilt cylinder.
Pressure oil flowing to chamber (p) enters chamber (n), and shifts the select valve to the left.
The circuit is configured so that oil from the tilt cylinder rod side flows from port C3 through the tilt lock
check valve and chamber (y) to chamber (g).
This generates a pressure differential before and after orifice G, and the shifting of the tilt lock valve to
the right causes the oil on the tilt cylinder rod side to return to the tank.
FORWARD tilt operation (tilt section)
Main flow/excess flow
Pilot flow

Tilt section
Load check

Attachment section
(a)

Section T-T
Port C2

(y)

Lift logic valve

Port C3

Tilt spool
Spring 7

Logic selection valve


T

(n)
(g)

(p)

Solenoid b2
Electromagnetic proportional valve

Solenoid a2
Electromagnetic proportional valve

9-19
8. REAR tilt operation
When the tilt lever is pushed to the REAR side, solenoid b2 is energized and the solenoid proportional
valve moves to the right. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (w) on the left side, and the tilt spool moves to the right side.
The volume of oil that flows to chamber (w) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check and shifts the tilt
lock check valve, then flows from port C3 to the tilt cylinder rod side.
The select valve does not operate at this time, so the select valve becomes simply a check valve.
The pressure differential between chamber (a) and chamber 7 is kept constant by the pressure
compensation mechanism and the load sensing mechanism, so the volume of pressure oil supplied to
port C3 is determined by the opening aperture of part O irrespective of the load.
REAR tilt operation (tilt section)
Main flow/excess flow
Pilot flow

Tilt section
Load check

Attachment section
(a)

Section U-U
O
Port C2

Lift logic valve


Port C3

Tilt spool
Logic selection valve
(w)

Spring 8
Solenoid b2
Electromagnetic proportional valve

Solenoid a2
7

Electromagnetic proportional valve

9-20
9. Attachment operation
When you operate the attachment lever, solenoid b3 is energized and the solenoid proportional valve
moves to the left. Then the pressure oil controlled by the pressure reduction valve flows to chamber (r)
on the left side and the spool moves to the right side.
Now the oil from chamber (s) drains out from 10 via the solenoid proportional valve.
The flow of the pressure oil after this is the same as for tilt operation.
Attachment operation (attachment section)
Main flow/excess flow
Pilot flow

Tilt section
Load check

Outlet
Section V-V
Attachment spool
(a)

Port C4

Port C5

(s)

(r)

Spring 9

Solenoid a3

Solenoid b3
Electromagnetic proportional valve

10

Electromagnetic proportional valve

9-21

Mini Lever Structure


Mini levers strongly desired in the US market are provided as options.
The material handling levers positioned above the instrument panel on previous models are installed on
the right front side of the seat and the lever stroke and operating force are decreased for easier
operation with less fatigue.
Since they are single-axis levers independent for the forward and backward directions like the manual
levers on previous models, previous model operators can easily handle new models.
The automatic fork leveling switch is installed behind the tilt lever. When the button is pressed once, the
operated state is stored mechanically by the lock mechanism in the switch for automatic leveling of the
fork at the time of stopping. Pressing it again releases locking to return to the original state without
automatic leveling. (See the mast control section for further details of the function.)
The lever box position can be adjusted in the longitudinal direction. Loosen the lever box fixing knob, set
the box in the position desired by the operator, and tighten the knob for fixing.
Levers are guarded all around.
Material handling operation is disabled while the operator leaves the seat.

Arm pad
Fork automatic
leveling switch
Tilt lever

Lift lever

Guard

Att lever

9-22

Armrest Structure
An armrest is provided for alleviating the right arm fatigue during traveling and material handling lever
operation.
The arm pad to be in contact with the arm and palm are made of soft urethane foam to fit the arm and
palm softly.
The armrest is fixed on the battery hood to be independent from seat sliding operation. A tall operator
with long arms and legs can obtain the best operating position by sliding the seat backward, and an
operator with short arms and legs by sliding the seat forward.
The armrest height can be adjusted. Loosen the armrest fixing knob, set the armrest at the desired
height and tighten the knob again.
Every operator can select the best position for lever operation.
Drivers position

Large operator

Medium operator
Small operator

Armrest fixing knob

Front-to-rear adjusting knob

Height adjusting knob

9-23

BATTERY ROLL-OUT SPECIFICATION


General
Provided for all models.

Structure
Battery roll-out vehicles have different frame structure from the standard vehicle as they replace battery
from the RH side.
The batteries are the same as those for standard vehicles.
The following indicate main structure:

Battery stopper

Part A
Metal roller guide and rollers can be installed under the battery. They enable battery replacement with
ease without using the tool.
Roller guide (steel)

Rollers
FR

RH

9-24

Battery replacement procedure


Follow the steps below when removing the battery:
(1) Open the battery hood.
(2) Raise the battery stopper to unlock.
(3) Turn the battery stopper. Slide the battery to remove it.
Installation procedure is the reverse of the removal procedure.
Open/close the battery hood following the same steps as the standard vehicle.

(1)

(3)

(2)

10-1

APPENDIX
Page

CAUTIONS FOR RECEIVING ORDERS................... 10-2


MAJOR SPECIFICATIONS .......................................... 10-3

2
3

FRAME NUMBER ........................................................... 10-5


TWO-PLANE DRAWING OF THE VEHICLE ........... 10-6
ELECTRIC WIRING DIAGRAM (VEHICLE
INSTALLED WITH OPTIONAL PARTS) ................ 10-9

10

10-2

CAUTIONS FOR RECEIVING ORDERS


Cautions for selling forklifts to customers in the marine product industry
1. Selling the standard vehicles to customers who handle fresh fish, pickles or tanned hides involving
possible salt water splashing onto vehicles may result in troubles of electrical parts such as motors.
Please sell the fisherman specification vehicles to a customer whose working conditions apply to any
of the following:
Conditions
Transportation of salty or other water tanks involving possible water splashing onto the vehicle
Vehicle being washed with salty water after the operation
For use in an environment where the ground surface is constantly wet with salty water
For use in an environment where the vehicle is possibly wetted with oxidizing fluid (such as
hydrogen peroxide or sodium hypochlorite)
For use in an environment where calcium chloride or other snow-melting agent is used
2. Attention should be paid for use in such industrial sectors as marine product processing, pickling,
leather tanning and fertilizer production.

Cautions for Vehicle Modification


1. Note
These forklifts use high-precision electronic devices. It is, therefore, necessary to pay sufficient
attention to prevent adverse influence on electronic devices when any auxiliary electric equipment not
specified by the manufacturer is to be installed.
2. Caution
When selecting any auxiliary electric equipment of other than the specified manufacturers for
installation on your forklift, check for abnormal surge* or noise generation beforehand and also pay
attention to the installation method.
If it is unknown whether the auxiliary equipment generates any surge, please consult with the auxiliary
equipment manufacturer.
*: Surge refers to local application of a high voltage instantaneously in a part of an electrical circuit due
to a sudden change in the current flowing in the circuit.
3. Other general supplementary advice
(1) Precautions for each type of auxiliary electric equipment are as follows:
1) Auxiliary equipment with built-in inductive load such as a motor or solenoid
Connect a reflux diode across the inductive load.
Connect a surge absorber across the ON/OFF switch.
2) Auxiliary equipment such as a buzzer or chime that generates sound
Use an electronic buzzer instead of a contact-type buzzer or chime.
3) Auxiliary equipment including a high voltage discharge circuit such as an igniter
Since this type is likely to generate a noise, always install after confirming no noise generation.
(2) Precautions about wiring are as follows:
1) Lay the harness for the auxiliary equipment as far from each vehicle harness as possible.
2) Do not branch a power or signal line from any portion in the vehicle harnesses. Connect the
power line for example from an option connector terminal or directly from the battery terminal.
3) The power supply for auxiliary equipment should be provided independently if possible.
(3) Others
1) Install the static straps when installing the non-marking or smooth non-marking tires.

10-3

MAJOR SPECIFICATIONS
7FBEF15, 7FBEF16
Vehicle model

Item
Standard lifting height
Free lift
Mast tilt angle
Overall length

Forward / Backward

Body length (to the front of fork)


Main
dimensions

Total width
Total
height

Mast raised
Mast lowered

Wheel base
Tread

Front wheel
Rear wheel

Ground clearance
Vehicle weight (without battery)
Minimum turning radius
Rated load
Load center

Performance

Traveling speed

No load

(forward)

Load

Traveling speed

No load

(reverse)
Raising speed
Lowering
speed

Travel
device

Tire size

Load
No load
Load
No load
Load
Front wheel
Rear wheel

mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
kg (lbs)
mm (in)
kg
mm (in)
km/h (mph)
km/h (mph)
km/h (mph)
km/h (mph)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)

Foot brake
Parking brake
Battery (STD)
Battery (High)

Drive
unit

mm (in)
mm (in)

Drive motor

Pump motor

Voltage
Capacity
Voltage
Capacity
Type
Output
Control device
Type
Output
Control device

V
Ah/5HR
V
Ah/5HR
kW

kW

7FBEF15
3000 (118)

7FBEF16
3000 (118)

150 (5.9)
5 / 6.5
2695 (106.1)

150 (5.9)
5 / 6.5
2795 (110.0)

1895 (74.6)

1995 (78.5)

1070 (42.1)

1070 (42.1)

3920 (154)

3920 (154)

1980 (78)

1980 (78)

1400 (55.1)

1505 (59.3)

915 (36.0)

915 (36.0)

175 (6.9)

175 (6.9)

85 (3.3)

85 (3.3)

1885 (4156)

1775 (3914)

1540 (60.6)

1640 (64.6)

1500

1600

500 (24)

500 (24)

16.5 (10.2)

16.0 (9.9)

15.0 (9.3)

15.0 (9.3)

16.5 (10.2)

16.0 (9.9)

15.0 (9.3)

15.0 (9.3)

610 (120)

610 (120)

430 (85)

420 (83)

550 (108)

550 (108)

500 (98)
1878/4.33
154.1/2-8/3.00
Mechanical
Manual
48
550
48
600
AC induction type
4.92
Transistor inverter
AC induction type
9.2
Transistor inverter

500 (98)
1878/4.33
154.1/2-8/3.00
Mechanical
Manual
48
660
48
720
AC induction type
4.92
Transistor inverter
AC induction type
9.2
Transistor inverter

2
3

10

10-4
7FBEF18, 7FBEF20
Vehicle model

Item
Standard lifting height
Free lift
Mast tilt angle
Overall length

Forward / Backward

Body length (to the front of fork)


Main
dimensions

Total width
Total
height

Mast raised
Mast lowered

Wheel base
Tread

Front wheel
Rear wheel

Ground clearance
Vehicle weight (without battery)
Minimum turning radius
Rated load
Load center

Performance

Traveling speed

No load

(forward)

Load

Traveling speed

No load

(reverse)

Load

Raising speed
Lowering
speed
Travel
device

Tire size

No load
Load
No load
Load
Front wheel
Rear wheel

mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
kg (lbs)
mm (in)
kg (lbs)
mm (in)
km/h (mph)
km/h (mph)
km/h (mph)
km/h (mph)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)

Foot brake
Parking brake
Battery (STD)
Battery (High)

Drive
unit

mm (in)
mm (in)

Drive motor

Pump motor

Voltage
Capacity
Voltage
Capacity
Type
Output
Control device
Type
Output
Control device

V
Ah/5HR
V
Ah/5HR
kW

kW

7FBEF18
3000 (118)

7FBEF20
3000 (119.5)

150 (5.9)
5 / 6.5
2800 (110.2)

125 (4.9)
5 / 6.5
3080 (121.3)

2000 (78.7)

2080 (81.9)

1070 (42.1)

1125 (44.3)

3920 (154)

3920 (154)

1980 (78)

1980 (78)

1505 (59.3)

1505 (59.3)

915 (36.0)

915 (36.0)

175 (6.9)

205 (8.1)

85 (3.3)

85 (3.3)

1895 (4178)

2215 (4884)

1645 (64.8)

1710 (67.3)

1750

2000

500 (24)

500 (24)

16.0 (9.9)

15.5 (9.6)

14.5 (9.0)

14.0 (8.7)

16.0 (9.9)

15.5 (9.6)

14.5 (9.0)

14.0 (8.7)

610 (120)

500 (98)

390 (77)

340 (67)

550 (108)

500 (98)

500 (98)
1878/4.33
154.1/2-8/3.00
Mechanical
Manual
48
660
48
720
AC induction type
4.92
Transistor inverter
AC induction type
9.2
Transistor inverter

500 (98)
200/50-10/6.50
166-8/4.33
Mechanical
Manual
48
660
48
720
AC induction type
4.92
Transistor inverter
AC induction type
9.2
Transistor inverter

10-5

FRAME NUMBER
Frame number punching location

2
3

Frame No. punching


position

Frame number punching format


Vehicle Model

Punching format

Vehicle Model

Punching format

7FBEF15

7FBEF15 10011

7FBEF16 to 20

7FBEF20 10011

10

10-6

TWO-PLANE DRAWING OF THE VEHICLE

Fr

Rr

P
N

Q
O

10-7
mm (in)
Position

Vehicle model
7FBEF15

7FBEF16

7FBEF18

7FBEF20

1070 (42.1)

1070 (42.1)

1070 (42.1)

1125 (44.3)

900 (35.4)

900 (35.4)

900 (35.4)

990 (39.0)

915 (36.0)

915 (36.0)

915 (36.0)

915 (36.0)

180 (7.1)

180 (7.1)

180 (7.1)

225 (8.9)

80 (3.1)

80 (3.1)

80 (3.1)

100 (3.9)

1670 (65.7)

1720 (67.7)

1730 (68.1)

1825 (71.9)

1540 (60.1)

1640 (64.6)

1645 (64.8)

1710 (67.3)

175 (6.9)

175 (6.9)

175 (6.9)

205 (8.1)

3920 (154.3)

3920 (154.3)

3920 (154.3)

3920 (154.3)

3000 (118)

3000 (118)

3000 (118)

3000 (118)

1970 (77.6)

1970 (77.6)

1970 (77.6)

1970 (77.6)

150 (5.9)

150 (5.9)

150 (5.9)

125 (4.9)

40 (1.6)

40 (1.6)

40 (1.6)

40 (1.6)

800 (31.5)

800 (31.5)

800 (31.5)

1000 (39.4)

1895 (74.6)

1995 (78.5)

2000 (78.7)

2080 (81.9)

355 (14.0)

355 (14.0)

355 (14.0)

370 (14.6)

1400 (55.1)

1505 (59.3)

1505 (59.3)

1505 (59.3)

1980 (78)

1980 (78)

1980 (78)

1980 (78)

6.5

6.5

6.5

6.5

10-8

10-9

ELECTRIC WIRING DIAGRAM (VEHICLE INSTALLED WITH OPTIONAL PARTS)


CPR

(P2,G)

F6

MB

P2

P3

F1

SW AC

P1

ACCEL
VRAD
+
TILT
VRAT

SW K

F5

(41,BR)

F4

(101,Y)

LIFT
LEVER
VRAL2

+ -

TILT
LEVER
VRAT2

VRAT1

+ -

ATT1
LEVER
VRAAT12

VRAAT11

+ -

ATT2
LEVER
VRAAT22

VRAAT21

+ -

SW MH1
SW TK DS F DS R

LS B

LS PB LS D

SPL

OPTO

MH1
D15V

(91,GR)
(90,O)
MH2-1
GNDD

LSAT2+

LSAT1+

LSL+

LSTF+

LSTR+

LSD

SWLE

(67,L)

(66,R)

(65,Y-G)
LSB

DSR

DSF

LSPB

(45,W)

(46,G-Y)

(70,BR)

(51,R-L)
LS-

LEDTK

SWTK

(31,P)

(27,Y-G)
POTAT22

POTAT21

POTAT2+

(26,B-Y)

(30,O)

(25,G-W)
POTAT12

POTAT11

POTAT1+

(24,P-W)

(29,W-R)

(23,B-R)
POTT2

POTT+

POTT1

(80,BR)

(81,B-W)
SSD22

SSD21

SSD2+

(79,G-R)

(88,W-G)

TD2+

CANGND

SSD2-,TD2-

CANL

CANH

CANTRD

SSD2
P71
(U)
P81

STMD1

(V)

P9

(W)

CUP

AMD1

KEYSTART

P8
(V)

P16
L F-R

CUDON

(U)

STMP

CUDID1

P7

CUDID0

(82,P)

(77,B-W)

SSD1

SSD12

(76,BR)

(75,G-R)

(87,W-G)

TD1+

SSD11

SSD1+

SSD1-,TD1-

CANL

CANH

CANGND

CUDON

CANTRD

(78,P)

AMP

(V)

KEYSTART

P15

CUDID1

(U)

CUDID0

P14

(W)

CUD1 (LH)

AMD2

STMD2

P91
(W)

CUD2 (RH)

N2
N1

N1

FOR STD(MINI LEVER LESS)

FAN, EXHAUST, CONTROL UNIT

MSCH STT

CONTACTOR, BATTERY

LS TR

SLL

GNDD

AC-R

+15V

AC-S

SMTDK
SDTMK

LCD
DISP

LS AT1 LS AT2

SDTMA

LAMP, WORKING

L F-LR

LAMP, FLASHER LH (REAR)

LS D

LIMIT SWITCH, DEADMAN

L F-RR

LAMP, FLASHER RH (REAR)

L F-L

LAMP, FLASHER LH

AM D2

MOTOR, DRIVE 2

CU D1

CONTROL UNIT, DRIVE 1

AM P

MOTOR, PUMP

CU D2

CONTROL UNIT, DRIVE 2

CU P

CONTROL UNIT, PUMP

SWAC

SWITCH, ACCEL

L F-R

LAMP, FLASHER RH

PB CPU

PRINT BOARD, COMPUTER

SWK

SWITCH, KEY

L ST-L

LAMP, STOP LH

SWL

SWITCH, LIGHT

L ST-R

LAMP, STOP RH

SOLST

SOLENOID, STEERING

SOLL

SOLENOID, LIFT

SOLT

SOLENOID, TILT

CPR

RESISTOR, CURRENT PROTECT

SWF

SWITCH, FLASHER

SOLLa1

SOLENOID, LIFT, a1(DOWN)

RT

TERMINATING RESISTANCE

SWH

SWITCH, HORN

L BU-R

LAMP, BACK-UP RH

SOLLb1

SOLENOID, LIFT, b1(UP)

SST

SENSOR, STEERING

SWTK

SWITCH, TILT KNOB

HR Y

RELAY, HEAD LAMP

SOLTa2

SOLENOID, TILT, a2(FRONT)

SPL

SENSOR, PRESSURE LIFT

SWMH1

SWITCH, HEIGHT NO.1

TR Y

RELAY, TAIL LAMP

SOLTb2

SOLENOID, TILT, b2(REAR)

SOLATa3

SOLENOID, ATTACHMENT, a3

SSD1

SENSOR, SPEED, DRIVE 1

L H-L

LAMP, HEAD LH

BZ

BUZZER

SOLATb3

SOLENOID, ATTACHMENT, b3

SSD2

SENSOR, SPEED, DRIVE 2

L H-R

LAMP, HEAD RH

SOLATa4

SOLENOID, ATTACHMENT, a4

SSP

SENSOR, SPEED, PUMP

L C-L

LAMP, CLEARANCE LH

SA

SURGE ABSOBER

SOLATb4

SOLENOID, ATTACHMENT, b4

STMD1

SENSOR, TEMPRETURE, DRIVE 1

L C-R

LAMP, CLEARANCE RH

HORN

SOLP

SOLENOID, PRESSUR

STMD2

SENSOR, TEMPRETURE, DRIVE 2

L T-L

LAMP, TAIL LH

FR Y

RELAY, FLASHER

STMP

SENSOR, TEMPRETURE, PUMP

L T-R

LAMP, TAIL RH

CHGLED4

LW

LIMIT SWITCH, PARKING BRAKE

MOTOR, DRIVE 1

CHGLED3

LIMIT SWITCH, BRAKE

LS PB

AM D1

CHGLED2

LS B

CHGLED1

VARI-OHM, ATTACHMENT2, NO.2

LCD DISPLAY

CHGSW3

LIMIT SWITCH, STOP LAMP

VRAAT22

LCD DISP

CHGSW2

LS ST

PB CPU
SOLP-

VARI-OHM, ATTACHMENT2, NO.1

SOLP+

LIMIT SWITCH, ATTACHMENT NO2

VRAAT21

SOLb4

LS AT2

SOLa4

VARI-OHM, ATTACHMENT1, NO.2

SOL4+

VRAAT12

POTL2
POTL+
POTT2
POTT+
POTAT12
POTAT1+
POTAT21
POTAT22
POTAT2+
LSAT2+

FUSE, FAN&SOLENOID

SOLb3

LIMIT SWITCH, ATTACHMENT NO1

F6

N1
48V

(63,P-W)

LIMIT SWITCH, TILT RR

LS AT1

LSAT1

LS TR

VARI-OHM, ATTACHMENT1, NO.1

LSAT1+

VARI-OHM, TILT, NO.2

VRAAT11

SOLa3

VRAT2

FUSE, CONTROL CIRCUIT

SOL3+

FUSE, LAMP

F5

(63,P-W)

F4

SOLb2

LIMIT SWITCH, TILT FR

SOLa1

LIMIT SWITCH, LIFT

LS TF

(62,B-R)

LS L

VARI-OHM, TILT, NO.1

(62,B-R)

VARI-OHM, LIFT, NO.2

VRAT1

LSTR

VRAL2

FUSE, DRIVE

LS-

BATTERY

F1

LSTF

NOTE)
THIS DRAWING SHOWS
CASE OF FULL OPTION.

BATT

CHGSW1

SMTDA

LSTR+

DIRECTION SWITCH, BACK-UP

SOLT-

DS BU

FOR D2 PEDAL
51(R-Y)

43(B-Y)

SOL L

(7,B-G)

VARI-OHM, LIFT, NO.1

LS TF

(61,G-R)

VRAL1

LS L

(61,G-R)

DIRECTION SWITCH, FORWARD OPTIONAL

(60,W-G)

DIRECTION SWITCH, REVERSE

DS FO

LSL

DS R

LSTF+

VARI-OHM, TIRE(HANDLE)

SOLT+

VRAH

SOLL-

DIRECTION SWITCH, FORWARD

(6,R-G)

DS F

(60,W-G)

VARI-OHM, TILT

LSL+

VRAT

(4,B-R)

VARI-OHM, ACCEL, DRIVE

SOLL+

VRAD

(51,R-Y)

MB

(3,W-R)

FANEX

N1

DS BU

DS FO

DS F

DS R

SOL T
103(R-W)

120(Y-R)

45(W)

46(G-Y)

SMTDA

SDTMA

SDTMK

SMTDK

SOL P

(141,W-R)

(142,R-B)

(143,R-G)

(16,R)

(14,B-W)

(144,G-R)

FANR-

FANR+

SOLP(13,R-Y)

SOLP+

SOLb4

(12,P)

(35,B-L)

(36,G-W)

SOLa4

SOL4+

SOLb3

(34,G-Y)

(10,R-L)

(11,G-B)

SOLa3

SOL3+

SOLb2
(8,P-G)

(7,B-G)

(9,Y-B)

SOLa2

SOL2+

SOLa1
(5,Y)

(6,R-G)

SOLb1

SOL1+

(4,B-R)

(3,W-R)

(330,GR)

SOLST-

SOLST+
(329,B-O)

LS-

STSC

(314,L)

(51,R-L)

(85,R-L)

SSP

SSP2

SSP1

(84,W-R)

(83,B-R)

(86,P-G)

(89,Y-G)

TP+

SSP+

SSP-,TP-

CANL

CANH

CUPID1

-RR

CANTRP

LF

-LR

KEYSTART

BZ

CUPID0

CUPON

(108,R-Y)

(109,G-Y)

-R

L F-L

SOL Ta2 SOL Tb2 SOL ATa3 SOL ATb3 SOL ATa4 SOL ATb4

SWF
L BU

LF

SOL La1

RT

CANGND

(110,GR)

SA

SOL Lb1

SOL ST

(120,Y-R)

(103,R-W)

FR Y

STS2

STS1

SST

VRAH
TIRE ANGLE

SWH

(313,R-Y)

(312,G-W)

(51,R-W)

(317,G-Y)

(316,R-Y)

FAN
FAN
EX
EX

POT-

POTH

POTH+

CANGND

CANL

(147,Y)

KEYSTART

CANH

(146,W)

(145,B)

(42,GR)

FAN-

FAN6
(39,B)

(135,Y)

FAN5
(134,Y)

FAN4

FAN2

FAN3
(133,Y)

-R

(132,Y)

L ST

(131,Y)

L H-R

FAN1

L T-R

-L

(39,Y)

L C-R

L ST

LW

(N2,W-B)

L H-L

FAN-

N2
L T-L

(130,Y)

(111,R-L)

(107,R-B)

(102,R-G)

N2

DS FO

DS BU

(104,G-R)

PB CPU

L C-L

(48,P)

(22,G-R)

(28,B-W)

(21,P-G)
POTL2

POTL1

POTL+

(20,W-G)

(57,L)

(51,R-L)
POT-

POTTA

(56,G)

(58,BR)

(59,Y-R)
SPL

SPL+

(53,R-G)
POTA+

(64,R)

(52,GR)
POTA

(51,R-W)
POT-

SWAC

(1,V)

(2,R)
MB-

(55,W-G)

MB+

CPR

VBMB

(18,O)

(44,Y-G)

(44,Y-G)

HM

POTTA+

HS

VBMB

SWL
T

BATT
48V

(41,BR)

VBKY

SWL

B48V

LS ST

HR Y
(115,P)

VBBT

TR Y
(116,LG)

(43,B-Y)

MB

(P1,B)

VRAL1

Published by

TOYOTA Material Handling Company


A Division of TOYOTA INDUSTRIES CORPORATION

1st Printing: May 2003

Pub. No. CE335-CD


Printed in JAPAN