7fbeu15-20 Ops Repair Manual Cu341

FOREWORD
This manual describes the explanation and service procedures concerning the
modified portions of the Toyota Battery Forklifts 7FBEU15, 18, 20. For the portions
not described herein, please refer to the New Model Features and Repair Manuals
shown below.
This repair manual contains the information on the vehicles manufactured as of

October 2005. Please understand that the description herein may not be applicable
to the vehicles produced thereafter. Any change or modifications thereafter will be
informed by Toyota Industrial Vehicles’ Parts & Service News.
The performance values described herein are for standard vehicles under our
specified test conditions. Since the conditions (weather, road surface, maintenance
and operation) are different in actual use, the values will vary accordingly.
<Reference>
New Model Features and Repair Manuals related to this manual are as follows:
{ NEW MODEL FEATURES

7FBEU15, 18, 20 (Pub. No. PU315)
{ REPAIR MANUAL
7FBEU15, 18, 20 (Pub. No. CU330) Vol. 1
7FBEU15, 18, 20 (Pub. No. CU331) Vol. 2
Service Information Bulletins affecting Models
(30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
Service Information Bulletin
1 SIB MA06-001 - 7FBCU Option Menu Changes
2 SIB CC06-001 - A5 Error Code Additional Information
3 SIB RA06-002 - Tie Rod Change
4 SIB FA06-003 - Front Axle Hub Change
5 SIB FA06-002 - Changes to Reamer Bolt Torque
6 SIB RA04-001 - New Tie Rod End Design
7 SIB MA05-009 7FBEU Option Set Menu Changes
8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload Specification)
9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion
10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks
11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust
12 SIB DU05-004 - Reduction Gear Change
13 SIB ST99-001R - Recommended Special Service Tools
14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting
15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting
16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32)
17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55)
18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32)
19 SIB FA05-001 - Gear Case Change (7FBCU35-55)
20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20)
21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~20
22 SIB CE05-001 Key Switch Change (All Models)
23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20)
24 SIB CE05-008 7FBEU Voltage Conversion
25 SIB CC05-011 Low Battery Voltage / Performance Reduction
26 SIB CC05-007 MB Contactor Cover (7FBEU15-20)
27 SIB ST06-001 - Recommended Special Service Tools
28 SIB CE05-006 Pump Motor Cooling Fan
29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit
30 SIB MA07-005 - Maintenance Indicator Changes
31 SIB RA07-001 Rear Axle Flange Change
32 SIB HS07-001 Addition of Back-Tilt Lock Valve
33 SIB CE06-005R - Display Battery Replacement
34 SIB CE06-005R Display Battery Replacement
35 SIB FA07-001R Front Axle Shaft Change
36 SIB CC07-004 - Tuning No. 14 Information
37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section
38 SIB CC08-003R Inching While Braking Option (Tuning Level 13)
39 SIB DU08-001R 7BNCU Drive Unit Repair Correction
40 SIB ST08-001 Recommended Special Service Tools
41 SIB CE08-002R Battery Connector Bracket
42 SIB HS08-002 Addition of OPSS Back-tilt Lock Valve
43 SIB CC08-010 7FB10-J35 Programming Changes
44 SIB Option Setting and Tuning Modes (7FB Models)
45 SIB BR09-001 7FB Repair Manual Corrections
46 CC09-001 7FB Revision of Repair Manual
47 CC09-003 Error Codes 31-1, 31-2 and 31-3
48 DU09-003 Gear Case Bolt Torque Change
49 CC09-004 5F and 5G codes
50 DM09-001 Drive, Pump and Steer Motor through Bolt Torque
51 DM09-002 Pump Motor Cable Clearance
52 CC10-001 Flashware v4.2
53 HS10-001 7FBEU Steering Circuit Hydraulic Schematics
54 SIB CE10-004 8FBC(H)U Voltage Conversion
55 SIB ST10-001 Measuring Parking Brake Force on 8FBC(H)U Trucks
56 SIB BR10-001 Stainless Steel Deadman Switch Mounting Screws
57 SIB CC10-005 v3.1 Software Update for Auxiliary Functions
58 SIB MA10-002 8FBCU Tuning Modes Explained
59 SIB CE10-006 7FBEU Motor Sensor Bearing Change
60 SIB CE10-007 8FBCU Height Selector Information
61 SIB CE10-008 8FBCU Shock Sensor Information
62 SIB MA10-003 8FBCU Auto Speed Control Information
63 SIB MA10-004 8FBCU Touch Pad Information
64 SIB MA10-006 AC Motor Controller Change
65 SIB CE11-001 Clamp Release Interlock (Mini Lever Units)
66 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin
67 SIB FA11-001 7FBEU Front Axle Repair Kits
68 SIB CC11-004 8FBCU Tuning No.1 Explained
69 SIB CE11-002 8FBCU Horn Wires Breaking
70 SIB CE11-003 Clamp Release Interlock (Standard Lever Units)
71 SIB DM11-002 7BNCU New Auxiliary Motor and Pump
Technical News Brief

1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal
Option, Over Heating Diagnosis, and 7FBCU Voltage Specs
2 TNB - 2004-07 - Hydraulic oil change
3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange
4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump
5 TNB - 2006-05 - Plate to Prevent Chain Rollback
6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates
7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure
8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage
9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display
10 TNB - 2006-09 - 7-Series Electric ROM Write
11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention
12 TNB-2006-03 - 7FBEU Counterweight Squeaking
13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure
14 TNB-2008-10 7BNCU Steer Sensor Alignment Tool
15 TNB-2008-16 Dual Contactor (Units with Pump Chopper)
16 TNB-2009-04 7FBEU Static Strap Update
Hotline Tech Tips

1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels
7FBCU
2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU
gradeability; 7FBCU CB1 and CB2
3 HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on
7FBEU and 7FBCU
4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential
Oil Level
5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing
6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU
Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction Mode and Lift Interrupt
Settings
7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement
8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 2
9 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers
10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon
11
HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel
12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures;
7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse Replacement
13
HTT-2006-01 - 7 Series Electric Lift Truck Erratic Display; 7FBE Drive Unit Part Numbers
14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes
15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-3
16 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement
17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm
18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption
19 HTT-2006-07 - 7FBEU Slow Motor Speed
20 HTT-2006-08 - 7FBEU E2-1 Error Code
21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N
22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes
23 HTT-2006-11 - 7FBCU Drive Transistors
24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor
25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install
26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added
27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU
28 HTT-2007-04 - Class 1 gear case oil
29 HTT-2007-05 - 7FBCU Gear Case Sealing
30 HTT-2007-06 - Steer Cylinder change
31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil
32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting
33 HTT-2007-09 - Repair Manual 322
34 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors
35 HTT-2007-11 - CU322 Repair manual clarification, 7FBEU 31-1, 31-2, 31-3
36
HTT-2007-12 - Class 1 Alarm with OPSS
37 HTT-2008-01 - Class I Gear Noise
38 HTT-2008-02 - Drive Unit Part Numbers, EF-1 & EF-2 Error Codes, Flashware Cable for
39 HTT-2008-03 - 7FBE Error Codes 64-2 & H9-2, 7FBCU15-55 A8, A1 & C3 Error Codes,
40 HTT-2008-04 - No Display with EZ Pedal, (30)7FBCU15-32 Complaint of Low Top Speed
41 HTT-2008-05 - 7FBCU20-32 Battery Slide out Field Installation Kit, (30)7FBCU15-55 Drive
42 HTT-2008-06 - 7FBE Front Hub Induction Hardening and Drive Axle Clattering
43 HTT-2008-07 - 7FBCU15-25 Inspecting the EHPS Transistor
44 HTT-2008-08 - 7FBE Internal Gear Hardened
45 HTT-2008-09 - (30)7FBCU15-32 Error Code C0-(1-6)
46 HTT-2008-10 - 7FBE Drive Axle Connector Rod Adjustment
47 HTT-2008-11 - Using The SST Tools In Diagnosing Board Issues and UL Ratings
48 HTT-2008-12 - Diagnostic Tips
49 HTT-2009-01 - Slow Lowering or Incorrect Staging During Lowering
50 HTT-2009-02 - C2-2 or C2-3 Error Codes and Trouble Shooting Error Codes H9-1,2,3 Or 64-
1,2,3
51 HTT-2009-03 - Static Strap Mounting and Lift Interrupt Settings
52
HTT-2009-04 - Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters
53 HTT-2009-05 - Error Codes After Card Replacement
54 HTT-2009-06 - Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On
55 HTT-2009-07 - Slow Travel Speed
56 HTT-2009-08 - Occurrence of Error Code AO-4
57 HTT-2009-09 - Jerky Travel at Slow Speeds
58 HTT-2009-10 - Gear Case Bolt Torque Increase
59 HTT-2009-11 - A5 Error Code On 7FBE and 7FBC Forklifts With OPSS, 5F and 5G Codes
for the 7BNCU Model Forklifts
60 HTT-2009-12 - 7FBCU Transistor Test Procedure & Speed Sensor Check
61 HTT-2010-01 - FE-4, E2-2, E2-4 Error Codes
62 HTT-2010-02 - Switch Adjust, RF Interference on AC Trucks
63 HTT-2010-03 - Documenting 7FBCU Brake Inspection and Adjustment During PDI,
Flashware v4.2
64 HTT-2010-04 - Class I Brush Warning Option 14, 7BNCU Diode Replace Instructions
65 HTT-2010-05 - Class I 7FBEU Front Axle Repair Kits
66 HTT-2010-06 - Class I AC Drive Motor Over Current Limit Checks, SAS Manual Lowering
Valve
67 HTT-2010-07 - 8FBCU Slow Travel or Surging Hydraulics, Setting Time/Date
68 HTT-2010-08 - 8FBCU Display, Main CPU and Changing Voltage
69 HTT-2010-09 - 8FBCU Measuring Parking Brake Force, 7BNCU Software v3.1
70 HTT-2010-10 - 8FBCU Service Information Bulletins
71 HTT-2010-11 - 8FBCU Slow Attachment Speeds, Seat Switch Failures
72 HTT-2010-12 - 8FBCU Travel Alarm in Both Forward and Reverse
73 HTT-2011-01 - Speed Limit Adjustment on 8FBCU
74 HTT-2011-02 - Class I-VI Common Electrical Acronyms, 7FBEU Error Codes 72-1, 72-2 or
Missing Manager's Functions
75 HTT-2011-03 - Class I 8FBCU Slow Lowering w/Standard Levers
76 HTT-2011-04 - Class I 8FBCU H Power Mode, 7FBEU RPM Sensor Bearing Damage
77 HTT-2011-05 - Class I Adding Electrical Devices,
78 HTT-2011-06 - Class I Battery Option/Type
79 HTT-2011-07 - Class I 7FBCU35-55 Using SST3 On CN112
80 HTT-2011-08 - Class I 8FBCU Tuning No. 1, Back to Basics Troubleshooting
81 HTT-2011-09 - Class I Important SIBs
82 HTT-2011-10 - Class I 8FBC(H)U Controller Software Change
83 HTT-2011-11 - Class I Adding Forward Travel Alarm
84 HTT-2011-12 - Class I C1-2 Error Codes, Hyd Oil Maint and Diagnosing Intermittent
Complaints
85 HTT-2012-01 - Class I 8FBCU Relief Valve Structure, Using DVOM to Check Voltage Drop
SECTION INDEX
NAME SECTION
GENERAL 0
OPS & IMPROVEMENTS 1
BODY 2
APPENDIX 3
0-1
GENERAL
Page 0
PERIODIC MAINTENANCE ............................... 0-2
1
OPS SYSTEM .................................................... 0-2
GENERAL ................................................................... 0-2
2
CHANGES FOR INSTALLATION OF 3
OPS FUNCTION ...................................................... 0-3
SYSTEM CONFIGURATION AND 4
OPERATION PRINCIPLE ........................................ 0-3
DISPLAY ............................................................ 0-5
5
GENERAL ................................................................... 0-5 6
7
8
9
10
11
12
13
14
15
16
17
18
0-2
PERIODIC MAINTENANCE
Comparison with Former Edition: Repair Manual, Pub. No. CU330, Page 0-22
Change:
INSPECTION METHOD
I : Inspection. Repair or Replacement if required.
M : Measurement. Repair or Adjustment if required.
T : Retightening C : Cleaning L : Lubrication
Inspection timing Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every

Item 250 hours 500 hours 1000 hours 2000 hours
SAFETY DEVICES, ETC.
Loosening and damage of mounting I ← ← ←

SEAT Seat belt damage and function I ← ← ←
Seat switch function I ← ← ←
OPS Function I ← ← ←
OPS SYSTEM
GENERAL
The OPS (Operator Presence Sensing) System is equipped as the standard feature on all models.
The switch installed on the seat detects the operator, and when the operator is not seated in the normal operating
position (operator’s seat), the OPS system interrupts the traveling power and restricts load handling operation.
When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding the
buzzer (pi-)* for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turning
off the seat switch. When the controller detects malfunction, the display indicate the diagnosis error code.
*: The buzzer sounds only export model.
S P H
0-3
CHANGES FOR INSTALLATION OF OPS FUNCTION

1. Change in return-to-neutral function
When the key switch or seat switch is turned ON with the direction lever in the forward or reverse position or the
accelerator pedal depressed, traveling is disabled unless the direction lever and accelerator pedal are returned
to the neutral positions.
0
SYSTEM CONFIGURATION AND OPERATION PRINCIPLE
Note:
1
When OPS operates, the power assistance of the steering wheel is lost because the pump motor is stopped.
(except for Mini-Lever Opt.) 2
3
4
Seat
5
switch
Key switch Display
Direction
6
switch Main
N1
controller
7
Battery Accelerator
pedal switch
Oil
8
control
Motor Motor
valve
9
driver driver
10
Lift
cylinder
Drive
motor
Pump
motor Oil
pump Tilt
11
Oil cylinder
tank
12
Item Operation explanation
When the controller detects the seat switch turned off for two seconds, the drive motor control is stopped.
13
14
Travel OPS Travel OPS is released by returning the direction lever and accelerator pedal to the neutral position and
turning on the seat switch.
Standard:
Material handling
OPS
When the controller detects the seat switch turned off for two seconds, the movement of lift down and tilt
forward is stopped by controlling the lift lock valve, tilt controlling valve. The movement of tilt backward, lift
15
up and attachment is stopped by stopping the pump motor. Material handling OPS is released by passing
one second after turning on the seat switch.
16
17
18
0-4
Item Operation explanation
Note:
• Tilt backward
When the tilt lever is operated in the state of OPS operation, the mast might move by the self-
weight in the state of backward tilting.
• Attachment
When the attachment lever is operated in the state of OPS operation, the attachment might
move by the self-weight.
Material
handling OPS Mini lever (OPT):
When the controller detects the seat switch turned off for two seconds, the movement of lift, tilt and
attachment is stopped by stopping the pump motor control and controlling the proportional solenoid valve.
Load handling material handling OPS is released by returning the all hydraulic control levers to the
neutral position and turning on the seat switch.
(In case of mini lever, it is additional to the condition of releasing material handling OPS to return the all
hydraulic control levers to the neutral position. Because the mini lever is small and physical operation
force is light, it is considered that the luggage etc. put on the armrest move the mini lever by mistake.)
OPS operation When the controller detects the seat switch turned off, it informs OPS operation to the operator by
information sounding the buzzer (pi-) for about 0.5 seconds and the display indication. Moreover, the display
(*) indication keeps while turning off the seat switch.
When the accelerator pedal is operated with turning on the seat switch without returning the direction
Return to
lever to the neutral position, it informs the operator that the travel OPS is not released by sounding the
neutral warning
buzzer (pipipipi).
Abnormality
When the controller detects malfunction, the display indicates the diagnosis error code.
warning
(*) The buzzer sounds only export model.
SEAT
STD equipped seat is the same one equipped on previous model. It has been equipped with non-suspension seat
with seat belt manufactured by Michigan seat.
Compared to previous model, variety of optional seat is increased. Optional seats are shown below. (Equipped seats
vary with the specification of option.)
All seats equip switches for operator presence sensing system.
When replacing seat, always use a genuine TOYOTA seat.
Otherwise, the OPS may fail to operate.
0-5
DISPLAY
GENERAL
The multiple display is provided in two types: standard easy model and optional all-round model.
0
Function list (only added or modified items)
{:Provided — :Not provided 1
Function Easy model (standard) All-round model (optional)
2
Status display function 1 OPS indicator { {
3
1. Return-to-neutral warning
(1) When the operator turns the key switch on while depressing the accelerator pedal or turning the direction
switch on to start the vehicle.
4
(2) After sat up, the operator depresses the accelerator pedal while turning the direction switch on and sitting
down.
5
2. OPS indicator
OPS indicator is displayed and the buzzer sounds for half seconds when the operator leaves the seat. 6
Note:
The buzzer sounds only export model. 7
8
9
S P H
10
11
12
13
14
15
16
17
18
1-1
OPS & IMPROVEMENTS

Page 0
GENERAL .......................................................... 1-2
1
MULTI-DISPLAY FUNCTIONS .......................... 1-3
MULTI-SCREEN DISPLAY......................................... 1-3
2
DIAGNOSIS ................................................................ 1-5 3
MASK FUNCTIONS .................................................... 1-5
4
TROUBLESHOOTING ....................................... 1-9
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1-2
GENERAL
Seat
switch
Key switch Display
Direction
switch Main
controller
N1
Battery Accelerator
pedal switch
Oil
control
valve
Motor Motor
driver driver Lift
cylinder
Drive Pump
motor motor Oil
pump Tilt
Oil cylinder
tank
1-3
MULTI-DISPLAY FUNCTIONS
MULTI-SCREEN DISPLAY
GENERAL 0
Display and Buttons
Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-2. 1
Change:
2
3
Initial screen upon key switch on When OPS is operated
SAS
TOYOT A
EQU I P P ED
S P H
S P H S P H
4
5
(1) (2) (3) (4) (8) (9)
6
7
SEP / 3 0 AM
8
11: 00
S P H
S P H 9
10
(5) (7) (6) (10) (11) 11
During traveling Upon error occurrence
12
13
1 1 : 0 0 A1 1 A1 2 A1 3
10
14
m ph 1 2 3 4 5 . Oh
S P H S P H
S P H S P H
(1) Parking brake ON indicator (7) Multiple display area

15
(2)
(3)
2-speed travel speed set indicator
Diagnosis ON indicator
(8)
(9)
DOWN button
UP button
16
(4)
(5)
Overheat warning indicator
Battery charge indicator

(10) Power select button
(11) Hour meter selector button

17
(6) Power select indicator
18
1-4
GENERAL FUNCTIONS
Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-7.
Change:
{: General function z: Manager’s function
Model USA model

Export model
Function (standard model)
Status display function OPS indicator { {
DISPLAY INDICATION LIST

Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-8, 9.
Add:
GENERAL Screen
Enter password
MASK FUNCTION Screen
To be set by dealer or serviceman
OPTION SET SEAT BUZZER The buzzer sound before OPS operation.*
*: The buzzer sound only export model.
1-5
DIAGNOSIS
DIAGNOSIS CODE LIST
Add: 0
Diag memory
Display code
code
Faulty Phenomenon on vehicle Detection controller
1
A5 A5 Seat switch Seat switch abnormality C/R
2
MASK FUNCTIONS 3
ANALYZER
Vehicle Abnormalities Not Stored in Diag Memory

4
5
Change:
Warning indicators Warning method Displayed code 6
Return to neutral warning:
4
Warning buzzer sounds when starting is attempted by
turning the key switch or seat switch ON with the direction
• Beep
Short beeps
No display 7
switch ON or the accelerator pedal depressed.
8
OPTION SET
OPTION SET Menu List

9
Add:
10
No. Indication Description
Indication Meaning
Selection
indication Meaning
11
OPT-23 SEAT BUZZER
Enable/disable
The buzzer sound only export Y Enable N Disable
12
model.
13
14
15
16
17
18
1-6
Operation Procedure for OPTION SET Screen

Comparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-65, 66, 67.
New:
1. Input the password on the GENERAL screen (see page 3-32) 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
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-23 OPTION SET screen to display the MASK MENU screen.
OPT-4 screen
Button (1)
Press button (3)
Button (2)
MASK MENU screen
= ME N U = <OPT 3>
3 . OP T I ON S ET P / C L OCK Y / N
S P H S P H
S P H S P H
Button (3)
Press button (3) Press button (3)
<OP T 1> <OP T 2>

D EMO MOD E Y / N H / M ST ART Y / N
S P H S P H
S P H S P H
Press
button (3)
OPT-2 (H/M START) hour meter starting method:
Press button (2) while keeping button (1) pressed
for 2 seconds or more.
1-7
OPT-3 screen
OPT-16 screen
Button (1) Button (2) Press button (3)
<OP T 4 > <OP T 1 5 >

DES T I J / I B T YPE 1 / 2
S P H S P H
S P H S P H
Button (3)
Not used
<OPT 5 > <OPT 1 4 >

B L EVEL Y / N T I L T F L I M Y / N
S P H S P H
S P H S P H
<OPT 6 > <OPT 1 3 >

MPH Y / N K NOB CONT Y / N
S P H S P H
S P H S P H

Not used
<OPT 7 > <OPT 1 2 >

C / CN T RE S Y / N T I L T C ON T Y / N
S P H S P H
S P H S P H
<OPT 8 > <OPT 1 1 >

B ATT ERY A / B P A RK I NG E R R Y / N
S P H S P H
S P H S P H

Not used
< OP T 9 > < OP T 10 >

S HOU T OK U Y / N S EAT P OF F Y / N
S P H S P H
S P H S P H
Press button (3)

1-8
OPT-15 screen
Button (2)
Button (1)
<OP T 1 6 >
3 6 V Y / N
S P H
S P H
Button (3)
Press button (3)
<OPT 1 7 >
2 WA Y V A L V E Y / N
S P H
S P H
Press button (3)
<OPT 1 8 >
4 WA Y V A L V E Y / N
S P H
S P H
Press button (3)
<OPT 1 9 >
U SA Y / N
S P H
S P H
MASK MENU screen

Not used
ADD:
< OP T 20 >
WH E E L I ND Y / N <OPT 2 3 >
S EAT BU Z Z E R Y / N
S P H
S P H S P H
S P H
MENU

Not used Not used
< OP T 2 1 > <OPT 2 2 >

S AS Y / N F I SH ERMA N Y / N
S P H S P H
S P H S P H
Press
button (3)
1-9
TROUBLESHOOTING
DIAGNOSIS CODE LIST
OPS relation
WHEN AN ERROR CODE IS DISPLAYED
Display code Diag memory code Error mode Page
A5 A5 Seat switch abnormality 1-10
WHEN NO ERROR CODE IS DISPLAYED
Display code Vehicle condition Page
Traveling and material handling fail with OPS operation display even after sitting on the seat. 1-12
Harness change relation
Display code Diag memory code Error mode Page
61-1, 2 61-1, 2 Load sensor abnormality 1-45
62-1, 2 62-1, 2 Tilt angle sensor abnormality 1-47
63-1, 2, 3 63-1, 2, 3 Tilt switch abnormality 1-14
67-1 67-1 Lifting height switch abnormality 1-49
72-1, 2, 3, 4 72-1, 2, 3, 4 Steering angle sensor abnormality 1-15
73-1, 2, 3 73-1, 2, 3 Steering knob synchronizer solenoid abnormality 1-20
A4 A4 Acceleration switch abnormality 1-22
A6-1, 3, 5 A6-1, 3, 5 Material handling switch abnormality 1-23
C4-1, 2, 3, 4 C4-1, 2, 3, 4 Accelerator potentiometer abnormality 1-25
C7 C7 Direction switch abnormality 1-27
EE-1, 2, 3 EE-1, 2, 3 Abnormal communication from multi-display 1-29
F1-1, 2 F1-1, 2 Main controller →multi-display communication abnormality 1-51
FF FF D15 overcurrent 1-30
H5-1, 2, 3, 4, 5 H5-1, 2, 3, 4, 5 Lift solenoid abnormality 1-31
H6-1, 2, 3, 4, 5 H6-1, 2, 3, 4, 5 Tilt solenoid abnormality 1-34
H7-1, 2, 3, 4, 5 H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality 1-37
H8-1, 2, 3, 4, 5 H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality 1-40
H9-1, 2, 3 H9-1, 2, 3 Unload valve solenoid abnormality 1-43
Display code Vehicle condition Page
— No display on multi-display 1-52
— Only traveling disabled (no motor revolution) 1-53
— Constant automatic fork leveling 1-55

1-10
OPS Relation
A5 Seat switch abnormality (STD)
Related Portion
CN161 CN22
CN101-5 (67, LSD)
5 1
CPU board Seat switch
CN101-16 (51, LS–)
12 2
Condition for Error Detection
Output when the seat switch is kept ON.
YES
Has the operator been sitting on the seat before key switch ON? Normal
NO
Disconnect the seat SW harness CN22 and check the LSD. LSD: 0
ANL.: I/O MONITOR 2 I/O 2-3 Seat switch abnormality
LSD ON/OFF check
LSD: 1
• CPU-CN22 harness abnormality (potential 67 grounded) or

• CPU board abnormality
1-11
A5 Seat switch abnormality (Mini Lever)
Related Portion
CN161 CN42 CN43

CN101-5 (67, LSD)
5 7 1
CN101-16 (51, LS–)
12 8 2
Output when the seat switch is kept ON.
YES
Has the operator been sitting on the seat before key switch ON? Normal
NO
Disconnect the seat SW harness CN43 and check the LSD. LSD: 0
LSD ON/OFF check
LSD: 1
• CPU-CN43 harness abnormality (potential 67 grounded) or

1-12
Traveling and material handling fail with OPS operation display even after sitting on the
seat. (STD)
Related Portion
CN161 CN22
CN101-5 (67, LSD)
5 1
CN101-16 (51, LS–)
12 2
Seat switch OFF or discontinuity.
Disconnect CN22, connect SST2 to CN22 and check the LSD. LSD: 1
LSD ON/OFF check
LSD: 0
• CPU-CN22 harness abnormality (potential 67 line discontinuity) or

1-13
Traveling and material handling fail with OPS operation display even after sitting on the
seat. (Mini Lever)
Related Portion
CN161 CN42 CN43

CN101-5 (67, LSD)
5 7 1
CN101-16 (51, LS–)
12 8 2
Output when seat switch OFF or discontinuity.
Disconnect CN43, connect SST2 to CN43 and check the LSD. LSD: 1
LSD ON/OFF check
LSD: 0
• CPU-CN43 harness abnormality (potential 67 line discontinuity) or

1-14
CPU Board
63-1, 2, 3 Tilt switch abnormality
Related Portion
CN101-23 (61, LSTF+) Tilt switch

CN161 CN122 CN87
CN102-8 (61, LSTF)
17 11 1
CPU CN101-17 (62, LSTR+)
13 10 3
board
CN102-9 (62, LSTR)
12 1 J2 4
CN101-16 (51, LS–)
J21 2
Output when open or short circuit of the tilt switch line from the CPU board to the tilt switch is detected.
63-1 Forward and backward tilt switch abnormality
63-2 Forward tilt switch abnormality
63-3 Backward tilt switch abnormality
Disconnect battery plug.

A6-3 error is indicated
Connect battery plug again and turn key Perform troubleshooting for A6-3.
switch ON.
No error
Check if an error is detected when the 63-1 error is indicated

• Tilt switch installation defect
tilt lever is operated in either direction.
• Tilt switch abnormality
No error
ANL : I/O MONITOR 3 I/O3-3

Operate the tilt lever in either direction 1 is displayed on either switch.
and check the switch input valve when
the tilt lever is neutral position.
0 is displayed on either switch after

operating the tilt lever several times.
Memory 63-2, 63-3

Check the diagnosis memory The tilt lever has been turned ON for
two minutes or more in the past.
Memory 63-1
The forward and backward tilt switches were turned ON

at the same time in the past.
(Check adjustment of each switch installation)
1-15
72-1, 2, 3, 4 Steering angle sensor abnormality
Related Portion
CN162 CN124 CN19

CN103-10 (16, D15V)
13 1 J4 1
CN161 CN120
CN101-24 (312, STS1) 3
9 10
Steering angle
CPU CN101-30 (313, STS2) 4 sensor
board 11 11
5
CN101-21 (314, STSC)
8 12
2
CN101-16 (51, LS–)
12 J21 1 J1
Output when open or short circuit of the sensor line from the CPU board to the steering angle sensor is detected.
72-1 Steering angle sensor STS1 abnormality
72-2 Steering angle sensor STS2 abnormality
72-3 Steering angle sensor STSC abnormality
72-4 Steering angle sensor open
• 72-1
72-1 error is
Connect battery plug and turn the key
not indicated
switch ON. Connector connection check.
Turn the steering wheel.
72-1 error is
indicated
ANL : I/O MONITOR 4 I/O4-1 Remain 1

Check the STS1 input value turning B
the steering wheel.
Remain 0
A
1-16
A B

Disconnect CN32.
Short between CN19-3 and CN19-2 of
main harness side with SST2.
switch ON.
ANL : I/O MONITOR 4 I/O4-1 Change to 1

Steering angle sensor defect
Check the STS1 input value
Remain 0

Disconnect CN101.
(SST2 is connection state.) No continuity
Main harness defect
CN101-24 (312)
b Continuity check
CN101-16 (51)
Continuity
Disconnect CN19.
CPU board defect Connect battery plug and turn the key
switch ON.
Change to 0 ANL : I/O MONITOR 4 I/O4-1

Remain 1

Continuity Disconnect CN19, CN101.
Main harness defect CN101-24 (312)
b Continuity check
CN101-16 (51)
No continuity
CPU board defect

1-17
• 72-2
Connect battery plug and turn the key 72-2 error is not indicated
switch ON. Connector connection check
72-2 error is indicated

Check the STS2 input value turning
the steering wheel.
Remain 0

Disconnect CN32.
switch ON.

Remain 0

Disconnect CN101.
Main harness defect
CN101-30 (313)
b Continuity check
CN101-16 (51)
Continuity Disconnect battery plug.
Disconnect CN19.
switch ON.
CPU board defect

Remain 1

b Continuity check
CN101-16 (51)
No continuity
CPU board defect

1-18
• 72-3
72-3 error is not indicated
Turn the steering wheel to left or right
for one round or more.

Check the STSC input value turning
the steering wheel.
Remain 0

Disconnect CN32.
switch ON.

Check the STSC input value
Remain 0

Disconnect CN101.
Main harness defect
CN101-21 (314)
b Continuity measurement
CN101-16 (51) Disconnect battery plug.
Disconnect CN19.
Continuity
switch ON.
CPU board defect

Check the STSC input value
Remain 1

b Continuity measurement
CN101-16 (51)
No continuity
CPU board defect

1-19
• 72-4
Connect battery plug and turn the key 72-4 error is not indicated

Disconnect CN19.
Connect battery plug.
Check voltage of power supply for Disconnect battery plug.

steering angle sensor. Approx. 0 V Disconnect CN101, CN103. Approx. 0 V
CN19-1 (16) Connect battery plug.
b Voltage measurement Check voltage of power supply for
CN19-2 (51) steering angle sensor (at controller side
connector).
Approx. 15 V
CN103-10 (16)
b Continuity check
CN101-16 (51)
Connect CN19. CPU board defect
Approx. 15 V
switch ON.
Perform troubleshooting for 72-1 (STS1), 72-2 (STS2) Main harness defect
1-20
73-1, 2, 3 Steering knob synchronizer solenoid abnormality
Related Portion
CN161 CN122 CN98

CN104-21 (329, SOLST+)
18 4 1 Steering knob
CPU
board synchronizer
CN104-28 (330, SOLST–)
20 3 2 solenoid
Output when open or short circuit of the solenoid line from the CPU board to the steering knob synchronizer
solenoid is detected.
73-1 Steering knob synchronizer solenoid open
73-2 Steering knob synchronizer solenoid short
73-3 Drive circuit MOS of steering knob synchronizer solenoid short
• 73-1
ACTIVE TEST : ACT-2 KSOL 73-1 error is not indicated.

Turn the steering knob synchronizer Connector connection check
solenoid ON.
73-1 error is indicated.

Disconnect CN98.

Disconnect CN104. 9.9 ± 1 Ω (at 25°C)
CN104-21 (329) CPU board defect
b Resistance measurement
CN104-28 (330)
Other than 9.9 ± 1 Ω (at 25°C)
Disconnect CN98.
CN98-1 (329) 9.9 ± 1 Ω (at 25°C)
b Resistance measurement Main harness defect
CN98-2 (330)
Other than 9.9 ± 1 Ω (at 25°C)
Steering knob synchronizer solenoid defect

1-21
• 73-2

solenoid ON.

Disconnect CN98.
ACTIVE TEST : ACT-2 KSOL 73-1 error is indicated.

Turn the steering knob synchronizer Steering knob synchronizer solenoid defect
solenoid ON.

Disconnect CN104. Continuity
CN104-21 (329) Harness defect
b Continuity check
CN104-28 (330)
No continuity
CPU board defect
• 73-3

solenoid ON.

Disconnect CN152 and turn the key
switch ON.
Check continuity Continuity
CN104-21 (329) to P1 Harness defect
CN104-21 (329) to P2
CN104-28 (330) to P1
CN104-28 (330) to P2
No continuity
CPU board defect

1-22
A4 Acceleration switch abnormality
Related Portion
CN162 CN121 CN26

CN102-1 (64, SWAC) 2
1 10
CPU Accelerator
board CN102-22 (51, POT–) 1 potentiometer
8 J22 4 J3
Output when the acceleration ON signal is detected upon battery plug ON.
Was the accelerator pedal operated YES

Normal
upon battery plug connection?
NO
Disconnect CN26.
Reconnect battery plug.
NO
Is A4 error displayed? Adjust acceleration switch
YES
Disconnect battery plug and disconnect

Continuity
CN102.
(Less than 20 Ω)
b Continuity check
CN102-22 (51)
No continuity
CPU board defect

1-23
A6-1, 3, 5 Material handling switch abnormality
Related Portion
CN11
CN101-32 (60, LSL+)
1
CN102-6 (60, LSL) Lift switch
CN161 CN122 2
12 12 CN21
CN101-11 (66, LSAT1+)
7 9 1
Attachment
CN102-10 (63, LSAT1) No.1 switch
2
CPU
board CN87
CN101-23 (61, LSTF+)
1
Forward
CN102-8 (61, LSTF)
17 11 2 tilt switch
CN101-17 (62, LSTR+)
13 10 3 Backward
CN102-9 (62, LSTR) tilt switch
12 1 J2 4
CN101-16 (51, LS–)
J21
Output when the material handling switch ON signal is detected upon battery plug ON.
A6-1 Lift switch abnormality
A6-3 Forward and backward tilt switch abnormality
A6-5 Attachment No. 1 switch abnormality
Was the material handling lever YES

Normal
operated upon battery plug connection?
NO
Disconnect CN11 (A6-1), CN87 (A6-3)

or CN21 (A6-5), and connect battery
plug.
NO
Is A6 error displayed? Adjust limit switch or switch abnormality.
YES
A
1-24

Disconnect CN101, CN102.
Continuity check
• A6-1
CN101-32 (60) to CN102-6 (60) NG (open circuit)
• A6-3 Harness defect
CN101-23 (61) to CN102-8 (61)
CN101-17 (62) to CN102-9 (62)
• A6-5
CN101-11 (63) to CN102-10 (63)
OK (short circuit)
Continuity check
• A6-1
CN102-6 (60) to CN101-16 (51)
• A6-3 NG (short circuit)
CN102-8 (61) to CN101-16 (51) Harness defect
CN102-9 (62) to CN101-16 (51)
• A6-5
CN102-10 (63) to CN101-16 (51)
OK (open circuit)
CPU board defect

1-25
C4-1, 2, 3, 4 Accelerator potentiometer abnormality
Related Portion
CN162 CN121 CN26

CN102-1 (64, SWAC) 2
1 10
CN102-2 (52, POTA) 3

2 1
CPU Accelerator
board CN102-14 (53, POTA+) potentiometer
4
5 7
CN102-22 (51, POT–) 1

J22 8 4 J3
C4-1 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is on.
C4-2 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is on.
C4-3 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is off.
C4-4 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is being
operated.
• C4-1
ANL : I/O MONITOR 2 I/O 2-1

Check the POTA value when the 0.3 V or more
CPU board defect
accelerator switch SWAC is turned
from 0 to 1.
Less than 0.3V
The POTA value

ANL : I/O MONITOR 2 I/O 2-1 changes.
Check the POTA value as the Potentiometer adjustment defect
accelerator is depressed further.
The POTA value

does not change.
Disconnect CN26, and short between Error is not indicated CN102-2 (52)
POTA and POTA+ with SST8. b Voltage measurement
N1
Error is indicated 4.8 V or more Less than 4.8 V
Potentiometer defect CPU board defect Main harness defect

1-26
• C4-2
Does C4-2 go out after disconnecting YES

Accelerator potentiometer check
CN26?
NO
CN102-2 (52) 4.5 V or more

b Voltage measurement Main harness defect
N1
Less than 4.5 V
CPU board defect
• C4-3

Check if the SWAC value changes 0 remains
Accelerator switch defect
from 0 to 1 as the accelerator pedal is
depressed.
Changes to 1.
ANL : I/O MONITOR 2 I/O2-1 Less than 2.5 V YES

Check maximum POTA value when Is C4-3 error displayed?
SWAC is 0.
NO
2.5 V or more
CPU board defect
Does C4-3 go out after disconnecting YES

CN26? Accelerator potentiometer check
NO
CN102-2 (52) 2.5 V or more

b Voltage measurement Main harness defect
N1
Less than 2.5 V
CPU board defect
• C4-4
If C4-2, 3 occurs at the same time, perform troubleshooting for C4-2, 3 first.

Check the POTA value when the 1.4 V or more
Potentiometer adjustment defect
SWAC display is turned from 0 to 1 or
from 1 to 0.
Less than 1.4 V
CPU board defect

1-27
C7 Direction switch abnormality (STD)
Related Portion
CN161 CN120 CN9

CN101-1 (45, DSF)
1 2 5
CPU CN101-2 (46, DSR) Direction

2 3 4
board switch
CN101-16 (51, LS–)
J21 12 1 J1 6
Output when both forward and reverse direction switches are ON.

CN9.
ANL : I/O MONITOR 2 I/O2-2 Becomes 0.

Direction switch inspection
Check the value of DSF, DSR.
DSF or DSR display will be 1.
CN101-1 (45)
CN101-2 (46) NG (Other than OK)
b Voltage measurement Harness short circuit
N1
OK (Approx. 5 V)
CPU board defect

1-28
C7 Direction switch abnormality (EZ Pedal)
Related Portion
CN161 CN120 CN9

CN101-1 (45, DSF)
1 2 5
CPU CN101-2 (46, DSR) Direction

2 3 4
board switch
CN101-16 (51, LS–)
J21 12 1 J1 1
Output when both forward and reverse direction switches are ON.

CN9.
ANL : I/O MONITOR 2 I/O2-2 Becomes 0.

Direction switch inspection
Check the value of DSF, DSR.
DSF or DSR display will be 1.
CN101-1 (45)
CN101-2 (46) NG (Other than OK)
b Voltage measurement Harness short circuit
N1
OK (Approx. 5 V)
CPU board defect

1-29
EE-1, 2, 3 Abnormal communication from multi-display
Related Portion
CN162 CN124 CN1
CN103-13 (144, SMTDK) CN70-23
17 2 7
CN103-14 (143, SDTMK) CN70-24
18 3 4
CN103-15 (142, SDTMA) CN70-21
14 9 8
CPU CN103-16 (141, SMTDA) CN70-22
board Display
15 8 3
CN103-10 (16, D15V) CN-14

13 1 2
CN103-12 (14, GNDD) CN-30
16 7 1
Output upon detection of communication data abnormality from display.
• EE-1
YES
Is F1 error displayed? See F1 error
NO
Was the battery plug connected when YES

Connect the display
the display is removed?
NO
Does the display turn on upon key NO Disconnect CN1

switch ON? CN103-10 (16)
b Voltage measurement
YES CN103-12 (14)
• EE-2 14 V or more Less than 14 V
• Sub harness defect • CPU board defect

• Display defect • Harness defect
Disconnect battery plug and disconnect NG
CN103 and CN70. (Other than 0 Ω)
Check the continuity. • Connector connection defect
CN103-15 (142) to CN70-21 (142) • Harness defect
CN103-14 (143) to CN70-24 (143)
OK (Approx. 0 Ω)
• Display defect
• CPU board defect
• EE-3
• Reset the tuning value.
• If EE-3 is displayed frequently, either the CPU board or the display may be defective.
1-30
FF D15 overcurrent
Related Portion
CN162 CN124 CN1

CN103-10 (16, D15V)
13 1 J4 2
Multi-display
CN103-12 (14, GNDD) board
16 7 1
CPU
board
Output when overcurrent of D15V power source is detected.
Disconnect CN70, connect battery plug, No error

Display defect
and turn key switch ON.
FF error is indicated.
Disconnect battery plug, disconnect

CN103, and measure the resistance
Approx.
between 10 pin and 12 pin of harness
1 kΩ or less
side. Harness defect
CN103-10 pin (Tester probe )
b Resistance measurement
CN103-12 pin (Tester probe )
Approx. 1 kΩ or more
CPU board defect

1-31
H5-1, 2, 3, 4, 5 Lift solenoid abnormality
Related Portion
CN163 CN122 CN75

CN104-3 (3, SOL1+) J45
4 12 4
Lift a1 (DOWN)
solenoid
CN164 11 8
CPU CN104-5 (5, SOLa1)
board 10 CN74
4
CN163 CN121 Lift b1 (UP)
CN104-4 (4, SOLb1) solenoid
5 5 8
Output when open or short circuit is detected in the lift solenoid line from CPU board to the lift solenoid (raise and/
or lower).
• Error indication (reference)
H5-1 Lift b1 (UP) solenoid open-circuit abnormality
H5-2 Lift b1 (UP) solenoid load short-circuit abnormality
H5-1 Lift a1 (DOWN) solenoid open-circuit abnormality
H5-2 Lift a1 (DOWN) solenoid load short-circuit abnormality
H5-5 Lift solenoid drive circuit MOS short-circuit
• H5-1
H5-1 error is
not indicated.
Turn key switch ON. Check connector connection
Lift raising operation.
H5-1 error is indicated.
ANL : I/O MONITOR3 I/O3-2 0.1 A or more

Check lift solenoid current (during lift CPU board defect
raising operation).
0.1 A or less

Replace CN74 with CN75.
(Use SST 20)
Connect battery plug and turn key H5-1 error is

switch ON. not indicated.
Lift b1 (UP) solenoid defect
Lift raising operation. (note that lift on
the vehicle is lowered.)
Harness defect
1-32
• H5-2
H5-2 error is
not indicated.

Disconnect CN74.
H5-1 error is
indicated.
Turn key switch ON. Lift b1 (UP) solenoid defect

b Continuity check
CN104-4 (4)
No continuity
CPU board defect
• H5-3
Connect battery plug. H5-3 error is
Turn key switch ON. not indicated.
Check connector connection
Lift lowering operation.

Check lift solenoid current (during lift CPU board defect
lowering operation).
0.1 A or less

(Use SST 20)

Lift a1 (DOWN) solenoid defect
Lift lowering operation. (note that lift on
the vehicle is raised.)
Harness defect
1-33
• H5-4

Disconnect CN75.
H5-3 error is
indicated.
Turn key switch ON. Lift a1 (DOWN) solenoid defect

b Continuity check
CN104-5 (5)
No continuity
CPU board defect
• H5-5
Lift raising/lowering operation.

Disconnect CN104.
Connect battery plug and turn key
switch ON. 10 V or more
Lift lever at neutral position. Harness defect
Check the voltage between
CN104-3 (3) and CN104-23 (N2),
CN104-5 (5) and CN104-23 (N2),
CN104-4 (4) and CN104-23 (N2).
10 V or less
CPU board defect

1-34
H6-1, 2, 3, 4, 5 Tilt solenoid abnormality
Related Portion
CN163 CN122 CN75

CN104-6 (6, SOL2+) J46
6 10 3
Tilt a2 (FRONT)
CN104-7 (7, SOLa2) solenoid
7 9 7
CPU
board CN74
3
Tilt b2 (REAR)
CN104-8 (8, SOLb2) solenoid
11 6 7
Output when open or short circuit is detected in the tilt solenoid line from CPU board to the tilt solenoid (forward
and/or backward).
H6-1 Tilt a2 (FRONT) solenoid open-circuit abnormality
H6-2 Tilt a2 (FRONT) solenoid load short-circuit abnormality
H6-3 Tilt b2 (REAR) solenoid open-circuit abnormality
H6-4 Tilt b2 (REAR) solenoid load short-circuit abnormality
H6-5 Tilt solenoid drive circuit MOS short-circuit
• H6-1
H6-1 error is
not indicated.
Forward tilt operation.

Check tilt solenoid current (during CPU board defect
forward tilt operation).
0.1 A or less

(Use SST 20)

Tilt a2 (FRONT) solenoid defect
Forward tilt operation. (note that mast is
tilted backward on the vehicle.)
Harness defect
1-35
• H6-2
H6-2 error is
not indicated.

Disconnect CN75.
H6-1 error is
indicated.
Turn key switch ON. Tilt a2 (FRONT) solenoid defect

b Continuity check
CN104-7 (7)
No continuity
CPU board defect
• H6-3
Backward tilt operation.

Check tilt solenoid current (during CPU board defect
backward tilt operation).
0.1 A or less

(Use SST 20)

Tilt b2 (REAR) solenoid defect
Backward tilt operation. (note that mast
is tilted forward on the vehicle.)
Harness defect
1-36
• H6-4
Backward tilt operation.

Disconnect CN74.
H6-3 error is
indicated.
Turn key switch ON. Tilt b2 (REAR) solenoid defect

b Continuity check
CN104-8 (8)
No continuity
CPU board defect
• H6-5
Forward/backward tilt operation.

Disconnect CN104.
Tilt lever at neutral position. Harness defect
CN104-6 (6) and CN104-23 (N2),
CN104-7 (7) and CN104-23 (N2),
CN104-8 (8) and CN104-23 (N2).
10 V or less
CPU board defect

1-37
H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality
Related Portion
CN164 CN122 CN74

CN104-11 (9, SOL3+) J47
12 8 2
Attachment 1
CN104-13 (11, SOLb3) b3 solenoid
14 11 6
CPU
board CN121 CN75
2
CN122 Attachment 1
CN104-12 (10, SOLa3) a3 solenoid
13 7 6
Output when open or short circuit is detected in the attachment 1 solenoid line from the CPU board to the
attachment 1 solenoid (raise and/or lower).
H7-1 Attachment 1 a3 solenoid open-circuit abnormality
H7-2 Attachment 1 a3 solenoid load short-circuit abnormality
H7-3 Attachment 1 b3 solenoid open-circuit abnormality
H7-4 Attachment 1 b3 solenoid load short-circuit abnormality
H7-5 Attachment 1 solenoid drive circuit MOS short-circuit
• H7-1
Attachment 1 raising operation.
ANL : I/O MONITOR3 I/O3-6

Check attachment 1 solenoid current 0.1 A or more
(during attachment 1 raising CPU board defect
operation).
0.1 A or less

(Use SST 20)

H7-1 error is
switch ON.
not indicated.
Attachment 1 raising operation. Attachment 1 a3 solenoid defect
(note that the attachment 1 is lowered
on the vehicle.)
Harness defect
1-38
• H7-2

Disconnect CN75.
H7-1 error is
indicated.
Turn key switch ON. Attachment 1 a3 solenoid defect

b Continuity check
CN104-12 (10)
No continuity
CPU board defect
• H7-3
Attachment 1 lowering operation.

(during attachment 1 lowering CPU board defect
operation).
0.1 A or less

(Use SST 20)

H7-3 error is
switch ON.
not indicated.
Attachment 1 lowering operation. Attachment 1 b3 solenoid defect
(note that the attachment 1 is raised on
the vehicle.)
Harness defect
1-39
• H7-4

Disconnect CN74.
H7-3 error is
indicated.
Turn key switch ON. Attachment 1 b3 solenoid defect

b Continuity check
CN104-13 (11)
No continuity
CPU board defect
• H7-5
Attachment 1 raising/lowering operation.

Disconnect CN104.
Attachment 1 lever at neutral position. Harness defect
CN104-11 (9) and CN104-23 (N2),
CN104-12 (10) and CN104-23 (N2),
CN104-13 (11) and CN104-23 (N2).
10 V or less
CPU board defect

1-40
H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality
Related Portion
CN164 CN122 CN75

CN104-16 (34, SOL4+) J48
15 6 1
Attachment 2
CN104-17 (35, SOLa4) a4 solenoid
16 5 5
CPU
board CN74
1
CN121 Attachment 2
CN104-18 (36, SOLb4) b4 solenoid
17 12 5
Output when open or short circuit is detected in the attachment 2 solenoid line from the CPU board to the
attachment 2 solenoid (forward and/or backward).
H8-1 Attachment 2 a4 solenoid open-circuit abnormality
H8-2 Attachment 2 a4 solenoid load short-circuit abnormality
H8-3 Attachment 2 b4 solenoid open-circuit abnormality
H8-4 Attachment 2 b4 solenoid load short-circuit abnormality
H8-5 Attachment 2 solenoid drive circuit MOS short-circuit
• H8-1
Attachment 2 forward tilt operation.

(during attachment 2 forward tilt CPU board defect
operation).
0.1 A or less

(Use SST 20)

H8-1 error is
switch ON.
not indicated.
Attachment 2 forward tilt operation. Attachment 2 a4 solenoid defect
(note that the attachment 2 is tilted
backward on the vehicle.)
Harness defect
1-41
• H8-2

Disconnect CN75.
H8-1 error is
indicated.
Turn key switch ON. Attachment 2 a4 solenoid defect

b Continuity check
CN104-17 (35)
No continuity
CPU board defect
• H8-3
Attachment 2 backward tilt operation.

(during attachment 2 backward tilt CPU board defect
operation).
0.1 A or less

(Use SST 20)

H8-3 error is
switch ON.
not indicated.
Attachment 2 backward tilt operation. Attachment 2 b4 solenoid defect
(note that the attachment 2 is tilted
forward on the vehicle.)
Harness defect
1-42
• H8-4

Disconnect CN74.
H8-3 error is
indicated.
Turn key switch ON. Attachment 2 b4 solenoid defect

b Continuity check
CN104-18 (36)
No continuity
CPU board defect
• H8-5
Turn key switch ON. not indicated. Check connector connection
Attachment 2 forward/backward
operation.

Disconnect CN104.
Attachment 2 lever at neutral position. Harness defect
CN104-16 (34) and CN104-23 (N2),
CN104-17 (35) and CN104-23 (N2),
CN104-18 (36) and CN104-23 (N2).
10 V or less
CPU board defect

1-43
H9-1, 2, 3 Unload valve solenoid abnormality
Related Portion
CN164 CN122 CN76

CN104-26 (12, SOLP+)
18 2 1
CPU Unload valve
board CN104-27 (13, SOLP–) solenoid
19 1 2
Output when open or short circuit is detected in the unload valve solenoid line from the CPU board to the unload
valve solenoid.
H9-1 Unload valve solenoid open-circuit abnormality
H9-2 Unload valve solenoid load short-circuit abnormality
H9-3 Unload valve solenoid drive circuit MOS short-circuit
• H9-1
ACTIVE TEST : ACT-3 PSOL H9-1 error is

Set the unload valve solenoid to ON in not indicated.
the ACTIVE TEST. Check connector connection
(Connect battery plug and turn key
switch ON.)

Disconnect CN104. 9.9 ± 1Ω (at 25°C)
b Harness continuity check
CN104-27 (13)
Other than 9.9 ± 1Ω
(at 25°C)
Disconnect CN76.
CN76-1 (12) 9.9 ± 1Ω (at 25°C)
Harness defect
b Solenoid resistance check
CN76-2 (13)
Other than 9.9 ± 1Ω
(at 25°C)
Unload valve solenoid defect

1-44
• H9-2

switch ON.)

Disconnect CN76.

the ACTIVE TEST. Unload valve solenoid defect
switch ON.)

Disconnect CN104. Continuity exists
Harness defect
CN104-26 (12)
b Harness continuity check
CN104-27 (13)
No continuity
CPU board defect
• H9-3

switch ON.)

Disconnect CN104.
Voltage check (short circuit in the Harness defect
harness) between
CN104-26 (12) and CN104-23 (N2),
CN104-27 (13) and CN104-23 (N2).
10 V or less
CPU board defect

1-45
61-1, 2 Load sensor abnormality
Related Portion
CN162 CN121 CN90 CN91

CN102-17 (58, SPL+)
7 9 4 1
CPU CN102-5 (59, SPL) Load

board 4 3 3 2 sensor
CN102-22 (51, POT–)
J22 8 4 J3 8 3
Output when the voltage of the load sensor is outside the specified range (open or short).
61-1 Load sensor open
61-2 Load sensor short
• 61-1

Disconnect CN90. 61-2 error is
Short between CN90-3 and CN90-4 of indicated.
• Load sensor defect
• Sub harness defect
switch ON.
61-2 error is not indicated.

Disconnect CN102.
Main harness defect
CN102-17 (58)
b Continuity check
CN102-5 (59)
Continuity
CN102-5 (59) No continuity

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

1-46
• 61-2
Disconnect battery plug, disconnect Change to 61-1 error.
CN90, connect battery plug, and turn
the key switch ON.
61-2 error remains.

Disconnect CN102. No continuity
b Continuity check
CN102-5 (59)
Continuity
• Main harness defect

Disconnect CN102.
CN102-5 (59)
b Continuity check
CN102-22 (51)
Continuity No continuity
• Load sensor defect Main harness defect

1-47
62-1, 2 Tilt angle sensor abnormality
Related Portion
CN162 CN121 CN8

CN102-16 (57, POTTA+)
6 8 1
CPU CN102-4 (56, POTTA) Tilt angle

board 3 2 2 sensor
CN102-22 (51, POT–)
J22 8 9 J3 3
Output when the voltage of the tilt angle sensor is outside the specified range (open or short).
62-1 Tilt angle sensor open
62-2 Tilt angle sensor short
• 62-1

Disconnect CN86. 62-2 error is
Short between CN86-1 and CN86-2 of indicated.
Tilt angle sensor defect
switch ON.
62-2 error is not indicated.

Disconnect CN102.
Main harness defect
CN102-16 (57)
b Continuity check
CN102-4 (56)
Continuity
(SST2 is connection state.)

CN102-4 (56) No continuity
CPU board defect
b Continuity check
CN102-22 (51)
Continuity
Main harness defect

1-48
• 62-2
Disconnect battery plug, disconnect Change to 62-1 error.
CN86, connect battery plug, and turn
the key switch ON.
62-2 error remains.

Disconnect CN102. No continuity
b Continuity check
CN102-4 (56)
Continuity
Main harness defect Disconnect battery plug.

Disconnect CN102.
CN102-4 (56)
b Continuity check
CN102-22 (51)
Continuity No continuity
Tilt angle sensor defect Main harness defect

1-49
67-1 Lifting height switch abnormality
Related Portion
Lifting height
CN161 CN120 CN90 CN92 switch
CN101-20 (91, MH2-1)
16 6 1 3
CPU CN101-19 (90, MH1)

board 15 7 6 2
CN101-16 (51, LS–)

J21 12 1 J1 2 1
Output when open or short circuit of the lifting height switch line from the CPU board to the lifting height switch is
detected.
ANL : I/O MONITOR 3-11 MH: 00–

Check the lifting height switch input A
value.
Other than MH: 00–

CN90.
ANL : I/O MONITOR 3-11 MH: 00–

Check the lifting height switch input • Sub harness defect
value. (with battery plug connected) • Lifting height switch defect
Other than MH: 00–

CN101, and check the continuity. No continuity
CN101-20 (91) to CN101-16 (51) CPU board defect
CN101-19 (90) to CN101-16 (51)
CN101-20 (91) to CN101-19 (90)
Continuity
Main harness defect

1-50
Disconnect battery plug and CN90, and

check continuity.
Check the lifting height upon error H2000 or more CN90-6 (90) to CN90-2 (51)
indicating. [OK] No continuity, [NG] Continuity
CN90-1 (91) to CN90-2 (51)
Less than H2000 [OK] Continuity, [NG] No continuity
NG OK
Disconnect battery plug and CN90, and

check continuity.
CN90-6 (90) to CN90-2 (51) NG
[OK] Continuity, [NG] No continuity
• Lifting height switch defect
CN90-1 (91) to CN90-2 (51)
[OK] No continuity, [NG] Continuity
OK

CN101 and CN103, and check the
continuity.
• Short between CN90-6 and CN90-2
of main harness side with SST2.
CN101-19 (90)
b Continuity check No continuity
Main harness defect
CN101-16 (51)
• Short between CN90-1 and CN90-2
of main harness side with SST2.
CN101-20 (91)
b Continuity check
CN101-16 (51)
Continuity
CPU board defect

1-51
F1-1, 2 Main controller →multi-display communication abnormality
Related Portion
CN162 CN124 CN1

CN103-16 (141, SMTDA) CN70-22 (141, SMTDA)
CPU 15 8 3
board CN103-13 (144, SMTDK) CN70-23 (144, SMTDK) Multi-display
17 2 7
Output upon detection of communication data abnormality from CPU board.
CN103, CN124, CN70 and CN1 NG

Correct the defect
connection condition check
OK

CN103 and CN70.
CN103-16 (141)
b Continuity check Continuity
CN70-22 (141) • CPU board defect
CN103-13 (144) • Multi-display defect
b Continuity check
CN70-23 (144)
No continuity
Harness defect
(Between CN103 and CN70)
Note:
Other error codes, if any, are not indicated because of no communication from the CPU board when F1-1
occurs. F1-1 is kept indicated on the multi-display screen regardless of key switch ON or OFF.
1-52
No display on multi-display
Related Portion
CN162 CN124 CN1

CN103-10 (16, D15V) CN70-14 (16, D15V)
CPU 13 1 2
board CN103-12 (14, GNDD) CN70-30 (14, GNDD) Muli-display
16 7 1
• No power supply to multi-display

• Multi-display defect
It is possible to perform traveling and NG

See page 4-145. (Vehicle does not move.)
material handling operation.
OK
Disconnect battery plug, disconnect Disconnect battery plug, connect CN1,

CN1, and connect battery plug. OK (Approx. 15 V) disconnect CN70, and connect battery NG (0 V)
CN1-2 (16) plug.
b Voltage measurement CN70-14 (16)
CN1-1 (14) b Voltage measurement
CN70-30 (14)
NG (0 V)
OK (Approx. 15 V)
Disconnect battery plug, disconnect Multi-display defect Harness defect

CN1 and CN103. (Between CN1 and
1. CN1-2 (16) CN70)
b Continuity check NG ( 1. ∞ Ω
CN103-10 (16) 2. Approx. 0 Ω)
b Continuity check (Between CN1 and CN103)
CN103-12 (14)
2. CN1-2 (16)
b Short-circuit check
CN1-1 (14)
OK ( 1. Approx. 0 Ω
2. ∞ Ω)
CPU board defect

1-53
Only traveling disabled (no motor revolution)
Related Portion
CN161 CN120 CN9
CN101-1 (45, DSF)
1 2 5
CN101-2 (46, DSR)

2 3 4 Direction switch
CN101-16 (51, LS–)

12 1 J1 6
CPU CN162 CN121 CN26

board CN102-1 (64, SWAC) 2
1 16
CN102-2 (52, POTA) 3

2 1
Accelerator
CN102-14 (53, POTA+) 4 portentiometer
5 7
CN102-22 (51, POT–) 1

8 4 J3
YES
Has beep sound been output? Accelerator OFF, direction switch OFF,
and parking OFF (It returns.)
NO
Both have no
ANL : I/O MONITOR 2 I/O2-1 change.
SWAC and POTA value check with Accelerator check
accelerator pedal depressing.
Both change.
ANL : I/O MONITOR 2 I/O2-2 No change

DSF and DSR value check with Direction switch check
direction switch operation.
Changes
Voltage measures with direction switch

ON and accelerator ON.
P7 , P8 , P9
b Voltage measurement Other than OK
N1 Traveling AC driver defect
P71 , P81 , P91
N1
OK (All approx. 24 V)
A
1-54
NO
Is there sound from the motor? Motor cable and motor check
YES

Does front wheels rotate when jack up Rotates
Brake check
the vehicle to cause the front wheels to
float?
Does not rotate
Perform troubleshooting for C8

1-55
Constant automatic fork leveling
Related Portion
CN161 CN122 CN84

CN101-18 (70, SWTK) 1
CPU 4 2
board Knob switch
CN101-16 (51, LS–) 2
12 1
ANL : I/O MONITOR 3 I/O3-9 ON (display 1) Operate normally

Check the valve of automatic fork Tilt knob switch OFF.
leveling switch.
Automatic fork leveling
OFF (display 0) is remained ON
Use it as it is.
OFF (display 0) ANL : I/O MONITOR 3 I/O3-9
Check the valve of automatic fork
leveling switch.
ON (display 1)
CN101-18 Approx. 0 V
CN101-16
Approx. 5 V
• Harness defect CPU board defect

• Switch defect
Leaned forward from
Lift down the fork and operate the tilt leveling position
lever to the forward position. Perform matching No.1, No.2
Not leaned forward

from leveling position
Does pump motor stop without a turning

steering wheel when direction switch is Stop
CPU board defect
neutral position and the fork is at
leveling position?
Does not stop
Tilt cylinder check

2-1
BODY
Page 0
SEAT SWITCH ................................................... 2-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2-2
SEAT SWITCH
Inspection:
Push the seat cushion to check seat switch continuity.
CN43 Measuring position : between seat switch CN22-1 and

CN22-2
Standard : When not pushed : ∞ Ω
When pushed :0Ω
Note:
If the standard is not satisfied, replace the cushion ASSY.
3-1
APPENDIX
Page 0
SST LIST ............................................................ 3-2
1
CONNECTOR DRAWING .................................. 3-3
CONNECTING DIAGRAM................................ 3-13
2
ELECTRIC WIRING DIAGRAM ....................... 3-14 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
3-2
SST LIST
Section
Illust. Part number Part name
1 2
09230-13130-71 AC controller diagnosis kit {

3-3
CONNECTOR DRAWING
CN1 DISPLAY CN8 TURN & LIGHT SW.
0
6 5 4 3 2 1 1 2 3 4 5 6
4 3 2 1
1 2 3 4 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14
8 7 6 5
5 6 7 8 TAB REC
NO P C
TAB
J NO P
REC
C J
NO
1
2
P C J NO
1
2
P C J
1
2
1 14 W CN70-30 1 14 W CN124-7 3 3
2 16 R CN70-14 2 16 R J4 4 4
3 141 V CN70-22 3 141 V CN124-8 5 5
4 143 SL CN70-24 4 143 SL CN124-3 6 6
3
5 5 7 7
6 6 8 115 - LH 8 115 P CN45-3
7 144 O CN70-23 7 144 O CN124-2 9 116 - LT 9 116 LG CN46-3
8 142 B CN70-21 8 142 B CN124-9 10 N2 - EL 10 N2 L J8
CN3 HORN SW.

11
12
13
108
109
-
-
TR
TL
11
12
13
108
109
SL
G
J14
J13
4
5
1 1 14 110 - TB 14 110 GR CN12-1
2 2
CN9 DIRECTIONAL SW.
TAB REC
NO P
1 48
2 41
C
-
-
J
HO+
HO-
NO P
1 48
2 41
C
P
GR
J
HORN
J6
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
6
CN4 KEY SW.
NO P
TAB
C J NO P C
REC
J
7
2 1 1 2 1 1
8
4 3 3 4 2 103 - DSBU 2 103 P CN123-6
3 120 - DSFO 3 120 Y CN123-5
( ):OPT TAB REC ( ):OPT
4 46 - DSR 4 46 G CN120-3
NO P C J NO P C J 5 45 - DSF 5 45 W CN120-2
9
1 41(-) - AM(-) 1 41(-) GR(-) CN29-1(-) 6 51 - LS- 6 51 B J1
2 (41) - (AM) 2 (41) (GR) (CN29-1) 7 43 - VBKY 7 43 Y J5
3 3 8 43 - VBKY 8 43 Y J5
4 43 - IG 4 43 Y CN29-2
10
9 9
10 10
CN5 STOP LAMP SW. 11 11
12 12
11
2 1 1 2 13 13
14 14
15 15
TAB REC
16 16
12
NO P C J NO P C J
17 17
1 101 R LS ST 1 101 Y J9
18 18
2 111 SL LS ST 2 111 R CN123-1
CN6 CN9 <OPT>

13
BRAKE SW. DIRECTIONAL PEDAL
3 2 1 1 2 3
2 1 1 2 6 5 4 4 5 6
14
TAB REC
NO P C J NO P C J
TAB REC
1 51 R LS 1 51 B J1 NO P C J NO P C J
B
1 51 - LS- 1 51 B J1
2 65 BR LS 2 65 Y CN120-4
15
B
2 120 - DSFO 2 120 Y CN123-5
3 103 - DSBU 3 103 P CN123-6
4 46 - DSR 4 46 G CN120-3
5 45 - DSF 5 45 W CN120-2
6
CN11
43 -
LIFT SW.
VBKY 6 43 Y J5
16
2
TAB
1 1
REC
2
17
18
NO P C J NO P C J
1 60 R LS L 1 60 R CN122-12
2 51 BR LS L 2 51 LG J2
3-4
CN12 FLASHER RILAY CN18 FR COMBI LH
1 1
2 1 1 2
2 2 4 3 3 4
TAB REC TAB REC

NO P C J NO P C J NO P C J NO P C J
1 110 - FRY 1 110 GR CN8-14 1 109 - LF-L 1 109 G-Y CN17-4
2 43 - FRY 2 43 Y J5 2 N2 - LF-L 2 N2 L CN17-5
3 N2 - LC-L 3 N2 W J51
4 104 - LC-L 4 104 G CN17-2
CN13 FR COMBI RH
3 2 1 1 2 3 CN19 STEERING SENSOR

6 5 4 4 5 6
TAB REC 2 1 1 2
NO P C J NO P C J 6 5 4 3 3 4 5 6
1 N2 W J51 1 N2 L J8
2 104 G CN14-4 2 104 O J10
3 102 Y CN16-1 3 102 G J11
TAB REC
4 108 G-Y CN14-1 4 108 SL J14 NO P C J NO P C J
5 N2 L CN14-2 5 N2 L J8 1 16 - IG 1 16 R J4
6 101 R CN96-7 6 101 Y J9 2 51 - ESS 2 51 B J1
3 312 - SS1 3 312 Y CN120-10
4 313 - SS2 4 313 V CN120-11
CN14 FR COMBI RH 5 314 - SSC 5 314 L CN120-12
6 6
2 1 1 2
4 3 3 4
CN20 HEAD LAMP LH
TAB REC
NO P C J NO P C J
2 1 1 2
1 108 - LF-R 1 108 G-Y CN13-4
2 N2 - LF-R 2 N2 L CN13-5 TAB REC
3 N2 - LC-R 3 N2 W J51
NO P C J NO P C J
4 104 - LC-R 4 104 G CN13-2
1 102 - LH-L 1 102 Y CN17-3
2 N2 - LH-L 2 N2 W J51
CN15 PARKING SW.

CN21 ATT SW.
2 1 1 2
TAB REC 2 1 1 2
NO P C J NO P C J TAB REC
1 51 - LS PB 1 51 B J1
NO P C J NO P C J
2 66 - LS PB 2 66 R CN120-8
1 63 R LS ATT 1 63 V CN122-9
2 51 BR LS ATT 2 51 LG J2
CN16 HEAD LAMP RH
CN22 SEAT SW.
2 1 1 2
2 1 1 2
TAB REC
TAB REC
NO P C J NO P C J
1 102 - LH-R 1 102 Y CN13-3 NO P C J NO P C J
2 N2 - LH-R 2 N2 W J51 1 67 - LS D 1 67 L CN161-5
2 51 - LS D 2 51 B J21
CN17 FR COMBI LH CN23 BACK CHIME
3 2 1 1 2 3
6 5 4 4 5 6 1 1
2 2
TAB REC
NO P C J NO P C J TAB REC
1 N2 W J51 1 N2 L J8 NO P C J NO P C J
2 104 G CN18-4 2 104 O J10 1 198 - CHI 1 198 GR J12
3 102 Y CN20-1 3 102 G J11 2 N2 - CHI 2 N2 L J31
4 109 G-Y CN18-1 4 109 G J13
5
6
N2 L CN18-2 5
6
N2 L J8
CN23-2 SMART ALARM
1 1
2 2
TAB REC
NO P C J NO P C J
1 103 - BZ 1 103 O J56
2 N2 - BZ 2 N2 W J54
3-5
CN24 FORWARD CHIME CN34 RR COMBI RH
1 1 2 1 1 2
2 2
4 3 3 4
0
TAB REC 6 5 5 6
NO P C J NO P C J
1 1 120 Y CN123-5
2 2 N2 L J31
TAB REC
1
NO P C J NO P C J
1 104 R TL 1 104 G J55
CN26 ACCEL 2 111 R STP 2 111 SL J53
3 103 R B/U 3 103 O J56
4 3 2 1
TAB
1 2 3 4
REC
4
5
6
108
N2
R
R
TRN
E
4
5
6
108
N2
BR
W
CN38-5
J54
2
3
NO P C J NO P C J
1 51 - E2 1 51 W J3 CN36 RR WORKING LAMP
2 64 - IDL 2 64 SL CN121-10
3 52 - VTA 3 52 GR CN121-1
4
4 53 - VC 4 53 O CN121-7 2 1 1 2
TAB REC
CN27 F4,F5,F6 FUSE
5
NO P C J NO P C J
1 107 - LW 1 107 V CN38-7
3 2 1 1 2 3
2 N2 - LW 2 N2 W J54
6 5 4 4 5 6
NO P
TAB
C J NO P
REC
C J
CN38 RR UPR
6
1 P2 - F6 1 P2 P CN136-6
3 2 1 1 2 3
2
3
4
P1
P1
44
-
-
-
F5
F4
F6
2
3
4
P1
P1
44
W
B
BR
CN136-4
CN136-3
J30
8 7 6 5 4
TAB
4 5 6 7 8
REC
7
5 41 - F5 5 41 GR J29
8
NO P C J NO P C J
6 101 - F4 6 101 Y CN123-4
1 43 Y J39 1 43 L FB
2 111 R CN123-1 2 111 SL J53
CN29 KEY SW. 3 198 GR CN165-5 3 198 O J56
2 1 1 2
4
5
6
104
108
109
O
SL
G
CN123-3
CN123-7
CN123-8
4
5
6
104
108
109
G
BR
G-Y
J55
CN34-5
CN31-3
9
7 107 B CN123-2 7 107 V CN36-1
NO P
TAB
C J NO P
REC
C J
8 N2 L J31 8 N2 W J54
10
1 41 GR CN4-1 1 41 GR J6
2 43 Y CN4-2 2 43 Y J5 CN41 <OPT>
5 4 3 2 1
MINI LEVER
1 2 3 4 5
11
CN31
12
RR COMBI LH 10 9 8 7 6 6 7 8 9 10
TAB REC
2 1 1 2 NO P C J NO P C J
13
4 3 3 4 1 20 R CN77-2 1 20 R CN161-19
2 21 B CN77-3 2 21 B CN164-2
TAB REC 3 28 G CN77-1 3 28 G CN164-6
4 22 O CN78-2 4 22 O CN161-17
14
NO P C J NO P C J
5 23 LG CN78-3 5 23 LG CN161-13
1 104 L TL 1 104 G J55
6 29 Y CN78-1 6 29 Y CN164-7
2 111 L STP 2 111 SL J53
7 24 V CN79-2 7 24 V CN161-7
3 109 L TRN 3 109 G-Y CN38-6
8 25 L CN79-3 8 25 L CN164-3
15
4 N2 L E 4 N2 W J54
9 30 GR CN79-1 9 30 GR CN164-8
10 51 W J49 10 51 W CN164-1
CN32 TIRE ANGLE SENSOR
3 2 1 1 2 3 16
NO P
1 51
TAB
C
-
J
GND
NO P
1 51
C
W
REC
J
J22
17
18
2 317 - OUT 2 317 Y CN163-13
3 316 - VCC 3 316 SL CN163-14
3-6
CN42 <OPT> MINI LEVER CN53 DM SPEED RH
4 3 2 1 1 2 3 4 1 2 1 2
8 7 6 5 5 6 7 8 3 4 3 4
TAB REC
TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 26 V CN80-2 1 26 V CN164-4
1 79 R SSD2+ 1 79 O CN109-9
2 27 SL CN80-3 2 27 SL CN164-5
2 80 W SSD21 2 80 BR CN109-11
3 31 LG CN80-1 3 31 LG CN164-9
3 82 B SSD2- 3 82 P J28
4 4
4 81 L SSD22 4 81 SL CN109-12
5 70 BR CN85-2 5 70 BR CN161-14
6 6
7 67 L CN43-1 7 67 L CN161-5
CN55 PM TEMP
8 51 B CN43-2 8 51 B J21
2 1 1 2
CN43 <OPT> SEAT SW TAB REC
NO P C J NO P C J
2 1 1 2 1 86 B TP- 1 86 P J26
2 89 R TP+ 2 89 BR CN111-13
TAB REC
NO P C J NO P C J CN56 PM SPEED
1 67 - SOL P 1 67 L CN42-7
2 51 - SOL P 2 51 B CN42-8 1 2 1 2
3 4 3 4
CN45 HEAD LAMP RELAY
TAB REC
2 1 1 2 NO P C J NO P C J
1 83 R SSP+ 1 83 LG CN111-9
4 3 3 4
2 84 W SSP1 2 84 W CN111-11
TAB REC 3 86 B SSP- 3 86 P J26
NO P C J NO P C J 4 85 L SSP2 4 85 R CN111-12
1 101 - COIL+ 1 101 Y J9
2 101 - SW+ 2 101 Y J9 CN58 DM TEMP LH
3 115 - COIL- 3 115 P CN8-8
4 102 - SW- 4 102 G J11
2 1 1 2
CN46 TAIL LAMP RELAY TAB REC

NO P C J NO P C J
2 1 1 2 1 78 B TD1- 1 78 P J27
4 3 3 4 2 87 R TD1+ 2 87 W CN110-13
TAB REC
NO P C J NO P C J
CN59 DM SPEED LH
1 101 - COIL+ 1 101 Y J9

2 101 - SW+ 2 101 Y J9 1 2 1 2
3 116 - COIL- 3 116 LG CN8-9 3 4 3 4
4 104 - SW- 4 104 O J10
TAB REC
CN50 FAN(EX) NO P C J NO P C J
1 75 R SSD1+ 1 75 O CN110-9
2 76 W SSD11 2 76 BR CN110-11
2 1 1 2 3 78 B SSD1- 3 78 P J27
4 77 L SSD12 4 77 SL CN110-12
TAB REC
NO P C J NO P C J
1 44 R FAN EX (+) 1 44 BR J30
2 39 B FAN EX (-) 2 39 B J23
CN52 DM TEMP RH
2 1 1 2
TAB REC
NO P C J NO P C J
1 82 B TD2- 1 82 P J28
2 88 R TD2+ 2 88 R CN109-13
3-7
CN70 DISPLAY CN76 <OPT> C/V PRESSURE SOL.
REC 2 1 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 TAB REC
NO P C J NO P C J
TAB 1 12 - SOL P 1 12 BR CN122-2
14 13 12 11 10 9 8 7 6 5 4 3 2 1 2 13 - SOL P 2 13 LG CN122-1
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
CN77 <OPT> LIFT LEVER
TAB REC
NO P C J NO P C J
4 3 2 1 1 2 3 4
1 43 - 48V 1
2 2
3 3
TAB REC
NO P C J NO P C J
4 137 - SL/L+ 4
1 28 - VC 1 28 G CN41-3
5 138 - SL/L- 5
2 20 - VTA1 2 20 R CN41-1
6 6
3 21 - VTA2 3 21 B CN41-2
7 180 - AVD(+) 7
4 51 - E2 4 51 W J49
8 124 - CHG LED1 8
9 125 - CHG LED2 9
10 126 - CHG LED3 10 CN78 <OPT> TILT LEVER
11 127 - CHG LED4 11
12 182 - AVD2 12 4 3 2 1 1 2 3 4
13 181 - AVD1 13
14 16 - D15V 14 16 R CN1-2 TAB REC
15 N2 - N1 15 NO P C J NO P C J
16 16 1 29 - VC 1 29 Y CN41-6
17 17 2 22 - VTA1 2 22 O CN41-4
18 18 3 23 - VTA2 3 23 LG CN41-5
19 139 - STT 19 4 51 - E2 4 51 W J49
20 140 - SLL 20
21 142 - SDTMA 21 142 B CN1-8
22 141 - SMTDA 22 141 V CN1-3
CN79 <OPT> ATT1 LEVER
23 144 - SMTDK 23 144 O CN1-7

24 143 - SDTMK 24 143 SL CN1-4 4 3 2 1 1 2 3 4
25 123 - CHG SW3 25
26 122 - CHG SW2 26 TAB REC
27 121 - CHG SW1 27 NO P C J NO P C J
28 183 - AVD3 28 1 30 - VC 1 30 GR CN41-9
29 184 - AVD4 29 2 24 - VTA1 2 24 V CN41-7
30 14 - GNDD 30 14 W CN1-1 3 25 - VTA2 3 25 L CN41-8
4 51 - E2 4 51 W J49
CN74 <OPT> C/V SOL.(UPR)

CN80 <OPT> ATT2 LEVER
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8 4 3 2 1 1 2 3 4
TAB REC
TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 34 - SOL ATa4 (+) 1 34 G J48
1 31 - VC 1 31 LG CN42-3
2 9 - SOL ATa3 (+) 2 9 L J47
2 26 - VTA1 2 26 V CN42-1
3 6 - SOL Ta2 (+) 3 6 LG J46
3 27 - VTA2 3 27 SL CN42-2
4 3 - SOL Lb1 (+) 4 3 R J45
4 51 - E2 4 51 W J49
5 36 - SOL ATb4 (-) 5 36 W CN121-12
6 11 - SOL ATb3 (-) 6 11 GR CN121-11
7 8 - SOL Tb2 (-) 7 8 P CN121-6
CN84 TILT KNOB SW.
8 4 - SOL Lb1 (-) 8 4 B CN121-5

2 1 1 2
CN75 <OPT> C/V SOL.(LWR)
TAB REC
4 3 2 1 1 2 3 4 NO P C J NO P C J
8 7 6 5 5 6 7 8 1 70 - SOLD(+) 1 70 BR CN122-2
2 51 - SOLD(-) 2 51 B J1
TAB REC
NO P
1 34
C
-
J
SOL ATa4 (+)
NO P
1 34
C
G
J
J48
CN85 <OPT> TILT KNOB SW.
2 9 - SOL ATa3 (+) 2 9 L J47

3 6 - SOL Ta2 (+) 3 6 LG J46 2 1 1 2
4 3 - SOL Lb1 (+) 4 3 R J45
5 35 - SOL ATa4 (-) 5 35 P CN122-5 TAB REC
6 10 - SOL ATa3 (-) 6 10 BR CN122-7 NO P C J NO P C J
7 7 - SOL Ta2 (-) 7 7 V CN122-9 1 51 - SWTK(-) 1 51 W J49
8 5 - SOL La1 (-) 8 5 O CN122-11 2 70 - SWTK(+) 2 70 BR CN42-5
3-8
CN86 TILT SENSOR CN92 HEIGHT SW.
3 2 1 1 2 3 3 2 1 1 2 3
TAB REC TAB REC

NO P C J NO P C J NO P C J NO P C J
1 57 - VRAT 1 57 L CN121-8 1 51 R CN90-2 1 51 - SWMH1
2 56 - VRAT 2 56 G CN121-2 2 90 O CN90-6 2 90 - SWMH1
3 51 - VRAT 3 51 W J3 3 91 B CN90-1 3 91 - SWMH1
CN87 TILT SW. CN98 STEERING SOL.
2 1 1 2
2 1
1 2 TAB REC
4 3
3 4 NO P C J NO P C J
1 329 B CN122-4 1 329 - SOL ST
TAB REC 2 330 GR CN122-3 2 330 - SOL ST
NO P C J NO P C J
1 61 - LSTF 1 61 O CN122-11 CN96 <OPT> CMP LAMP SW
2 51 - LS- 2 51 LG J2
3 62 - LSTR 3 62 LG CN122-10 1
1
4 51 - LS- 4 51 LG J2 7
7
TAB REC
CN88 LIFT SOL.
NO P C J NO P C J
1 117 - STPOT- 1 117 SL LCMP
2 1 1 2 2 2
3 3
4 4
TAB REC 5 5
NO P C J NO P C J 6 6
1 3 - SOL L + 1 3 P CN163-4 7 101 - SPL 7 101 R CN13-6
2 4 - SOL L - 2 4 LG CN163-5 8 8
CN89 TILT SOL. CN109 DRIVE CONT.RH
6 5 4 3 2 1 1 2 3 4 5 6
2 1 1 2 13 12 11 10 9 8 7 7 8 9 10 11 12 13
TAB REC
TAB REC NO P C J NO P C J
NO P C J NO P C J 1 82 - CUDID0 1 82 P J28
1 6 - SOL T + 1 6 G CN163-6 2 - CUDID1 2
2 7 - SOL T - 2 7 B CN163-7 3 145 - CANH 3 145 B J64
4 146 - CANL 4 146 V J65
CN90 MAST HARNESS 5 - CANTRD 5
6 147 - CANGND 6 147 G J66
1 2 3 4 7 42 - KEYSTART 7 42 L J25
4 3 2 1
8 7 6 5 8 - CUDON 8
5 6 7 8
9 79 - SSD2+ 9 79 O CN53-1
10 82 - SSD2-,TD2- 10 82 P J28
TAB REC
11 80 - SSD21 11 80 BR CN53-2
NO P C J NO P C J
12 81 - SSD22 12 81 SL CN53-4
1 91 B CN92-3 1 91 GR CN120-6
13 88 - TD2+ 13 88 R CN52-2
2 51 R CN92-1 2 51 B J1
3 59 Y CN91-2 3 59 Y CN121-3
4 58 BR CN91-1 4 58 BR CN121-9 CN110 DRIVE CONT.LH
5 5
6 90 O CN92-2 6 90 O CN120-7 6 5 4 3 2 1 1 2 3 4 5 6
7 7 13 12 11 10 9 8 7 7 8 9 10 11 12 13
8 51 R CN91-3 8 51 W J3
TAB REC
NO P C J NO P C J
CN91 PRESSURE SENSOR 1 - CUDID0 1
2 - CUDID1 2
1 3 145 - CANH 3 145 B J64
1
2 4 146 - CANL 4 146 V J65
2
3
3 5 - CANTRD 5
6 147 - CANGND 6 147 G J66
TAB REC
7 42 - KEYSTART 7 42 L J25
NO P C J NO P C J
8 - CUDON 8
1 58 - SP L 1 58 BR CN90-4
9 75 - SSD1+ 9 75 O CN59-1
2 59 - SP L 2 59 Y CN90-3
10 78 - SSD1-,TD1- 10 78 P J27
3 51 - SP L 3 51 R CN90-8
11 76 - SSD11 11 76 BR CN59-2
12 77 - SSD12 12 77 SL CN59-4
13 87 - TD1+ 13 87 W CN58-2
3-9
CN111 PUMP CONT. CN120 JOINT
6 5 4 3 2 1 1 2 3 4 5 6
13 12 11 10 9 8 7 7 8 9 10 11 12 13
4 3 2 1 1 2 3 4
TAB REC 8 7 6 5 5 6 7 8
NO P C J NO P C J
12 11 10 9 9 10 11 12
1 - CUPID0 1
2 86 - CUPID1 2 86 P J26
3 145 - CANH 3 145 B J64
TAB REC
4 146 - CANL 4 146 V J65 NO P C J NO P C J
5 - CANTRD 5 1 51 B J21 1 51 B J1
6 147 - CANGND 6 147 G J66 2 45 W CN161-1 2 45 W CN9-5
7 42 - KEYSTART 7 42 L J25 3 46 G CN161-2 3 46 G CN9-4
8 - CUPON 8 4 65 Y CN161-3 4 65 Y CN6-2
9 83 - SSP+ 9 83 LG CN56-1 5 5
10 86 - SSP-,TP- 10 86 P J26 6 91 GR CN161-16 6 91 GR CN90-1
11 84 - SSP1 11 84 W CN56-2 7 90 O CN161-15 7 90 O CN90-6
12 85 - SSP2 12 85 R CN56-4 8 66 R CN161-4 8 66 R CN15-2
13 89 - TP+ 13 89 BR CN55-2 9 9
10 312 Y CN161-9 10 312 Y CN19-3
11 313 V CN161-11 11 313 V CN19-4
CN112 RESISTOR 12 314 L CN161-8 12 314 L CN19-5
3 2 1 1 2 3
CN121 JOINT
TAB REC
NO P C J NO P C J
1 145 B J64 1 145 - R 6 5 4 3 2 1 1 2 3 4 5 6
2 146 V J65 2 146 - R 12 11 10 9 8 7 7 8 9 10 11 12
3 147 G J66 3
CN113 FAN(EX) NO P C J NO P C J
1 52 GR CN162-2 1 52 GR CN26-3
2 56 G CN162-3 2 56 G CN86-2
2 1 1 2 3 59 Y CN162-4 3 59 Y CN90-3
4 51 W J22 4 51 W J3
TAB REC 5 (4) (B) (CN163-5) 5 (4) (B) (CN74-8)
NO P C J NO P C J 6 (8) (P) (CN164-11) 6 (8) (P) (CN74-7)
1 44 R FAN EX (+) 1 44 BR J30 7 53 O CN162-5 7 53 O CN26-4
2 39 B FAN EX (-) 2 39 B J23 8 57 L CN162-6 8 57 L CN86-1
9 58 BR CN162-7 9 58 BR CN90-4
CN114 FAN(EX) 10 64 SL CN162-1 10 64 SL CN26-2
11 (11) (GR) (CN164-14) 11 (11) (GR) (CN74-6)
1 2 12 (36) (W) (CN164-17) 12 (36) (W) (CN74-5)
2 1
TAB REC
NO P C J NO P C J CN122 JOINT
1 44 R FAN EX (+) 1 44 BR J30
2 39 B FAN EX (-) 2 39 B J23
4 3 2 1 1 2 3 4
CN126 RESISTOR
8 7 6 5 5 6 7 8
12 11 10 9 9 10 11 12
1 1
3 2 2 3 ( ):OPT TAB REC ( ):OPT
TAB REC NO P C J NO P C J
1 51(13) LG J2(CN76-2) 1 51(13) LG J21(CN164-19)
NO P C J NO P C J
2 70(12) BR CN84-1(CN76-1) 2 70(12) BR CN161-14(CN164-18)
1 1
3 330 GR CN98-2 3 330 GR CN161-20
2 55 W CPR 2 55 L CN163-8
4 329 B CN98-1 4 329 B CN161-18
3 P2 W P2 3 P2 G CN136-5
5 (35) (P) (CN75-5) 5 (35) (P) (CN164-16)
6 (34) (G) (J48) 6 (34) (G) (CN164-15)
7 (10) (BR) (CN75-6) 7 (10) (BR) (CN164-13)
8 (9) (L) (J47) 8 (9) (L) (CN164-12)
9 63(7) V CN21-1(CN75-7) 9 63(7) V CN161-7(CN163-7)
10 62(6) LG CN87-3(J46) 10 62(6) LG CN161-13(CN163-6)
11 61(5) O CN87-1(CN75-8) 11 61(5) O CN161-17(CN164-10)
12 60(3) R CN11-1(J45) 12 60(3) R CN161-19(CN163-4)
3-10
CN123 JOINT CN162 MAIN CONT.
4 3 2 1 1 2 3 4 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
18 17 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 17 18
8 7 6 5 5 6 7 8
TAB REC
( ):OPT TAB REC NO P C J NO P C J
NO P C J NO P C J 1 64 - SWAC 1 64 SL CN121-10
1 111 R CN5-2 1 111 R CN38-2 2 52 - POTA 2 52 GR CN121-1
2 107 B SWR 2 107 B CN38-7 3 56 - POTTA 3 56 G CN121-2
3 104 O J10 3 104 O CN38-4 4 59 - SPL 4 59 Y CN121-3
4 101 Y J9 4 101 Y CN27-6 5 53 - POTA+ 5 53 O CN121-7
5 120 Y CN9-3(CN9-2) 5 120 Y CN24-1 6 57 - POTTA+ 6 57 L CN121-8
6 103 P CN9-2(CN9-3) 6 103 P J32 7 58 - SPL+ 7 58 BR CN121-9
7 108 SL J14 7 108 SL CN38-5 8 51 - POT- 8 51 W J22
8 109 G J13 8 109 G CN38-6 9 145 - CANH 9 145 B J64
10 146 - CANL 10 146 V J65
CN124 JOINT 11
12
147
199
-
-
CANGND
OPT0
11
12
11
147
199
G
BR
J66
CN165-6
13 16 - D15V 13 16 R CN124-1
6 5 4 3 2 1 1 2 3 4 5 6
14 142 - SDTMA 14 142 B CN124-9
12 11 10 9 8 7 7 8 9 10 11 12 15 141 - SMTDA 15 141 V CN124-8
16 14 - GNDD 16 14 W CN124-7
TAB REC 17 144 - SMTDK 17 144 O CN124-2
NO P C J NO P C J 18 143 - SDTMK 18 143 SL CN124-3
1 16 R J4 1 16 R CN162-13
2 144 O CN1-7 2 144 O CN162-17
3 143 SL CN1-4 3 143 SL CN162-18 CN163 MAIN CONT.
4 4
5 41 GR J6 5 41 GR J29 6 5 4 3 2 1 1 2 3 4 5 6
6 N2 L J8 6 N2 L J31 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14
7 14 W CN1-1 7 14 W CN162-16
8 141 V CN1-3 8 141 V CN162-15
9 142 B CN1-8 9 142 B CN162-14 NO P C J NO P C J

10 10 1 43 - VBKY 1 43 Y J39
11 11 2 41 - VBBT 2 41 GR J29
12 43 Y J5 12 43 Y J39 3 18 - B48V 3 18 O J29
4 3 - SOLL+(SOL1+) 4 3 P(R) CN88-1(CN122-12)
CN136 CONTACTOR 5 4 - SOLL-(SOLb1) 5 4 LG(B) CN88-2(CN121-5)
6 6 - SOLT+(SOL2+) 6 6 G(LG) CN89-1(CN122-10)
3 2 1 1 2 3 7 7 - SOLT-(SOLa2) 7 7 B(V) CN89-2(CN122-9)
6 5 4 4 5 6 8 55 - CPR 8 55 L CN126-2
TAB REC 9 44 - VBMB 9 44 BR J30
NO P C J NO P C J 10 1 - MB+ 10 1 V CN136-2
1 2 R CN163-11 1 2 - MB- 11 2 - MB- 11 2 R CN136-1
2 1 V CN163-10 2 1 - MB+ 12 N2 - N2 12 N2 W N2 TERM
3 P1 B CN27-3 3 P1 - P1 TERM 13 317 - POTH 13 317 Y CN32-2
4 P1 W CN27-2 4 P1 - P1 TERM 14 316 - POTH+ 14 316 SL CN32-3
5 P2 G CN126-3 5 P2 - P2 TERM
6 P2 P CN27-1 6 P2 - P2 TERM
CN164 <OPT> MAIN CONT.
CN161 MAIN CONT.

9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20
20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20
TAB REC
NO P C J NO P C J
NO P C J NO P C J
1 51 - POT- 1 51 W CN41-10
1 45 - DSF 1 45 W CN120-2
2 21 - POTL2 2 21 B CN41-2
2 46 - DSR 2 46 G CN120-3
3 25 - POTAT12 3 25 L CN41-8
3 65 - LSB 3 65 Y CN120-4
4 26 - POTAT21 4 26 V CN42-1
4 66 - LSPB 4 66 R CN120-8
5 27 - POTAT22 5 27 SL CN42-2
5 67 - LSD 5 67 L CN22-1(CN42-7)
6 28 - POTL+ 6 28 G CN41-3
6 39 - FAN- 6 39 B J23
7 29 - POTT+ 7 29 Y CN41-6
7 63(24) - LSAT1(POTAT11) 7 63(24) V CN122-9(CN41-7)
8 30 - POTAT1+ 8 30 GR CN41-9
8 314 - STSC 8 314 L CN120-12
9 31 - POTAT2+ 9 31 LG CN42-3
9 312 - STS1 9 312 Y CN120-10
10 5 - SOLa1 10 5 O CN122-11
10 42 - KEYSTART 10 42 L J25
11 8 - SOLb2 11 8 P CN121-6
11 313 - STS2 11 313 V CN120-11
12 9 - SOL3+ 12 9 L CN122-8
12 51 - LS-(POT-) 12 51 B J21
13 10 - SOLa3 13 10 BR CN122-7
13 62(23) - LSTR(POTT2) 13 62(23) LG CN122-10(CN41-5)
14 11 - SOLb3 14 11 GR CN121-11
14 70 - SWTK 14 70 BR CN122-2(CN42-5)
15 34 - SOL4+ 15 34 G CN122-6
15 90 - MH1 15 90 O CN120-7
16 35 - SOLa4 16 35 P CN122-5
16 91 - MH2-1 16 91 GR CN120-6
17 36 - SOLb4 17 36 W CN121-12
17 61(22) - LSTF(POTT1) 17 61(22) O CN122-11(CN41-4)
18 12 - SOLP+ 18 12 BR CN122-2
18 329 - SOLST+ 18 329 B CN122-4
19 13 - SOLP- 19 13 LG CN122-1
19 60(20) - LSL(POTL1) 19 60(20) R CN122-12(CN41-1)
20 20
20 330 - SOLST- 20 330 GR CN122-3
3-11
CN165 BACK RELAY

EXCEPT
EZ PEDAL
3 2 1 1 2 3
6 5 4 4 5 6
TAB REC
NO P C J NO P C J
1 1 16 R J70
2 2 N1 L J11
3 3 43 Y J19
4 103 G CN165-5 4 103 O CN9-3
5 103 G CN165-4 5 198 GR CN38-3
6 6 199 BR CN161-10
CN165 BACK RELAY

EZ PEDAL
3 2 1 1 2 3
6 5 4 4 5 6
TAB REC
NO P C J NO P C J
1 16 W IN+ 1 16 R J70
2 N1 B GND 2 N1 L J11
3 43 R OUT+ 3 43 Y J19
4 4 103 O CN9-3
5 198 W OUT- 5 198 GR CN38-3
6 199 W IN- 6 199 BR CN161-10
3-12
JOINT ( ):OPT
CN123-3 CN55-1 CN75-4 CN38-4

CN6-1
CN84-2 CN120-1 CN17-2 CN111-2
J10 J26 CN56-3 J45 CN74-4 J55 CN31-1
J1 CN90-2
CN19-2 CN15-1 CN13-2
CN9-6(CN9-1) CN46-4 CN111-10 CN122-12 CN34-1
(104,O) (86,P) (3,R) (104,G)

(51,B)
CN13-3 CN58-1 CN75-3 CN162-9
CN87-4
CN11-2 CN110-3
J2 CN165-2 J11 CN45-4 J27 CN59-3 J46 CN74-3 J64 CN109-3
CN87-2 CN122-1 CN111-3
CN21-2 CN17-3 CN110-10 CN122-10 CN112-1
(51,LG) (102,G) (78,P) (6,LG) (145,B)
CN8-13 CN52-1 CN75-2 CN162-10

CN121-4
CN109-1 CN110-4
CN90-8
J13 CN17-4 J28 CN53-3 J47 CN74-2 J65 CN109-4
J3
CN86-3 CN111-4
CN123-8 CN109-10 CN122-8 CN112-2
CN26-1
(109,G) (82,P) (9,L) (146,V)
(51,W)
CN1-2 CN8-12 CN27-5 CN75-1 CN162-11

CN163-3 CN110-6
J4 CN19-1 J14 CN13-4 J29 J48 CN74-1 J66 CN109-6
CN163-2 CN111-6
CN124-1 CN123-7 CN124-5 CN122-6 CN112-3
(16,R) (108,SL) (41,GR) (34,G) (147,G)
CN9-7(CN9-6) CN22-2(CN42-8) CN27-4 CN77-4 CN38-3
CN12-2 CN122-1 CN114-1 CN85-1 CN78-4

J5 J21 CN161-12 J30 J49 CN79-4 J70 CN23-1
CN29-2 CN124-12 CN50-1 CN113-1 CN80-4
CN9-8 CN120-1 CN163-9 CN41-10 CN165-5
(43,Y) (51,B) (44,BR) (51,W) (198,GR)
CN3-2 CN32-1 CN124-6 CN16-2,CN20-2
CN121-4 CN23-2
J6 CN29-1 J22 J31 J51
CN24-2 CN38-8 CN13-1,CN17-1
CN124-5 CN162-8 N2 TERMINAL CN14-3,CN18-3
(41,GR) (51,W) (N2,L) (N2,W)
CN8-10 CN161-6 CN23-1 CN31-2

CN13-1 CN50-2 CN114-2 CN38-2
CN17-5 J8 CN17-1 J23 J32 CN123-6 J53
CN13-5 CN124-6
H
CN113-2 CN38-3 CN34-2
(N2,L) (39,B) (103,P) (111,SL)
CN5-1 CN111-7 CN163-1 CN31-4

CN45-1 CN123-4 CN161-10 FB CN23-2-2
CN13-6 J9 CN45-2 J25 CN165-3 J39 CN38-1 J54 CN38-8
CN46-1 CN109-7 CN36-2
CN46-2
SWR CN110-7 CN124-12 CN34-6
(101,Y) (42,L) (43,Y) (N2,W)
<LEVER CONT. UNIT>
<KEY-LESS-KEY OPT> CN9
TAB
SWD SW TK
REC
SWH
CN3 SWD
SWR
SWH SWL
TAB
REC
SST DISPLAY
LS PB SWK SW K CN19 TAB
(101,Y) (107,B)
TAB TAB REC
REC J9 CN123-2
TAB
REC
REC
CN70
CN4 CN4 CN8
CONNECTING DIAGRAM
FR Y TR Y HRY SWL CN84

TAB
REC
TAB <COMPARTMENT LAMP OPT>

TAB REC
REC
CN46 CN45 TAB
CN12 REC SW CMP
TAB TAB TAB R LF-R LH-R
REC REC CN15 COM TAB
REC REC
NO
BR (N1,L)
CN29 LC-R CN96
NC
LS ATT L CMP (117,SL)
CN16
TAB CN14 TAB
REC REC
TAB
REC
CN21
LH-L LF-L REC
CN6 TAB
LC-L REC TAB
TAB CN5 REC REC
TAB CN13
CN1
TAB TAB TILT
REC REC <MINI-LEVER OPT>
COM
R VRAT
CN20 CN18
NO
BR
ACCEL CN86 TAB
NC REC SWTK
TAB LS B VRAD LIFT TILT ATT1 ATT2
REC (48,P)CN3-1 LEVER LEVER LEVER LEVER
CN17 R TAB
COM
(N2,L)J8
H REC
NO CN26
NC
SL
TAB TAB TAB TAB TAB
LS ST REC REC REC REC REC
CN77 CN78 CN79 CN80 CN85
(1) (2) (3) (4)
CN90
REC
TAB
REC
TAB
REC <DIRECTIONAL
CN11 REC TAB CN87 CN98
TAB CONTROL PEDAL OPT>
LS D
R
COM
BR
LS L NO
CN91 NC
REC
CN43
TAB TAB
REC
LS TF CN9
LS TR SOL ST TAB
REC
<MINI-LEVER OPT>
SP L
SOL SOL SOL SOL
AT2L AT1L TR LU CN74
COM
TAB
REC
NO
TAB
REC
NC CN92
SW MH1 SOL L SOL T U
V
BATT
W AM P CN55
STM P
TAB
REC
CN52
STM D
TAB
REC
W CN76
AM D CN56
TAB
REC
SSP
TAB
REC
RH V CN53 - +
SOL
SSD
TAB
REC
U CN75 CN41 CN42
TAB TAB
TAB
REC
SOL SOL SOL SOL REC REC

AT2U AT1U TF LD
CN120 CN121 CN122 CN123 CN124
CN58 REC REC TAB TAB TAB
TAB TAB REC REC REC
STM D
TAB
REC
W
AM D
LH V CN59
SSD CN89
TAB
PUMP CONTROL
REC
U +
UNIT
U
TAB TAB
REC REC
CONTACTOR
CN88
PANEL
V
P3 P1
W
- F4 F6
R F5
REC TAB CN136
TAB REC CN27 REC
TAB
FAN EX
REC
CN112 CN111 TAB TAB
CN50 REC
DRIVE CONTROL DRIVE CONTROL
+ +
UNIT LH UNIT RH
U U
V V <MINI-LEVER OPT>
MAIN CONTROL <STD>
CN164 (EXCEPT MINI
PANEL
W W
TAB
REC
-LEVER OPT)
N2 TERMINAL - - CN163
TAB TAB CN162
REC REC LS D
CN110 CN109 CN161
TAB TAB TAB
REC REC REC
CN22
TAB
REC TAB
CN126 REC
LW
TAB
FB FAN EX
REC
BZ
CN113
B
R
TAB
FAN EX
REC
CN36 CN23-2 CHI BACK

RELAY CN114
TAB TAB
REC REC CN32
REC
W
L
TAB
TAB TAB
CN24 REC REC CN23 REC
(F) (R) CN165
ONLY EZ PEDAL VRAH
L T -L L T -R
LF-LL L BU -R L F -RR
L ST -L L ST -R
TAB TAB
REC REC
CN31 CN34
CN38
TAB
REC
3-13
3-14
ELECTRIC WIRING DIAGRAM

7fbeu15-20 Ops Repair Manual Cu341

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FOREWORD

This repair manual contains the information on the vehicles manufactured as of

{ NEW MODEL FEATURES

Technical News Brief

Hotline Tech Tips

Inspection timing Every Every Every Every

Every Every Every Every

SAFETY DEVICES, ETC.

Loosening and damage of mounting I ← ← ←

Seat switch function I ← ← ←

CHANGES FOR INSTALLATION OF OPS FUNCTION

Key switch Display

Item Operation explanation

OPS & IMPROVEMENTS

Key switch Display

(1) Parking brake ON indicator (7) Multiple display area

Battery charge indicator

(11) Hour meter selector button

Model USA model

Status display function OPS indicator { {

DISPLAY INDICATION LIST

MASK FUNCTION Screen

To be set by dealer or serviceman

Vehicle Abnormalities Not Stored in Diag Memory

OPTION SET Menu List

Operation Procedure for OPTION SET Screen

<OP T 1> <OP T 2>

Button (1) Button (2) Press button (3)

<OP T 4 > <OP T 1 5 >

<OPT 5 > <OPT 1 4 >

Press button (3) Press button (3)

<OPT 6 > <OPT 1 3 >

Press button (3) Press button (3)

<OPT 7 > <OPT 1 2 >

Press button (3) Press button (3)

<OPT 8 > <OPT 1 1 >

Press button (3) Press button (3)

< OP T 9 > < OP T 10 >

Press button (3)

Press button (3)

Press button (3)

MASK MENU screen

Press button (3) Press button (3)

< OP T 2 1 > <OPT 2 2 >

WHEN AN ERROR CODE IS DISPLAYED

Display code Diag memory code Error mode Page

A5 A5 Seat switch abnormality 1-10

WHEN NO ERROR CODE IS DISPLAYED

Display code Vehicle condition Page

Harness change relation

WHEN AN ERROR CODE IS DISPLAYED

Display code Diag memory code Error mode Page

61-1, 2 61-1, 2 Load sensor abnormality 1-45

62-1, 2 62-1, 2 Tilt angle sensor abnormality 1-47

63-1, 2, 3 63-1, 2, 3 Tilt switch abnormality 1-14

67-1 67-1 Lifting height switch abnormality 1-49

72-1, 2, 3, 4 72-1, 2, 3, 4 Steering angle sensor abnormality 1-15

73-1, 2, 3 73-1, 2, 3 Steering knob synchronizer solenoid abnormality 1-20

A4 A4 Acceleration switch abnormality 1-22

A6-1, 3, 5 A6-1, 3, 5 Material handling switch abnormality 1-23

C4-1, 2, 3, 4 C4-1, 2, 3, 4 Accelerator potentiometer abnormality 1-25

C7 C7 Direction switch abnormality 1-27

EE-1, 2, 3 EE-1, 2, 3 Abnormal communication from multi-display 1-29

F1-1, 2 F1-1, 2 Main controller →multi-display communication abnormality 1-51