5fbe10-20 Repair Manual Ce306-3

FOREWORD
This manual covers the service procedures of the TOYOTA BATTERY

FORKLIFT 5FBE10-20 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of September 1998. Please
understand that disagreement can take place between the descriptions
i n the manual and actual vehicles due t o change i n design and specifi-
cations. Any change or modifications thereafter will be informed b y
Toyota Industrial Vehicles' Parts & Service News.
TOYOTA Material Handling Company

A Division of TOYOTA INWSRIES CORPORATION
SECTION INDEX
NAME SECTION
GENERAL
BATTERY
OTHER THAN U.S.A.] (1993.1 - 1998.8)
CONTROL ClRCU IT [FOR
IFOR u.s.A.1 (1993.1 -1999.1 )
-
CONTROL CIRCUIT [FOR OTHER THAN U.S.A.] (1998.9

[FOR UL. U.S.A.. CANADA] (1999.2
-)
-)
A
-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8)
MULTI-DISPLAY FUNCTIONS [Fouu.s.A.j (1993.1 - )
-
ELECTRICAL SYSTEM TROUBLESHOOTING [FoRu.s.A.1 (1993.1 -1
ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHERTHAN U.s.Ad(199889 -I A A
MOTOR
/ FRONT AXLE & TRANSMISSION (lgg3.1 - lgg8-l)
FRONT AXLE & DRIVE UNIT (1998-2-1
REAR AXLE (1993.1- 1998.1)
1 A
STEERING
-
-
BRAKE (1998.2- I
BODY & FRAME
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL ]
APPENDIX
GENERAL
Page
EXTERIOR VIEWS ........................... 0-2
VEHICLE MODEL ........................... 0-3
FRAME NUMBER ........................... 0-3
HOW TO USE THIS MANUAL ................ 0-4
EXPLANATION METHOD .......................... 0-4
TERMINOLOGY .................................. 0-5
ABBREVIATIONS ................................. 0-5
LIST OF ABBREVIATIONS AND SYMBOLS .......... 0-6
OPERATIONAL TIPS ......................... 0-7
JACK-UP POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
CIRCUIT TESTER ............................ 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE ................................. 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ....................................... 0-11
TIGHTENING TORQUE TABLE ..................... 0-12
PRECOAT BOLTS ........................... 0-13
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ..................... 0-13
WIRE ROPE SUSPENSION ANGLE LIST ....... 0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ..................... 0-14
COMPONENTS WEIGHT ..................... 0-15
RECOMMENDED LUBRICANTS
AND CAPACITIES ......................... 0-15
LUBRICATION CHART ....................... 0-16
PERIODIC MAINTENANCE ................... 0-17
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................ 0-22
0-2
EXTERIOR VIEWS
VEHICLE MODEL
Battery capacity Voltage
Load capacity Model Control circuit
AH/5HR V
1.0 ton 5FBE10 280 *36 or 48 MCS-IIIA
1.25 ton 5FBE13 t t t

1.5 ton 5FBE15 390 t t
1.75 ton 5FBE18 t t t
1.815 ton 5FBE20 375 t t
*: 36 V is provided for UL specification.
FRAME NUMBER
Punching
position
Upper face of side member

of frame RH
Vehicle model Punching format
5FBE13-10011
5FBE10 5FBE13E10011 (EEC spec.)
1 ton
series
-
(1993.1 1993.9)
5FBE13
(1993.10 -
5FBE130 10011 (EEC spec.)
)
5FBE18-10011
5FBE15 5FBE18E10011 (EEC spec.)
1.5 ton
series
-
(1993.1 1993.9)
5FBE18010011 (EEC spec.)
5FBE18
(1993.10 -
)
2.0 ton 5FBE20-10011
5FBE20
series
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustra-
tion, followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T=N.m (kgf-cm)[ft-lbfl
--
T = 46.09 48.05
(470 490)
134.00- 35.451
Disassembly Procedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 21 Operation explained later
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 11
Disassembly:
J
Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
2. How to read components figures (Example)
(1) The components figure use the illustra-
fl
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of FIG number in parts catalog
each components figure indicates the
Fig. number in the parts catalog.
3. Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removed parts as required
@ visual inspection (Partially described)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to observe them.
Note:
lmportant items of which negligence may cause accidents or matters in operation procedure
requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly RR Rear
Electrical hydraulic power Society of Automotive
EHPS SAE
steering Engineers (USA)
FR Front SST Special service Tool
I-/ Less STD Standard
LH Left hand T= Tightening torque
0PT Option OOT Number of teeth (00)
01s Oversize U/S Undersize
PS Power steering w/ With
RH Right hand
LIST OF ABBREVIATIONS AND SYMBOLS
Symbol Name Symbol Name Symbol Name
BATT Battery FRY Flasher Relay PBsN Snubber Print Board
BZ Buzzer H Horn PLw Working Pilot Lamp
CA Absorber Capacitor IWP Wheel Position Indicator RA Absorber Resistor
CADIP Drivelpump Absorber LBU-~ Back-up Lamp, LH RADIP Drivelpump Absorber
Capacitor LBU-~ Back-up Lamp, RH Resistor
CH Charger LC-L Clearance Lamp, LH PCKI I 2 Check Resistor No.112
CHIF Forward Chime LC-R Clearance Lamp, RH SA Surge Absorber
CHIR Reverse Chime LF-L Flasher Lamp, LH SLL Lequid Level Sensor
CSDIP DriveIPump Current L F - ~ ~Flasher Lamp, LH (Rear) SN1 Sunbber No.1
Sensor LF-R Flasher Lamp, RH SNCI 12 Snubber Capacitor 112
CSps Power Steering Current LF-RR Flasher Lamp, RH (Rear) SNR112 Snubber Resistor 112
Sensor LH-L Head Lamp, LH SSP Steering Pressure Sensor
DADIP Drivelpump Absorber LH-~ Head Lamp, RH SSL Speed Sensor, LH
Diode LR-F Rotaly Forward Lamp SSR Speed Sensor, RH
DCH Charger Diode LR-~ Rotaly Reverse Lamp STH Thermo Sensor
DC-SDD DC-DC Converter & LSAnI2
l Attachment Limit Switch SWAC Accel Switch
Source Drive (Drive) No.112 SWF Flasher Switch
DC-SDP DC-DC Converter & LSB Brake Limit Switch SWH Horn Switch
Source Drive (Pump) LSD Dead Man Limit Switch SWKy Key Switch
DF112 FLY-WHEEL Diode, LSL1/2 Lift Limit Switch No.112 SWL Light Switch
No.112 LSsT Stop lamp limit Switch SWPB Parking Brake Limit
DF314 FLY-WHEEL Diode No.314 L S T - ~ Stop Lamp, LH Switch
DlSP Display L s T - ~ Stop Lamp, RH SWsc Speed Control Switch
DMDlP DriveIPump Motor LST Tilt Limit Switch TF Transformer
DMps Power Steering Motor LT-~ Tail Lamp, LH THR Thermal Relay
DSBu Back-up Direction Switch LT-~ Tail Lamp, RH TM Main Transistor
DSF Forward Direction Switch Lw Working Lamp TMD Main Drive Transistor
DSFo Forward Optional MFL Forward Contactor, LH TMP Main Pump Transistor
Direction Switch MFR Forward Contactor, RH TMps Main Power Steering
DSR Reverse Direction Switch MP Pump Contactor Transistor
F1 Drive Fuse MPS Power Steering Contactor TU Timer Unit
F2 Pump Fuse MRL Reverse Contactor, LH VRAD Accel Drive Variable
F3 Power Steering Fuse MRR Reverse Contactor, RH resistor
F4 Lamp Fuse MScH Charger Magnet Switch VRSP Steering Position Variable
F5 Control Circuit Fuse PBcpu Computer Print Board resistor (Steering
FCH Charger Fuse PBEHPs EHPS Print Board potentiometer)
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks on rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve
in load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil
pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange
the parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean
tools and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassem-
bly. If no tightening torque is specified, tighten the bolt or nut according to the standard
tightening torque table.
3. Grasping the troule state

When a trouble occurs, du not attempt immediate disassembly or replacement but first check
if the trouble requires disassembly or replacement for remedying.
4. How to treat liquid waste

When draining liquid waste from a vehicle, use a pan or other suitable container to collect the
liquid.
Do not throw away oil, fuel, cooling water, oil filters, batteries, or other injurious materials since
these materials may adversely affect human health and the environment. Sort liquid waste into
different types and seek the service of experts for proper disposal.
Hoisting the vehicle

Loop wire ropes on the mast hook hole and the rear of the
head guard to hoist the vehicle.
JACK-UP POINTS
The vehicle often needs to be jacked up during assembly and reassembly.
Be sure to jack up the vehicle at the right positions. Placing a jack in the wrong position or jacking up
the vehicle in the wrong manner may cause an unexpected accident.
Front jack-up Rear jack-up
Front jack-up
If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with
a bearing plate at least 80 m m long.
Rear jack-up
When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the
weight on the opposite side.
The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle
maintains its balance during jack-up.
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively
according to the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the mea-
sured value should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or
movement.
1. Difference in measurement results with the digital type and analog type
*The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual. Cautions when the polarities are
different between the analog type and digital type are described below.
(1) Analog circuit tester

I Measurement result example
Tester range:KR range
Forward direction Reverse direction
Analog type
Continuity
I Forward I shall exist I
No continuity
Reverse
(2) Digital circuit tester

Measurement result example
Tester range: 2 M Q range
Forward direction Reverse direction
Digital type
I Forward
I
I
NO continuity I
1
Continuity
Reverse shall exist
2 MR
2. Difference i n result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is
used. The resistance of a semiconductor such as a diode varies with the circuit tester power
supply voltage.
The diode characteristics are shown in the figure below.
(m~) The resistance values of the same semiconductor
5 measured with t w o types of circuit testers having
different power supply voltages are different.
Current 4
in This manual describes the results of measurement
forward
direction
with a circuit tester whose power supply voltage is
3.0 V.
2
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Voltage in forward direction lV)
3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement range switches over the internal
circuit to vary the circuit resistance. Even when the same diode is measured, the measure-
ment result varies with the measurement range.
Always use the range described in the repair manual

for measurement.
Variable resistor
Current
flow
I ,-
Resistor
Range: x 10
, (SW 1)
,,
Resistor
41 ,
TEwer
4
(SW2)
Range: x 1
source: 1.5 V
"0 Red 6@
Black
STANDARD BOLT AND NUT TIGHTENING TORQUE
How to judge tightening torque of a standard bolt or nut.
1. How to judge tightening torque of a standard bolt.

Find out the type of the bolt from the list below.
Then, find the bolt tightening torque from the table.
2. How to judge tightening torque of a standard nut.

The nut tightening torque can be judged from the bolt type. (See the item above.)
BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.
Shape and class Class Hexagon head bolt I

4=4T
Hexagon
@- Bolt head No.
5 = 5T
6 = 6T
7 = 7T
8 = 8T
Part No.
91611-40625
T L e n g t h (mml
head bolt
Diameter (mm)
0 No mark 4T
Hexagon 4T iameter
No mark
flange bolt
Hexagon Two protruding 5T

head bolt lines
Stud bolt
Two protruding
Part No.
921 32-40614
Length (mm)
Four protruding Diameter (mm)
0-12
TIGHTENING TORQUE TABLE
I I I I
14 1.5 75 1 760 j 55 83 1850 161

16 1.5 113 j 1150 i 83 -
I
I _ I
I _
6 1 .O 6.4 1 65 i 56 in-lbf 7.5 1 75 j 65 in-lbf

8 1.25 16 j
I
160
I
12 18 j
I
175 j
I
13
10 1.25 32 j 330 j 24 36 j 360 j 26
5T
12 1.25 59 j
I
600 j
I
43 65 j
I
670 j
I
48
14 1.5 91 i
I
930 i
I
67 100 1 1050
I
1 76
16 1.5 137 1 1400 1 101 157 11600 ill6
6 1 .O 7.8 j
I
80 1
I
69 in-lbf 8.8 j
I
90 j
I
78 in-lbf
8 1.25 19 1 195 1 14 21 1 215 1 16
I I I I
10 1.25 38 j 400 29 43 1
1
440 j 32
6T I I I
12 1.25 72 1
I
730 1 53
I
79 1810 159
I I
14 1.5 110 j1100 i 8 0 123 1 1250 j 90

I I I I
16 1.5 170 11750 1127 191 11950 1141

6 1.O l1 I1 1 1 0 1
I
8 12 j
I
120 j
I
9
8 1.25 25 1260 119 28 1290 121
I I I I
7T
10 1.25 52 i
I
530 j
I
38 58 j
I
590 j
I
43
12 1.25 95 1
I
970 1 70
I
103 1 1050
I
:
I
76
14 1.5 147 j
I
1500 i 108
I
167 ,
11700 j123
16 1.5 226 1 2300
L
1 166 -
I
I
I
- I
I
I -
I
6 1.O 12 i
I
125 j
I
9 l4 1I 145
I
9
8 1.25 29 1
I
300 1 22
I
32 1 330 1I 24
10 1.25 61 j 620 j 45 68 1
I
690 j 50
8T I I I
12 1.25 108 11100 180 123 1 1250 1 90

14 1.5 172
I
1750 i 127
I
196 ,1 2000
I
j
I
145
16 1.5 265 1 2700 1 195 299 1 3050 1 221
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the fol-

lowing cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or
tightened) by tightness check, etc.
I I Note:
For toraue check. use the lower limit of the allowable
tighteni;lg torque range. If the bolt moves, retighten it
according to the steps below.
2. Method for reuse of precoat bolts

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

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact sur-
faces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage
on the contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and
tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N-m (kgf-cm) [ft-lbf] Hose inside
of screw diameter
Standard Tightening range m m (in)
7/16 - 20UNF 25 (250) [18.1 1 24-26 (240-270) [17.4-19.51 6 (0.24)
9/16 - 18UNF 49 (500) [36.2] 47-52(480-530) 134.7-38.31 9 (0.35)
314 - 16UNF 59 (600) [43.4] 56-62 (570-630) [41.2-45.61 12 (0.47)
718 - 14UNF 59 (600) [43.4] 56-62 (570-630) [41.2-45.61 12 (0.47)
718 - 14UNF 78 (800) [57.9] 74-82 (760-840) [55.0-60.81 15 (0.59)
1.1116 - 12UNF 118 (1200) [86.8] 112-123 (1140-1250) [82.5-90.41 19 (0.75)
1.5116 - 12UNF 137 (1400) [101.3] 130-144 (1330-1470) [96.2-106.41 25 (0.98)
PF1/4 25 (250) [18.1] 24-26 (240-270) [17.4-19.51 6 (0.24)
PF3/8 49 (500) [36.2] 47-52 (480-530) [34.7-38.31 9 (0.35)
PF1/2 59 (600) [43.4] 56-62 (570-630) 141.2-45.61 12 (0.47)
PF314 118 (1200) [86.8] 112-123 (1140-1250) [82.5-90.41 19 (0.75)
PF1 137 (1400) [101.3] 130-144 (1330-1470) [96.2-106.41 25 (0.98)
WlRE ROPE SUSPENSION ANGLE LIST
Lifting Compres- Suspension Lifting Compres- Suspension
~~~~i~~ Tension
angle sion method angle sion method
o0 1.00 time 0 time
-Ll
7
90" 1.41 time 1.00 time
by5
2' A
30' 1.04 time 0.27 time
h0
- 120' 2.00 time 1.73 time
60' 1.16 time 0.58 time
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [lbf]
Rope Cutting Single-rope Two-rope suspension Four-rope suspension

diameter load suspension
0" 0" 30' 60" 90° o0 30° 60' 90"
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[48071 [683.6] [I3671 [I3231 [ I 1691 [9701 [27341 [26461 [2337] [I9401
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [I9851 [I9181 [I7201 [I4111 [39691 [39371 [34401 [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 m m
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(Om4 in)
[ I1.691 L1565.61 [31531 [30211 [26461 [22051 L61741 [59541 152921 [44101
21280 18630 14710 43150 41190 37270 29420
12.5 m m 76880 10980 21570
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[173871 [2469.5] [4851] [4631] [4190] [33081 [97021 [9261I [83791 [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 m m
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[216751 [3087] [61741 [59541 [5292] [41901 [I23481 [ I19071 [I05841 [83791
COMPONENTS WEIGHT
Item Weight kg [Ibl
Drive motor
Approx. 41 1901
(One unit)
Pump motor Approx. 35 [771
5FBE10: Approx. 393 I8671
5FBE13: Approx. 556 112261
Counter weight 5FBE15: Approx. 620 [I3671
5FBE18: Approx. 785 11731I
5FBE20: Approx. 1070 I23601
Mast Wllift bracket
*Approx. 400 [8821
(with lift cylinder, less fork)
**Approx. 410 19041
[max. fork height = 3000 m m (118 in)]
RECOMMENDED LUBRICANTS AND CAPACITIES

Application Type Capacity
Transmission STD: Hypoid gear oil SAE85W-90 Right side: 1.7 t? (0.45 USgal)
(API GL-4) Left side: 1.8 (0.47 USgal)
(1993.1 - 1998.1)
45s: Hypoid gear oil SAE75W-80W 1.5 e (0.40 Usgal)
(API GL-4) (1.998.2 - )
Hydraulic (total) STD: Hydraulic oil IS0 VG32 *I6 e (4.2 USgal)
45s: MIL-H-5606-D **21 e (5.5 USgal)
Brake line STD: SAE J-1703 DOT-3
45s: SAE J-1703 DOT-3
Proper quantity
(1993.1 - 1998.1)
Brake fluid arctic S (1998.2 -
Chassis part STD: MP grease No.2
Proper quantity
45s: MIL-G-3278-A
45s: Refrigerator specification vehicle

*: For 3000 mm (118 in) maximum fork height
**: For 6000 mm (236 in) maximum fork height
LUBRICATION CHART
1. Chain I lnspect every 8 hours (daily)
2. Mast strip I1 lnspect every 40 hours (weekly)
3. Tilt cylinder front pin 111 lnspect every 170 hours (monthly)
4. Mast support bushing IV lnspect every 1000 hours (6 monthly)
5. Front axle hub V lnspect every 2000 hours (annually)
Transmission housing 0 lnspect and service
Reservoir tank Replace
Oil control valve link pin

Accelertor pedal link @ MP grease (STD)
Tilt steering locking mechanism MIL-G-3278-A (45s)
Brake pedal link @ Engine oil
Oil tank @ Hypoid gear oil
Rear wheel bearing @ Brake fluid
Rear axle bearing @ Hydraulic oil
Steering rack & pinion

Limit switch controller
(cold storage models only)
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment i f required.
T : Retightening C: Cleaning L: Lubrication
* : For n e w vehicle * 1: Flaw detector
Every Every Every Every
Inspection Period 1 month 3 months 6 months 12 months
Item Every Every Every Every
170 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Abnormal sound during revolution I t c t
Loose terminal T c +- t
Insulation resistance M t c
Motor
Brush wear and sliding contact status I c
Commutator fouling and damage I c
Brush spring fatigue M

Charge I +- c t
Battery fluid level I t c t
Battery fluid specific gravity M c +- c
Loose terminal I C +- C
Battery Abnormality at top of battery and

I C C t
battery case
Insulation resistance M c t
Cell voltage measurement after

M
charging
Timer operation I t c t
Terminal loosening I c c t
Charger Operating voltage measurement M t +-
Magnet switch function, contact

I
fouling and roughening
Loose contact, damage and wear I t t c
Auxiliary contact function, fouling and

I C t C
wear
Magnet I
Arc chute installation status
contactor
Timing and functioning I
Loose coil installation I
Loose main circuit lead installation I
Timing and operating function I t c c
Microswitch
Damage and loose installation I t t c
Direction lever Operating conditions and damage I c c c
Operation I c C +-
Controller Inside fouling and damage C c c t
Overcurrent limit valve M

Fuse Loosening I c C c
Damage of wiring harness and loose

I t C C
Wiring clamp
(including Loose connection and taping status I c c c
charging cord) Battery connector damage and

I C C C
connection status
Accelerator Operating and damage I c c t
POWER TRAIN
Oil leak I c c c
Transmission Oil level I c c c
Gear function and sound I c c c
TRAVELING EQUIPMENT
Tire air pressure M t c c
Tire cuts, damage and uneven wearing I t c c
Loose rim and hub nuts T t t t
Tire groove depth M t t c
Metal chips, pebbles and other foreign

I t C C
Wheels matter trapped in tire grooves
Rim and disc wheel damage I t @ C
Abnormal sound and looseness of

I C C C
front wheel bearing
Abnormal sound and looseness of rear
I C C C
wheel bearing
Cracks, damage and deformation of
Front axle I
case
Cracks, damage and deformation of
Rear axle I
rear axle

STEERING SYSTEM
Play and looseness I t t t
Steering wheel
Function I t t t
Hydraulic Oil leak I t t t
control valve Looseness of mounting T t t t
Oil leak I t t t
Power steering Mounting and linkage Looseness I t t t
Damage of power steering hose I
BRAKING SYSTEM
Play and reserve M t t t
Brake pedal
Braking effect I t t t
Pull margin I t t t
Braking effect I t t t
Parking brake
Rod and cable looseness and damage I t t t
Ratchet wear and damage I
Brake pipe and

Leakage, damage and mounting status I t t t
hose
Brake fluid Fluid level I t t t
Clearance between diskwheel and M t t t
lining
Pad wear and damage M
Disk brake wheel wear and damage M
Disk brake lever operating status I t t
Disk brake wheel set bolt loose T

Disk brake
Return spring fatigue M
Caliper body leak brake fluid I t t t
Master cylinder and wheel cylinder I

operation
Cylinder and piston cup wear and I
damage
1 70 hours 500 hours 1000 hours 2000 hours
Abnormality of fork and stopper pin I c c c
Misalignment between left and right

Forks I c c 4-
fork fingers
Cracks at fork root and welded part I *'
Deformation and damage of each part
I 4- C t
and crack at welded part
Mast and lift bracket looseness I +- t +
Wear and damage of mast support

Mast and lift I
bush
bracket
Wear, damage and rotating condition
I C t t
of rollers
Wear and damage of roller pins I
Wear and damage of mast strip I c c c
Tension, deformation and damage of

I C t t
chain
Chain and Chain lubrication I t 4- C
chain wheel Abnormality of chain anchor bolt I t c c
Wear, damage and rotating condition

I t t C
of chain wheel
Various Abnormality and mounting condition
I 4- 4- 4-
attachments of each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
I C C C
mounting
Deformation and damage of rod, rod
I t C C
screw and rod end
Cylinder operation I c c c
Natural drop and natural forward tilt

Cylinder M c c C
(hydraulic drift)
Oil leak and damage I +- @ t
Wear and damage of pin and cylinder

I C 4- t
bearing
Lifting speed M +- t c
Uneven movement I t t t
Oil pump Oil leak and abnormal sound I t t c
Oil level and contamination I t 4- c

Hydraulic oil
Tank and oil strainer C t
tank
Oil leak I +- t 4-
Loose linkage I t c t
Control lever
Operation I c C +
Oil leak I t c t
Oil control Relief pressure measurement M

valve Relief valve and tilt lock valve
I C t t
functions
Oil leak I t c c
Hydraulic Deformation and damage I t c c
piping Loose joint T c t t
Hose tension and twisting I c c c
SAFETY DEVICES, ETC.

Cracks at welded portion I +- c c
Head guard
Deformation and damage I + t c
Loosening of mounting I +- c C
Back-rest
Deformation, crack and damage I t c t
Lighting
Function and mounting condition I t c c
system
Horn Function and mounting condition I t t c
Direction
Function and mounting condition I t t c
indicator
Instruments Functions I c c c
Back up buzzer Function and mounting condition I t c c
Rear-view Dirt, damage I c t c
mirror Rear reflection status I t c t
Seat Loosening and damage of mounting I t c t
Damage and cracks of frame, cross

I
Body members, etc.
Bolt looseness T
Other Grease up L c t t
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
Inspection (operating hours or 1 month 3 months 6 months 12 months
months, whichever is earlier) Every Every Every Every
1 70 hours 500 hours 1000 hours 2000 hours
Brake fluid C
Hydraulic oil c
Hydraulic oil filter C

(New vehicle)
Transmission oil
Wheel bearing grease
Master cylinder rubber parts
Wheel cylinder rubber parts
Reserve tank tube

(Every 2 years)
Power steering hose

(Every 2 years)
Internal rubber parts of power steering system

(Every 2 years)
Material handling house

(Every 2 years)
Chain
(Every 3 years)
BATTERY
Page
SERVICE STANDARDS ........................................ 1-2
DISPLAY INDICATION ........................................... 1-2
OVERDISCHARGE ALARM FUNCTION ..................... 1-2
BATTERY COMPARTMENT & MINIMUM
WEIGHT REQUIRED .......................................... 1-3
TROUBLESHOOTING ........................................... 1-4
BATTERY ASSY ................................................... 1-5
INSPECTION ..................................................... 1-6

SERVICE STANDARDS
Specific gravity in fully charged state (OC) [OF1 1.280 (20) [681
Specific gravity in fully discharged state (OC) [OF] 1.150 (20) I681
Discharge end voltage 3 6 V specification 32.0
V 4 8 V specification 42.5
Electrolyte Sulfuric acid diluted with distilled water
Fluid t o be spplied Distilled (deionized) Water
Insulation resistance Mfl I or more
DISPLAY INDICATION
1. The display indicates the remaining battery charge
level in 1 0 stages. When the remaining charge drops
to the set level or below, the indication flashes the
warn the timing for charging.
2. When the battery is discharged fully (100 %), the

overdischarge alarm function operates as follows:
OVERDISCHARGE ALARM FUNCTION

1. Material handling with traveling becomes impossible.
If simultaneous operation is attempted, priority is
given to traveling and material handling is not ef-
fected. (For prevention of battery from damage by
large current flow)
2. When material handling is attempted, all indicators on

the display flash and the buzzer sounds to alarm over-
discharge.
Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on, how-
ever, material handling operation can be performed.
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by re-
ferring to the table below. Always use a case allowing fixation of the battery stopper.
Compartment dimensions m m (in) Minimum required

Maximum battery
Vehicle battery weight
Front t o rear weight (with case)
model Width Y Height Z (with case)
length X N (kg) [Ibl
N (kg) [Ibl
451
5FBE 10 928 (36.54) 641 (25.24) 5099 (520) I 11471 6796 (693) 115301
(17.76)
5FBE13 t t t t t
5FBE15 551 (21.69) 997 (39.25) t 6865 (700) 115451 9591 (978) [21591
5FBE18 t t f t t
5FBE20 t t f t t
f
38 mm
(1.5 in)
4
Y
-
i
TROUBLESHOOTING
Pole plate corrosion Pole plate warping and

fallen acting substance
Insufficient charge
Shorting between
service
Deposition of fallen
- acting substance in Dirty terminal or plug-
Electrolyte leakage Loosened or corroded

and decrease connections
1-5
BATTERY ASSY
REMOVAL-INSTALLATION
Removal Procedure
1 Disconnect the battery plug.
2 Remove the battery hood catch.
3 Open the battery hood.
4 Remove the battery stopper.
5 Remove the battery ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
INSPECTION
1. Electrolyte level inspection
GS battery:
Open the cap and add distilled water if the white line
on the red float is invisible. Add water until the white
line on the float appears and stop addition there be-
cause further addition until the contact between the
float and stopper results in overfilling.
YUASA battery:
Open the cap and add distilled water if the ring of the
red float is dropped. Add water until the float ring
comes into contact with the top portion.
As the level gauge is provided on the side surface of

the battery case, the electrolyte level can generally be
checked at a glance. However, periodically inspect the
level by opening the cap.
The green indicator of the level gauge is lit to indicate
activation of the level gauge sensor, and the red indi-
cator flashes to indicate the necessity of water addi-
tion.
Insufficient electrolyte
Flashing
level
Caution:
Never change the mounting position of the plug with
sensor.
Note:
The electrolyte consumption can be calculated by the following equation:
Consumption (CC) = 5 hour rating capacity x 0.0336 x number of cells x charging frequency
2. Electrolyte inspection
(1) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.
3. Inspection of electrolyte specific gravity
(1) Use a hydrometer and measure the specific gravity
of the electrolyte
Specific gravity in fully charged state:

1.280 (at 20 O C )
Specific gravity in fully discharged state:
1.150 (at 20 OC)
The specific gravity of the electrolyte is expressed
by the value at 20 O C as the standard.
Specific gravity conversion equation
,S
, = St+ 0.0007 (t-20)
:S
,, Specific gravity at 2 0 OC
St : Specific gravity at t O C
t : Temperature at the time of measurement
"How to use the hydrometer

aInsert the nozzle of the hydrometer into the wa-
ter supply port and suck the electrolyte into the
outer cylinder.
@ Let the hydrometer in the outer cylinder float
correctly without contact with the top, bottom
and side wall of the outer cylinder, and read the
graduation at the electrolyte surface as shown
at left after disappearance of bubbles in the
sucked electrolyte.
@ After the measurement wash outside and in-
side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.
Nozzle
4. Insulation resistance inspection

Use an insulation resistance meter (megger) and mea-
sure the resistance between the battery and battery
case.
Insulation resistance: 1 MQor more
Note:
If the insulation resistance is less than 1 MQ, remove
the battery from the vehicle and wash it with water.
Dry the battery case roughly, and measure the insu-
lation resistance again. Install the battery on the ve-
hicle after checking that the insulation resistance is
1 MQor more.
* Battery control table
Prepare the control table for each battery to record and retain the inspection result.
Inspection Electrolyte
Specific Added wa-
date and Inspected cell No. tempera- Remarks Inspector
gravity ter volume
time ture
CONTROL CIRCUIT
(1993.1 - 1998.8)
[FOR OTHER THAN U.S.A.]
[FOR U.S.A.] (1993.1 - 1999.1)
Page
MCS-IIIA CONTROLLER .....................
2-2
GENERAL ........................................ 2-2
SPECIFICATIONS ................................. 2-3
COMPONENTS ................................... 2-4
CONTROL PANEL REMOVAL. INSTALLATION ....... 2-9
CONTACTOR PANEL REMOVAL . INSTALLATION .... 2-10
INSPECTION .....................................2-11
DISASSEMBLY ................................... 2-29
REASSEMBLY .................................... 2-30
PANEL PARTS TIGHTENING TORQUE .............. 2-33
CONTINUITY CHECK WITH CIRCUIT TESTER ....... 2-34
OCL (OVERCURRENT LIMIT) VALUES .............. 2-35
ACCELERATION POTENTIOMETER
ADJUSTMENT ............................ 2-37
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT ............................ 2-38
PARKING BRAKE SWITCH ADJUSTMENT ..... 2-39
MATERIAL HANDLING SWITCH
ADJUSTMENT ............................ 2-40
DIRECTION SWITCH ........................ 2-41
DISASSEMBLY-INSPECTION-REASSEMBLY ........ 2-42

PS CONTROLLER ........................... 2-44
COMPONENTS ................................... 2-44
INSPECTION (STD) ............................... 2-45
REMOVAL.INSTALLATION(EHPS) ................. 2-46
EHPS CONTROLLER VOLTAGE MEASUREMENT .... 2-47
INSPECTION (EHPS) .............................. 2-48
REASSEMBLY (EHPS) ............................. 2-49
STEERING POTENT10 INSTALLATION
ADJUSTMENT ............................ 2-50
MCS-IIIA CONTROLLER
GENERAL
The 5FBE series is provided with the diagnostic (self-diagnosis) function for automatically detecting
any abnormality in the main traveling/material handling circuit, operating system such as the acceler-
ator and sensors t o sound the buzzer (bleep, bleep) and t o display the abnormal portion by the corre-
sponding error code on the multi-display.
A t the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken t o ensure safety.
When the display is set t o the analyzer (fault analysis) mode, defect detection and functional check of
the main drivelmaterial handling circuit, operating systems, and sensors are performed.
See the Multi-display section (page 3-21 for the diagnosis. See the Multi-display section (page 3-7) for
the analyzer.
Control Panel ASSY Contactor Panel ASSY

SPECIFICATIONS
Portion 5FBE10.13.15.18~20
F1 (Drive circuit) 225 A "'275 A
F2 (Pump circuit) 225 A "'275 A
Fuses F3 (PS circuit) 50 A
F4 (For lamps) 10 A
F5 (Control circuit) 10 A
T M (For drive motor) TSM003 (3 pcs.)
Transistors TMP (For material handling pump: OPT) TSM003 (2 pcs.)
TMps (For PS: OPT) ~~1MI1 0 0 ~ - 0 2 5
DAD (For drive motor) 30M F40
DAP (For material handling pump: OPT) 30M F40
DFI (DM flywheel) SR250L-6s
Diodes D F ~ (DM
R flywheel) 70M30
DF2L (PM flywheel) 70M30
DF3 (PM flywheel: OPT) 45M30
DF4 (PS flywheel) *21M1100H-025
CSD (For drive motor) HS800RT
Current
CSP (For material handling pump: OPT) HS800RT
sensor
CSps (For PS: OPT) MBP20A-10MJN
CAD (Absorber for drive motor) 60pF (2 pcs.)
Capacitors
CAP (Absorber for pump motor: OPT) 60pF (1 pcs.)
RAD (Absorber for drive motor) 1.5 R 120 W
Resistors
RAP (Absorber for pump motor) 1.5R 1 2 0 W
MFR.MFL(For forward drive) ME250
MRR.MRL(For reverse drive) ME250
Contactors
MP (For material handling) ME251
MPS(For PS) C48-A11 * 3 ~ 3 6 / 4 8 ~ 1
*' : 36V specification

**: The PS transistor and diode are integrated.
*3: UL specification (36VI48V)
COMPONENTS
Control panel
Resistor panel
Control panel Wlmaterial handling chopper (OPT)
2-7
Contactor panel
2-8
MF-MR contactor
MP contactor
CONTROL PANEL REMOVAL-INSTALLATION
1 Battery plug 4
5 Connector
6 Wiring
Removal Procedure
2 Remove the side panel LH.
3 Remove the side panel under cover.
4 Remove the control panel cover.
5 Disconnect the connector.
6 Disconnect the wiring.
7 Remove the control panel.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose,
the control panel elements may be damaged.
CONTACTOR PANEL REMOVAL.lNSTALLATlON
1 Banery plug
2 Toe board
5 Wiring
-
Removal Procedure
2 Remove the toe board.
3 Remove the side panel LH.
4 Remove the side panel under cover.
5 Disconnect the wiring.
6 Remove the contactor panel.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug.
INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.
As the CPU board and DC-SD boards require battery voltage application, they must be inspected while
being mounted on the vehicle. (Use SST 09240-1 2240-71 .)
Inspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1 Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
Measurement terminals Controller side of battery plug - Body

The resistance should be as high as possible, but it varies greatly, depending on
Standard
the vehicle use status, place and weather. (Approx. 1 MQ)
2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor)
(OPT)
(1) lnspection method
Disconnect the wiring of CAD and CAP after discharging the CAD and CAP with a resistor of
about 1 0 0 Q.
Inspection point Measurement terminals Circuit tester range

CAD (Control panel) Both terminals of CAD (DAD side - TM side)
Q X ~ K
CAP (Control panel) Both terminals of CAP (DAP side - TMP side)
Standard
When circuit tester probes are brought into contact with both terminals of CAD or CAP, the pointer deflects
once to the 0 Q side and gradually deflects toward the oo Q side.
3. T M (drive circuit main transistor).TMP (pump circuit main transistor)

Disconnect wiring from each of TM-TMP
Inspection point Measurement terminals Standard Clrcuit tester range

D: (-1 probe - S: ( + ) probe w Q
D-S
D: ( + ) probe - S: (-1 probe con
TM (control panel) D: (-1 probe - G: ( + ) probe 00 Q

D -G QXIK
TMP (control panel) D: ( + ) probe - G: (-1 probe (conduction)
G: (-) probe - S: ( + probe (conduction)
G-S
G: ( + ) probe - S: (-1 probe cx, Q
If any T M or TMP is found abnormal in inspection replace them (all TMs or all TMPs) as a set.
3- 1. DRD (Direction of Reverse Conductive Diode)
(1 lnspection method
Remove the DRD.
Inspection point Measurement terminals Standard Circuit tester range

Forward Anode: - probe - Cathode: + probe Approx. 1.6 k 0
DRD n x IK
Reverse Anode: + probe - Cathode: - probe 0352
u u
Conduction N o Conduction
4. DF1 (flywheel diode No.1)

Disconnect the wiring from DF1

(Forward)
DF1 Anode: (-) probe - Cathode: ( + probe Approx. 3 KQ
n x i ~
(control panel) (Reverse)
Anode: ( + ) probe - Cathode: (-1 probe co Q
5. DF2,-DF2, (flywheel diode No.2)
(1 ) lnspection method
Disconnect the wiring from DF2,-DF2,

(Forward)
DF2,.DF2, Anode: (-) probe - Cathode: ( + ) probe Approx. 3 KQ
0 x 1 ~
(contactor panel) (Reverse)
+
Anode: ( ) probe - Cathode: (-1 probe co fl
6. DF3 (flywheel diode No.3 in panel with pump chopper)

( 1 ) lnspection method

(Forward)
DF3 Anode: (-1 probe - Cathode: ( + 1 probe Approx. 3 Kn
n x l K
(control panel) (Reverse)
+
Anode: ( ) probe - Cathode: (-1 probe con
7. DAD (drive circuit absorber diode).DAP (pump circuit absorber diode)
Disconnect the wiring from DAD-DAP.

(Forward)
DAD
Anode: (-) probe - Cathode: ( + ) probe Approx. 6 KQ
DAP 62xIK
(Reverse)
(control panel)
Anode: ( + ) probe - Cathode: (-1 probe 00 Q
8. MFR.MFL (forward contactors).MR,.MR, (reverse contactors)-MP (material handling pump con-

tactor)
(1 Measure the coil resistance of each of MFR.MFL.MRR.MRL.MP.

(In control panel)
MFRcoil , MFRcoil connector
MFL coil MFL coil connector Approx. 20 Q
Q x l
MRRcoil MRRcoil connector (at 20°C)
MRL coil MRL coil connector
MP coil MP coil connector
9. RAD (drive circuit absorber resistor)-RAP (pump circuit absorber resistor)
(1 ) lnsepction method
Battery removal
Disconnect the wiring from RAD-RAP (RAD: CN 1 18-RAP: CN 1 1 9).

RAD
Both terminals of RAD-RAP Approx. 1.5 62 62x1
RAP
When inspecting with the battery installed, disconnect the CN1 17 connector.

RAD: CN117-2- CN117-3
RAD
RAP: Approx. 1.5 62 62x1
RAP
CN 1 1 7-1 - Controller P I I terminal
CN 1 17 (Main harness side)

10. CPU board-DC-SD board
If the trouble cause is judged to be in the CPU board or DC-SD board, apply the battery voltage,
install SST09240-12240-71, and measure the applied voltage and resistance at each connector.
Caution:
Always disconnect the battery plug before removing or installing the CPU board or DC-SD board.
Note:
When replacing the CPU board or DC-SD board judged to be causing the trouble as a result of trou-
bleshooting, always measure the applied voltage and resistance at related portions before replace-
ment.
Use SST 09240-12240-71 for the measurement.
(1) SST connection method

@ Turn the key switch to OFF.
@ Disconnect the battery plug.
@ Disconnect the CPU board-DC-SD board connectors (CN101 to CN 107.CN11 1 .CN1 12).
@) Connect the SST.
Inspection side connector
CN107
(2) Lists of measurement methods and standards
@ Explanation on list format
+
r Circuit tester ( probe
Circuit tester (-1 probe
Connector pin No.
1
Connector No.
CN102-1
- Connector No.
CN102-9
1
SWKy: ON
Conditions Standard Remarks
(43, K36 V) (N,,GND) SW

:, OFF
C
I A
Signal (part) name
C
-conditions for measurement
L ~ e v eNo.
l
@ Lists
C N 101 connector Basic conditions (battery plug ON.SWKy ON)
Connector No. * Connector No. Conditions Standard Remarks

CNIOI-I I Unused
CN101-2
CN101-3 I CN101-20
Approx. 18 3V
(15,+30V) I (N1,GND)
I
CN101-4 I CN101-20
Approx. 18 3V
(15,+30V) I (N1,GND)
Unused &
CN101-5 I CN101-20 SWKy ON Approx. 4 8 Vl36 V Voltage after

(10, C36 V) I (NI, GND) SW, OFF OV key switch
CN101-6 I
I
(32, CHOPD + ) I
CN101-20
(NI, GND)
5 * 0.25 V
CN101-7 I CN101-20
5 * 0.25 V
(30,VDD+) (N1,GND)
CN101-8 I CN101-20
Unused - 5V - -6 V
( ,- 5V) I (N1,GND)
CN101-9 I CN101-20 SWKy ON Approx. 4 8 Vl36 V Voltage after
(14, VBKY) I IN1, GND) SW, OFF OV key switch
CN101-11 CN101-20 SW, ON Approx. 4 8 Vl36 V Voltage after
(43, K36 V) I (N1, GND) SW, OFF 0V key switch
CN101-12
Unused
CN101-13 I
-
CN101-14 I CN101-20
I ov
(11, GND) I (NI, GND)
CN101-15 I Unused
CN101-16 CN101-20
(11,GND) I (N1,GND)
ov
CN101-17 I CN101-20
Traveling stop state 4 - 5 V
(33, CHOPD-) I (Nl, GND)
I
CN101-18 I CN101-20
(31, VDD-1 I (NI, GND)
Traveling stop state 4 - 5V
CN101-19 I Unused
CN101-20 Panel N1 Battery plug OFF
(N1, GND) I terminal SW, OFF
on
CN101-21 I CN101-20
Approx. 48 Vl36 V
(13,VBBT) I (N1,GND)
I
CN101-22 I CN101-20
(41, 836 V ) I ( N l , GND)
Approx. 48 Vl36 V Battery voltage
CN102 connector: Basic conditions (Battery plug ON.SWKy ON)

CN102-1 j CN102-9 SWKy ON Approx. 4 8 V l 3 6 V Voltage after
(43, K36 V) I ( N l , GND) SW, OFF OV key switch
CN102-2 1 CN102-9
(41, 836 V I j (N1, GND)
Approx. 4 8 V l 3 6 V Battery voltage
CN102-3 1 Unused
I
I 4 8 V vehicle:
CN102-4 CN102-9 43f 5V
(P8,RCKl) I (N1,GND) 36 V vehicle:
I
I 32f 5V
CN102-5 I CN102-9
(P9,RCKl) I (N1,GND)
Approx. 48 Vl36 V
CN102-6 I CN102-9
ov
(N2, TMS) I (NI, GND)
I
CN102-7 I CN102-9
I Unused Approx. 48 Vl36 V Battery voltage
(41, B36 V ) I (N1, GND)
CN102-8 I CN102-9
(41, D36 V) I ( N l , GND)
Approx. 4 8 Vl36 V Battery voltage
Connector No. o Connector No. Conditions Standard Remarks
on
(NI, GND) terminal SW, OFF
CN102-10 Unused
I 48 V vehicle:
I
CN102-11 I CN102-9 43* 5V
(P8, TMD) (N1, GND) 3 6 V vehicle:
I
I
32 *
5V
CN102-12 I CN102-9
Traveling stop state -5 - - 6V
(92, TMG) I ( N l , GND)
Connector No. ++ Connector No. Conditions Standard Remarks

CN103-1 CN103-3
(35, VDP+) I (11, GND)
5 * 0.25 V
CN103-2 CN103-3
(37, CHOPP +) I (11, GND)
5 * 0.25 V + 5V
I
CN103-3 I Panel N1
(11, GND) I terminal
Battery plug OFF.SWKy OFF on
CN103-4 CN103-3 SW, ON Approx. 4 8 Vl36 V Voltage after
(10, C36V) I (11, GND) SW, OFF OV key switch
CN103-5 I CN103-3
Approx. 1 8 3 V
(15, +30V) I (11, GND)
I
CN103-6 I CN103-3
(30, VDD + 1 (11, GND)
5 * 0.25 V
CN103-7 I CN103-3
*
5 0.25 V
(32, CHOPD + ) 1, GND)
(I
CN103-8 I CN103-3
ov
(11, GND) I (11, GND)
I
CN103-9 I CN103-3
(36, VDP-) I (11, GND)
Material handling stop state 4- 5V
CN103-10 I CN103-3
4- 5v
(38, CHOPP-) I (11, GND)
CN103-11 I CN103-3
ov
(11, GND) I (11, GND)
CN103-12 CN103-3
(13, VBBT) I (1 1, GND)
Approx. 4 8 Vl36 V
CN103-13 CN103-3 SW, ON Approx. 48 Vl36 V

(14,VBKY) I (11,GND) SWKyOFF OV
CN103-14 CN103-3
Traveling stop state 4- 5V
(31, VDD-1 I (11, GND)
I
CN103-15 I CN103-3
(33, CHOPD-1 I (I
I,GND)
4- 5v
I
CN103-16 I
Unused
(11,GND) I

I
Battery plug OFF.SWKy OFF
CN104-1 CN104-14 MFR
(41MFR) I (Ir+ )
Measure with the tester negative
probe connected to CN104-14.
Approx. 20 Q
contactor
I
CN104-1 I CN104-8 Measure with the tester positive

(4, MFR) 1 (74, CSD -1 probe connected to CN104-1.
Approx. 46 Vl35 V MFRcoil
I
CN104-2 I CN104-14
Measure with the tester negative Approx. 20 Q MRR
15' MRR) j (I'
probe connected to CN104-1 4.
contactor
I
(5, MRR) 1 (74, CSD -1 probe connected to CN104-2.
Approx. 46 Vl35 V MRRcoil
I
CN104-3 CN104-14
Measure with the tester negative Approx. 20 Q MFLcontactor
(2' MFL) II (I
' + )
1
(2, MFL) 1 (74, CSD-1 probe connected to CN104-3.
Approx. 46 Vl35 V MFL coil
I
CN104-4 I CN104-14
Measure with the tester negative Approx. 20 Q MRL cotactor
13' MRL) I (I
' +)
CN104-4 CN104-8 Measure with the tester positive
(3, MRL) 1 (74, CSD-1 probe connected to CN104-4.
Approx. 46 Vl35 V MRL coil
I Battery plug OFF.SWKy OFF
CN104-5 CN104-15
Measure with the tester negative Approx. 20 Q MP contactor
(7,MP) I (I,M+)
7
I probe connected to CN104-1 5.
CN104-5 CN104-8 Measure with the tester positive
Approx. 46 Vl35 V MP coil
(7, MP) f (74, CSD-) probe connected to CN104-5.
CN104-6 CN104-8
(75, STH) 1 (74, CSD-)
5 f 0.25 V + 5V
CN104-8 I Panel N1
Battery plug OFF.SWKy OFF On
(74, CSD-) terminal
CN104-9 I CN104-8
Traveling stop state Approx. 1.2 V
(71, CSD) I (74, CSD - 1
I
CN104-10 I CN104-8
+12V
(73, CSD + I 1 (74, CSD -
1 2 f 0.6 V
CN104-11 I CN104-8
Approx. 4 8 V l 3 6 V
(P2, VBP2) 1 (74, CSD-)
I Battery plug OFF.SWKy OFF
~ ~ 1 0 4 - 1 I2 ~~104-13 Approx. I 10n
Measure with the tester negative Mps contactor
(6' Mps) (I (USA spec..: 68 n)
probe connected to N 104-13.
+
CN104-1 2 I CN104-8 Measure with the tester negative

Approx. 4 6 Vl35 V Mps coil
(6, Mps) 1 (74, CSD -) probe connected to CN104-1 2.
CNl04-13 I CN104-8
(I,M+) 1 (74,CSD-)
Approx. 4 6 Vl35 V
CN104-14 CN104-8
(1, M + ) 1 (74, CSD-)
CN104-15 I CN104-8
(1, M + ) I (74, CSD-)
I
CN104-16 I C N l 0 4 -8 Greater than 0 V and
(76, STHl 1 (74, CSD-) smaller than 5 V
CN1 04-1 7 I CN104-8 Traveling and material handling stop
Approx. 4 8 Vl36 V
(P9, VBP9) 1 (74, CSD-) state
CN104-18 I CN104-8
ov
(74, CSP-) 1 (74, CSD-)
CN104-19 I CN104-8
(72, CSP) 1 (74, CSD-)
Material handling stop state Approx. 1.2 V
CN104-20 I CN104-8
1.2* 0.6 V + 12 V
(73, CSP )+ 1 (74, CSD -)
CN105 Connector: Basic conditions (Battery plug ON.SWKy ON)

CN105-1 CN105-10 LSLOFF *
5 0.25 V
(60, LS,) I (1 I,GND) LS, ON OV
5 *0.25 V
I
CN105-2 I CN105-10 LSL2OFF
(68, LSL21 I (1I,GND) LSL2ON OV
Connector No.
CN105-3
-
I
I
Connector No.
CN105-10 LSTOFF
Conditions Standard
5 f 0.25 V
Remarks
(61, LS,) I (11, GND) LS, ON OV

CN105-4 I Unused
I
CN105-5 I Unused
CN105-6 I CN105-10 LSATTl ON 5 f 0.25 V
(63, LSATT1) ] (1 1, GND) LSArrl OFF OV
CN105-8 CN105-10
Approx. 5 V
(55, VRSP + I (1 1, GND)
CN105-9
(56, VRSP) I
CN105-10
(1 1, GND)
Approx. 0.9 - 3.9 V
CN105-10 Panel N 1 Battery plug OFF
on
(11, GND) I terminal SW, OFF
CN105-11 I Unused
CN105-12 I Unused
-
C N 1 0 6 Connector: Basic conditions (Battery plug ON.SWKy ON)
Connector No. Connector No. Conditions Standard Remarks

I
CN106-1 I CN106-2
I Traveling stop state OV
- (82, SSR) 1 (81, SSR)
CN106-2 CN106-1
Traveling stop state OV
(81, SSR) 1 (82, SS,)
CN106-3 CN106-4
Traveling stop state OV
(84, SSL) I (83, SSL)
I
CN106-4 I CN106-3
I Traveling stop state OV
(83. SSL) 1 (84, SSL)
CN106-5 CN106-13 DSFOFF 5 f 0.25V
(45, DSF) 1 (51, GND) DSF ON OV
CN106-6 CN106-13 DSROFF 5f0.25 V
(46, DSR) I (51, GND) DSRON OV
I
CN106-7 I CN106-13 SWAc OFF 550.25 V
(64, SWAc) 1 (51, GND) SWAc ON OV
CN106-8 I CN106-13
3 - 5 v
(53, VRAD + 1 (51, GND)
CN106-9 CN106-13
( , OPTl) 1 (51, GND)
I
I 4 8 V vehicle:
CN106-10 I CN106-1 3 Traveling and material handling stop 43 f 5V
(P6, VBP6) 1 (51, GND) state 36 V vehicle:
I
I 32 f 5V
I
I 4 8 V vehicle:
CN106-1 1 I CN106-1 3 Traveling and material handling stop 43f 5V
(P61,VBP61) 1 (51,GND) state 3 6 V vehicle:
I
I 32f 5V
CNlO6-12 I CNlO6-13 LSD OFF 5 * 0.25 V
(67, LSD) 1 (51, GND) LSD ON OV
(51, GND) I terminal SW, OFF
on
CN106-14 CN106-13
(51, GND) (51, GNDl
ov
CN106-15 I CNlO6-13 SWscOFF 5 f 0.25 V
(77, SWsc) 1 (51, GND) SWsc ON OV
CN106-16 I CN106-13 SWpBOFF 5 f 0.25 V
I
(66, SWpB) 1 (51, GND) SWpB ON OV
CN106-17 CN106-13 LSB OFF OV
(65,LSs) 1 (51,GND) LSBON 5 f 0.25 V
CN106-18 I CN106-13 Shall vary smoothly according t o the
(52, VRAD) 1 (51, GND) traveling acceleration state.

CN107-1 CN1 07-6
0 - 1 v
(141, SMTDA) (17, GND)
CN107-2 Cannot be measured with a circuit
(142, SDTMA) tester
CN107-3 CN107-6 Approx. 4 8 Vl36 V
Unused
( , VBKY) (17, GND) OV
CN107-4 CN107-6
(144, SMTDK)
ov
(17, GND)
CN107-5 Cannot be measured with a circuit
(143, SDTMK) tester
CN1 07-6 Panel N1 Battery plug OFF
(17, GND) terminal
ov
SW, OFF
CN107-7 Unused
CN107-8 CN107-6
(16, +30V) (17, GND)
18 *3V
2-26
-
CN 1 1 1 connector: Basic conditions (Battery plug ON.SWKyON)

CN111-1
Unused
- CN111-2 I
CNlll-3 I CN111-20
Unused Approx. 1 8 +3V
(15,+30V) I (N1,GND)
I
CN111-4 I CN111-20
(15, + 3 0 V) / (NI, GND)
Unused Approx. 1 8 & 3V
CNlll-5 I CNlll-20
Unused
Approx. 4 8 Vl36 V
(10, C36 V ) 1 (NI, GND) OV
CNlll-6 / CNlll-20
5 * 0.25 V
(37, CHOPP + I (N1, GND)
I
5 * 0.25 V
CN111-7 I CN111-20
(35,VDP+) (N1,GND)
CNlll-8 I CNlll-20
Unused - 5V - - 6V
(,-5V) I (N1,GND)
CN111-9 I CN111-20 Approx. 4 8 V l 3 6 V
Unused
(14, VBKY) / (NI, GND) ov
CN111-10 I Unused
CN111-11 CN111-20 SWKyON Approx. 4 8 Vl36 V
(43, K36 V) / (NI, GND) SW, OFF OV
CNIII-I2
CN111-13
/
I
Unused
I
CN111-14 I CN111-20
(11, GND) / ( N l , GND)
Unused OV
CN111-15 Unused
CNlll-16 CNlll-20
Unused OV
(11,GND) f (N1,GND)
CNlll-17 I CNlll-20
Material handling stop state 4 - 5 V
(38, CHOPP-) I (NI, GND)
CNlll-18 CN111-20
(36, VDP-1 I (NI, GND)
Material handling stop state 4 - 5 V
CNlll-19 Unused
CN1 1 1-20 Panel N 1 Battery plug OFF
on
(N1, GND) 1 terminal SW,, OFF
CN111-21 I CNlll-20
Unused Approx. 48 Vl36 V
(13, VBBT) I (NI, GND)
I
CNlll-22 I CN111-20 Battery
Approx. 48 V136 V
(41, B36 V) I (N1, GND) voltage

CN112-1 I CN112-9 Approx. 4 8 Vl36 V
(43, K36 V ) I (NI, GND)
Unused
ov
CN112-2 1 CN112-9
Unused Approx. 48 V l 3 6 V
(41, B36 V) I (N1, GND)
CN102-3 I Unused
I 4 8 V vehicle:
CN112-4 I CN112-9 27f 5V
IP14,RCKP) I IN1,GNDl 3 6 V vehicle:
I 20f 5V
II
CN112-5 I CN112-9
(PI 5, RCK2) I (Nl, GND)
Approx. 4 8 V136V
CN112-6 I CN112-9
ov
(N2, TMPS) (NI, GND)
CN112-7 I CN112-9
Unused Approx. 4 8 Vl36V
(41, 8 3 6 V) (N1, GND)
I
CN112-8 1 CN112-9
Approx. 4 8 Vl36V
(41, D36 V) 1 (NI, GND)
Unused
CN112-9 PanelN1
Unused Conduction
(NI, GND) I terminal
CN112-10 I Unused
CN112-11
(P14,TMPD) I
CN112-9
(N1,GND)
10 - 25V
- 5 - - 6V
CN 2-1 CN1 2-9
(93, TMPG) I (N1, GND)
Material handling stop state
11. Display
If the cause of a trouble is judged to exist in the display, apply the battery voltage and measure
the voltage at the connector.
CN 1 20 connector basic condition (battery plug ON)

CN120-9 I CN 120-19
Approx. 18 =t3 V
(16, + 3 0 V ) 1 (17, GND)
CN 120-10 CN 120-20
Approx. 4 8 V
(104, BL) I ( N I , GND)
DISASSEMBLY
The control panel is overhauled infrequently. Defective part replacement according to the cause of the
trouble by inspection is performed in most cases. Please perform correct operation by referring to the
component parts drawing, assembly drawing and internal connection diagram.
Cautions for Parts Replacement

Tighten the bar and harness set nuts and screws to the specified torques.
Looseness or insufficient tightening will cause other troubles.
When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indi-
cating the mounting position. At the time of reassembly, prevent incorrect installation or wiring by
referring to the memo or tag. Incorrect installation or wrong wiring will cause other troubles.
Always coat silicone grease on parts which have been coated with silicone grease. Omission of
coating may cause overheating.
After reassembly, check no contact of the bars and cables at other than the contact portions. Before
installation on the vehicle, check continuity at points with a circuit tester. (See page 2-34 for the
inspection points with the circuit tester.)
2-30
REASSEMBLY
Control panel assembly drawing (STD)
DAD (B) CAD ( B )
(Y
P7
CSD
P2
DF 1
N1 TMD
DCISD b
Control panel assembly drawing (with pump chopper)
DAD (B) CAD (B) CAP (L) DF3
(Y)
P7
CSD
P2
DF 1
v
N1 TMD P I 3 P 1 2 CSP TMP D'AP
CNlOO CN1 15 CN1 17
T?!AiF?d
DClSD board
DCISD b
2-32
Contactor panel assembly drawing

PANEL PARTS TIGHTENING TORQUE
(Control panel)
ltem Tightening torque N.m (kgf-cm) [ft-lbfl
Main terminals
M5 2.16 - 2.75 (22 - 28) 11.59 - 2.031
TM-TMP M4 1.18 - 1.77 (12 - 18) 10.87 - 1.301
For installation M5 2.16 - 2.75 (22 - 28) [ I.59 - 2.031
Main terminals M6 3.14 - 3.73 (32 - 38) i2.32 - 2.751
5.10 - 5.69 (52 - 58) i3.76 - 4.201
DF1
For installation M6
Main terminals M6 2.1 6 - 2.75 (22 - 28) [ I.59 - 2.031
13.44 - 14.02 (137 - 143) 19.91 - 10.351
DF3
For installation MI2
DAD-DAP For installation M6 2.16 - 2.75 (22 - 28) f1.59 - 2.031
Heat sink For installation M5 2.13 - 2.75 (22 - 28) 11.59 - 2.031
Terminal set nuts for external connection M8 7.85 - 11.77 (80 - 120) l5.79 - 8.681
(Contactor panel)

Main terminals M6 2.16 - 2.75 (22 - 28) [1.59 - 2.031
21.28 - 21.87 (217 - 223) [15.70 - 16.131
DF2,-DF2,
For installation M 20
MFL.MFR Main terminals M8 7.85 - 11.77 (80 - 120) 15.79 - 8.681
MRL.MRR
MP For installation M5 2.13 - 2.75 (22 - 28) l1.59 - 2.031
Heat sink For installation M5 2.13 - 2.75 (22 - 28) [1.59 - 2.031
Terminal set nuts for external connection M8 7.85 - 1 1.77 (80 - 120) [5.79 - 8.681
(For power steering)
Item Tightening torque N.m (kgf-cm) [ft-lbfl

Main terminals M5 1.96 - 2.94 (20 - 30) [ I.45 - 2.171
1.96 - 2.94 (20 - 30) 11.45 - 2.1 71
TMPS
For installation M5
CONTINUITY CHECK WITH CIRCUIT TESTER
Control panel (STD) Control panel (Wlchopper)
Contactor panel
Inspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe
Inspection points Standard Circuit tester

P2: + probe - N1: - probe Approx. 1 0 to 2 5 Q
Q xlK
Between P2 and N 1
P2: - probe - N1: + probe *an
P12: + probe - N l : - probe Approx. 1 0 t o 2 5 62
Q x 1K
Between P 1 2 and N 1
P I 2: - probe - N 1: + probe *an
Tester probes may be used in either
Between P2 and frame a0 Q ax IK
direction.
Between N1 and Tester probes may be used in either
a Q Q x 1K
frame direction.
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects t o 0 Q and returns t o 00 Q then.
OCL (OVERCURRENT LIMIT) VALUES
1. Drive circuit OCL value measurement
(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Standard OCL value:
48 V vehicle: 460
3 6 V vehicle: 6 10
;+*: 6 0A A
Ammeter:
5 0 mV, 7 5 0 A
Shunt:
5 0 mV, 7 5 0 A
(2) Judgment method If the measured OCL value is not within the standard range, the current sen-
sor (CS) or CPU board may be defective. Make judgment as follows:
@ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
@ Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON.SWKy ON
Measurement terminals: CN104(9)71 @ - CN104(8) 74 @
Standard: Approx. 1.2V
* Use a digital voltmeter for measurement.
@ Operate the accelerator t o set the speed t o approx. 8 kmlh ( 5 milelh). Read the ammeter
and measure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN104(9)71 @ - CN 104(8)74 @
* Use a digital voltmeter for measurement.
@ Calculation
Measured value C - measured value B = D
Convert the calculated value D according t o the following equation. (Converted value: E)
1V = 100A
@ Judgment
Compare converted value E with measured value A in step @.
*
The current sensor can be judged normal if the result is within 5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.
Pump circuit OCL value measurement
The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.
As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.
ACCELERATION POTENTIOMETER
ADJUSTMENT
Make adjustment in the state of acceleration potentiometer
wlfront toe board.
1. Operate the accelerator pedal and check if the acceler-

ation switch is turned ON and OFF.
Measurement terminals: 51 and 64
Standard
When the pedal is not depressed: co
When the pedal is depressed: 0 S2
2. Acceleration potentiometer installation adjustment

(1) Insert a 1.5 mm (0.06 in) thickness gauge between
the accelerator link stopper and accelerator bracket.
(2) Temporarily install the potentiometer so that the
switch (SW), is set to ON.
(3) Inspect the switch (SW), ON and OFF changeover
points.
When 1.0 mm (0.04 in) thickness gauge is inserted:
OFF
When 2.0 mm (0.08 in) thickness gauge is inserted:
T = 1.57-2.35 N.m
ON
Set screw (4) After the end of switch ONmOFF adjustment, fully
tighten the set screws.
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT
1. Adjust protrusion (A) of the brake switch (LS,) and
stop lamp switch (LS,).
A = 26 m m (1.02 in)
2 After installing LS, and L,S

,, check ON and OFF.
(1) Operate the brake pedal and check conduction at
each switch connector.
Standards
Switch Not operated Operated

LSS on n
00
LSST a0 n on
(2) Adjust each switch ONIOFF timing when the brake

pedal is operated. Make adjustment by turning the
adjusting bolt so that each switch is operated when
the brake pedal is depressed by dimension B in the
figure from the free state.
10 mm (0.39 in.)
Switch
on-an
an- on
2-39
PARKING BRAKE SWITCH ADJUSTMENT

1. Inspect parking brake switch (SW,,) ONIOFF.
Standard
Lever state Returned Pulled

SWPB on con
Adjust the SW, installation state.

(1) Return the lever fully to the stroke end.
(2) With the limit switch pushed to its stroke end to-
ward the lever side, fix the switch by tightening the
switch bracket set bolts 1 and limit switch set
screws 2 .
MATERIAL HANDLING SWITCH
ADJUSTMENT
1. Adjustment the switch (LS,,-LS,) ON timing when the
control lever is operated.
(1) Adjust LS, .LS, roller protrusion (A).
Dimension A is a reference value for reassembly.
A = 26 mm (1.02 in)
(2) The switch shall be turned ON at dimension A at the

tip end of the control lever.
Standard
B= 5 - 20 mm (0.20 - 0.79 in)
If the standard is not satisfied, make adjustment by
changing the roller protrusion and mounting position.
1 When pump chopper (OPT) is provided:
2. Adjust the pump chopper switch (LS,) ON timing.

(1) Adjust LS, roller protrusion (C).
C = 26 mm (1.02 in)
10-15mm (2) Adjust by turning the adjusting bolt so that the

switch (LS,) is turned on when the lift lever is
fulled to 1 0 - 15 mm (0.39 - 0.59 in) before its
stroke end.
Stroke end
DIRECTION SWITCH
Removal Procedure
1 Remove the steering rear cover.
2 Disconnect the direction switch connector.
3 Remove the steering tilt lever.
4 Remove the steering front cover and display.
5 Remove the direction switch.
1 Remove the plate.
2 Remove the micro switch base.
3 Remove the microswitch Wlwire harness. [Point 11
4 Remove the cam roller and spring.
5 Remove the direction lever Wlknob.
6 Remove the cam.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operation
[Point 11
Reassembly: Install the microswitches in the correct posi-
tions.
Reassembly: When replacing a microswitch, connect the

cables according t o the cable colors in the fig-
ure.
Inspection: After assembling the direction switch, check

conduction of each microswitch before install-
ing the direction switch.
PS CONTROLLER
COMPONENTS
STD (Mpscontactor: The Mpscontactor is installed on the PS motor.)
EHPS
INSPECTION (STD)
1. P22-N 1 voltage measurement
Battery plug ON.SWKyON
Measurement terminals P22 - N1

Circuit tester range DC 5 0
Standard Battery voltage
As seen from the motor
2. Mps contactor coil conduction measurement

Battery plug OFF.SWKyOFF
Measurement terminals Both terminals of connector (CN42) of Mps Contactor

Circuit tester range Q x l
Standard Approx. 1 1 0 Q (at 20°C (68OF))
REMOVAL.INSTALLATION (EHPS)
1 Battery plug
Removal Procedure
2 Remove the side panel.
3 Remove the toe board.
4 Disconnect the wiring connectors.
5 Remove the PS controller.
EHPS CONTROLLER VOLTAGE MEASUREMENT
When the cause of a trouble is judged t o exist in the EHPS controller, measure the battery voltage and
measure the voltage and conduction at the EHPS controller connector.
Measure the battery voltage at the terminal in the PS cont-

C27 loller. (See the illustration.)
Battery plug ON
P21 (TMps C 1 terminal) -N 1 (CS, N 1 terminal)
SW, ON: Battery voltage
SW, OFF: 0 V
P22 (TMps C2E1 terminal)- N1 (CS, N1 terminal)
SW, ON
When the steering wheel is operated: Approx. 0 V
(C2E1 terminal)
When the steering wheel is not operated: Battery
voltage
CN27
No. Connected circuit Potential

1 Key switch (SW), 43
2 Steering pressure sensor (SSP) 162
4 Display (DISP) 151
Measurement terminals
-
CN27 Connector Basic conditions (Battery plug ON.SWKy ON)

I
When the steering wheel is op-
CN27-2 ,
I
I CN27-5 erated 10 V or more
(162, SSP) I (163, SSP) When the steering wheel is not 2 V or less
I operated
I
CN27-3 I
I CN27-5 SW:, ON 12 * 0.8V
(161,SSP) 1 (163,SSP) SW
:, OFF OV
CN27-4 I CN27-5 SWKy: ON OV
I
(151,DISP) 1 (163,SSP) SW
:, OFF 5V
I
CN27-1 I Terminal SW
:, ON Battery voltage
(43, SWKy) II CSps N1 SWKy: OFF OV
INSPECTION (EHPS)
1. TMps
Disconnect the wiring from TMps.

Between C2E1 C2E1: - probe - E2: + probe Q
cs,
and E2 C2E1: + probe - E2: - probe Conduction

TMPS QXIK
Between G2: - probe - E2: + probe con
G2 and E2 G2: +probe - E2: - probe co a
Forward:
C2E1: - probe - C1: + probe Conduction
DF4 QXIK
Reverse:
C2E1: + probe - C1: - probe co fl
Note:
When shifting to check C2E1-E2 from G2-E2 short connect G2-E2 to avoid the possibility of conti-
nuity on both directions.
Never touch to 6 2 terminal with a naked hand.
REASSEMBLY (EHPS)
EHPS Control Panel Part Tightening Torques

Main terminals M5 1.96 - 2.94 (20 - 30) 11.45 - 2.171
TMPS
Set screw M5 1.96 - 2.94 (20 - 30) [ I.45 - 2.171
Cover M5 1.96 - 2.94 (20 - 30) [ I.45 - 2.171
Harness M4 1.27 - 1.67 (13 - 17) [0.94 - 1.231
Shunt resistor (CSps) M3 0.49 - 0.88 (5 - 9) 10.36 - 0.651
STEERING POTENT10 INSTALLATION ADJUSTMENT
1. Jack up the vehicle and support the frame at the front and rear with wooden blocks.
2. Install the steering potentio (VRSP) as illustrated below.

Note:
When fitting the potentio bolt on the potentio plate, fix the potentio plate with a vise or spanner.
Bring the tip end of the potentio bolt into contact with the flat face of the potentio shaft.
Carefully operate so as not to pry the potentio shaft.
T=N.m (kgf-cm)[ft-lbfl
T = 1.47 - 2.94
(15 - 30)
11.09 -
2.171
Steering potentio I
. in)
13.98 - 5.061
Potentio bolt
3. Adjust the steering sensor neutral position.

(1 Set the battery plug to ON and key switch to ON.
(2) Set the analyzer mode on the display and select test operation mode in category 1, subcategory
2. (See page 3-9 for how to use the analyzer.)
(3) Release the parking brake. Set the direction lever to the forward position and operate the steer-
ing wheel to set the rear wheel to the straight traveling position (neutral position).
(4) Pull the parking brake and return the direction lever to the neutral position.
Indicator mark
(5) Operate the up or down switch on the display to se-
lect monitor code No.7 (steering potentiometer volt-
age).
If the parking brake indicator mark comes on when
I 1
- monitor code No.7 is selected, it means the correct
tc neutral position. The adjustment in step (6) below is

unnecessary.
[,r 2.3\,1,
/ \ )
Monitor No. Potentio voltage
(6) Loosen the steering potentio set screw, and grad-

Front ually turn the potentio body clockwise or counter-
clockwise until the indicator mark comes on.
t Then, tighten the potentio set screw.
I
Turn the potentio clockwise to increase the po-
tentio voltage.
Turn the potentio counterclockwise to decrease
the potentio voltage.
Steering potentio
Note:
The indicator mark comes on when the potentio voltage is
in a range between 2.3 V and 2.4 V.
First, determine the potentio position for a potentio voltage
of 2.3 V. Then turn the potentio slowly clockwise to search
the indicator mark lighting position.
(7) Turn the steering wheel slowly clockwise and

counterclockwise and confirm the following con-
trols are performed.
Forward rotation control, single wheel rotation
control and reverse rotation control.
CONTROLLER
[FOR OTHER THAN U.S.A.] (1998.9 - 1
[FOR UL. U.S.A.. CANADA] (1999.2 - )
Page
OPERATION
GENERAL . . .. . . . . .. . . . . . . ... . . . . . . .. . .. . . . . . . . 2A-2
SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . 2A-2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3
MAJOR FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-5
MAIN CIRCUIT COMPONENTS . . . . . . . . . . . . . . . . . . 2A-8
DRIVE CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . 2A-13
MATERIAL HANDLING CIRCUIT OPERATION . . . . . 2A-17
REPAIR
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-19
COMPONENTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-20
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-25
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-35
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-36
PANEL PARTS TIGHTENING TORQUE . . . . . . . 2A-39
CONTINUITY CHECK WITH CIRCUIT TESTER . ... 2A-39
OCL (OVERCURRENT LIMIT) VALUES .... . . . . . . . 2A-40
For the follwing matters, see chapter 2

(CONTROL CIRCUIT)
CONTROL PANEL REMOVAL.INSTALLATI0N
CONTACTOR PANEL REMOVAL-INSTALLATION
DISPLAY INSPECTION
ACCELERATION POTENTIOMETER ADJUSTMENT
BRAKE SWITCH.STOP LAMP SWITCH ADJUSTMENT
PARKING BRAKE SWITCH ADJUSTMENT
MATERIAL HANDLING SWITCH ADJUSTMENT
DIRECTION SWITCH
PS CONTROLLER
STEERING POTENT10 INSTALLATION ADJUSTMENT
GENERAL
1. A controller (MCS-IIIA) making full use of the most advanced electronics technologies, such as
multifunctional control by the microcomputer and communication with the digital multi-display,
is adopted in this series.
2. For the control element, a power MOS FET (metal-oxide semiconductor field-effect-transistor)
has replaced the SIT (static induction transistor) that have been used i n the previous models.
Modification has been put into effect from the following frame Nos:
Model Frame No.
5FBE10.13 From 12903
5FBE15.18 From 26973
5FBE20 From 10976
SYSTEM CONFIGURATION
Communication
data
Digital
multi-display
- Key switch
..r Direction switch
MCS-IIIA Acceleration sensor
Brake switch
L
Vehicle speed sensor
Material handling switch
System Configuration
1. Communication between MCS-IUA and Digital Multi-display

Each of the MCS-III and digital multi-display is mounted with the CPU for communication of each
control date. The transferred data is checked to prevent error data transfer caused by a fault in the
signal transmission line or electromagnetic interference.
(1 Vehicle speed data for vehicle speed display (MCS-IIIA + Multi-display)
(2) Each power control tuning set data (Multi-display += MCS-IIIA)
(3) Diagnostic error code (MCS-IIIA += Muiti-display)
(4) Analyzer test item and test result (MCS-IIIA S Multi-display)
(5) Remaining battery charge display data (MCS-IIIA + Multi-display)
(6) MCS-IIIA control specification selection data (Multi-display += MCS-IIIA)
DESCRIPTION
Internal Configuration of MCS-IIIA
1 CPU board
: Material handling chopper (OPT)
I _ _ _ _ _ _ _ _ _ _
CPU : Central Processing Unit

ROM : Read Only Memory
I f 0 : InputfOutput
2A-4
Panel Structure
A: Contactor panel B Control panel

Drive contactor Drive main circuit
Material handling contactor CPU board
F1 fuse Material handling main circuit
F2 fuse
F3 fuse
DF2 * : OPT
C Under battery case
Resistor panel (resistor RA)

Though replacement of the resistor panel requires battery unloading, resistor panel inspection
does not require battery unloading as the resistance value can be checked at the harness on the
control panel side.
MAJOR FUNCTIONS
1. Inner wheel forwardlreverse rotation control [dual motor control]
Forced reverse rotation control is provided to ensure the motor driving force at the time of turn-
ing. The range of forwardlreverse rotation has been reviewed to reduce the shock at the time of
forward-reverse changeover. The range is restricted as the inner wheel is locked as the center of
rotation approaches the center of the inner wheel to overload the inner wheel motor if the forced
forward/reverse rotation control is performed in the whole range.
Vehicle model Forward rotation range Reverse rotation range
All models 0 - 40" 80 - 90"
2. Drive power control function (Standard)
The acceleration force can be adjusted in 8 levels by the switch panel on the digital multi-display.
3. Traveling speed selection in 2 stages (Standard)

The maximum traveling speed can be restricted by the speed control switch operation. The limit
speed can be set by switch panel operation on the digital multi-display.
Setting level 1 2 3 4 5 6 7 8
Maximum speed setting (kmlh) 5+1 6fl 7+1 8+1 9+1 10f1 11f1 12+1
Maximum speed setting (mph) 3.2k0.6 3.8k0.6 4.4f0.6 5.0k0.6 5.6f0.6 6.2f0.6 6.8k0.6 7.5k0.6
4. Thermal protector (Standard)

The temperature sensor installed in the drive controller panel detects the main circuit temperature.
When it reaches the set level, it is displayed on the digital multi-display for warning the operator
and the controller output is restricted.
5. Remaining battery charge calculating function (Standard)

The voltage drop resulting from battery discharge is detected and calculated by the controller, and
the remaining battery charge level is displayed on the digital multi-display.
6. Parking brake application failure warning (Standard)

If the deadman switch is turned off when the parking lever is not pulled, warning display occurs on
the digital multi-display. (Valid only in the vehicle with deadman switch)
7. Diagnostic function (with memory) (Standard)

The self-diagnostic function is provided to detect an abnormality in the operating system or sensor
for the main drive circuit, main material handling circuit or accelerator to display the correspon-
ding error code on the digital multi-diaplay and to take a proper action.
8. Analyzer function (Standard)

When the digital multi-display is set to the analyzer mode, faulty part detection and functional
check of operating parts (Switches and accelerator), sensors and main drive and material handling
circuits are possible to improve serviceability.
9. Overdischarge warning function (lift interrupt) (standard)
When the remaining battery charge reaches the specified level, warning on the digital multidis-
play is made and material handling operation is restricted for battery protection and urging the
operator to charge the battery.
Vehicle specification General export specification
Display All-roundteasy model
Material handling option With material handling chopper Without material handling chopper
Material handling specification at Prohibition of simultaneous traveling Prohibition of material handling

overdischarge and material handling operations (priori- The material handling operation can tem-
ty on traveling) porarily be made possible for only 30
Soft start 114 for lifting only seconds by turning the key switch OFF
once and to ON again.
10. Material handling chopper (Option)

(1) Easier operation
As the material handling speed rises steplessly to the maximum speed even when the
material handling lever is operated rapidly, shock to the load is reduced and inching operation
1s easy.
(2) Extended life of material handling motor brush
As the rash current at the start of the material handling motor rotation, the motor brush life is
extended.
(3) Extended life of material handling contactor contact.
The motor current is turned ON or OFF not by the contactor contact but by the transistor, the
service life of the contactor contact is lengthened.
(4) Energy saving
As the hydraulic oil flow is optimized by lowering the material handling motor speed by the
chopper to obtain the optimum tiliting speed, hydraulic loss is minimized to bring about the
energy saving effect.
11. Maximum traveling speed limiter (Standard)

The maximum traveling speed is controlled at the specified level.
The speed can be set after selecting the mask function by inputting the password on the digital
multi-display.
* While traveling speed selection in 2 stages in 6 is for speed restriction only when the speed con-
trol switch is on, the maximum traveling speed limiter restricts the traveling speed irrelevant to
the speed control switch position.
* The limit speed setting range for the traveling second speed is automatically restircted to within
the limit set by the maximum traveling speed limiter.
12. No bypass contactor

A low-loss large-capacity transistor is adopted to eliminate the bypass contactor both for travel-
ing and material handling (when the material handling chopper is provided). This has reduced
the contactor noise and eliminated the bypass contactor closing shock at traveling speed accel-
eration and ramp start.
As the traveling bypass contactor is eliminated, ascending a slop exceeding the 3-minute grade-
ability performance of the motor is impossible.
13. Ramp start function (Standard)

The ramp start function is provided for easy starting on a slope.
14. Material handling power control ( * Option)

The material lifting and tilting speeds can be adjusted in eight levels by switch panel operation on
the digital multi-display.
* Valid only when the material handling chopper and digital multi-display all-round model are com-
bined.
(The lift power control, however, is invalid in the dustproof specification models.)
Explanation of Operation
The controller can roughly be divided into the main circuit where large currents flow and the control cir-
cuit where small currents flow. They are separately installed in three panels. (Control panel, coutactor
panel, and resistor panel)
Controller
Control circuit
Display
Steering
4 potentiometer
Traveling - b
d
accelerator
Limit switches Left wheel

b 4
LSL, LSLP
CPU
Limit switches Right wheel
b 4
LSB. LSD speedsensor
Controller
Direction switches 4 temperature
4
-
sensor
4
e- Right drive
e- -
--, Main drive -
Speed control swtich motor
DMDR
A A A +
+ circuit +-
Left drive
Current -- motor
Key switch sensor DMDL
SWKY
Material
b Main material handling motor
Fuse F5
handling
circuit - DMP
-
Fuse F2
Battery -
Fuse F1
u
% : Option
MAIN CIRCUIT COMPONENTS
I
I
I
I
N1
BAT : Battery SNI : Surge absorber for DFI

F1 : Drive motor fuse DF3 : Flywheel diodes No. 3
F2 : Pump motor fuse CA : Absorber capacitor
DMP : Pump motor MFL : Forward contactor (Left)
DMDL : Drive motor (Left) M FR : Forward contactor (Right)
DMDR : Drive motor (Right) MRL : Reverse contactor (Left)
TMD : Drive circuit main transistor MRR : Reverse contactor (Right)
TMP : *Material handling circuit main transistor MP : Pump contactor
RA : Absorber resistor CSD : Drive circuit current sensor
DAD : Drive circuit absorber diode CSP : *Material handling circuit current sensor
DAP : "Material handling circuit absorber diode
DFI : Flywheel diode No. 1 (For drive)
DFPL : Flywheel diode No. 2 (For drive) (Left)
DF~R : Flywheel diode No. 2 (For drive) (Right)
* Indicates an option.
Explanation of the Operation of the Main Circuit
(drain)
First to be explained is the operation of the FET, the main
switching element of the main circuit. As shown in the dia-
gram on the right, the FET includes three terminals: the
gate (G); drain (D);and source ( S ) .
When a voltage (VGs)is applied across the gate and the
source, this voltage-controlled element allows current (ID) (gate)
to flow between the drain and the source.
S
(source)
The main circuit has four modes (I-IV) of operation, each

with a different current flow.
The diagram to the right shows the voltage waveform of VDS
the TMD main transistor in one cycle. (Modes I-IV are ex- ON
plained in the next page.) 11 111
As the circuit operation of the main drive circuit and main Mode I P
material handling circuit is the same, the following ex- T
planation of the operation is given with reference to the t
T
drive circuit.
TMD Voltage waveform
In the 5FBE 10-18, drive motors are installed on the left and
right sides to drive the left and right wheels a t the same
time.
The explanation of each mode hereafter assumes the case

where only the left motor is driven for easy understanding
of the operation.
ModeI
Indicates that the TMD is on. In the drive circuit, a cur-
rent flows in the order of B A T @, MFL, DMD, MRL,
CSD, TMD and BATT @ .
As a sufficient gate current is supplied to the TMD
then, voltage VDsbetween D and S is in the saturated
state (approx. 0.8 V or less), the energy loss in the TMD
is extermely small to supply almost the full battery
voltage to the drive motor.
Mode I1
In this mode, gate voltage supply to the TMD is
stopped to turn the TMD off.
When gate current supply to the TMD stops, voltage
VDs between D and S of the TMD increases gradually.
At the same time drain current IDdecreases gradually
to cause the TMD to be turned off. The surge voltage
upon turning off is absorbed by CA via DAD.
3. Mode I11
When the TMD is perfectly turned off, the surge ener-
gy stored in CA is discharged through the closed cir-
cuit formed by CA, RA, battery and CA. The surge ener-
gy is discharged as heat at RA and a part returns to the
battery.
4. Mode I V
Indicates the state where the TMD is turned off and the
surge energy in CA is fully discharged.
When TMD is turned off, the counter electromotive
force induced in the motor is circulated through DFI.
The voltage applied to the motor is controlled, with
0-F
c 2 DAD RA
modesIto I V above as one cycle.
w
Operation of the Main Control Circuit
1. CPU Board
The CPU Board incorporates a microcomputer circuit for processing data from switches, poten-
tiometers, sensors, and other elements and transmitting command signals to the main circuit,
a drive circuit for driving the TMD and TMP, a power source circuit, and a contactor drive circuit.
Shown below is a block diagram of the circuit configuration of the CPU Board.
MPU (Micro Processing Unit) --- Central Processing Unit (CPU)
The MPU processes inputted data (signal)according to the program and transmits the processed
data (signal) to other LSI and boards in the MPU.
The MPU contains.
ROM (Read Only Memory)
A ROM allows fast access to permanently stored data but prevents addition to or modifica-
tion of the data. Programs stored in this type of memory do not dissipate when the power
is turned off.
RAM (Random Access memory)
A RAM allows both access and addition to or modification of the data. The data stored in this
type of memory dissipates when the power is turned off.
I10 (Input/Output) Port
An 110 port is a signal port for an input or output device. Each board receives and sends one
ONIOFF signal.
AID (AnalogIDigital) conversion
Analog signals are converted to digital signals before received by the CPU.
Contactor drive circuit

The contactor drive circuit turns on and off contactors according to the commands issued by the
CPU.
Travel OCL circuit

The travel OCL circuit generates a signal that turns off the chopper of the TMD for a certain period
when the drive motor current reaches a predetermined OCL value (set by the CPU).
Power source circuit

The power source circuit generates from the battery voltage a +5 V power supply to the digital
circuit, a +I2 V power supply to the analog circuit, and a +I5 V power supply to the display circuit.
Travel drive circuit

The travel drive circuit drives the TMD according to the commands issued by the CPU.
Material handling drive circuit

The material handling drive circuit drives the TMP according to the commands issued by the CPU.
TMD abnormality detecting circuit

The TMD abnormality detecting circuit receives the drain and gate voltages of theTMD and sends
a signal to the CPU when an abnormality is detected in the TMD.
TMP abnormality detecting circuit

The TMP abnormality detecting circuit receives the drain and gate voltages of the TMP and sends
a signal to the CPU when an abnormality is detected in the TMP.
Plugging signal detecting circuit

The plugging signal detecting circuit determines whetherthe right and left motors are in the plug-
ging state based on the P2, P6, and P61 potentials.
DRIVE CIRCUIT OPERATION
In the drive circuit, the drive motor current is controlled by the TMD chopper operation.
As the chopper operation follows the command output from the control circuit according to the de-
tected vehicle ststus, safe, comfortable driving is possible.
In forward (reverse) traveling

Driving starts when the key (SWKy)is set to ON, direc-
tion switch (DSF)is ON (DSRON for reverse traveling),
and accelerator switch (SWAc) is ON. If steering is
straight in this state, MFLand MFRare set to ON (or MFL
and MRRON in reverse traveling) in the main circuit.
At the same time, the ON signal is applied to the TMD
gate to turn it ON. The drive motor current flows as il-
lustrated to start driving by the chopper.
The drive motor wiring is connected reversely on the
left and right sides to drive the left and right drive mo-
tors in the forward direction. The vehicle travels
straight as a result.
2. Right turn in forward traveling (tire turning angle between 40" and 80")
When the steering wheel is turned to the right (clockwise),the MFRcontactor is set to OFF to stop
driving by the DMDR.
As the vehicle is driven only by the left motor, right turn is possible without overloading the right
motor.
(I!r
tire turning angle between 40" and 80"
% C-
CPU
3. Right turn in forward traveling (tire turning angle over 80")
When the steering wheel is further rotated clockwise, MRRcontactor is set to ON to drive DMDR
in the reverse traveling direction. As the right and left drive motors are driven in the opposite
directions, turning with a small radius is possible.
For control in left turn or reverse traveling, please

understand by referring to the patterns shown above.
tire turning angle over 80"
CPU
4. In switchback braking
In switchback operation, MFLand MRLare changed over to or from MFRand MRRt o apply voltages
in the reverse direction to the left and right motors.
If switchback is attempted when the motor running speed is high, the motor rotating energy
causes a current flow in a route different from the one for ordinary operation to start plugging brak-
ing. The CPU detects the plugging state according t o the potential difference between both ends
of DF2L and DF& t o output the chopper command for plugging braking for same braking.
CPU
MATERIAL HANDLING CIRCUIT OPERATION
The material handling circuit is provided in two types: Standard specification without the material
handling chopper and the option specification with the material handling chopper.
1. Standard specification without material handling chopper

(1) When the lift lever is operated:
When lift switch No. 1 (LSL)is turned on bythe lift lever, MP is closed to apply the full battery
voltage to the pump motor. When LSLis turned off, MP is opened and the pump motor
stops.
(2) When the tilt lever is operated:
As in lift operation, tilt switch (LST)on or off closes or opens the MP to start or stop the pump
motor.
*The same applies to the attachment operation.
CPU
2. Option specification with the material handling chopper
(1) When the lift lever is operated:
When lift switch No.1 (LSL)is turned on by the lift lever, the MP is closed t o cause the TMP t o
operate the chopper at a predetermined command duty while a current flows through the ma-
terial handling motor as indicated by the arrow in the diagram below.
If the lever is further operated to turn on lift switch No.2 (LSL2),the TMP operates the chopper
at a predetermined command duty greater than when only lift switch No.1 (LSL)is on. Mean-
while the revolving speed of the material handling motor is increased.
As described above, the material handling motor can be operated at two different duty levels.
The duty levels for the two lift switches (LSLand LSL2)can be set independently.
(2) When the tilt lever is operated:
As in lift operation, when the tilt switch is turned on, MP is closed to cause the TMP to operate
the chopper at a predetermined command duty.
Note that only one duty level is available with the tilt lever.
The duty levels for each switch can be set independently.
* The same applies to the attachment operation.
CPU
SPECIFICATIONS (For other than UL-USA-CANADA)
Portion 5FBE1013~15~18
F1 (Drive circuit) 225 A
F2 (Pump circuit) 225 A
F4 (For lamps) 10 A
TMD (For drive motor) TMMOOI (2 pcs.)
Transistors TMP (For material handling pump: OPT) TMMOOI (2 pcs.)
TMps (For PS: OPT) "'1 M1100H-025
DFI (DM flywheel) PE608N
D F ~ (DM
R flywheel) PE608N
Diodes DF2L(DM flywheel) PE608N
DF3 (PM flywheel: OPT) PE608N
DF4 (PS flywheel) ""1 M1100H-025
CSD (For drive motor) HC-T800V8P12
Current
CSP (For material handling pump: OPT) HC-T800V8P12
Sensor
Resistors RA (Absorber) 0.8 Q 220W
MRR.MRL(For reverse drive) ME253
Contactors
MPS(For PS) C48-A1l
*':The PS transistor a n d diode are integrated.

2A-20
SPECIFICATIONS (For UL-USA-CANADASPECIFICATIONS)

Portion 5FBE10~13~15~18~20
F1 (Drive circuit) 48V: 225A 36V: 275A
F2 (Pump circuit) 48V: 225A 36V: 275A
F4 (For lamps) 10 A
TMD (For drive motor) TMMOOI (3 pcs.)
Transistors TMP (For material handling pump: OPT) TMMOOI (2 pcs.)
TMps (For PS: OPT) *11M1100H-025
DFI (DM flywheel) PE 1008N
D F ~ (DM
R flywheel) PE1008N
Diodes D F ~(DM
L flywheel) PE 1008N
DF3 (PM flywheel: OPT) PE608N
DF4 (PS flywheel) *11M1100H-025
CSD (For drive motor) HC-T800V8P12
Current
CSP (For material handling pump: OPT) HC-T800V8P12
Sensor
Resistors RA (Absorber) 0.8 R 220W
MRR-MRL(For reverse drive) ME253
Contactors .
Mps (For PSI C48-A1l
*':The PS transistor and diode are integrated.

Control panel (For other than UL-USA-CANADA)
Control panel W / material handling chopper (OPT)
(For other than UL-USA-CANADA)
C-¤ 2401
N
W
.
.
.L
Control panel (For UL-USA-CANADA)
2A-24
Control panel W/ material handling chopper (OPT)

(For UL-USA-CANADA)
Resistor panel
2A-26
Contactor panel
2A-27
MF-MR contactor
r--- 10
---2 2403
($+ AY
E 8 - H
CY- ~ A Z
BC
L
a
.
- 8 ...J
2403-0688
MP contactor
11
r--- ---2
E0-V
CY-@
8 ..-A
2403-089
INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.
As the CPU boards require battery voltage application, they must be inspected while being mounted
on the vehicle.
Inspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1) Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
Use a resistor of approximately 100 i2 t o discharge CA before you perform the measurement.
Measurement terminals Controller side of battery plug - Body

The resistance should be as high as possible, but it varies greatly, depending on
Standard
the vehicle use status, place and weather. (Approx. 1 Mil)
2. TMD (drive circuit main transistor), TMP (material handling circuit main transistor)
Establish a short circuit between G and S for discharge.
Remove the wiring and the copper bars of the TMD and the TMP.
Inspection Circuit tester

Measurement terminals Standard
portion range
D @ - S @
Between D-S
D @ - S @ Approx. 3 KR
TMD
D @ - G @ m R
Between D-G R x Ik
D Q - G @ m R
TMP
G @ - S O R
Between G-S -
G Q - S @ m R
Source
3. DFI (flywheel diode No.l), DF2R.DF2L,(flywheel diode No.2 R/L), DF3 (flywheel diode No.3) Dis-
connect the wiring and copper bars from each flywheel diode.
portion range
Forward
DF 1 Cathode: @ probe - f node:@ probe Approx. 3 kR
direction
DF2R.DF2L R x Ik
DF3 Reverse
Cathode:@ probe - Anode:@ probe m R
direction
4. CA (absorber capacitor)
Disconnect the wiring of the snubber board after discharging the TP9 and TNI with a resistance
of about 100 Q.
Inspection portion Measurement terminals Circuit tester range
CA TP9 - TNI [On snubber board1 S2 x I k
Standard
When circuit tester probes are brought into contact with both measurement terminals, the pointer de
flects once to the 0 Q side and eventually points to rn Q. (The tester indicates m Q because the capacitor is
charged by the tester current.)
5. DAD (drive circuit absorber diode).DAP (material handling circuit absorber diode)
Disconnect the wiring of the snubber board
portion range
Forward TP9 (cathode)@ probe - TDAD (anode)@ probe Approx. 2.5 kS2
direction
DAD
Reverse TP9 (cathode)@ probe - TDAD (anode)@ probe Approx. 10 kS2
direction
S2 x I k
TP9 (cathode)@ probe - TDAP (anode)@ probe Approx. 2.5 kS2
direction
DAP
Reverse TP9 (cathode)@ probe - TDAP (anode)@ probe Approx. 20 kS2
direction
6. MFR.MFL(forward contactors), MRR.MRL(reverse contactors), MP (material handling pump con-
tactor)
Remove the connectors from the contactors.
portion range
MFRcoil
MFL coil
Approx. 20 R
MRRcoil Both terminals of the connector of each contactor a x 1
(at 20°C)
MRL coil
MP coil
7. RA (absorber resistor)
Remove the battery and disconnect CN118.

portion range
RA CN118-1 (PI) - CN118-3 (P9) Approx. 0.8 Q Q x Ik
When inspecting with the battery installed, disconnect the PI round connector and the CN100 connec-
tor.
lnspection Circuit tester

portion range
RA P I [wiring side] - CN100-2(P9)[REC] Approx. 0.8 Q Q x Ik
8. CPU board
If the trouble cause is iudsed to be in the CPU board apply the battery voltage, install SST
09240-23400-71 (IC clipj, a d measure the applied voltage and resistance at each connector.
Caution:
Always disconnect the battery plug before removing or installing the CPU board.
Note:
When replacing the CPU board judged to be causing the trouble as a result of troubleshooting, al-
wavs measure the applied voltage and resistance at related portions before replacement.
US; SST 09240-23400-71 (IC clipifor the measurement.
(1) SST connection method

@ Turn the key switch to OFF.
@ Disconnect the battery plug.
@) Remove the CPU board cover.
@ Connect the SST.
(2) Lists of measurement methods and standards
@ Explanation on list format
Circuit tester @ probe
v I
-,
Circuit tester Q probe
Connector pin No.
-
1
CN101-2 ~~10312 Key switch: ON Approx. 48 V
(?3, VB,KY) (NI, N2) Key switch: OFF 0V
1/ 1 I
Signal (part) name

1 Conditions for measurement
Level No.
@ Lists
A: 48V Vehicle
CNlOl Basic conditions (battery plug ON, key switch OFF)
B: 36V Vehicle
Connector No. *Connector No. Conditions Standard Remarks
CN101-1 CN101-3
(75, THC+) (N2, N2) 5 V f 0.25 V
CN101-2 : Unused -
CN101-3 CN101-3
(N2, N2) (N2, N2) Approx. 0 V
CN101-4 CN101-3 Approx. 0 V

(93, TMP-G) (N2, N2)
I
CN101-5 -
:
I
CN101-6 Unused
CN101-7 CN101-3 Key switch: OFF Approx. 0 V

(73, CSD+) (N2, N2) Key switch: ON 12 V k 0.5 V
CN101-8 CN101-3 Key switch: OFF Approx. 0 V
(73, CSP+) I (N2, N2) Key switch: ON 12 V k 0.5 V
CN101-9 CN101-3 Key switch ON 1 . 2 V f 0.1 V
(71, CSD) I (N2, N2) Traveling stop state
CN101-10 CN101-3 Key switch ON 1.2Vf0.1 v
(72, CSP) I (N2, N2) Material handling stop state
CN101-11 ' CN101-3
Approx. 0 V
(74, CSD-) (N2, N2)
CN101-12 I CN101-3 Approx. 0 V
(74, CSP-) (N2, N2)
CN101-13 Unused -
I
Key switch OFF Approx. 39 V (A)
CN101-14 I CN101-3 Approx. 29 V (B)
(P8, TMD-D) (N2, N2) Key switch ON, Approx. 48 V (A)
I direction SW ON, SWAc Approx. 36 V (B)
Key switch OFF Approx. 26 V/
I Approx. 0 V (A) Withiwithout
CN101-15 CN101-3 Approx. 20 V/ material
(P14, TMP-D) (N2, N2) Approx. 0 V (B) handling
, Key switch ON, Approx. 48 V (A) chopper
I
control lever SW ON Approx. 36 V (B)
CN101-16 I CN101-3
(92, TMD-GI (N2, N2) Approx. 0 V
CN101-17 CN101-3
(N2, N2) (N2, N2) Approx. 0 V
Connector No. *Connector No. Conditions Standard Remarks
CN101-18
CN101-19 : Unused -
CN101-20
CN101-21 i
CN101-22 CN101-3 Approx. 0 V
(N2, TMD-S) (N2, N2)
CN101-23 CN101-3 Approx. 0 V
(N2, TMP-S) (N2, N2)
CN101-24
(76, THCD)
CN101-3
(N2, N2)
2.5 V - 5.0 V
CN101-25 CN101-3 Approx. 0 V
(N2, N2C) (N2, N2)
CN101-26 CN101-3 Approx. 48 V (A)
(P9, VBP9) (N2, N2) Approx. 36 V (B)
CN102 Basic conditions (battery plug ON, key switch OFF)

(1, M-1 : (N2, N2)
CN102-2 CN101-3 Approx. 48 V (A)
(PI1, VBPI 1) (N2, N2) Approx. 36 V (B)
, Battery plug OFF 26°C
CN102-3 CN102-1 Measure the resistance with Approx. 20 52 MFRcoil
(4, MFR+) M-1
(I, the tester negative probe
, resistance
connected to CN102-1.
Key switch ON
CN102-3 CN101-3 Measure the voltage with the Approx.
(4, MFR+) : (N2, N2) tester positive probe
I connected to CN102-3.
Battery plug OFF 25°C
CN102-4 CN102-1 Measure the resistance with Approx. 20 52 MFL coil
(2, MFL+) M-1
(I, the tester negative probe resistance
I connected to CN102-1.
Key switch ON
(2, MFL+) (N2, N2) tester positive probe
, connected to CN102-4.
CN102-5 CN102-1 Measure the resistance with Approx. 20 l2 MRRcoil
(5, MRR+) , M-)
I
I
Key switch ON
CN102-5 CN101-3 Measure the voltage with the
(5, MRR+) (N2, N2) tester positive probe
Approx.
CN102-6 CN102-1 Measure the resistance with
Approx. 20 52 MRL coil
(3, MRL+) ; M-1
Key switch ON
CN102-6 CN101-3 Measure the voltage with the
(3, MRL+) (N2, N2) Approx.
tester positive probe
CN102-7 I Unused -
4
CN102-8 CN101-3 Approx. 39 V (A)

(P6, VBPG) (N2, N2) Approx. 29 V (B)
Connector No. t,Connector No. Conditions Standard Remarks
CN102-9 CN101-3 Approx. 39 V (A)
(P61, VBP61) (N2, N2) Approx. 29 V (B)
CN102-10 Unused -
CN102-11 CN101-3 Approx. 48 V (A)
(P2, VBP2) (N2, N2) Approx. 36 V (B)
, Battery plug OFF 25°C
CN102-12 CN102-1 Measure the resistance with Approx. 20 C l MP coil
(7, MP+) M-1
, Key switch ON
(7, MP+) (N2, N2) tester positive probe
Connector No. t, Connector No. Conditions Standard Remarks

(1, MPS-) : (N2, N2)
Battery plug OFF, Key switch Applicable
OFF when EHPS is
CN103-2 CN103-1 Measure the resistance with Approx. 68 R not provided.
(6, MPS+) MPS-) the tester negative probe 25°C MPs coil
I
connected to CN103-1. resistance
I Key Switch ON
(6, MPS+) (N2, N2) tester positive probe
I
CN103-3 ' CN101-3 SWpB OFF 5 V f 0.25 V
(66, LSPB) (N2, N2) S W p ~ON 0V
CN103-4 I CN101-3 LSD OFF 5 V f 0.25 V
(67, LSD) (N2, N2) LSD ON 0V
CN103-5 CN101-3 LSAn OFF 5 V f 0.25 V
(63, LSAT) I (N2, N2) LSAT ON 0V
CN103-6 I CN101-3 LST OFF 5 V f 0.25 V
(61, LST) (N2, N2) LST ON 0V
CN103-7 CN101-3 DSF OFF 5 V f0.25 V
(45, DSF) (N2, N2) DSF ON OV
CN103-8 CN101-3 DSR OFF 5 V f 0.25 V
(46, DSR) I (N2, N2) DSR ON OV
CN103-9 Unused -
CN103-10 CN101-3 LSL OFF 5 V f 0.25 V
(60, LSL) (N2, N2) LSL ON 0V
CN103-11 CN101-3 LSL2 OFF 5 V f 0.25 V
(68, LSL2) (N2, N2) LSL2 ON OV
CN103-12 CN101-3 SWsc OFF 5 V f 0.25 V
(77, SWSC) (N2, N2) SWsc ON 0V
CN103-13 I CN101-3 LSB OFF 0V Step brake
(65, LSB) (N2, N2) LSB ON 5 V f 0.25 V
I
Key Switch OFF Approx. 0 V
CN103-14 CN101-3 Approx. 48 V (A)
(43, VBKY2) (N2, N2) Key Switch ON
Approx. 36 V (B)
CN103-15 Unused -
CN103-16 CN101-3 Approx. 48 V (A)
(41, VBBT2) (N2, N2) Approx. 36 V (B)
CN103-17 CN101-3 Approx. 0 V
(51,LS-) (N2,N2)
CN103-18 Unused -
2A-37
Connector No. tt Connector No. Conditions Standard Remarks

CN104-1 I CN104-2 Approx. 0 V
(81, SSR+) (82, SSR-) Stop state
(82, SSR-) (81, SSR+) Traveling stop state
CN104-3 CN101-3 Approx. 48 V (A)
(41, VBBT) I (N2, N2) Approx. 36 V (B)
Key switch OFF Approx. 0 V
CN104-4 CN101-3 Key switch ON Approx. 48 V (A)
(43, VBKY) (N2, N2) Approx. 36 V (B)
I
CN104-5 CN101-3 Key switch ON 0 V: with EHPS

(94, PSH) 1 (N2, N2) 5 V: without EHPS
(83, SSL+) (84, SSL-) Traveling state
(84, SSL-) (83, SSL+) Traveling state
CN104-8 :
CN104-9
CN104-10 : Unused -
CN104-11
CN104-12 :
Connector No. tt Connector No. Conditions Standard Remarks

CN105-1 1 CN101-3 SWAc OFF +
5 0.25 V
(6, LSAC) (N2, N2) SWAc ON Approx. 0 V
CN105-2
(53, POTA+)
CN101-3
(N2, N2)
4.2 V - 5.25 V
I
Change must occur smoothly
CN105-3
(52, POTA)
I CN101-3
(N2, N2)
with operation of traveling 0.4 V - 4.7 V
accelerator
CN105-4
(55, POTST+)
CN101-3
(N2, N2)
4.6 V - 5.25 V
CN105-5 CN101-3 When moved from right 0.4 V - 4.5 V
(56, POTST) (N2, N2) stroke end to left stroke end
(50, POT-) (N2, N2)
CN105-7 :
CN105-8 : Unused -
CN105-9
:
1
CN105-10
CN105-11 : Cannot be measured with a -
(144, SMTDK) circuit tester
CN105-12 ; Cannot be measured with a -
(143,SDTMK) , circuit tester
CN105-13 Cannot be measured with a -
:
1
(142, SDTMA) circuit tester

CN105-14 : Cannot be measured with a -
(141,SMTDA) circuit tester
CN105-15
CN105-16
:
9
Unused -
CN105-17 CN101-3 13.5Vf 1 V
(16, + I 5 V) : (N2, N2)
CN105-18 CN101-3 Approx. 0 V
(17, GND) : (N2, N2)
DISASSEMBLY
The control panel is overhauled infrequently. Defective part replacement according to the cause of the
trouble by inspection is performed in most cases. Please perform correct operation by referring to the
component parts drawing, assembly drawing and internal connection diagram.
Cautions for Parts Replacement

Tighten the bar and harness set nuts and screws to the specified torques.
Looseness or insufficient tightening will cause other troubles.
When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indi-
cating the mounting position. A t the time of reassembly, prevent incorrect installation or wiring by
referring t o the memo or tag. Incorrect installation or wrong wiring will cause other troubles.
Always coat silicone grease on parts which have been coated with silicone grease. Omission of
coating may cause overheating.
After reassembly, check no contact of the bars and cables at other than the contact portions. Before
installation on the vehicle, check continuity at points with a circuit tester. (See page 2A-39 for the
inspection points with
- -the circuit tester.) -
a When you replacethe TMD and TMP, always replace them as a 2-part set. (For ULUSACANADA
specifications are 3-part set.)
The MOS FET module is blue and the SIT is red, so take care to avoid making installation errors.
REASSEMBLY
Control panel assembly drawing (STD) (For other than UL.USA.CANADA)
Control panel assembly drawing (W/ material handling chopper) (For other than
UL-USA-CANADA)
Snubber board
(L)
i"
(R)
,
Control panel assembly drawing (For UL-USA-CANADA)
CNlOl CN100
CPU board
Control panel assembly drawing (W/ material handling chopper)
(For UL-USA-CANADA)
2A-43
Contactor panel assembly drawing

PANEL PARTS TIGHTENING TORQUE
Control panel
Main terminals
M5 +
2.5 f 0.5 (25 f 5) (1.8 0.41
TMD.TMP M4 1.5 f 0.5 (15 f 5) 11.1 f 0.41
For installation M5 2.5 f 0.5 (25 f 5) [ I .8f 0.41
Main terminals M5 2.5 f0.5 (25 f 5) [I .8f0.41
DFI.DF3
For installation M5 2.5 f0.5 (25 f 5) [I .8f0.41
Heat sink For installation M5 2.5 f 0.5 (25 f 5) [I .8 f 0.41
Set bolts for external connection terminal M8 9.8 f2 (100 f20) [7.23 f 1.41
Nuts and bolts for conductive parts
Contactor panel
DF~R.DF~L
Main terminals M5 +
2.5 f 0.5 (25 f 5) [1.8 0.41
For installation M5 2.5 f 0.5 (25 f 5) [I .8 f 0.41
MFR.MFL Main terminals M8 9.8 f 2 (100 f 20) [7.23 f 1.41
MRR.MRL.MP For installation M5 2.5 f 0.5 (25 f 5) 11.8 f 0.41
Heat sink For installation M5 2.5 f 0.5 (25 f 5) [1.8 f 0.41
Set bolts for external connection terminal M8 9.8 f 2 (100 f 20) [7.23 f 1.41
Nuts and bolts for conductive parts
CONTINUITY CHECK WITH CIRCUIT TESTER
Control panel Contactor panel
lnspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe
Inspection points Standard Circuit tester

P2: + probe - N1: - probe Approx. 1 0 t o 2 5 Q
Between P2 and N 1 n x lk
P2: - probe - N1: + probe *eon
- P12: + probe - N l : - probe
Approx. 1 0 t o 25 Cl
Between P I 2 and N1 n x lk
P I 2: - probe - N I: + probe *eon
Tester probes may be used in either
Between P2 and frame 00 Q n x lk
direction.
Between N 1 and Tester probes may be used i n either
00 n Stx I k
frame direction.
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects to 0 Q and returns to co Q then.
OCL (OVERCURRENT LIMIT) VALUES
1. Drive circuit OCL value measurement
(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Standard OCL value:

+ 70
-
460 50 A (48 V vehicle)
610 + 60 A (36 V vehicle)
(For UL. U.S.A.. CANADA)
Ammeter:
50 mV, 750 A
Shunt:
50 mV, 750 A
(2) Judgment method if the measured OCL value is not within the standard range, the drive cur-
rent sensor (CSD) or CPU board may be defective. Make judgment as follows:
@ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
@ Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON.SWKy ON
Measurement terminals: CN101-9 (71) @ - CN101-11 (74) @
Standard: Approx. 1.2 V
*Use a digital voltmeter for measurement.
@ Operate the accelerator to set the speed to approx. 8 k m l h (5 milelh). Read the ammeter
and masure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN101-9 (71) @ - CN101-11 (74) @
*Use a digital voltmeter for measurement.
@ Calculation
Measured value C - measured value B = D
Convert the calculated value D according to the following equation. (Converted value: E)
1V = 100A
@ Judgment
Compare converted value E with measured value A in step @.
*
The current sensor can be judged normal if the result is within 5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.
Pump circuit OCL value measurement
The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.
As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.
MULTI-DISPLAY FUNCTIONS
-
[FOR U.S.A.] (1993.1 - )
Page
DIAGNOSIS ........................................................ 3-2
GENERAL ......................................................... 3-2
ANALYZER ......................................................... 3-7
GENERAL ......................................................... 3-7
USING THE ANALYZER MODE .............................. 3-9
METHOD FOR SELECTING EACH ITEM .................. 3-12
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM ...................................................... 3-17
MASK FUNCTIONS ........................................... 3-31
PASSWORD INPUT METHOD ............................... 3-33
DIAGNOSIS
GENERAL
The 5FBE Series has the self diagnostic function, which automatically detects errors in the main drive
and material handling circuits, operation systems such as the accelerator, sensors, etc., and sounds
the buzzer while displaying these errors by corresponding error codes on the multi-display.
At the same time, safe operation is ensured by automatic stop of traveling, stop of material handling
and or traveling speed control.
Depending on the trouble only the error code appears on the multi-display. Although the vehicle may
be operated, make necessary repairs as soon as possible.
The self diagnosis mode may be switched to the analyzer (error analysis) mode, in which failure is de-
tected and, the main drive and material handling circuits, each operation system, sensors, etc. are
checked for functions.
Use these functions fully for early detection and elimination of electrical system troubles.
1. Error code display

@) Error code
The error code appears in part a in the illustration,
and the warning sound bleeps. Make repairs soon ac-
cording to the error code displayed by self diagnosis
while referring to "Troubleshooting" in Repair Manual.
32.s Sh
---
Hours used indication

(Example figure shown)
Diagnostic Error Code List
Error Phenomenon in vehicle

Faulty portion Fault mode
code
A0 MCS main circuit Overheat Lowering of traveling speed
A2 CPU board Abnormal temperature rise (Display only)
Stop of traveling and

A3 Battery Abnormally high voltage
material handling
Acceleration potentiometer
A4 Traveling accelerator Traveling stop
abnormality

A6 Material handling switch Material handling stop
abnormality
Departure from vehicle

A7 Parking brake application
(Display onlyl
without applying the parking
*1 failure warning
brake
A8 Drive motor fuse F1 Fuse open Traveling stop
Temperature sensor
AA CPU board (Display only)
abnormality on CPU board.
Analog input detection Stop of traveling and

AE CPU board
Excessive processing time material handling.
CPU processing data Stop of traveling and

AF CPU board
abnormality material handling
Can be enabled or disabled by the display mask function (provided only for the vehicle with deadman switch).
Error
Faulty portion Fault mode Phenomenon in vehicle
code
Traveling SIT short or open

circuit
CO Main drive circuit Traveling stop
Traveling DCISD board
abnormality
Current sensor harness short

C1 Drive current sensor Traveling stop
or opencircuit
C4 Traveling accelerator Traveling stop
short or opencircuit
C7 Direction switch Switch short Traveling stop
C8 Speed sensor Sensor harness open circuit Traveling stop
C9 MF-MR contactor Contactor short Traveling stop
MF-MR contactor drive Coil chopper transistor short

Traveling stop
circuit (CPU board) or opencircuit
Traveling and material

CE CPU board ROM abnormality
handling stop
Traveling and material

CF CPU board RAM abnormality
handling stop
Error Faulty portion Fault mode Phenomenon in vehicle
code
Material handling SIT short

Eo or open circuit Material handling stop
Main material handling circuit
*2 Material hand,ing DC,SD
board abnormality
El Material handling current Current sensor harness short

Material handling stop
'2 sensor or open circuit
The direction switch is al-

ready set t o F or R or the
E3 acceleration switch is on
Return t o neutral warning Traveling stop
"3 when the key switch and
deadman switch is turned
on.
Switch 1 harness open
E6 circuit Material handling stop
Lift switch
*2 Switch 2 harness short
circuit
Display-MCS communication MCS receiving data

EE (Display only)
system abnormality
Excessive CPU processing

EF CPU board (Display
time
"2. Only for vehicle with material handling chopper (OPT1

'3. Only for U.S.A. specificaton vehicle
Error Faulty portion Fault mode Phenomenon in vehicle
code
FO Power steering (only in

Power steering abnormality (Display only)
"4 EHPS)
Display-MCS communication
Communication failure (Display only)
system
F2 Communication data error (Display only)
system
Display-MCS communication (Display only)

F3 Echoback error
system
Power control memory value

F4 Display (Display only)
inconsistency
(Display only) (Automatic

F5 Charger (on-vehicle type Charging timer memory
equalizing charging
"5 only) abnormality
impossible)
F6 Charging safety timer

Charger (on-vehicle type Charging stop
"5 operation
only)
*6
F7
Charger (on-vehicle type Charging starting failure (Display only)
"5
"6 only)
F8 Charger (on-vehicle type

Charging end failure (Display only)
"5 only)
Steering potentio
F9 Steering potentio Traveling stop
abnormality
FA RAD RAD harness disconnection Traveling stop
"4. Only for vehicle with EHPS (OPT)

'5. Only for vehicle with on-vehicle type charger
*6. No alarm sound
ANALYZER
GENERAL
The 5FBE series has the analyzer for function check and defect detection of the main drive and mate-
rial handling circuits, operating system such as accelerator, and sensors by switching the multidisplay
into the analyzer mode for quick and easy servicing.
Use these functions fully for early solution of troubles in the electrical system.
General Description of Analyzer Functions

The analyzer supports controller system inspection and locating of defective parts by making full use
of the computer function of the MCS-IIIA controller and the communication function between MCS-
IIIA and multidisplay.
(1) Monitoring the history of past errors (diagnosis monitor)
(2) Testing the connections and insulation defects of wiring and connectors (switch input test)
(3) System check with actual travel and material handling operations (test operation)
3-8
Test items by analyzer

Category Class Description
1 Simple test Past diagnosis display and continuous quality
check for main circuits, switch systems and
sensor systems
2 Test operation Test operation while checking analog input

Simple test and (voltage, current values .(motor current, accelerator input
test operation and temperature voltage, etc.) and error occurrence
display)
(traveling speed values (traveling speed) and error occurrence
display)
1 Diagnosis Past error display with hour meter readings at

2 Diagnosis monitor monitor the time of error occurrences
1 Switch ONIOFF Display of every switch onloff state

information display
2 Buzzer check Information of each switch onloff state by

buzzer sound
3 Switch input test

3 Momentary Testing defective contacts of wirings and
interruption test connectors
4 Short circuit test Testing defective insulation of wirings and

connectors
USING THE ANALYZER MODE
Preparation for analyzer mode
Caution:
Before starting analyzer mode operation, always jack
up the frame until the front and rear wheels leave the
ground, support the frame with wooden blocks for sta-
bilization, and bring the fork down to the lowermost
position.
Diagnosis error display 1. Set the battery plug t o ON.
2. Set the key switch t o ON.

i
I
Note:
-j/ 1- If diagnosis error code "AF", "CE", "CF", "EE",
17I- "Fl", "F2" or "F3" is displayed, the analyzer mode
cannot be used.
[o 32.st1)
1
T
I
Switching t o the analyzer mode

The multidisplay is generally set t o the diagnosis mode.
This display is protected by mask functions t o prevent the important internal data from being de-
stroyed by incorrect user operation.
Switching t o the analyzer mode, therefore, requires password entry from the switch panel.
1. Primary password entry
Operate the display switch panel according t o the se-

Short bleep quence shown in the illustration.
1
[x)
Within 1 0 seconds
Short bleep
If not operated within 10 seconds, the mode returns t o
the ordinary travelinglmaterial handling mode (diagno-
sis mode).
1 Within 10 seconds Keep pressing the switch in the final step for 2 sec-
onds. The intermediate mode screen is displayed.
0 Short bleep If the operation is mistaken halfway, set the key

switch t o off once and repeat the operation from the
I
[X [r]
Within 1 0 seconds
:Ztaneousfy.
Note:
beginning.
Your finger must be used for the panel switch operation.

If sharpened tools are used instead, it would be a cause of
Keep pressing for 2 sec. damage on switch.
I Short bleep
lntermediate
2. lntermediate mode display
Transition t o the analyzer, hour meter start or MCS-

lllA tuning mode occurs from this mode.
3. Analyzer mode input

Within 10 seconds
Operate the display switches in the sequence shown in
the illustration.
Within 10 seconds
Short bleep
4. Analyzer activation
Lighting for 2 seconds followed by
flashing 5 times
The display changes as illustrated and the analyzer is
activated.
Then the initial display appears.

If the analyzer cannot be activated by the operation
above, turn the key switch OFF once and repeat from
the primary password input again. If not activated by
O UEr-2.8 repeated operation, system abnormality may exist.
Version display
5. Initial display
Flashing
I Transition t o each analyzer mode occurs from this dis-
\ p
I 3 play state.
\ / \
DW/ DW/
1
I-! I-!
1 \ \
[ RnL I
7
I,
I
AnL: analyzer
METHOD FOR SELECTING EACH ITEM
Each item can be selected by adjusting the speedometer display t o the corresponding category and
class numbers.
1. Item selection from analyzer activation state (initial display) (Example: 12)
Step Operation method Display
0 Flashing Indicates the ready
End of analyzer activation state for category
-P
([I
14- 11
- number input.
.-u
V)
-
.-
([I
UU
.-+
-
C
AnL: analyzer
@ To increase the numeral Display the desired Flashing
C
I.U
.-0+ llrl
0
-Q)
Q)
To decrease the numeral by 1
V)
2 0 Press this switch Flashing The category

0
U)
when the desired number is
Q)
+ category number is determined and
([I
o displayed. class number input
mjo] is enabled.
llrl
@ To increase the numeral Display the desired Flashing

by 1 class number.
C
.-
0
+
0
-Q,
8 @ Press this switch Flashing stops when
V)
rn the class number is
-cu determined t o
0
complete item
selection.
3-13
2. To select another item from one item

(1 1 To select another class in the same category (Example: 12+13)
0
r State of testing a certain item (12)
-P
([I
.-
V)
u
-
.-.-c
([I
C,
0 Press this switch t o The item selection

display appears t o
C,
rn
a enable class number
C,
input.
\C
0 ( O i
u
c
LLI
[run)
0 Display the desired Flash~ng
To increase the numeral by 1 class number.
c
.-0
C,
-aa0 To decrease the numeral by 1
@ - 1 Press this switch Flashing stops when

V)
the class number is
-
o
V)
([I
determined t o com-
plete item selection.
( o .Lr D.D ,J
3-14
(2) To select an item in a different category (Example: 13+New item)
0
State of testing a certain item (13)
>
-n
m
.-
u
V)
-
.-(C1
.-c
C,
[ o Lr U.L? ,.)
-
@ Press this switch t o The item selection

end the test. display appears t o
enable class number
input.
COI / I-/
/ / \ \
+
[ run I
V)
a
C,
+
u
" 0 Press this switch t o Returns t o the initial
c Flashing display upon ana-
w set class number 0.
lyzer activation
when class number
0 is set.
i-..rl(01
L E I
AnL: analyzer
@
1. Select the desired item according t o the
$c procedure from "Analyzer activation
a .2 state (initial screen)".
E5
Z$
V) V)
V)
oE
08
a --
5S (I)
SE
l= E
r E
.-3 E
SU
"lE
." 'g
L
a
2%
2:
L .-
3. Ending analyzer mode (transition to diagnosis mode)
0
State of testing a certain item (1 1 ) Category Subcategory
>
-P
([I
.-rn
u
-
.-
(0
.-
C,
-C ESY ( s ~ m p l ~ f ~test-
e d ) 00

C,
rn
al
C,
LC
0
c 0 Press this switch Returns t o the initial

w and set class
Flashlng
display upon
number 0. analyzer activation
when class number
0 is set.
AnL: analyzer
C @ Press this switch "n" flashes.

.-
0
C, and set category
0
-al
9) Analyzer mode
rn completion
u confirmation
C
al
L
Y: Yes t o end the
al analyzer mode
-:
([I
n: No t o continue
the analyzer
4 mode
C
.-0
0 Press this switch "Y" flashes.
C, and select Y (end
-al0al
rn
u
C
al
-z>
([I 1
2
8 Press this switch to
a end the analyzer
m mode.
E
-i>m.
I
C
(0
+
0
m
C
W
When the switch in step @ is pressed in step @ (flashing of "nu), the display returns to
display).
a (initial
It is also possible to end the analyzer mode by setting the key switch to OFF.
FUNCTIONAL EXPLANATION OF EACH TEST ITEM
Category 1 Class 1 Simple test
The simple test consists of 3 5 test items ESY-01 t o ESY-35, each with its specific display.
Simple test item selection method
-
Category Subcategory
1. Initial display
ESY (simplified) test- 00
2. Switch operation method

@ Next test item
1 Press @: Proceeding t o the next test item
I \ (Ex. ESY01+02)
r m Press @: Returning t o the preceding test item

- +@
[s][T) Retest
(Ex. ESY 02+0 1
/!'0
T
@ Test end
@ Preceding test item
#
Press @: Repeating the same test item
Press @: Ending the simple test (returning t o the

class selection display)
3-18
Simple Test Function Map

Category 1 Class 1
Test No. Description
ESY-01 Automatic check of main circuits, current and speed sensors etc.
The most recent diagnosis error code and
ESY -02
corresponding hour meter reading
The second most recent diagnosis error code and
ESY -03
The third most recent diagnosis error code and
ESY -04
The 4th most recent diagnosis error code and
ESY -05
ESY-06 Reading the memory of Past corresponding hour meter reading
diagnosis errors (10 most
recent errors) The 6th most recent diagnosis error code and
ESY-07
ESY -08
ESY-09
ESY-10
ESY-11
Detected voltage value display Voltage detected before key switch SW,
ESY-l
(to enable judgement on the (intermediate tap)
performance of the detecting
function based on the Voltage detected after key switch SW,
ESY-l
difference from the actual (intermediate tap)
value measured with a
ESY-14 multimeter) Voltage detected at P9 terminal
Automatic judgement on
abnormality or defective Check of accelerator switch SW
,,, drive accel-
ESY-15 adjustment of the drive erator potentiometer VRA, and drive acceleration
accelerator by accelerator sensor
operation
Automatic judgement on temperature on CPU board or judgement based on the
ESY-l difference between the detected temperature value and actual temperature
ESY-17 Automatic judgement on steering potentiometer quality and detection of voltage
ESY-l Judgement On the qualitiesOf ONIOFF of forward right contactor MFR

the contactor and contactor
drive circuit by visual check of
ESY-19 contactor attractionIr&?ase ONIOFF of reverse right contactor MFR
state by outputting each
contactor ONIOFF signal
ESY- 2 0 ONIOFF of forward left contactor MFL
ESY - 2 1 ONIOFF of reverse left contactor MFL
ESY-22 ONIOFF of pump contactor MP
ESY - 2 3 ONIOFF of PS contactor MPs
ESY-24 Judgement On the qualities Of ONIOFF of forward direction switch DSF

switch and switch detecting
circuit by ONIOFF state
ESY-25 display of each switch and ONIOFF of reverse direction switch DSR
buzzer sound
ESY-26 ONIOFF of accelerator switch SW,,
ESY-27 ONIOFF of brake switch LS,
ESY-28 ONIOFF of speed control switch SW,,
ESY - 2 9 ONIOFF of parking brake limit switch LS,,
ESY-30 ONIOFF of lift limit switch LS,
ESY- 3 1 ONIOFF of lift limit switch LS,,
ESY-32 ONIOFF of tilt limit switch LST
ESY-33 ONIOFF of deadman limit switch LSD
ESY- 3 4 ONIOFF of attachment limit switch LS,
ESY -35 ONIOFF of attachment limit switch LS,

3-20
Test No.: ESY-01

The following items are checked automatically and the results are displayed:
1 Main drive circuit and main pump circuit check ...........................................COmEO
2 Drive current sensor and pump current sensor zero point check ..................... C1 - E l
3 Speed sensor discontinuity detection .........................................................C 8
1. If the check result is normal, 00 is displayed on the

Error code speedometer.
ESY -02 Retest
2. If abnormal, the corresponding error code is displayed
with buzzer sounding.
3. If multiple errors occur, they are displayed sequen-

tially.
ESY -00
Test end Action: lnvestigate the error position by referring to the
troubleshooting.
Test No.: ESY-02 to 1 1
Past diagnosis errors are displayed.
ESY-02: Most recent error

I
ES$-~
1: 0ldes; error
1. Select the function by pressing the switch.
Next test item (1) ESY-xx is displayed with blinking three times on
the hour meter.
RD (2) The error occurrence time and error code are dis-
played on the hour meter and speedometer, re-
spectively.
Preceding test item Time of error duration
Simplified test end Action: lnvestigate the error position by referring to the
troubleshooting.
The voltage at the voltage input terminal is measured and

displayed.
ESY-12: Voltage at battery terminal (intermediate tap)

ESY-13: Voltage at key switch terminal (intermediate tap)
(0 : OK H : NG) ESY - 1 4: VBP9 voltage at P9 terminal
(1) ESY-xx is displayed with blinking three times on

the hour meter.
Voltage 48.0 V
Next test item (2) The voltage is displayed on the hour meter.
#
1 * (3) Measure the input voltage at each terminal with a
multimeter, and check the difference from the dis-
--
played value.
[=) [T) Standard (See page 2-21 .)
**
Retest
VBBTNBKY: Within 1%
VBP9: Within 5%
#
(4) AS the VBKY over 5 4 V cannot be displayed, con-
Simplified test end dact this check only when it is 5 4 V or less.
Preceding test item
Action: @ Abnormality of trimmer potentiometer in CPU

-, Replace the CPU board.
Note:
Never tamper with the trimmer potentiometer.
@ When the voltage is 0, check the harness.

Test No.: ESY-15
:::$
' Adjustment condition
(No display : OK H: NG) The potentiometer voltage with satisfaction or dissatisfac-
Indicate at tion of the specified range and the properness of the corre-
sponding switch ONIOFF state are displayed.
ESY-15: Accel potentiometer (SWAc.VRA)
1. Press the switch t o select the function.

( oP/-fl-z. 1 .
1
/ (1) ESY-15 is displayed with blinking 3 times on the
A -, hour meter.
Potentiometer voltage
PTA : Accelerator potentiometer
Next test item (2) The potentiometer type and potentiometer volt-
b
1 age are displayed on the hour meter.
I \
rm (3) The speedometer displays whether the potenti-

ometer voltage is within the specified range and
[-ad) [T]
- -Retest whether the switch onloff state is proper.
+ '10 #
Actions: @ Check the potentiometer installation state.
@ Check the harness.
@ Replace the potentiometer.
Simplified test end
Preceding test item @) Replace the CPU board.
Test No.: ESY-16
Temperature sensor check
The temperature detected by the thermistor on the CPU board is displayed. The properness of the tem-
perature and voltage range is checked and displayed.
1. Press the switch to select the function.

Theremistor voltage Temperature range
(0:OK H:NG) (0: OK H : NG)
(11 ESY-16 is displayed with blinking 3 times on the
hour meter.
(2) The temperature on the CPU board is displayed on

the hour meter.
(3) The speedometer displays whether the tempera-

TH : Thermistor Ambient temperature ture range is normal and whether the thermistor
voltage is normal.
ESY-17 Retest Actions: @ Check the ambient temperature of the CPU

board by comparison with the data measured
by the thermometer. Within f 5OC.
[".I)[01
ESY 15
Simplified test end
Test No: ESY-17

Voltage check
(O:OK, H:NG)
\, Steering potentiometer check
\
\
-
The steering potentiometer voltage is displayed.
(1) ESY-17 is displayed with blinking 3 times on the

w r1r - 2 . 3
0 1 3 hour meter.
J,
(2) The potentiometer type and voltage are displayed
on the hour meter.
Next test item
(3) The speedometer displays whether the potenti-
ometer voltage is in the specified range or not.
Preceding test item

End of test
Test No.: ESY-18 to 23
Contactor closing test
ESY-18: Forward right contactor (MFR)test

ESY-19: Reverse right contactor (MRR)test
ESY-20: Forward left contactor (MF,) test
ESY-21: Reverse left contactor (MR,) test
ESY-22: Pump contactor (MP) test
ESY-23: PS contactor (Mps) test
rnFr : Contactor MF, 1. Press the switch to select the function.
the hour meter.
(2) The contactor code is displayed on the hour
meter.
Retest (3) Visually check closing or opening of each contac-
[El tor.
Preceding test Item Actions: @ Check welding of the contactor.

Simpl~fiedtest end @ Check the resistance of the contactor coil.
Check the voltage at the time of contactor
closing.
(The contactor is defective if it is 30 V or
more. 1
Switch ONIOFF and buzzer check
ESY -24: Forward direction switch (DS,)

ESY-25: Reverse direction switch (DSR)
ESY-26: Accelerator switch (SW),
ESY-27: Brake switch (LS,)
ESY-28: Speed control switch (SW,) (Not in US specifi-
cation)
ESY -29: Parking brake limit switch (LS,)
ESY -30: Lift limit switch 1 (LS,)
ESY -31 : Lift limit switch 2 (LS,) (Only in vehicle with
A A J,
T material handling chopper)
I I
DS,: Forward switch 0: ON
ESY-32: Tilt limit switch (LS,)
F: OFF ESY -33: Deadman limit switch (LSD)
ESY -34: Attachment limit switch )L ,S
(,
ESY -35: Attachment limit switch 2),,L S
,(

Next test item
(1) ESY-xx is indicated with blinking three times on
the hour meter.
(2) The switch code is indicated on the hour meter.
(3) When the selected switch is set to ON, F dis-
played on the hour meter is changed t o 0 and the
buzzer sounds.
Preceding test item
Simplified test end Actions: @ Check the switch.
@ Check the switch harness.
8
3 Check the CPU board.
4 Replace the CPU board.
Category 1 Class 2 Test operation (voltage-current or temperature display)
In the test operation, traveling and/or material handling are possible while monitoring the analog input
value of each sensor.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles to be confirmed.
Analog input items to be monitored
No. Item Description

0 Drive motor current A Abnormality of current sensor or current detecting circuit,
deviation of OCL value or abnormal forklift load
1 Pump motor current A Abnormality of current sensor or current detecting circuit or
abnormal forklift load
2 Battery terminal Abnormality of voltage detecting circuit (excessive charge
voltage V indicator display error)
3 Key switch terminal voltage Abnormality of voltage detecting circuit (excessive charge
V indicator display error)
4 P2 terminal voltage V Abnormality in voltage detecting circuit
5 Accelerator potentiometer Abnormality of acceleration sensor, or abnormality in accel-

voltage V eration potentiometer detecting circuit (maximum speed)
6 Atmospheric temperature Abnormality of thermo sensor or abnormality in thermo sen-
OC sor detecting circuit
7 Steering potentiometer Abnormality of steering potentiometer voltage
voltage V
The analog input value is displayed in the test operation.
The error code is displayed when an error occurs and is retained until the error clear switch is pressed.

Display in normal state: 12
Display in error state: error code (1 The test No. is displayed on the hour meter.
I
I
I \\ (2) The current value, etc. during the test operation
are displayed on the hour meter.
(3) 12 (Category: 1, class: 2) is displayed on the

speedometer in normal state.
Indicated upon
\ (4) If an error occurs, the error code is displayed on
Analog input display
switch ON the speedometer and is retained until the error
and steer- Preceding item No. clear switch is pressed.
ing potentio
meter in neutral state
--
Action: lnverstigate the error position and the part show-
ing an abnormal value by referring to the trouble-
shooting procedure.
Next test item
2. Steering potentiometer neutral state check
(1 Select monitor code 7 and set the tire in the neu-

Test operation jl,.lI [ Error clear
tral position, and confirm that the parking brake
end indicator mark is displayed.
(2) If not displayed, adjust the steering potentiometer

Preceding test item until the indicator mark appears. (See page 2-50
for detail.)
Category 1 Class 3 Test operation (traveling speed display)
Traveling while monitoring the traveling speed value input from the speed sensor is possible during the
test operation.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles to be confirmed.
-
,
(kmlh) (kmlh) (kmlh)
Right and left wheels
drive speed display
- Left wheel drive speed
display
Right wheel drive speed
display
milelhi, milelhi, display

Right and left wheels Left wheel drive speed Right wheel drive speed
drive speed display display (milelh)
Display in normal state: 13
Display in error state: error code
(1) The test No. is displayed on the hour meter.
A
(2) The traveling speed or speed sensor input data is
I -I displayed on the hour meter.
r (3) When an error occurs, the error code is displayed
[ oLr H.6 J on the speedometer and is retained until the error
I
t
I
t clear switch is pressed.
I
Speed sensor display
Speed sensor being monitored Action: lnverstigate the error position and the part show-
shooting procedure.
Left
+T+hror
and 1 -
1- I
To increase the number by 1 right
Sensor display
being monitored Left /
1-
Test operation Right r

end I, clear
To decrease the number by 1
Display and Switch Operation

Category 2 Class 1 Diagnosis monitor
Past errors (10 items in total) are displayed with the corre-
sponding hour meter readings.
Use this test when the user found an error during operation
but failed in reappearance.
10th most recent error E~~~~code

1. Press the switch to select the function
(1 The serial number of error occurrence is displayed

on the battery charge indicator.
(2) The time of error occurrence is displayed on the

hour meter.
Hour meter reading upon error occurrence (3) The error code is displayed on the speedometer.
Action: lnverstigate the error position by referring to the
troubleshooting procedure.
Diagnosis
monitor end +q
Most recent error display
[El
Second most recent error

1. The corresponding part is lit, when a switch is set to
ON.
Action: If the switch ONIOFF state is different from the

display, check the switch, harness and CPU board
Switch input and repair the defective part.
test end
Category 3 Class 2 Switch input test: Buzzer check
The ONIOFF state of each switch is informed by the buzzer.
Uses:
(1 Tuning of limit switch or potentiometer
(2) Switch ONIOFF check in a place where the display is invisible
1. Press the switch to select the switch to be tested.
(1) See page 3-28 "Display and Switch Table" for

the types of switches.
2. Operate the switch and check if the buzzer sounds.
Action: If the switch ONIOFF state differs from the buzzer

indication, check and repair the switch, harness
or CPU board.
Upper switch in the list

I
Switch input
test end
- - Buzzer
stop
Lower switch in the list

Category 3 Class 3 Switch input test: Momentary interruption test
Memory interruption (open-circuit) in the switch input line

is checked.
1. Set the switch to be checked to ON.
2. Press a switch to match the display with the desired

switch to be checked.

the switch types.
(2) When the buzzer is sounding, stop it by pressing

the stop switch.
3. Shake or apply vibration to the wiring to be checked.
Switch input Buzzer

(1 The buzzer sounds if momentary interruption
test end (opencircuit) occurs.
Action: Repair the switch or harness.

Lower Switch in the list
Category 3 Class 4 Switch input test: Short-circuit test
Short-circuit in the switch input line is checked.
1. Set the switch to be checked to OFF.
2. Press the switch to match the display with the desired


the switch types.
+Ft
the stop switch.
Switch input
(1) The buzzer sounds if shortcircuit occurs.
test end I7 Buzzer
stop

MASK FUNCTIONS
The digital multi-display has built-in mask functions for vehicle maintenance and specification setting
by the service man in addition to the general functions displayed in the owner's manual for use by gen-
eral users.
To prevent destruction of important internal data by incorrect use of mask functions by the user, the
mask functions are protected by prohibiting use unless the password is input from the switch panel.
The password is described in this manual and repair manual, but is not described in the vehicle owner's
manual.
Display Mask Functions (1)

Time of use
Name Function At board Upon
Other
replacement delivery
Corrects the battery
Only when the
Battery charge meter when the
battery is not
(mountedlnot discharge characteristic
mounted.
mounted) is different from that of
the standard battery.
0
Material handling Only when the
chopper Sets the data showing material handling
(providedlnot use of the material chopper is
provided) handling choppers. provided.
(option input) 0
Soft start adjustment
made by the trimmer
on the conventional When requested by
MCS-IIIA tuning control board is made the user.
possible by switch
operation.
When tires are
Tire constant changed to a
rewriting
Speedometer correction 0
different type.
Selects the unit for Only for display in
Unit changeover speed and distance mile.
(km or mile)
display. 0
Charge counter Resets the charge When the battery
reset counter to zero. is replaced.
Parking brake
Stops warning when
application failure Only when warning When requested by
warning
the parking brake is unnecessary.
warning is the user.
(validlinvalid)
unnecessary. 0
(option input)
Stops warning when a
Battery fluid level battery without Only when warning
warning electrolyte level is invalid.
(validlinvalid) warning terminal is 0
used.
Time of use
Other
"Itage Only for 48V

Sets the data according When the battery
(36V148V) specification
to the battery voltage. is replaced.
(option input) 0
Enables simultaneous
traveling and material When a
mode demonstration is to
handling operations
(validlinvalid)
before starting the hour be made.
(option input)
meter.
Sets the data such as Vehicle with the
Speed control
speed control switch speed control
switch set
setting which varies switch
(option input)
with the destination. 0
Starts counting by the
Hour meter start
hour meter. 0 0

The following mask functions are provided for the manager of the user. The dealer should advise the
manager of the user how to operate as required.
Name Function
Displays the check result of each vehicle part by
Analyzer the corresponding numeric code.
Locks the switch panel to accept no switch in-
put for other than the password and hour meter
Power control input (locklunlock)
changeover (option), or unlocks the locked
state.
PASSWORD INPUT METHOD
Password list
Primary password Intermediate mode Secondary password Processing
[
,..
I] - IErll 1 Analyzer mode
[Stan
r m ' l
Hour meter start
MCS-IIIA tuning
mode
Primary password Tire diameter constant

acceptance mark
\
rewrite mode WI
Z
Press
7'
Simultaneouslv
km -
Unit changeover
mile
simultaneously press for 2 sec.

Charging counter start
Battery
Mounted * Not
mounted
-
Battery fluid level
warning
Valid Invalid
lOl
Irl
- -
Power control input
Unlock Lock
Option input mode

] pq
I 1-
L a +
I I
For items described as start in the processing column (analyzer mode, MCS-IIIA tuning mode, tire diameter con-
stant rewrite mode and option input mode), follow the operation procedure described below after inputting the
secondary password. For any other item, processing automatically ends here upon input of the secondary pass-
word.
Note:
If sharpened tools are used instead, it would be a cause of damage on switch.
1. Hour meter start
The hour meter does not start counting when a new vehicle is delivered. Always start the hour
meter when the vehicle is delivered from the dealer to each user. See the password list for start-
ing the hour meter.
Note:
Once the hour meter is started, it cannot be stopped. Hour meter starting is necessary also after re-
placement of the meter control board ASSY.
2. MCS-IIIA tuning mode

When restriction of the maximum speed or weakening of the plugging braking force is desired,
key in the password and start the MCS-IIIA mode. Then tuning is possible similarly as power con-
trol adjustment.
The 11 items shown below can be adjusted:
Item Tuning mode display

(1) Braking torque C1
(2) Material handling chopper soft start *1 C2
(3) Material handling chopper duty after activation *1 C3
(4) Battery charge meter correction C4
(5) Maximum traveling speed limiter C5
(6) Attachment power control 1 *1 C6
(7) Spare C7
(8) Lifting power control *1 C8
(9) Tilting power control *1 C9
(10) Overdischarge alarm function activation timing CA
(11 Material handling chopper duty in 1st stage *1 CC
(12) Spare CE
(13) Spare CF
Note:
Items marked "1 are invalid in models without the material handling chopper. (Display appears.)
MCS-IIIA Tuning mode Initial Level Setting List
Tuning mode Level (eInitial setting)

Item
display 1 2 3 4 5 6 7 8
C1
Braking torque:
Varying the regenerative braking
torque in switchback operation
-
Weak
A
w
Strong
L
Material handling chopper soft

small Great
start: a
C2 4 w C
Varying the degree of rise of the
material handling chopper duty
Material handling chopper duty
after activation: Small Great
A
C3 Varying the initial duty in soft C
start of the material handling

chopper
C4
Battery charge meter correction:
Correcting the decreasing rate of -----+--
slow Quick
battery charge meter reading

Low No
Maximum traveling speed limiter:
wed hit
C5 Limiting the maximum traveling
speed
C6
Attachment power control 1:
Varying the pump motor
revolving speed when attachment
-
Low High
switch 1 is ON
C8
Lifting power control:
revolving speed during lifting
-
LOW High
C9
Tilting power control:
revolving speed
-
LOW
a
High
C
Lift interrupt set level: NO
CA
Varying the operation timing
(discharge level) for
-
Small o
%
l:
alarm-
overdischarge alarm function

Material handling chopper duty in
small Great
1st stage: +
CC
Varying the duty of material
handling chopper 1 st speed
(1) Tuning method
@ Input the primary password and secondary password.
Irl
[ol--(xJ--~- [ol
Press
El
Simultaneously
0 ol- [a]
simultaneously press for
2 seconds.
Pr~rnarypassword
Secondary password
@ When the power control select switch is pressed, the tuning mode is indicated by the
speedometer on the display and the power control level indicates the current tuning
level of the mode.
As the tuning mode is changed sequentially (C1 4 C2 -, C3) each time the power con-
trol select switch is pressed, select the desired tuning mode.
@ Carry out tuning by pressing the level setting (up or down) switch.
To increase the tuning level: Press the up switch.
To decrease the tuning level: Press the down switch.
The tuning level is indicated on the display.
If another item is to be tuned in succession, repeat steps @ and 0.
Tuning mode
UP switch
t / \
\\
Power control
select switch select switch 0
-
+ d 1
t
3z.sh
1
1/
Down switch Tuning level Hours used indication
@ Use one of the three methods shown below for returning from the tuning mode.
Press the hour meter select switch to return to the standard display (speed display).
Turn the key switch to the OFF position.
Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
3. Tire diameter coefficient rewriting
The speedometer indication is influenced subtly by the tire type (tire diameter).
Setting for a new vehicle is made according to the tires installed on the vehicle. When tires are
replaced with other tires in a different size (new tires), set the tire diameter constant rewriting.
Also perform this setting when tires are exclusively worn or when special tires are used.
Select any of the three following methods for setting:
Method A: When replaced with new tires in a different size (excluding special tires)
Method B: When replaced with special tires
When the installed tires are worn to make the speedometer indication be felt incorrect.
Method C: When tires are worn to make the speedometer indication be felt incorrect while the
outside diameter of the tire in the new state is known.
(1 Tire constant rewriting method (method A)

lol--m--m- El
@ El El-
m
Press
simultaneously
Simultaneously
press for
[
,..
I]
2 seconds.
Primary password Secondary password
@ Select the tire constant from the tire constant table below. i
Tire type
18 x 7 x 8-10PR
Applicable
vehicle model
5FBE10
Tire constant
22
I
Rib lug 18 x 7 x 8-14PR 5FBE13.15 22
18 x 7 x 8-16PR All models 22
Pneumatic tire
18 x 7 x 8-10PR 5FBE10 18
J-lug 18 x 7 x 8-14PR 5FBE13.15 18
18 x 7 x 8-16PR 5FBEl8.20 18
Unique track-shoe tire 1 8 x 7 ~ 8 All models 18
Cushion tire
@) On the display, the speedometer indicates the current tire constant (2 numeral digits)
and the hour meter indicates the tire mark indicator.
Each time the power control select switch is pressed, the 10's digit or 1's digit of the
tire constant blinks alternately. The blinking numeral is incremented or decremented
when the level setting (up or down) switch is pressed. Set the tire constant selected in
step @. (The tire constant can be set between 0 0 and 99.)
To increase the tire constant: Press the up switch. (Increments by 1 each time.)
To decrease the tire constant: Press the down switch. (Decrements by 1 each time.)
Up switch Tire constant
/
Power control Hour meter
select switch select switch
\ Indicator
Down switch
@ Select any of the three following methods for returning from the tire constant rewriting
mode:
Press the hour meter select switch to return to the standard (speed) display.
(2) Tire constint rewriting method (method B)

@ Obtain the tire constant as follows:
1 I2 of maximum [Cushion tire]
allowable load Set the 112 of maximum allowable load
state, measure dimension A, B in the figure,
and calculate tire constant W by the follow-
ing equation:
W = 0.55A (mm) - 100
(W = 14A (in) - 100)
[Pneumatic tire and unique track-shoe tire]
With a load at 1 I2 of the maximum allowable
load on the fork, measure dimensions A and
B in the figure.
Calculate the tire constant W by the follow-
ing equation:
W = 0.31A (mm) +
0.238 (mm) - 85
(W = 7.9A (in) + 5.8B (in) - 85)
Count fractions of 5 and over as 1 and disre-
gard the rest.
@ Input the primary password and secondary
password. (See method A.)
@) Then, follow steps 3 and 4 in method A.
Use the value calculated from the actually
measured value as the tire constant.
(3) Tire constant rewriting method (method C)
@ Obtain the tire constant as shown below.
Calculate tire wear C by the following equa-
tion:
C = Tire radius in new state - radius of
worn tire
@ Calculate tire constant W by the following
equation:
1
W = W' - - C (mm)
2
(W = W' - 12.7 C (in))
W' = Tire constant in new state
@ Rewrite the tire constant according to steps
3 and 4 in method A by using the tire con-
stant calculated from the tire wear.
4. Battery electrolyte level warning

The warning function can be enabled or disabled by
password input. If A1 is indicated on the speed display
portion, the warning function is enabled. If A 0 is indi-
cated, this function is disabled.
5. Power control input

The power control input can be locked or unlocked by
password input. If P I is indicated on the speed display
portion upon password input, the power control input
is set to the locked state. If PO is displayed, the power
control input is unlocked.
6. Battery (mountedlnot mounted)

It is possible to select battery mounted state or not
mounted state by passwork input. The speedometer
on the display indicates T I when the not mounted
state is selected, and TO when the mounted state is
set.
Note: This data is provided for changing over the constant

for calculation for the battery charge indicator. Set it to the
mounted state when the standard battery is to be used, or
to the not mounted state when any other type of battery is
to be used.
7. Option input mode
Demonstration mode
Effective * lneffective
*
Primary password Parking brake applica-
acceptance mark
tion failure warning
Effective +,lneffective
*
lo] --=--m-- El
la ' Voltage selection
3,4+48v
TPress P
Simultaneously
simultaneously press for 2 sec. Hours used indication Material handling
chopper
Provided 4+ Not pro-
vided
*
Speed control switch
Set * Reset
These are passwords for option items newly added in the 5FBE series.
As these are set according t o the specifications at the time of new vehicle delivery, no setting is re-
quired unless any change is made.
The items with * are not provided in the vehicle specifications. Although indication on the display ap-
pears, proceed t o the next option item by pressing the power control select switch.
These items should be set in any of the following cases:
When the display board is replaced
When a demonstration is t o be made
When the parking brake application failure warning is t o be reset
(1) Demonstration mode switching effectivetineffective.
For the transportation reason, the condition of the truck before starting the hourmeter has
been so arranged that the parking application failure warning and the simultaneous opera-
tions of the traveling and material handling should be preset to "lneffective".
This condition, however, is changeable to "Effective" by turning the demonstration mode on
the mask function.
This changeover, in especial, in useful for the demonstration of the New Trucks, where the
warning and simultaneous operation are in need.
lneffective + Effective changeover
T
r 4
, 1 4m- End
Transition to next option
Effective -t lneffective changeover
[ E l - (m)
Demonstration mode : Effective
dEnno
Demonstration mode : Ineffective
Use the UP or DOWN switch for selection.

Press the UP switch to change from ineffective to effective. Press the DOWN switch to change form
effective to ineffective. Pressing the UP switch in the effective state or the DOWN switch in the inef-
fective state causes no change. When the power control select switch is pressed, the next option item
is selected.
When the hour meter changeover switch is pressed, the mode returns from option input to normal dis-
play-
Note:
It takes about a second after pressing the select (UP or DOWN) switch until display change.
(2) Parking brake application failure warning effectivelineffective selection
I
I 5
I
,[-ni m+ End
Transition t o next option
Effective + lneffective changeover
Pflr - E r PRr - E r
Parking brake applrcation failure alarm : Parking brake application failure alarm :
Effective Ineffective
(Note) Keep the setting at Effective as the ineffective specification is not provided as the vehicle specification.
(3) Voltage selection
36 V + 48 V changeover
e
/ *
r d
0 m-l End
'
*
1
4
I
[m=
[mj- 36 V specification 48 V specification
As 36V specification is not provided as the vehicle specification.

Keep this setting at 48V.
(4) Material handling chopper providedlnot provided selection
The method is the same as that for demonstration mode selection in item (1) above.
Not provided + Provided changeover
P r *
, (01.: End
Provided + Not provided changeover
With material handling chopper Without material handling chopper
(5) Speed control switch setlreset selection

The method is the same as that for demonstration mode selection in item (1 ). The operation,
however, shall be made after pressing the speed control switch to on.
Reset + Set changeover
* r 5
,@ [o)-+ ~ n d
Transit~onto next option
Set + Reset changeover
Switch : Set Switch : Reset
(Note) Keep this setting at Set as speed control switch reset is not provided as the vehicle specification.
MULTI-DISPLAY FUNCTIONS
[FOR OTHER THAN U.S.A.] (1998.9 - 1
Page
DIAGNOSIS ........................................................ 3 ~ - 2
GENERAL ........................................................... 3A-2
ANALYZER ......................................................... 3 ~ - 7
GENERAL .......................................................... 3A-7
USING THE ANALYZER MODE .............................. 3A-9
METHOD FOR SELECTING EACH ITEM .................. 3A-12
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM ...................................................... 3A-17
M A S K FUNCTIONS ............................................ 3 ~ - 3 2
PASSWORD INPUT METHOD ............................... 3 ~ - 3 4
DIAGNOSIS
GENERAL
The 5FBE Series has the self diagnostic function, which automatically detects errors in the main drive
and material handling circuits, operation systems such as the accelerator, sensors, etc., and sounds
the buzzer while displaying these errors by corresponding error codes on the multi-display.
At the same time, safe operation is ensured by automatic stop of traveling, stop of material handling
and or traveling speed control.
Depending on the trouble only the error code appears on the multi-display. Although the vehicle may
be operated, make necessary repairs as soon as possible.
The self diagnosis mode may be switched to the analyzer (error analysis) mode, in which failure is de-
tected and, the main drive and material handling circuits, each operation system, sensors, etc. are
checked for functions.
Use these functions fully for early detection and elimination of electrical system troubles.
1. Error code display

The error code appears in part @ in the illustration,
@ Error code and the warning sound bleeps. Make repairs soon ac-
cording to the error code displayed by self diagnosis
while referring to "Troubleshooting" in Section 4A.
3i'.s Sh
--

(Example figure shown)
Diagnostic Error Code List
Error Fault mode Phenomenon in vehicle

Faulty portion
code
A0 MCS main circuit Overheat Lowering of traveling speed
A2 CPU board Abnormal temperature rise Lowering of traveling speed
Traveling, material handling,

A3 Battery Abnormally high voltage
and PS stop
A4 Traveling accelerator Traveling stop
abnormality

A6 Material handling switch Material handling stop
abnormality
Departure from vehicle

A7 Parking brake application
without applying the parking (Display only)
*I failure warning
brake
A8 Drive motor fuse F1 Fuse open Traveling stop
A9 Material handling fuse F2 Fuse open Material handling stop
Temperature sensor (Display only)

AA CPU board
abnormality on CPU board
Analog input detection Traveling, material handling,

AE CPU board
Excessive processing time and PS stop
CPU processing data Traveling, material handling,

AF CPU board
abnormality and PS stop
*l.Can be enabled or disabled by the display mask function (provided only for the vehicle with deadman switch).
3A-4 4
.
Error Faulty portion Fault mode Phenomena\%
code
CO Main drive circuit Traveling transistor open short Traveling stop
Traveling current sensor

-
abnormality
C1 Drive current sensor Traveling stop
Traveling current sensor
harness open short
Traveling thermo sensor

C3 Traveling thermo sensor Lowering of traveling speed
harness open short
C4 Traveling accelerator Traveling stop
short or opencircuit
C7 Direction switch Direction switch short Traveling stop
Sensor rightlleft harness open

C8 Speed sensor Traveling stop
circuit
C9 Traveling contactor Contactor short Traveling stop
Traveling contactor drive Contactor coil chopper Traveling, material handling,

circuit (CPU board) transistor short and PS stop

CE CPU board ROM abnormality
and PS stop

CF CPU board RAM abnormality
and PS stop
Error
Faulty portion Fault mode Phenomenon in vehicle
code
Eo Material handling transistor

Main material handling circuit Material handling stop
*2 open short
Material handling current

El Material handling current sensor abnormality
Material handling stop
*2 sensor Material handling current
sensor harness open short
Switch 1 harness open
E6 circuit
Lift switch Material handling stop
*2 Switch 2 harness short
circuit
Display-MCS communication MCS receiving data

EE (Display only)
system abnormality
Excessive CPU processing

EF CPU board (Display only)
time
*2.Only for vehicle with material handling chopper (OPT)

Error Fault mode phenomenon in vehicle
Faulty portion
code
FO Power steering (only in

Power steering abnormality (Display only)
"3 EHPS)
F1 Communication failure (Display only)
system
F2 Communication data error (Display only)
system
Display-MCS communication (Display only)

F3 Echoback error
system
Power control memory value

F4 Display (Display only)
inconsistency
(Display only) (Automatic

F5 Charger (on-vehicle type Charging timer memory
equalizing charging
"4 only) abnormality
impossible)
F6
Charger (on-vehicle type Charging safety timer
++4 Charging stop
only) operation
*5
F7
Charger (on-vehicle type (Display only)
*4 Charging starting failure
"5 only)
F8 Charger (on-vehicle type (Display only)

Charging end failure
"4 only)
Steering potentio abnormality Traveling stop

F9 Steering potentio
Harness open short
Traveling, material handling

FA RA RA harness disconnection
stop
'3.Only for vehicle with EHPS (OPT)

*4.Only for vehicle with on-vehicle type charger
*5. No alarm sound
3A-7
ANALYZER
GENERAL
The 5FBE series has the analyzer for function check and defect detection of the main drive and mate-
rial handling circuits, operating system such as accelerator, and sensors by switching the multidisplay
into the analyzer mode for quick and easy servicing.
Use these functions fully for early solution of troubles in the electrical system.
General Description of Analyzer Functions

The analyzer supports controller system inspection and locating of defective parts by making full use
of the computer function of the MCS-IIIA controller and the communication function between MCS-
IIIA and multidisplay.
(1) Monitoring the history of past errors (diagnosis monitor)
(2) Testing the connections and insulation defects of wiring and connectors (switch input test)
(3) System check with actual travel and material handling operations (test operation)
3A-8
Test items by analyzer

Category Class Description
1 Simple test Past diagnosis display and continuous quality
check for main circuits, switch systems and
sensor systems

Simple test and (voltage, current values (motor current, accelerator input
test operation and temperature voltage, etc.) and error occurrence
display)
(traveling speed values (traveling speed) and error occurrence
display)
1 Diagnosis Past error display with hour meter readings at

2 Diagnosis monitor monitor the time of error occurrences
1 Switch ONIOFF Display of every switch onloff state

information display
2 Buzzer check Information of each switch onloff state by

buzzer sound
3 Switch input test

3 Momentary Testing defective contacts of wirings and
interruption test connectors
4 Short circuit test Testing defective insulation of wirings and

connectors
USING THE ANALYZER MODE
Preparation for analyzer mode
Caution:
Before starting analyzer mode operation, always jack
up the frame until the front and rear wheels leave the
ground, support the frame with wooden blocks for sta-
bilization, and bring the fork down to the lowermost
position.
Diagnosis error display 1. Set the battery plug to ON.
2. Set the key switch to ON.

/
t 73
Note:
11- 1- If diagnosis error code "AF", "CE", ##CF##, "EE#r,
nr "Fl", "F2" or "F3" is displayed, the analyzer mode
cannot be used.
3z.5, )
1
T //
I
Switching t o the analyzer mode

The multidisplay is generally set to the diagnosis mode.
This display is protected by mask functions to prevent the important internal data from being de-
stroyed by incorrect user operation.
Switching to the analyzer mode, therefore, requires password entry from the switch panel.
1. Primary password entry
Operate the display switch panel according to the se-

Short bleep quence shown in the illustration.
Within 10 seconds
If not operated within 10 seconds, the mode returns t o
the ordinary travelinglmaterial handling mode (diagno-
Short bleep sis mode).
Within 10 seconds
Keep pressing the switch in the final step for 2 sec-
onds. The intermediate mode screen is displayed.
0 Short bleep If the operation is mistaken halfway, set the key

switch to off once and repeat the operation from the
beginning.
Within 10 seconds
Note:
If sharpened tools are used instead, it would be a cause of
Keep pressing for 2 sec. damage on switch.
Short bleep
Intermediate
2. Intermediate mode display
Transition to the analyzer, hour meter start or MCS-
7
I kmlh
lllA tuning mode occurs from this mode.
32.5h
I
]
? //
3. Analyzer mode input

Within 10 seconds
Operate the display switches in the sequence shown in
the illustration.
[=)Short bleep
1
Within 10 seconds
] p] g~:taneously
Short bleep
4. Analyzer activation
Lighting for 2 seconds followed by
flashing 5 times
The display changes as illustrated and the analyzer is
activated.
\ \ I / / \\
Then the initial display appears.
- DW# DW# If the analyzer cannot be activated by the operation
I
1717- I \ \
above, turn the key switch OFF once and repeat from
the primary password input again. If not activated by
(0 UEr-3.0 ) repeated operation, system abnormality may exist.
*
I
I
I
Version display
5. Initial display
Flash~ng
I
1 Transition t o each analyzer mode occurs from this dis-
\ \ p /
play state.
11
- PI
'
I-/ I-/
I \ \
( flnL A
1,
7
I
AnL: analyzer
.METHOD FOR SELECTING EACH ITEM
Each item can be selected by adjusting the speedometer display t o the corresponding category and
class numbers.
1. Item selection from analyzer activation state (initial display) (Example: 12)
0 Flashing Indicates the ready
End of analyzer activation state for category
-lua 14- 14- number input.
,
.-
V)
-0
-m
.-
D L ! L!
.-
,
C,
-C
AnL: analyzer
@ TO increase the numeral Display the desired Flashlng

number
s
@ m /.DL!
.-0
C,
[lrl [ RnL I
0
-Q,
a, To decrease the numeral by 1
V)
2 0 Press this switch The category

0 when the desired - number is
CI)
Q,
+ category number is determined and
lu
o displayed. class number input
( 0 ) is enabled.
@ To Increase the numeral Display the desired Flashlng

by 1 class number. --
/ I \ \
c
.-
0
C,
-0
Q,
Q,
V)
0 Press this switch Flashing stops when
V)
-m the class number is
o determined t o
complete item
selection.
3A-13
2. To select another item from one item

(1) To select another class in the same category (Example: 1 2 4 1 3)

0
- 5
P
.-
U
V)
-m
.-.-+
-C

C,
display appears t o
V)
al
enable class number
+,
+
0
U
C
W
I 1
0 Display the desired Flash~ng
To increase the numeral by 1 class number.
C
.-0
El
C,
0
- al
a
V)
@ 7Press this switch Flashing stops when
the class number is
-a
V)
H-TJ
ed:::rclass
l number
desired
is dis-
7)
[ ~r DO ..]
determined t o com-
plete item selection.
(2) To select an item in a different category (Example: 13-+New item)

0
-
>
-
a
n
.-
V)
-
.-([I
.-
C,
[ o ~ Ur . 3 3
-
C

~j enable class number

input.
B i0J / / \ \
+J
[ run I
V)
al
C,
w-
u
c
0 Press this switch t o Returns t o the initial
W set class number 0. display upon ana-
lyzer activation
when class number
0 is set.
AnL: analyzer
@
1. Select the desired item according t o the
&c procedure from "Analyzer activation
0 .E!
E t; state (initial screen)".
2%
V) V)
V)
mE
U B
al "
5 Bal
s Ez
-c=
'S
s
0 0
.- +
+J
3-
."E E
"2
5al
3 t;;
2-
a .9
3. Ending analyzer mode (transition to diagnosis mode)
0
State of testing a certain item (11 ) Category Subcategory
>
-n
lu
.-
u
V)
-
.-
lu
.-
C,
-c [Trn ESY (simplified) test -00

' I , \
C,
V)
a
C,
LC
0
c 0 Press this switch Returns t o the initial
w and set class display upon
number 0. analyzer activation
\ \ I ,
when class number
llrl
AnL: analyzer
c @ Press this switch "n" flashes.

.-
0
C, and set category
-aa0 number 0. Analyzer mode
V)
u
C
a Y: Yes t o end the
L
a
N
-4 CI1] analyzer mode
-> [IIl n: NO t o continue
([I
the analyzer
4 mode
C 0 Press this switch t o select Y. "Y" flashes.
.-0+ (End the analyzer mode) Flashing
-a0
%
u
C
a
L
a
N
-
>
m
[ End
4 Press this swtich to select N.
8 Press this switch to
Q) end the analyzer
w
mode.
E
L
al
N
-lu>
C
lu
CC
0
w
C
111
When the switch in step @ is pressed in step @ (flashing of "n"), the display returns to @ (initial
display).
It is also possible to end the analyzer mode by setting the key switch to OFF.
3A-17
FUNCTIONAL EXPLANATION OF EACH TEST ITEM
Category 1 Class 1 Simple test
The simple test consists of 37 test itmes ESY-01 t o ESY-37, each with its specific display.
Simple test item selection method

Category Subcategory
1. Initial display
I I
t t
if- if-
ESY-SD-~
----
t
I
ESY (simplified) test- 00
2. Switch operation method

@ Next test item
F 1 *
Press a:Proceeding t o the next test item
(Ex. ESY01+02)
rm Press @: Returning t o the preceding test item

[a]
[TI4 +@ Retest
(Ex. ESY02+01)
/ i '0
@ Test end T@ Preceding test item
#
Press @: Repeating the same test item
Press @: Ending the simple test (returning t o the

class selection display)
3A-18
Simple Test Function Map

Category I Class 1
ESY-01 Automatic check of main circuits, current and speed sensors etc.
The most recent diagnosis error code and

ESY-02
The second most recent diagnosis error code and
ESY-03
The third most recent diagnosis error code and
ESY-04
ESY-05
ESY-06 Reading the memory of past corresponding hour meter reading
diagnosis errors (10 most
recent errors) The 6th most recent diagnosis error code and
ESY-07
ESY-08
ESY-09
ESY-10
ESY-11
Voltage detected before key switch SWKY
ESY-12
(intermediate tap)
Detected voltage value display Voltage detected after key switch SWKy
ESY-13 (to enable judgement on the (intermediate tap)
performance of the detecting
ESY-14 function based on the Voltage detected at P2 terminal
difference from the actual
value measured with a
ESY-15 multimeter) Voltage detected at P9 terminal
ESY-16 Voltage detected at P I1 terminal
Automatic judgement on
abnormality or defective
Check of accelerator switch SWAc, drive accelerator
ESY-17 adjustment of the drive
potentiometer VRA, and drive acceleration sensor
accelerator by accelerator
operation
Automatic judgement o n temperature o n CPU board or judgement based o n the
ESY-18
difference between the detected temperature value and actual temperature.
Automatic judgement o n the performance of the controller traveling thermo sensor and
ESY-19
detection of voltage
ESY-20 Automatic judgement o n steering potentiometer quality and detection of voltage
ESY-21 Judgement o n the qualities of ONIOFF of forward right contactor MFR

the contactor and contactor
drive circuit b y visual check of
ESY-22 contactor attractionjrelease ONIOFF of reverse right contactor MFR
state b y outputting each
ESY-23 contactor ONIOFF signal ONIOFF of forward left contactor MFL
ESY-24 ONIOFF of reverse left contactor MFL
ESY-25 ONIOFF of p u m p contactor MP
ONIOFF of PS contactor MPs

ESY-26 (Unapplicable t o vehicles w i t h EHPS since they do
not have this contactor.)
ESY-27 Judgement o n the qualities of ONIOFF of forward direction switch DSF

switch and switch detecting
circuit b y ONIOFF state
ESY-28 display of each switch and ONIOFF of reverse direction switch DSR
buzzer sound
ESY-29 ONIOFF of accelerator switch SWAc
ESY-30 ONIOFF of brake switch LSB
ESY-31 ONIOFF of speed control switch SWsc
ESY-32 ONIOFF of parking brake limit switch LSpB
ESY-33 ONIOFF of lift limit switch LSL
ESY-34 ONIOFF of lift limit switch LSLS
ESY-35 ONIOFF of tilt limit switch LST
ESY-36 ONIOFF of deadman limit switch LSD
ESY-37 ONIOFF of attachment limit switch LSAT

3A-20
Test No.: ESY-01

The following items are checked automatically and the results are displayed:
I Main drive circuit and main pump circuit check ........................................... CO-EO
2 Drive current sensor and pump current sensor zero point check .....................C l v E l
3 Speed sensor discontinuity detection ......................................................... C 8
1. If the check result is normal, 00 is displayed on the

Error code speedometer.
Next test item Retest
2. If abnormal, the corresponding error code is displayed
with buzzer sounding.
3. If multiple errors occur, they are displayed sequen-

tially.
Preceding test item
Test end Action: lnvestigate the error position by referring to the
troubleshooting.
Past diagnosis errors are displayed.
ESY-02: Most recent error
ESY-11: Oldest diagnosis error stored in memeory.
the hour meter.
(2) The error occurrence time and error code are dis-
played on the hour meter and speedmeter, re-
spectively.
Preceding test itern Time of error duration
Simplified test end Action: lnvestigate the error position by referring to the
troubleshooting.
The voltage at the voltage input terminal is measured and
(0: OK H : NG) displayed.
ESY-12: Voltage at battery terminal (intermediate tap)

ESY-13: Voltage at key switch terminal (intermediate tap)
ESY-14: VBP2 voltage at P2 terminal
ESY-15: VBP9 voltage at P9 terminal
Voltage 48.0 V ESY-16: VBPI 1 voltage at P I1 terminal
Next test item
t
1 \
1. Select the function b y pressing the switch.
(1) ESY-xx is displayed with blinking three times o n the

hour meter.
(2) The voltage is displayed on the hour meter.
(3) Measure the input voltage at each terminal with a

multimeter, and check the difference f r o m the dis-
Simplified test end played value.
Preceding test item
Standard (See page 2-21.)
VBBTIVBKY +
Within 1 %
VBP2.VBPS.VBPI 1: Within f 5 %
(4) AS the VBKY over 54Vcannot be displayed, condact

this check only when it is 54 V o r less.
Action: @ Abnormality of trimmer potentiometer in

CPU + Replace the CPU board.
Note:
Never tamper with the trimmer potentiometer.
@ When the voltage is 0, check the harness.

~ L:;G'~, ' . ~
Adjustment condition
(No display : OK H: NG)
~ ~ Test No.: ESY-17
Indicate at
The potentiometer voltage with satisfaction or dissatisfac-
I tion of the specified range and the properness of the corre-
sponding switch ONIOFF state are displayed.
ESY-17: Accel potentiometer (SWAc.VRA)
( opm-z.
A
.1 ] /// \
I. Press the switch t o select the function.
Potentiometer voltage
PTA : Accelerator potentiometer hour meter.
Next test Item
fi
1
1 \ (2) The potentiometer type and potentiometer voltage
are displayed on the hour meter.
r=
[ a ] [T)
- -Retest
(3) The speedometer displays whether the potentiome-
ter voltage is within the specified range and wheth-
' 10 i
er the switch onloff state is proper.
Criteria for voltage

Simplified test end
Acceptable range when SWAC is OFF: 1.7 V or more
Preceding test item Acceptable range when SWAC is ON: between 0.3 V
and 4.4 V inclusive
How to determine the adjustment condition

NG is displayed if the accelerator switch is shorted
when the test frame is displayed. (Only when A4 is
indicated.)
How t o judge the performance of the accerelator poten-

tiometer
a Operate the accelerator pedal (switch) and read
the voltage (A) when the "@" is shown.
@ Read the voltage (B) when the accelerator ped-
al is pressed to the stroke end.
83 B-A=C.
4 C=1.4Vormore.
W
Actions: 1 Check the potentiometer installation state.
2 Check the harness.
3 Replace the potentiometer.
4 Replace the CPU board.
Test No.: ESY-18
The temperature detected by the thermistor on the CPU board is displayed. The properness of the tem-
perature and voltage range is checked and displayed.

Theremistor voltage Temperature range
( 0 : OK H : NG) ( 0 : OK H : NG)
(1) ESY-18 is displayed with blinking 3 times on
the hour meter.
(2) The temperature on the CPU board is displayed on

the hour meter.
(3) The speedmeter displays whether the tempera-

TH : Thermistor Ambient temperature
ture range is normal and whether the themistor
voltage is normal.
Next test item Retest

Actions: @ Check the ambient temperature of the CPU
board by comparison with the data mea-
sured by the thermometer.
Preceding test item

Simplified test end
Test No.: ESY-19

Voltage check Temperature range
(0:OK, H: NG) (0:OK H: NG) The voltage of the controller traveling thermo sensor is
/ 3 checked and displayed. The properness of the temperature
and voltage ranges is displayed.
( f t i d Y.5 .+) J (1) ESY-19 is displayed with blinking 3 times on the

1
I \. J hour meter.
/
THD: Controller traveling \
Voltage (2) The voltage of the controller traveling thermo sen-
thermo sensor
sor is displayed on the hour meter.
Next test item
Retest (3) The speedmeter displays whether the temperature
range and the sensor voltage are normal.

Acceptable range: 0.3 V or more
Preceding test item Criteria for temperature
End of test Acceptable range: 3.2 V or more
Test No: ESY-20
Voltage check
(0:OK, H: NG) Steering potentiometer check
\
\
The steering potentiometer voltage is displayed.

0 1
O r r
3, -z.
3 hour meter.
(2) The potentiometer type and voltage are displayed

on the hour meter.
Next test item
(3) The speedmeter displays whether the potentiome-
ter voltage is in the specified range or not.

Acceptable range: 0.6 V to 4.3 V inclusive
Preceding test item

End of test

Contactor closing test
ESY-21: Forward right contactor (MFR)test

ESY-22: Reverse right contactor (MRR)test
ESY-23: Forward left contactor (MFL)test
ESY-24: Reverse left contactor (MRL) test
ESY-25: Pump contactor (MP) test
mFr : Contactor MF, ESY-26: PS contactor (Mps) test
Next test item During traveling contactor tests from ESY-21 to 24, the trav-
eling transistor is checked for a fault. If a fault is discovered,
the speedmeter displays error code "CO" and the contac-
tors are not turned ON.
Preceding test item (1) ESY-xx is displayed with blinking three times on the
Simplified test end hour meter.
(2) The contactor code is displayed on the hour meter.
(3) Visually check closing or opening of each contactor.
Actions: 81 Check welding of the contactor.

2 Check the resistance of the contactor coil.
Check the voltage at the time of contactor
closing.
(The contactor is defective if it is 30 V or
more.)
Switch ONIOFF and buzzer check
ESY-27: Forward direction switch (DSF)

ESY-28: Reverse direction switch (DSR)
- 3 ESY-29:
ESY-30:
Accelerator switch (SWAc)
Brake switch (LSB)
ESY-31: Speed control switch (SWsc)(Not i n US specifica-
tion)
ESY-32: Parking brake limit switch (LSpe)
ESY-33: Lift limit switch 1 (LSL)
dSF I
0
A
I, ESY-34:
ESY-35:
Lift limit switch 2 (LSL2)(Only in vehicle with mate-
rial handling chopper)
Tilt limit switch (LST)
I I ESY-36: Deadman limit switch (LSD)
DS,: Forward s w ~ t c h0: ON
F: OFF
ESY-37: Attachment limit switch (LSArr)
(1) ESY-xx is indicated with blinking three times on

Next test item the hour meter.
(2) The switch code is indicated on the hour meter.
(3) When the selected switch is setto ON, F displayed
on the hour meter is changed to 0 and the buzzer
sounds.
Actions: @ Check the switch.

Preceding test item @ Check the switch harness.
Simplified test end
@ Check the CPU board.
@ Replace the CPU board.
Category 1 Class 2 Test operation (voltage current or temperature display)
In the test operation, traveling and/or material handling are possible while monitoring the analog in-
put value of each sensor.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to
enable very infrequent troubles to be confirmed.
Analog input items to be monitored
No. Item Description

0 Drive motor current A Abnormality of current sensor or current detecting circuit,
deviation of OCL value or abnormal forklift load
1 Pump motor current A Abnormality of current sensor or current detecting circuit or

abnormal forklift load
2 Battery terminal voltage V Abnormality of voltage detecting circuit (excessive charge

indicator display error)
3 Key switch terminal voltage V Abnormality of voltage detecting circuit (excessive charge
indicator display error)
6 P I1 terminal voltage V Abnormality in voltage detecting circuit
7 Accelerator potentiometer V Abnormality of acceleration sensor, or abnormality in

voltage acceleration potentiometer detecting circuit (maximum speed)
8 Atmospheric temperature "C Abnormality of thermo sensor or abnormality in thermo sensor

detecting circuit
9 Voltage of the controller V Abnormality of thermo sensor

traveling thermo sensor Abnormality of thermo sensor detecting circuit
10 Steering potentiometer V Abnormality of steering potentiometer voltage

voltage
The analog input value is displayed in the test operation.
The error code is displayed when an error occurs and is retained until the error clear switch is pressed.

Display i n normal state: 12
Display i n error state: error code (1 The test No. is displayed on the hour meter.
I
1 (2) The current value, etc. during the test operation
33 are displayed on the hour meter.
(3) 1 2 (Category: 1, class: 2) is displayed on the

speedometer in normal state.
B
Indicated upon \ \ // (4) If an error occurs, the error code is displayed on
switch ON Analog input display the speedometer and is retained until the error
and steering (300 A)
clear switch is pressed.
potentio meter
neutral state Preceding item No.
shooting procedure.
Press this switch t o increment
the test No. by one. 2. Steering potentiometer neutral state check
(1) Select monitor code 10 and set the tire i n the neu-
tral position, and confirm that the parking brake
Error clear indicator mark is displayed.
end
(2) If not displayed, adjust the steering potentiometer

until the indicator mark appears. (See page 2-50
Press this switch t o decrement for detail.)
the test No. by one.
Category 1 Class 3 Test operation (traveling speed display)
Traveling while monitoring the traveling speed value input from the speed sensor is possible during the
test operation.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed t o en-
able very infrequent troubles t o be confirmed.
,
(kmlh) (kmlh) (kmlh)
Right and left wheels -'
Left wheel drive speed
drive speed display display display
1 (m
elih
/,i (milelhi, display mile/h)b
Right and left wheels Left wheel drive speed Right wheel drive speed
drive speed display display (milelh)
Display in normal State: 13
Display in error state: error code (1) The test No. is displayed on the hour meter.
A
a (2) The traveling speed or speed sensor input data is
4-
4 displayed on the hour meter.
r 3 (3) When an error occurs, the error code is displayed
( eLr 18.6 h]
on the speedmeter and is retained until the error
?
1 L
? // clear switch is pressed.
I
Speed sensor display
Speed sensor being monitored
+T+hrOr
shooting procedure.
TO increase the number by 1
Left
and 1 -
1- I
right
Test operation Sensor display
end I, clear
being monitored I
Left 1-
To decrease the number by 1 Right r
Category 2 Class 1 Diagnosis monitor
Past errors (10 items in total) are displayed with the corre-
sponding hour meter readings.
Use this test when the user found an error during operation
Initial display
but failed in reappearance.
1. Press the switch to select the function
(1) The serial number of error occurrence is displayed

on the battery charge indicator.
(2) The time of error occurrence is displayed on the

hour meter.
Hour meter reading upon error occurrence (3) The error code is displayed on the speedmeter.
Action: lnverstigate the error position by referring to the
troubleshooting procedure.
Most recent error display
Diagnosis
monitor end ++I LEI
Second most recent error

Category 3 Class 1 Switch input test: ONIOFF information display
I
The ONIOFF state of every switch is displayed to allow confirmation at a glance.
A level line in the battery charge indicator or a level line in the power control level gauge corresponds
to each switch.
The corresponding position comes on when a switch is ON.
Lights at the parking

brake release (ON)
f,
-
/
.
0- -7 d'
(0 SL'/ ]
J
Initial display
-O -
Display and switch table
Deadman switch
(LSD)
(SWsc)
up,)
-
Parking brake limit switch
o Brake switch (LsB)
-Accelerator switch (SW),
0 Reverse direction switch

Forward direction switch
(DSR)
(DSF)
Lift limit switch 1 (LSJ
Lift limit switch 2 (LSL~)
Tilt limit switch (LST)
1
Attachment limit switch (LSATT)
1. The corresponding part is lit, when a switch is set to
ON.
Action: If the switch ONIOFF state is different from the

display, check the switch, harness and CPU board
Switch input -- and repair the defective part.
test end
Category 3 Class 2 Switch input test: Buzzer check
The ONIOFF state of each switch is informed by the buzzer.
Uses:
(1) Tuning of limit switch or potentiometer
(2) Switch ONIOFF check in a place where the display is invisible
1. Press the switch to select the switch to be tested.
(1) See page 3A-29 "Display and Switch Table" for

2. Operate the switch and check if the buzzer sounds.
Action: If the switch ONIOFF state differs from the buzzer

indication, check and repair the switch, harness
SW: switch or CPU board.
Press this switch to display the switch

immediately above on "Display and
Switch Table".
Switch input
test end -
I
Press this switch to display the switch
immediately below on "Display and
Switch Table".
Category 3 Class 3 Switch input test: Momentary interruption test
Memory interruption (open-circuit) in the switch input line

is checked.
1. Set the switch to be checked to ON.
2. Press a switch to match the display with the desired


SW: switch
the stop switch.
3. Shake or apply vibration t o the wiring to be checked.
Switch input Buzzer

(1 The buzzer sounds if momentary interruption
test end (opencircuit) occurs.

Lower Switch in the list
Category 3 Class 4 Switch input test: Short-circuit test
Short-circuit in the switch input line is checked.
1. Set the switch to be checked to OFF.
2. Press the switch to match the display with the desired


Type of switch
Switch input
test end
+F+ SW: switch
I
,
stop

the stop switch.

(1) The buzzer sounds if shortcircuit occurs.

MASK FUNCTIONS
The digital multi-display has built-in mask functions for vehicle maintenance and specification setting
by the service man in addition t o the general functions displayed in the owner's manual for use by gen-
eral users.
To prevent destruction of important internal data by incorrect use of mask functions by the user, the
mask functions are protected by prohibiting use unless the password is input from the switch panel.
The password is described in this manual and repair manual, but is not described in the vehicle owner's
manual.
Display Mask Functions (I)

Time of use
Other
Corrects the battery
Only when the
Battery charge meter when the
battery is not
(mountedlnot discharge characteristic
mounted.
mounted) is different from that of
the standard battery.
0
Material handling Only when the
chopper Sets the data showing material handling
(providedlnot use of the material chopper is
provided) handling choppers. provided.
(option input) 0
Make soft start
When requested by
MCS-IIIA tuning adjustments by switch
the user.
operation
When tires are
Tire constant
rewriting
Speedometer correction 0 changed to a
different type.
Selects the unit for Only for display in
unit changeover speed and distance mile.
(km or mile)
display. 0
Charge counter Resets the charge When the battery
reset counter to zero. is replaced.
Parking brake
application failure Stops warning when Only when warning
warning the parking brake is unnecessary. When requested by
the user.
(validlinvalid) warning is unnecessary. 0
(option input)
Stops warning when a
Battery fluid level battery without Only when warning
warning electrolyte level is invalid.
(validlinvalid) warning terminal is 0
used.
Time of use
Other
"Itage selection Sets the data according Only for 48V When the battery
(36V148V) specification
to the battery voltage. is replaced.
(option input) 0
Enables simultaneous
Demonstration When a
traveling and material
mode demonstration is to
handling operations
(validlinvalid)
before starting the hour be made.
(option input)
meter.
Sets the data such as Vehicle with the
Speed control
speed control switch speed control
switch set
setting which varies switch
(option input)
with the destination. 0
Starts counting by the
Hour meter start
hour 0 0

The following mask functions are provided for the manager of the user. The dealer should advise the
manager of the user how to operate as required.
Name Function
Displays the check result of each vehicle part by
Analyzer
the corresponding numeric code.
Locks the switch panel to accept no switch in-
put for other than the password and hour meter
Power control input (locklunlock)
changeover (option), or unlocks the locked
state.
PASSWORD INPUT METHOD
Password list
(is] +
Analyzer mode
piq
Irl
m +
Hour meter start

[is]
MIS-IIIA tuning
+ I>[ mode PI
( Tire diameter constant
Primary password
acceptance mark El+a.-(]
rewrite mode VI
lo] --=--m-- = {'pqR 7
\
>
Lrr:
L Unit changeover
I-..I] o-
h [o
\/km,h
[T] k m * mile
1 Irl
+
f ?' 3Z.5h
Press Simultaneously &\ I JJ
simultaneously press for 2 sec.

Hours used indication El
[zi][ZG]+ Charging counter start
Battery
El- Mounted * Not
[z] mounted
[z] Battery fluid level

warning
Valid r Invalid
[rl
[ol Power control input
Unlock * Lock
Irl
El + ) Option input mode
Vj
For items described as start in the processing column (analyzer mode, MCS-IIIA tuning mode, tire diameter con-
stant rewrite mode and option input mode), follow the operation procedure described below after inputting the
secondary password. For any other item, processing automatically ends here upon input of the secondary pass-
word.
Note:
If sharpened tools are used instead, it would be a cause of damage on switch.
1. Hour meter start
The hour meter does not start counting when a new vehicle is delivered. Always start the hour
meter when the vehicle is delivered from the dealer to each user. See the password list for start-
ing the hour meter.
Note:
Once the hour meter is started, it cannot be stopped. Hour meter starting is necessary also after re-
placement of the meter control board ASSY.
2. MCS-IIIA tuning mode

When restriction of the maximum speed or weakening of the plugging braking force is desired,
key in the password and start the MCS-IIIA mode. Then tuning is possible similarly as power con-
trol adjustment.
The 10 items shown below can be edjusted:
Item Tuning mode display

(1) Braking torque C1
(2) Material handling chopper soft start *1 C2
(3) Material handling chopper duty after activation *1 C3
(4) Battery charge meter correction C4
(5) Maximum traveling speed limiter C5
(6) Attachment power control 1 *1 C6
(7) Spare C7
(8) Lifting power control *1 C8
(9) Tilting power control *1 C9
(10) Overdischarge alarm function activation timing CA
(11 Material handling chopper duty in 1st stage *1 CC
(12) Spare CE
(13) Spare CF
-
Note:
Items marked * 1 are invalid in models without the material handling chopper. (Display appears.)
3A-36
MCS-IIIA Tuning mode Initial Level Setting List
Tuning mode Level ( 0 Initial setting)

Item
display 1 2 3 4 5 6 7 8
C1
Braking torque:
Varying the regenerative braking
torque in switchback operation
-
Weak
a
Strong
C
Material handling chopper soft Great

small
start: a
C2 Varying the degree of rise of the
L
material handling chopper duty

Material handling chopper duty
C3
after activation:
Varying the initial duty in soft
start of the material handling
-
Small
-
a
Great
C
chopper
C4
Battery charge meter correction:
Correcting the decreasing rate of
battery charge meter reading
slow
- Quick
C
Low No
Maximum traveling speed limiter: limit
speed
C5 Limiting the maximum traveling a
speed
Attachment power control 1 : High

Low
C6 revolving speed when attachment
+
switch 1 is ON
Lifting power control: L OW High
C8 Varying the pump motor 4 •
revolving speed during lifting
C9
Tilting power control:
revolving speed
- LOW
a
w
High
C
Lift interrupt set level:

-
NO
Small %:ol
Varying the operation timing alarm*
CA (discharge level) for
overdischarge alarm function
Material handling chopper duty in Great
small
CC 1 st stage: t
Varying the duty of material
handling chopper 1 st speed
(1) Tuning method
Iol--=--[rl-El [ol
Press
Irl
Simultaneously
0 i-[
,..
I]
simultaneously press for
2 seconds.
Primary password
Secondary password
@ When the power control select switch is pressed, the tuning mode is indicated by the
speedometer on the display and the power control level indicates the current tuning
level of the mode.
As the tuning mode is changed sequentially (C1 -, C2 + C3) each time the power con-
trol select switch is pressed, select the desired tuning mode.
@ Carry out tuning by pressing the level setting (up or down) switch.
To increase the tuning level: Press the up switch.
To decrease the tuning level: Press the down switch.
The tuning level is indicated on the display.
If another item is to be tuned in succession, repeat steps @ and 0.
Tuning mode
UP switch
f
t
Power control -
\ J
3.5 1
Down switch Tuning level Hours used indication
@ Use one of the three methods shown below for returning from the tuning mode.
Press the hour meter select switch to return to the standard display (speed display).
(2) Maximum traveling speed limiter
The maximum traveling speed limit can be selected from the eight levels shown in the following
table.
Set level and corresponding speed limit
Set level 1 2 3 4 5 6 7 8
Speed limit km/h 6f I 7f1 8f I 9+1 10f I Ilk1 12 f I Unlimited
(3) Display on the battery charge meter (low battery warning and over-discharge warning)
1 2 3 4 5 6 7 8
4 4
5 lines blinking 5 lines lighting
60 % 4
70 %
-0- \ \ 1 1 1 battery
4
warning
/Ill\\\
\ I / 0
80%
iEji&$g:lk'g -
10 lines 2 lines blinking
4 --
blinking
(Over-dis-
charge 10 lines blinking
warning)
I A (Over-discharge
warning)
90 % dis-
charge
0 "I I ''
//I\\\\
battery
warning
warning) 1 lines blinking
I I
A
10 lines blinking
I (Over-discharge
warning)
dis- '
charge (No
warning) warning)
3. Tire diameter coefficient rewriting
The speedmeter indication is influenced b y the tire type (tire diameter).
The speedmeter indication for new vehicles is factory-set according t o the installed tires. Correct
the tire diameter constant i n any one of the following cases:
(1) When the tires are replaces with new tires of a different size
( 2 ) . When using specialized tires
(3) When tires are extremely worn.
Three methods are available for rewriting the tire constant.

Method A: When replaced with new tires in a different size (excluding special tires)
Method B: When replaced with special tires
When the installed tires are worn t o make the speedometer indication be felt incorrect.
Method C: When tires are worn t o make the speedometer indication be felt incorrect while the
outside diameter of the tire in the new state is known.
(1 ) Tire constant rewriting method (method A)

Inl--[rl--m-
@
[rl
[rl El-
m
Press
simultaneously
Simultaneously
press for
[,.rl)
2 seconds.
Pr~marypassword Secondary password
@ Select the tire constant from the tire constant table below.
Applicable
Tire type Tire constant
vehicle model
1 8 x 7 x 8-10PR 5FBE 1 0 22
Rib lug 1 8 x 7 x 8-14PR 5FBE13.15 22
1 8 x 7 x 8-16PR All models 22
Pneumatic tire
1 8 x 7 X 8-10PR 5FBE10 18
J-lug 1 8 x 7 x 8-14PR 5FBE 18.20 18
18 X 7 X 8-16PR 5FBE18 18
Unique track-shoe tire 1 8 x 7 ~ 8 All models 18
1 8 x 6 - 1 2 118CP 5FBE10.13 24
Cushion tire
1 8 x 7 - 1 2 118 5FBE 18.20 24
@ On the display, the speedometer indicates the current tire constant (2numeral digits)
and the hour meter indicates the tire mark indicator.
Each time the power control select switch is pressed, the 10's digit or 1's digit of the
tire constant blinks alternately. The blinking numeral is incremented or decremented
when the level setting (up or down) switch is pressed. Set the tire constant selected in
step a. (The tire constant can be set between 0 0 and 99.)
To increase the tire constant: Press the up switch. (Increments by 1 each time.)
To decrease the tire constant: Press the down switch. (Decrements by 1 each time.)
Up switch Tire constant
/
\ Indicator
Down switch
@ Select any of the three following methods for returning from the tire constant rewriting
mode:
Press the hour meter select switch to return to the standard (speed) display.
Turn the key switch t o the OFF position.
(2) Tire constant rewriting method (method B)

@ Obtain the tire constant as follows:
=IpTB
112 of maximum [Cushion tire]
allowable load Set the 112 of maximum allowable load
state, measure dimension A, B in the figure,
and calculate tire constant W by the follow-
ing equation:
W = 0.55A (mm) - 100
(W = 14A (in) - 100)
[Pneumatic tire and unique track-shoe tire]
With a load at 112 of the maximum allowable
load on the fork, measure dimensions A and
B in the figure.
Calculate the tire constant W by the follow-
ing equation:
W = 0.31A (mm) + 0.23B (mm) - 85
(W = 7.9A (in) + 5.8B (in) - 85)
Count fractions of 5 and over as 1 and disre-
gard the rest.
@ Then, follow steps 3 and 4 in method A.
Use the value calculated from the actually
measured value as the tire constant.
(3) Tire constant rewriting method (method C)
@ Obtain the tire constant as shown below.
Calculate tire wear C by the following equa-
tion:
C = Tire radius in new state - radius of
worn tire
@ Calculate tire constant W by the following
equation:
Worm state 1
W = W' - - C (mm)
2
(W = W' - 12.7 C (in))
W' = Tire constant in new state
@ Rewrite the tire constant according to steps
3 and 4 in method A by using the tire con-
stant calculated from the tire wear.
4. Battery electrolyte level warning

The warning function can be enabled or disabled by
password input. If A1 is indicated on the speed display
portion, the warning function is enabled. If A 0 is indi-
cated, this function is disabled.
5. Power control input

The power control input can be locked or unlocked by
password input. If P I is indicated on the speed display
portion upon password input, the power control input
is set to the locked state. If PO is displayed, the power
control input is unlocked.
6. Battery (mountedlnot mounted)

It is possible to select battery mounted state or not
mounted state by passwork input. The speedometer
on the display indicates T I when the not mounted
state is selected, and TO when the mounted state is
set.
Note: This data is provided for changing over the constant

for calculation for the battery charge indicator. Set it to the
mounted state when the standard battery is to be used, or
to the not mounted state when any other type of battery is
to be used.
3A-42
7. Option input mode
Demonstration mode
*
Primary password Parking brake applica-
acceptance mark
tion failure warning
*
lo] ----~-(YJ---
El
El + Voltage selection
36, 4,
TPress P
Simultaneously
simultaneously press for 2 sec. Hours used indication
@
Material handling
chopper
Provided * Not pro-
vided
*
Set * Reset
These are passwords for option items in the 5FBE series.

As these are set according to the specifications at the time of new vehicle delivery, no setting is re-
quired unless any change is made.
The items with * are not provided in the vehicle specifications. Although indication on the display ap-
pears, proceed to the next option item by pressing the power control select switch.
There items should be set in any of the following cases:
When the display board is replaced
When a demonstration is to be made
When the parking brake application failure warning is to be reset
(1) Demonstration mode switching effectivetineffective.
For the transportation reason, the condition of the truck before starting the hourmeter has
been so arranged that the parking application failure warning and the simultaneous opera-
tions of the traveling and material handling should be preset to "lneffective".
This condition, however, is changeable to "Effective" by turning the demonstration mode on
the mask function.
This changeover, in especial, in useful for the demonstration of the New Trucks, where the
warning and simultaneous operation are in need.
lneffectrve + Effective changeover
#
r +
r=
, l q
m+ End
\ #
Effective lneffective changeover
[m])[m]
+
& dEnno
Demonstration mode : Effective Demonstration mode : Ineffective
Use the UP or DOWN switch for selection.

Press the UP switch to change from ineffective to effective. Press the DOWN switch to change form
effective to ineffective. Pressing the UP switch in the effective state or the DOWN switch in the inef-
fective state causes no change. When the power control select switch is pressed, the next option item
is selected.
When the hour meter changeover switch is pressed, the mode returns from option input to normal dis-
play.
Note:
It takes about a second after pressing the select (UP or DOWN) switch until display change.
3A-44
(2) Parking brake application failure warning effectivetineffective selection
8
I %
r=
1~
m- ~ n d
b #
Effective + lneffective changeover
-[
[Ej F
l
Parking brake application failure alarm :
2 PRr -E r
Parking brake application failure alarm :

Effective Ineffective
(Note) Keep the setting at Effective as the ineffective specification is not provided as the vehicle specification.
(3) Voltage selection
36 V + 4 8 V changeover
8
/ \
r d
0 l0l-l End
' '4
\ a
[
36 V specification
qwl 48 V specification
(Note) As 36V specification is not provided as the vehicle specification.

Keep this setting at 48V.
(4) Material handling chopper providedlnot provided selection
The method is the same as that for demonstration mode selection in item (1) above.
Not provided + Provided changeover
f 1 I b
rm
, 1~ i- I
~ n d
Provided + Not provided changeover
With material handling chopper Without material handling chopper
(5) Speed control switch setlreset selection

The method is the same as that for demonstration mode selection in item (1). The operation,
however, shall be made after pressing the speed control switch to on.
Reset + Set changeover
I r \
rm
,@ m- End
1 9
Z a
[m]
Set + Reset changeover
[ n ]- SLJ SET
Switch : Set Switch : Reset
(Note) Keep this setting at Set as speed control switch reset is not provided as the vehicle specification.
ELECTRICAL SYSTEM TROUBLESHOOTING
[FOR OTHER THAN U.S.A.] (1993.1 - 1998.8)
[FOR U.S.A.] (1993.1 - )
Page
GENERAL ......................................................... 4-2
TROUBLESHOOTING EXPLANATION ............... 4-2
DRIVE SYSTEM-MATERIAL HANDLING
SYSTEM TROUBLES ...................................... 4-4
WHEN DIAGNOSTIC ERROR CODE IS
DISPLAYED .................................................... 4-4
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (DRIVE SYSTEM) ........................... 4-67
DISPLAYED (MATERIAL HANDLING SYSTEM) .... 4-87
TROUBLESHOOTING-OTHERS ............................. 4-94
TROUBLESHOOTING RELATED TO MULTI-DISPLAY
AND MCS COMMUNICATION SYSTEM ............. 4-95
STEERING SYSTEM TROUBLES ....................... 4-98
DIAGNOSIS ERRORS ........................................ 4-98
DISPLAYED (STD) ........................................... 4-101
. .
DISPLAYED (WIEHPS) .......... .... ............ ......... 4- I03
This troubleshooting is t o pursue the causes of diagnostic errors indicated by the error codes on the
multi-display and other electric troubles for quick repair.
Measuring instruments such as the megger and multimeter (circuit tester) are used for the error check.
Some error items may be checked by the analyzer on the vehicle.
Descriptions in this manual are for the mechanics who have mastered handling of measuring instruments,
can read wiring and connection diagrams accurately and can make actual measurements using the con-
nector drawing.
Please make use of the attached connection diagram, connector drawing and connector terminal ar-
rangement.
TROUBLESHOOTING EXPLANATION
1. Drive system . material handling system troubles
(1 When an error code is displayed:
See the "Diagnosis Errors" section.
(2) When no error code is displayed:
@ Drive system abnormality
See the "When Diagnostic Result is Not Displayed (Drive System)" section.
@ Material handling system abnormality
See the "When Diagnostic Result is Not Displayed (Material Handling System)" section.
2. Trouble shooting-other
See the "Trouble shooting-other" section
3. Troubleshooting related t o multi-display and MCS communication system

See the "Multi-display MCS Communication System" section.
4. Steering system troubleshooting

(1 When an error code is displayed:
See the "Diagnosis Error" section.
(2) When no error code is displayed (STD):
See the "No Diagnosis Error" section.
(3) When no error code is displayed (wIEHPS)
See the "No Diagnosis Error" section.
5. TROUBLESHOOTING EXPLANATION
Are CO and C1 displayed

alternately?
1
x
1 Action for error code CO
1NO (only C1 error)

Check the wiring between
CN104 and drive current
sensor.
- NG - Test again after correction.
ANL11: Simplified test 0 Traveling current sensor defect

Is C1 displayed? o Open circuit or defective connector contact be-
tween CN104 and traveling current sensor
0 Was switch back operation

Inspection 1
CSD output voltage check
performed when C1 error CN104-7 (71)
occurred? 5 voltage check (2.0v 0 Wiring defect
CN104-1 (74) or morel
IYES 1
OK (approx. 1.2 V) 4
Measure with a
To A on next page 0 CPU board defect circuit tester.
0 Drive motor defect (short circuit)
I
Repair or replace.
Indicates the item that can be checked by the analyzer.

(Single frame is used when analyzer check is impossible.)
Potential level Analyzer test item
lnspection 1
CSD output vqltage check
CN104-7 (71)-
3 Voltage check
CN104-1 (74)-
f t
1
Tester probe ( +
Tester probe (-1

i ANL11: Simplified test
(ESYO1)
is C1 displayed?
~ o n n e k t o rNo.
Pin No.
4-4
DRIVE SYSTEM MATERIAL HANDLING SYSTEM TROUBLES

WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED
ERROR CODE AO: MCS MAIN CIRCUIT OVERHEAT
CN 104-6 (75: + 5V) - T -
CPU board STH

CN104-16 (76 : STH)
P
i Connector STH Ternpereture

sensor
Estimated causes
@ Overheat (continued use with overload)
@ Temperature sensor defect
@ Temperature sensor wiring and connector contact defect
@ CPU board defect
I
I
Continued use of vehicle with overload
=I
I I
Stop the vehicle and restart traveling 3 0
minutes later. I
I
NO
Inspection 1
Disconnect connector STH and check the -
NG
- 0 Temperature sensor defect
resistance of temperature sensor. (2 kQ or more)
OK (less than 2 kQ)
0 Defective contact or disconnection between CN104 and connector STH

0 CPU board defect
Inspection 1 . Temperature sensor resistance check
Battery plug OFF, connector STH disconnection
Measurement terminals Both terminals of connector STH (sensor side)

Circuit tester range ~ x l
Standard Less than 2 kfl
OK (less than 2 kS2) CPU board defect, or defective contact or disconnection between CN104
+
and connector STH

NG (2kO or more) + Temperature sensor defect
ERROR CODE A2: CPU BOARD ABNORMAL TEMPERATURE RISE
CPU board
Temperature sensor (TH10)
-m-
Estimated causes
@ Temperature CPU board around at 80°C or more
@ Temperature sensor defect (CPU board defect)
Abnormally high CPU board temperature

(at 80°C or above)
-
YES- Leave the vehicle unoperated for some
time (about 30 minutes)
NO
Continued use of vehicle with overload - YES Restart traveling for confirmation after
stopping for 30 minutes
NO
0 CPU board defect
* The CPU temperature sensor is included on the CPU board. CPU board defect is conceivable
when this error code (A21 is displayed.
ERROR CODE A3: ABNORMALLY HIGH BATTERY VOLTAGE
Estimated causes
@ Connection of other than specified battery voltage t o battery plug
I @ CPU board defect

I
The charger plug is connect-
ed t o the controller.
YES
- 0 Start charging after connecting the charger
plug t o the battery side.
I
The mounted battery is other 0 Mount the specified battery.

than the specified one.
I Inspection 1 I
is connect the battery plug, 0 Abnormally high battery voltage.
and measure the battery
voltage. Replace the battery.
I I
OK (69V or less) ,
NG (over battery voltage)

Voltage measurement at -0 CPU board defect
terminal P9.
0
I OK (battery voltage or less)
P9 voltage wiring defect (contact with other portion, etc.)

Inspection 1. Battery voltage measurement
Battery plug OFF
Measurement terminals Battery @ - Battery @

Circuit tester range DC100 V
Standard 69 V or less (normally approx. 48 V )
* The criterion in troubleshooting is 69 V or less.

ERROR CODE A4: ACCELERATION POTENTIOMETER INSTALLATION DEFECT
Related portion
Acceleration potentio meter
+) -
CN25
CN106-8 (53 POTA -
CN106-18 (52 POTA) -
CPU board VRAD
CN106-14 (51 GND) -
- CN106-7 (64 SWAc)
- -
-
imated causes
@ Acceleration potentiometer defect (between 6 4 and 51
I @ Acceleration potentiometer installation adjustment defect I
I @ Accelerator switch wiring short circuit (between CN106-3 and GND) I
I @ CPU board defect I
Is the battery plug connected Is the normal state recovered
YES- YES
while the accelerator pedal is when the accelerator pedal is 0 Normal
depressed? released?
I I
ANL31: Switch input test

Is the accelerator switch turned CPU board defect
ON or OFF when the accelera- (switch ON)
tor pedal is not depressed?
P I]
Not Lit (Switch OFF)
0 Carry out ANL31: again after disconnecting

the acceleration potentiometer connector.
i
Is the accelerator switch turned
- 0 Accelerator switch wiring short circuit
(short circuit between 6 4 and 51 )
I
1Not lit (switch OFF)
Inspection 1 NG
Individual acceleration poten- -0 Acceleration potentiometer defect
tiometer inspection (always 0 Q)
--
OK co Q in ordinary state and

0 Q in operated state
!
Installation adjustment defect
Inspection 1. Individual acceleration potentiometer inspection
Individual acceleration potentiometer removal
Measurement terminals Acceleration potentiometer S W ~ c ( 6 4 -

) GND(51)
Circuit tester range 62x1
Standard oo 62 in ordinary state and 0 62 in operated state
OK (co 62 in ordinary state and 0 62 in operated state) + Installation adjustment defect

NG (Always 0 62) + Acceleration potentiometer defect
ERROR CODE A6: MATERIAL HANDLING SWITCH INSTALLATION ABNORMALITY
Related portion
I
CN 105-6 (63 LS,,) --
CNl1
CN105-1 ( 6 0 LSL)
-
Lift/
CPU board
CN105-3 (61 LST) - tilt/
CN 105-2 (68 LSu)
- Attachment switch
--
CN106-13 (51 GND)
I
-
1 CN39
Estimated causes
@ Defect of each material handling switch
@ Installation/adjustment defect of each material handling switch
@ Short circuit of each material handling switch wiring
@ CPU board defect
Is the battery plug connected Recovered to the normal YES

YES- state when the material
while any material handling- Normal
I lever is operated?
I
handling lever is released
I
- 0
I-
Is each material handling switch
ON or OFF when the 0 To A on next page
(switch ON)
corresponding material handling
lever is not pulled?
Not lit (switch OFF)
0 CPU board defect

A
(When LS2 is ON)
Recheck after disconnecting

CN39 0 Wiring short circuit (between 68 and 51)
I
I
Inspection 1 NG
-0 L S L replacement
~
L S L individual
~ check ( 0 Q at switch
OFF)
1 OK
0
1 (00 Q at switch OFF)
Installation readjustment
(When LSL is ON)
Recheck after disconnecting

(switch ON)
- 0 Wiring short circuit (between 6 0 and 51 )
Inspection 2
LSL individual check
NG
(0 Q at switch
- 0 LSL replacement
OFF)
I OK
(m Q at switch OFF)
0 lnstallation readjustment
For LST, LSATI, L S A Tand

~ LSAT~,
carry out troubleshooting in the same way as for LSL.
lnspection 1. LSL2individual check
LSL2individual removal
Measurement terminals LSL2terminals

Circuit tester range Q X 1
Standard oo Cl at switch OFF and 0 Q in operated state
OK (oo Q at switch OFF) + Installation readjustment

NG (0Q at switch OFF) -, LSL2replacement
lnspection 2. LSL individual check

LSL individual removal
Measurement terminals LSL terminals

Standard Switch OFF: oo Q Operated state: 0 Q
OK (oo Q at switch OFF) + Installation readjustment

NG (0Q at switch OFF) + LSL replacement
ERROR CODE A7: PARKING BRAKE ALARM
I I CNIOB-13 151 GND)

J U Deadman switch
I
CPU board
I I CN106-13 151 OND)

I U Parking brake switch
I
Estimated causes
@ Parking brake switch defect
@ Parking brake switch installation adjustment defect
@ Parking brake switch wiring shortcircuit
@ Deadman switch defect
@ Deadman switch installation adjustment defect
@ Deadman switch wiring short circuit or disconnection
@ CPU board defect
- Occurrence of A7 error while
the parking brake is pulled?
YES
NO
NO
Is the error reset
when the parking Occurrence of A7 error while
-
brake lever is pulled the operator sits on the seat?
or the operator sits
on the seat?
I
YES
I
I II
t ANL31: Switch input test
0 Normal
when the parking brake lever is -0 CPU board
pulled? (switch OFF) defect
Lit (switch ON)

I1 1I
I ( I ~ f t eopening
r the parking brake 11
switch (CN1 5)
ANL31: Switch input test 0 Wiring shortcir
Is parking brake switch turned (switch ON) cuit (between
ON or OFF? 66 and 51)
0 Switch
replacement
switch OFF)
I 1 OK (m Q at switch ON)
0 ~ e f e c t i d einstallation
adjustment
t
Lit
Is the deadman switch turned -0 Defective CPU board
ON or OFF when the operator (switch ON)
switch CN22 shorted Not lit o Wiring disconnection

ANL31: Switch input test - 0 Connector contact
(switch OFF) defect
Is the deadman switch turned
0 CPU board defect
Lit (switch ON)

Inspection 2 NG
Deadman switch individual -o Switch replacement
(00 Q at
check switch OF,F)
] at switch ON)
0 Deadman ;witch installation defect
lnspection 1. Parking brake switch individual check
Parking brake switch individual removal
Measurement terminals Both terminals of parking brake switch connector

Circuit tester range Slxl
Standard co 0 at switch OFF
OK (aQ at switch OFF) + Installation readjustment

NG (0Q at switch OFF) + Switch replacement
lnspection 2. Deadman switch individual check

Deadman switch removal
Measurement terminals Both terminals of deadman switch

Circuit tester range a x 1
Standard 0 Q at switch ON
OK (0Q at switch ON) -, Installation adjustment defect

NG (aQ at switch ON) + Switch replacement
ERROR CODE A8: TRAVELING FUSE ABNORMALITY
-4Related portion 1
CN 104-1 7 (P9 VBP9)
0 P9
DClSDD board
CN103-12 (13 VBBT) CN 102-8 (41 VBBT)

0 SWKY
CN100-1
(41 VBBT)
@ Drive fuse (F1) open
@ P9 wiring disconnection
@ Short circuit of P 9 wiring
@ CPU board defect
Inspection 1
Traveling fuse (F1 ) check
NG - Inspection 3 replacement
After F1
Q)
P2 NG - 0 Short circuit
5 resistance measurement (0a) between P2
N1 wiring and
N1
OK (other than 0 Q)
0 Normal
i
lnspection 2
P2 0 Disconnection in cable between battery and
5 voltage check fuse F1
N1
0
1
To A on next page
OK (battery voltage)
Inspection 4 Disconnection in wiring
CN104-17 -CN103-8 NG
-
0
0 Short circuit between P9 and N1
P9 voltage check (5 Or less) 0 Disconnection between CN104-17 - and
P9
OK
(over 5 V )
1.-
ANL12: Test operation (No.4)
Voltage measurement at
terminal P9
OK (over 5 V)
CPLJ board defect
0 Momentary disconnection (CN104-1 7 - P9)

lnspection 1. Traveling fuse (F1) check
Battery plug OFF
Measurement terminals Both terminals of F1

Standard 0a
OK (0 0) -, To inspection 2
NG (co 0) -, F1 replacement -+ To inspection 3
lnspection 2. P2 - N1 voltage check

Battery plug ON
Measurement terminals ~ 2 @- NIB

NG (0 V ) -, Disconnection in battery cable between battery and fuse F1
lnspection 3. P2-N1 resistance measurement
Battery plug OFF
Measurement terminals P2 - N1
Standard Other than 0 f l
OK (other than 0 Q) -, Normal

NG (0 Q) + Contact between P2 wiring and N1
lnspection 4. P9 voltage input check
SWKYOFF and use of SST
Measurement terminals CN104-17 - CN103-8
Circuit tester range DCl00 V
Standard 5 V or more (normally approx. 48 V )
* The criterion in troubleshooting is 5 V or more.

ERROR CODE AA: CPU BOARD TEMPERATURE SENSOR OUTPUT ABNORMALITY
CPU board
Temperature sensor (TH10)
-m-
@ CPU board disconnection
ERROR CODE AE: EXCESSIVE AID PROCESSING TIME
@ CPU board defect
CPU board replacement for AE display
ERROR CODE AF: CPU PROCESSING DATA ABNORMALITY
@ CPU board defect
CPU board replacement for AF display

4-22
ERROR CODE CO: MAIN DRIVE CIRCUIT ABNORMALITY
DClSDD board
LCN103-7(32CHOPD+) ~ c N ~ o ~ - ~ ( ~ ~ C H O P D + I CN102-6 (N2 TMS)

CN103-15 (33 CHOPD+) i CN101-17 (33 CHOPD-) CN102-5 (P9 RCKI
CN103-6(31VDD+) ~CNIO~-~(~OVDD+)
CPU board
CN103-14 (31 VDD-) i CNIOI-18 (31 VDD-)
CN102-4 (P8 RCK 1 )
CN102-11 (P8 TMD)

D
- CN102-12 ( 9 2 TMG)
DAD JL TM v
G
S
CAD ==
.-
@ TM defect
@ Blown drive fuse
@ Main drive circuit connection defect
@) Drive current sensor (CSD) disconnection, defect or defective contact
@ TM-DCISD wiring disconnection or defective contact
@ CPU-DCISD wiring disconnection
@ Defective contact of each connector
@ Drive DC/SD board defect
@ CPU board defect

Alternate display of CO and C1 0 Defective drive current sensor
with SWky on? 0 Connector contact defect or open circuit
Display of FA, CA or A 8 in
traveling stop state IYES 0 Take the action for A8
P-
Check connector CN101, 1 02
or 103 disconnection or TM o Perform traveling test after correction.
connection loosening.
OK
Inspection 1 NG Inspection 4
Voltage check between P7 and (less = TM Individual check after dis- NG (TM
N1. than 8V) connecting TM wiring copper damage)
bar
OK I
lnspection 2
L
wk- :
Continuity check between TM TM replacement
and DCISDD NG -0 Wiring
I disconnection
0 To A on next page
lnspection 3
Continuity check of wiring 0 Wiring
between CPU and DCISDD disconnection OK Inspection 8
DF1 lndividual check
0 DCISD defect 0 DF1 set screw and

0 CPU board defect copper bar discolo-
DAD Individual check ration or loosening
0 DAD wiring loosening
or TM copper bar
loosening
I
NG
o DAD connecting terminal loosening
Inspection 5 Inspection 7
Continuity check between P2 NG- RAD individual check after dis- NG-o RAD defect
and DAD cathode (heat sink) connecting CN 1 1 6
OK OK
0 CN117orCN118defect
I
lnspection 6
Continuity check between
CN 102-5 DAD cathode (heat 0 Disconnection
sink) and CN102-4 TM(D)
t
0 Drive DCISD defect
lnspection 1. P7-N 1 Voltage check
Battery plug ON, SW, OFF, direction switch OFF, acceleration switch OFF
Measurement terminals ~ 7 @- NIB

Standard 48 V vehicle: 43 + 5V 36 V vehicle: 32 + 5V
OK (8V or more) + To inspection 2 The standard voltage between P7 and N1 is as

NG (less than 8 V ) + To inspection 4 shown above, but the criterion for troubleshoot-
ing is 8 V or more.
lnspection 2. TM-DCISDD continuity check

Battery plug OFF, SST connection
Measurement terminals TM - DCISDD

Standard 0Q
OK (0Q) + To inspection 3
NG -, Wiring disconnection
lnspection 3. CPU-DCISDD continuity check
Measurement terminals CPU - DCISDD

Circuit tester range ~ x l
Standard 0Q
CNlOl 1 t t t t OK (0Q) + DCISDD board defect or CPU board defect

NG (a Q) + Wiring disconnection
3 5 6 7 9 11
14 16 17 18 20 21 22
t I t ! t t
CN103
1 2 3 4 5 6 7 8
lnspection 4. TM individual check

Battery plug OFF, copper bar disconnection
+
Between D and S
8 8
D - - S
D + - S-
Measurement terminals Between D and G

~ 8 +- ~ 8
D - - G
Circuit tester range

Between G and S
8 8
G - - S
G + - S-
Q x 1K
Between D and S
8 8-+: :aann
D - -
D + -S
S+ : a Q
Standard Between D and G

8 8
D -
D +
- G
- G - : Continuity shall exist
Between G and S
8 8
G -
G +
- S + : Continuity shall exist
- s -:an
OK + To inspection 5
NG + To inspection 8
lnspection 5. P2-DAD cathode (heat sink) continuity check
Battery plug OFF
Measurement terminals P2 - DAD cathode (heat sink)

Circuit tester range 0 x 1
Standard Approx. 1.5
OK (approx. 1.5 Q) + To inspection 6.

NG (co Q) 4 To inspection 7.
Inspection 6. (CN102-5 - DAD cathode CN102-4 - TM (D)) Continuity check

CN102-5 - DAD cathode (heat sink)

CN 102-4 - TM(D)
Circuit tester range n x l

Standard 0a
OK -, Drive DCISDD board defect

NG 4 Wiring disconnection
lnspection 7. Individual RAD measurement
Battery plug OFF, CN 1 1 8 disconnection
Measurement terminals RAD connector terminals

Standard Approx. 1.5 h2
OK (approx. 1.5 Q) -, Disconnection between main circuit and CN117 - CN118

NG (con) RAD defect
lnspection 8. Individual DF1 check

Battery plug OFF, DF1 wiring disconnection
Anode - - Cathode +
Forward:
Reverse: 8
Anode + - Cathode - 8
Circuit tester range h2 x 1K
Forward: Approx. 3 kh2
Standard Reverse: co62
OK (forward: approx. 3 kQ, reverse: co Q) -, To inspection 9

NG +Discoloration or loosening of DF1 set screw or copper bar
Inspection 9. Individual D A D measurement
Battery plug OFF, D A D wiring disconnection
Anode - - Cathode +
Forward:
Reverse: 8
Anode + - Cathode -8
Circuit tester range nx IK
Forward: Approx. 6 kQ
Standard Reverse: oo Q
OK (forward: approx. 6 kQ, reverse: 00 Q) -, Loosening of CAD wiring or copper bar

NG + Loosening of D A D lead or round terminal
ERROR CODE C1: DRIVE CIRCUIT CURRENT SENSOR ABNORMALITY
Connector CSD
CN104-10 (73 CSD + )

Drive
current
CN104-9 (71 CSD) sensor
CPU board
CN104-8 (74 CSD-)
CSD
Estimated causes
@ Drive current sensor defect
@ Disconnection or defective connector contact between CN104 and traveling current sensor
@ Drive motor defect (short circuit)
@ CPU board defect
Is C1 displayed while the ve-

hicle is in stop state?
YES Inspection 1
CSD output voltage NG (over 2.5 V or
check less than 0.35 V)
CN104-9
t
CN104-8
NO OK (approx. 1.2 V)
C1 display upon starting 0 CPU board defect
!
Wire continuity
check between NG
CN104 and CSD
I
t
I
(No.0 CSD display)
CDS value = 0 in traveling
YES
0
OK
CSD defect
0
0
1
Disconnection
Contact defect
(OA)
1
0
0
NO (other than OA)
CPU board defect
Drive motor defect 0 CSD defect
I
(short circuit) 0 Drive motor or main circuit wiring defect
Inspection 1. CSD output voltage measurement
Battery plug ON, SWKYON, SST connection
Measurement terminals CN 1 0 4 - 9 0 - CN 1 0 4 - 8 0
Circuit tester range DClO V
Standard Approx. 1.2 V
OK (approx. 1.2 V ) + CPU board defect or drive motor defect (short circuit)
NG (over 2.0 V or less than 0.35 V ) -, CSD defect, or wiring defect
ERROR CODE C4: TRAVELING ACCELERATOR ABNORMALITY
CPU board
1- CN106-18 (52 POTA)
CN106-14 (51 GND) 1 Acceleration

potentionmeter
VRAD
Estimated causes
@ Acceleration potentiometer defect
@ Short circuit or open circuit in wiring between CN106 and acceleration potentiometer
@ Defective contact of CN106 . CN25 and CN26
@ CPU board defect
Check disconnection of CN106 C N 2 5 and Disconected -

Traveling test after correction
CN26
Not disconected
1
ANL11: ESY-15
(acceleration potentiometer check) 0 To A on next page
Check the potentiometer voltage when the
accelerator pedal is not depressed.
I'
OK (0.1 V or more)
r 11
ANL11: ESY-15
(acceleration potentiometer check) 0 To B on next page
accelerator pedal is fully depressed.
1 ANLl 1: ESY-15 1
(acceleration potentiometer check) o Disconnection at CN106-7
and disconnection or short
switch is turned from OFF to ON while 1.4 V or more) circuit with other portion at
depressing the accelerator pedal gradually.
CN1 06-8
I'
OK (1.3 V or less)
! * The acceleration potentiorne-
0 CPU board defect
ter is defective i f the switch
is not turned ON.
Inspection 1 Does the acceleration
Disconnect the acceleration - potentiometer resistance vary NO 0 Acceleration
potentiometer and check it from 0 Q to about 2 to 4 kQ
potentiometer
individually. when it is turned?
replacement
YES
\
0 Adjustment defect. Readjust it.
B
Recheck after disconnecting the acceleration
potentiometer connector.
ANL11: ESY-15
NG
(acceleration potentiometer check) = 0 Short circuit of wiring between
Check the potentiometer voltage when the (4.6 V or more) CN106-18 and CN106-8
accelerator pedal is not depressed.
OK (0 V)
lnspection 2
Disconnect the acceleration potentiometer,
and check it individually.
Does the acceleration potentiometer voltage

vary from 0 Q t o about 2 to 4 kQ when it is
turned? 0 Acceleration potentiometer
replacement
0
1
Adjustment defect. Read just it.
lnspection 1. Individual acceleration potentiometer measurement
Battery plug OFF
Measurement terminals Terminals of acceleration potentiometer connector

Standard Variation from 0 Q to about 2 - 4 kn
YES (variation from 0 Q to about 2 -

4 kQ) + Acceleration potentiometer adjustment defect
NO + Acceleration potentiometer replacement
lnspection 2. Individual acceleration potentiometer check

Same as inspection 1.
ERROR CODE C7: DIRECTION SWITCH ABNORMALITY
Direction
switch
Estimated causes
@ Direction switch abnormality
@ Short circuit or disconnection in wiring between CN106 and direction switch
@ CPU board defect
Discon-
Check if CN106 or CN9 connector is dis- Confirmation test after correction
I nected
connected.
I
1
Not disconnected
1I
When the direction lever is operated to 0 Direction switch defect
the forward or reverse position, is the 0 Short circuit or disconnection of wiring
opposite direction also set to ON?
0
I
CPU board defect
ERROR CODE C8: SPEED SENSOR ABNORMALITY
Related portion
CN21
CN106-1 (82SSR-)
Speed sensor
CN106-2 (81 SSR+) - SSR
CPU board CN106-3 (84 SSL-)

Speed sensor
CN106-4 (83 SSL+) SSL
CN20
@ Speed sensor defect (coil disconnection)
@ Disconnection in wiring between CN106 and speed sensor
@ Connector contact defect
@ CPU board defect
ANL13: Test operation

(vehicle traveling speed display)
0 To A on next page
Run the wheels by floating tires
above the ground and check
whether the abnormality lies in
the left side or right side.
] 0 km/h on R side
I
Disconnection check of CN106 ~ i ~ ~ ~ ~

and CN21 connectors -- 0 Traveling test after correction
I
1 Not disconnected
Inspection 1
0 Speed sensor defect
700 Q)
OK (approx. 700 Q)
0 CPU board defect

Disconnection check of CN106
and C N 2 0 connectors
. Disconnected -,Traveling test after correction
] Not disconnected
Inspection 1
Individual speed sensor check 0 Speed sensor defect
7 0 0 Q)
OK (approx. 7 0 0 Q)
0 CPU board defect

Inspection 1. Individual speed sensor measurement
Battery plug OFF
Measurement terminals Terminals of speed sensor connector

Standard Approx. 700
OK (approx. 700 !J) + CPU board defect

NG (other than 700 Q) -, Speed sensor replacement
ERROR CODE C9: MF-MR CONTACTOR DRIVER ABNORMALITY
Related portion
CN103-7 132 CHOPD + ) CN701-6 (32CHOPD + ) CN102-6 (N2, TMS)

CN102-5 (P9, RCK1)
CN103-15 (33, CHOPD) CN101-17 (33, CMOPD)
CN102-12 (92, TUG)
CN 103-6 (30, VDD + CN101-7 (30, VDD +
CN102-11 (P8, TMD)
CN103-14 (31, VDD-) CN101-18 (31, VDD-) CN102-4 (P8, RCK1)
p2
F MRL F
E E
I
D
CAD TM;~
S
N1
0
CN104-14 (1, M + ) CN115-2 -

CN115
CN116-3 (1, M + ) -
CN116
CN104-1 (4, MFR) CN115-6 CN116-6 (4, MFR)

MFR
CN104-2 (5, MRR) CN115-7 CN166-7 (5, MRR)
MRR
CN104-3 (2, MFL) CN115-8 CN116-8 (2,MFL)
MFL
CN104-4 (3, MRL) CN11 5-9
- CN116-9 (3, MRL)
- MRL
I Alternate display of CO and C9
with SWky on?
1 YES
eo Same as the action for CO
Check welding of MFR, MFL, Welded

MRRor MRL. -0 Contactor repair
I
1Not welded
ANL11: ESY 18, 19, 2 0 N~ Continuity check be- NG
and 21 check tween CPU and con- * 0 Repair the harness
tactor coil
ONIOFF of each contactor
lnspection 1 DF2R
lnspection 2 DF2L
lnspection 3 DF1
Inspection 4 DAD 0 Repair the part judged NG.
lnspection 5 SN1
I Individual check of each part I
0 Harness pinching
0 CPU defect
0 DCISDD abnormality
The standards for inspection 1 to inspection 4 are the same as the inspection standard for each element.
Inspection 5. SN 1 inspection
Disconnect SN 1 wiring
Measurement terminals Both terminals of SN1
Circuit tester range 62x l K

Standard The pointer shall deflect once to 0 62 and then returns to co 62.
OK + CPU board defect, harness pinching, or DCISDD defect

NG -+ Replace the part judged NG.
ERROR CODE CA: MF-MR CONTACTOR DRIVE ClRCUYlT ABNORMALITY
-
CPU board
internal junction
@ CPU board defect
Replace the CPU board when CA is displayed.
ERROR CODE CE: ROM ABNORMALITY IN CPU
@ CPU board defect
Replace the CPU board when CE is displayed.
ERROR CODE CF: RAM ABNORMALITY IN CPU
Estimated causes
@ CPU board defect
Replace the CPU board when CF is displayed.

ERROR CODE EO: MAIN MATERIAL HANDLING CIRCUIT ABNORMALITY
DClSDP
CN103-2 (37 CHOPP+I i CN111-6 (37 CHOPP+) CN112-6 (N2 TMPS)
CN103-10 (38 CHOPP-)i CN111-17 (38 CHOPP-) CN 1 12-5 (PI 5 RCK2)

CN103-1 (35 VDP+) ! CN111-7 (35 VDP+)
CPU board
CN103-9 (36 VDP-) ! CN111-18 (36 VDP-1
Material
handling
panel
CN1 12-4 (PI 4 RCK2)
PI1
CN112-4 (PI 4 RCKP)
0
-D
- fi CN112-12 (93 TMPG)

DAP .!L TMP v
-
-
- P I5 6 G
CN119 CN117
--
--
CAP
-
.d
@ Pump fuse (F2) flown
@ TMP defect
@ Main material handling circuit connection defect
@ Open circuit, connector disconnection or defective contact in RAP wiring
@ Disconnection or defective contact of wiring between TMP and DCISDD
@ Disconnection of wiring between CPU and DCISDD
@ Defective contact of each connector
@ Material handling DCISDD board defect
@ CPU board defect

I
lnspection 1.
Pump fuse (F2) check
4-1 I I
F2 replacement
I
OK (10 n)
Check disconnection of
each connector and NG
loosening of TMP -0 Material handing oper-
(Disconeected or loosenned 1
ation after correction
connection.
I OK (Not disconnected or loosenned)
I lns~ection2 I I Inspection 5 I
*PI 3 Remove TMP wiring To A on
$ voltage check copper bar and check
next
N1 TMP individually. page af-
ter TMP
OK (8 V or morel l OK replace-
lnspection 5 ment
lnspection 3
P I1
TMP
resistance To B on
$ continuity check
DCISDD (using SST)
0 Wiring dis-
connection
I measurement
DAP cathode (heat sink)
next
page
I
OK ( 0 Q each) 1OK (approx. 1 .B Q)

lnspection 7
CN1 12-5
Inspection 4
$ continuity check NG
CPU NG
-0 Wiring dis- DAP cathode (heat sink) Wiring
$ continuity check Q)
connection CN1 12-4 (00 discon-
DCISDD (using SST)
5 continuity check nection
TMPD
0
0
l OK (O each)
DCISDD board defect
CPU board defect
0
0
I
OK ( 0 n)
Material handling DCISDD defect

CPU board defect
lnspection 8 NG -0 Inspect loosening or discoloration of screw or
Individual DF3 check copperbar after DF3 replacement
I
lnspection 9 0 Round lead terminal loosening check after

Individual DAP check DAP replacement
0 Loosening of DAP wiring

0 Loosening of TMP copper bar
~is'connectCN1 19 and
check the RAP
EQio RAP defect
I individually. 1.
0
1 OK (approx. 1.5 62)
Disconnection between
main circuit and CN117,
CN119
lnspection 1. Pump fuse (F2 check)
Battery plug OFF
Circuit tester range Q x i
Standard 0Q
OK (0Q) -, Check disconnection of each connector and loosening of TMP connection.

NG (ooQ) -, F2 replacement
lnspection 2. P I 3-N 1 voltage measurement

Battery plug ON, SWk ON
Measurement terminals ~ 1 3 -0 ~ 1 0
Circuit tester range 50 V DC

Standard 48 V vehicle: 27 k 5 V 36 V vehicle: 20 + 5V
OK (8 V or more) -+ To inspection 3 The standard voltage between P I 3 and N1 is as

NG (less than 8 V) -+ To inspection 5 shown above, but the criterion for troubleshoot-
ing is 8 V or more.
lnspection 3. TMP-DCISDP continuity check
Measurement terminals TMP - DCISDP

Circuit tester range Q X I
Standard 0Q
NG (00 Q) + Wiring disconnection
Inspection 4. CPU-DCISDP continuity check

Measurement terminals CPU - DCISDP

Standard 0n
OK (0Q) -. DCISD board defect or CPU board defect

NG (00 Q) + Wiring disconnection
Inspection 5. Individual TMP check
Battery plug OFF, TMP wiring and copper bar disconnection
+
Between D and S
8 8
D - - S
D + - S-
Measurement terminals Between D and G

~ 8 - ~ 8
D - - G+

Between G and S
8 8
G - - S
G + - S-
ax IK
- - s
Between D and S
D
D 8+ - s 8 + : = a
-:=a
Standard Between D and G
8 8
D - - G+ : = a
D + - G - : Continuity shall exist
Between G and S
8 8-+ : a n
G - -S
G + -S
: Continuity shall exist
NG -+ To inspection 8
lnspection 6. P I 1-DAP cathode (heat sink) continuity check
Battery plug OFF
Measurement terminals P I 1 -DAP cathode (heat sink)
Standard Approx. 1.5 Q
OK (approx. 1.5 Q) + To inspection 7

NG (oo Q) + To inspection 1 0
lnspection 7. CN 1 1 2-5 - DAP Cathode and CN 1 1 2-4 TMP (D) continuity check
Battery plug OFF
CN 1 12-5 - DAP cathode (heat sink)

CN 1 12-4 - TMP(D)
Standard 0n
OK (0 Q) Material handling DCISDP defect or CPU board

+
defect
NG (a Q) +Wiring disconnection
Inspection 8. Individual DF3 measurement
Battery plug OFF, DF1 wiring connection

Forward:
Reverse: 8
Anode - - Cathode +
Anode + - Cathode -
62 x 1K
8
Forward: Approx. 3 kQ
Standard
Reverse: m 62
OK (forward: approx. 3 kQ, reverse: oo Q) + To inspection 9

NG -, DF3 defection, or discoloration or loosening of screw and copper bar
lnspection 9. Individual DAP measurement
Battery plug OFF, DAP wiring disconnection

Forward:
Reverse:
Anode
Anode 8
- - Cathode +
+ - Cathode -
62 x l K
8
Forward: Approx. 6 k62
Standard
Reverse: eo 62
OK (forward: approx. 6 kQ, reverse: co Q) + Loosening of DAP wiring or TMP copper bar terminal
NG + Loosening of DAP lead or round terminal
lnspection 10. Individual RAP measurement

Battery plug OFF, CN119 disconnection
Measurement terminals RAP connector terminals

Standard Approx. 1.5 62
- -
OK (approx. 1.5 Q) Main circuit CN 1 1 7 CN 1 1 9 open circuit
NG (00 Q) RAP defect
+
ERROR CODE E l : MAIN MATERIAL HANDLING CIRCUIT CURRENT SENSOR
ABNORMALITY
Related portion
Connector CSP
CN104-20 (73 CSP+)

Material
CN104-19 (72 CSP) handling
CPU board current
sensor
CN104-18 (74 CSP-) CSP
Estimated causes
@ Material handling current sensor defect
@ Defective contact between CN 1 0 4 and connector CSP
@ TMP short circuit
@ CPU board defect
Is E l displayed while material

handling is in stop state? P- Inspection I
CSP output voltage check
CN104-19
voltage check
1
ON
( E l display upon material
handling operation)
0
IoK (approx. 1.2 V )
CPU board defect
I ANLI 2: T e n operation
(No. ICSP display)
0 CSP defect
Is the CSP value when the o Main pump motor circuit
material handling lever is not wiring defect
pulled?
IYU
0
l o t h e r than OA
CPU board deiect

I (Less than 0.35 V or over 2.5 V)
0 Motor defect (short circuit) 0 Disconnection or contact

defect
0
I°K
CSP defect
Inspection 1. CSP output voltage measurement
Battery plug ON, S W K ON,
~ and use of SST
Measurement terminals ~ ~ 1 0 4 - 1-
9 0~ ~ 1 0 4 - 1 8 0
Standard Approx. 1 .2V
OK (approx. 1.2 V ) + CPU board defect

NG (2.5 V or more) + CSP defect or wiring defect
ERROR CODE E3: RETURN TO NEUTRAL
Related portion
CN 106-6 (46 DSR) CN9
CN106-5 (45 DSF) Direction

switch DS
CN106-13 (51 GND)
-
CN106-7 (64 SWAc) CCN26
z
CN106-13 (51 GND) Accel
-
CN106-12 (67 LSD) C%? CN28
CPU
board Deadman switch
CN106-13 (51 GND)
LSD
I
1CN102-1 JWKY - P1
CN103-13 (14VBKY) CN101-3 (43 K36V)
0 0 -
' '-1
CN103-12 (13 VBBT) CN101-14 CN101-22 (41 B36Y)
DClSDD board
I
///
@ Momentary disconnection of battery plug power supply line
@ Direction switch defect
@ Direction switch wiring short-circuit
@ Accelerator switch defect
@ Accelerator switch short-circuit
@ Deadman switch wiring defect
@ CPU board defect
@ DCISDD defect
Occurrence during traveling YES CN106-12.13 NG
S wiring check -0 Deadman
CN22 switch wiring
defect
NO OK
No error display in normal No error Inspection 1

NG-o Deadman
traveling operation after acceler- display Deadman switch in-
switch defect
ation switch OFF with direction dividual check
switch in neutral position
1 OK
Error display 0 Normal I
I
0 ~omentary disconnection in the line between
CN106 and CN22
DSFand DSRcheck with direc- 0 Momentary disconnection in battery plug
power supply line VBBT-VBKY
0 DCISDD defect
0 CPU board defect
Lit - Direction
Inspection 2
switch in-
OK
Short-circuit
(switch ON) -0
dividual check in wiring
I
Not lit between
NG CN106 and
(switch OFF)
CN9
0 Direction switch defect 0 CPU board
- - -
1 -- - -
defect
SWACcheck with accelerator
Not lit
(switch OFF)
0
t
CPU board defect
Inspection 3
Accelerator switch Short circuit
(switch ON)
individual check in wiring
between
CN106 and
CN25
0 Acceleration circuit 0 CPU board
defect defect
Measurement terminals Deadman switch (CN22)

Circuit tester range n x1
-
Standard Normal: co Cl actuated state: 0 Cl
OK Momentary disconnection of the line between CN106 and CN22, momentary disconnec-
4
tion of the BIT plug power supply line, DCJSDD defect, or CPU board defect
NG + Deadman switch defect
lnspection 2. Direction switch individual check

Direction switch removal
Measurement terminals Direction switch (CN9)

Circuit tester range 62x 1
In neutral state
Standard (46.DSR)- (51.GND): co SZ
(45.DSF)- (51.GND): SZ
-
OK CN106-CN9 wiring short-circuit or CPU board defect

NG 4 Direction switch defect
Inspection 3. Accelerator switch individual check
Accelerator switch removal
Measurement terminals Accelerator switch SWAC(64) - GND (51)
Circuit tester range nx 1

Standard Normal: co 62 Actuated state: 0Q
OK -+ Momentary interruption between CN106 and CN25, or CPU board defect

NG -+ Accelerator switch defect
ERROR CODE E6: MATERIAL HANDLING SWITCH ABNORMALITY
Related portion
-- -
CN105-1 (60 LSLI) -CN11 Material handling
--
CN106-13 (51 GND) switch No. 1 (LSL)
CPU board
CN 105-2 (68 LSLZ) -- Material handling

switch No. 1 (LSJ
CN39
Estimated causes
@ Material handling switch No. 1 (LSL)defect (open)
@ Material handling switch No. 1 (LSL)wiring disconnection
@ Defective adjustment of LSL or L S L ~
@ CPU board defect
CN105 and CN106 connector

Material handling operation after
disconnection check
correction
Not disconnect

0 LSLopen
Is LSL set to ON with L S L kept
~ at OFF
LSL wiring disconnection
when the material handling lever is pulled
LSL-LSL~ adjustment
slightly?
II
Not set to ON
0
t
CPU board defect
ERROR CODE EE: MCS RECEIVING DATA ABNORMALITY
Related portion
-
CN 1 CN120
CN 107-2 ( 1 4 2 SDTMA)
Multi-
CPU board display
DlSP
CN107-5 (143 SDTMK)
Estimated causes
@ Multi-display defect
@ CN107 contact defect
@ Disconnection of wiring between CN107 and multi-display
@ CPU board defect
Discon-
CN107 disconnection check, wiring
nected
disconnection check and display side >o Display check after correction
connector check (CN1 and CN120)
0
0
1Not disconnected
CPU board defect

Multi-display board defect
(Replace the CPU board first.)
ERROR CODE EF: CPU PROCESSING TIME ABNORMALITY
@ CPU board defect
Replace the CPU board when EF is displayed.

ERROR CODE F9: STEERING POTENTIOMETER DEFECT
-
CN32
CN105-8 (55 VRSP+)
CN105-9 (56 VRSP) Steering

CPU board potentio
VRSP
CN106-13 (51 GND)
Estimated causes1
@ Steering potentiometer (VRSP)
@ Open or short of wiring between CPU and CN32
@ CPU board defect
CN1 05-9 Steering potentiometer individu-
$ voltage measurement al check
CN106-13
OK
0 Wiring disconnection
\ or short circuit
Cpu board defect

0 Neutral position adjustment
Neutral check 1 OK 0 Stering poter;tiometer
0 Defective contact of wiring and

connector
lnspection 1. Steering potentiometer output voltage check
Battery plug ON, voltage check below while rotating the wheel slowly
Measurement terminals - CN106 (13)

CN105 ( 9 1 0 0
Circuit tester range DCIO V
Standard 0.5V - 4.4 V
OK -+ ANL12: Test operation

NG -+ To inspection 2
lnspection 2. Steering potentiometer indurdual check

Steering potentiometer wiring disconnection
Measurement terminals CN32
Circuit tester range Q x 100
Between CN32-1 and CN32-3: Approx. 2 KQ

Standard Between CN32-1 and CN32-2: Variation from 0 to 2 KQ
Between CN32-2 and CN32-3: Variation from 0 to 2 KQ
OK + Wiring disconnection or short circuit

NG + Steering potentiometer
4-63
ERROR CODE FA: RAD DISCONNECTION
P2
0
CN117 CN118
-
- I
RAD
-
CN104-17 (P9 VBP9)
CPU
board
-I-
///
-
CN4
-
-
CN103-12 (13 VBBT) CN102-8 (41 D36V) -0SWKY
CN101-21 (13 VBBT)
1
DClSDD board
Estimated causes
@ RAD wiring disconnection
@ RAD defect
@ P9 wiring disconnection
@ CPU board defect
Display of A8 at the same time

P- o Take the corrective action for A 8 error.
CN117-CN118 connector con-

nection check P- o Connector connection defect
Inspection 1
RAD individual check L
Io
- RAD defect
1OK (approx. 1.5 Q)
0 To A on next page
Inspection 2
CN104-17 0 PZ-CN117-CNl18-P9-CN104
$ voltage measurement ,iring defect
CN 103-8 battery voltage)
F
lnspection 3
CN103-12 0 Wiring defect
5 voltage measurement (battery voltage or 0 DC/SDD defect
CN103-8 more)
0
l°K
CPU board defect
lnspection 1. RAD individual check
RAD removal
Measurement terminals CN118

Circuit tester range nx I
Standard Approx. 1.5 Q
OK + Approx. 1.5 Q
NG + RAD defect
lnspection 2. P9 voltage input check

SWKYOFF, use of SST

Standard 8 5 % of battery voltage
NG + P2-CNl17-CNl18-P9-CNl04 wiring deftct
Inspection 3 Battery volatge input check
SWKYOFF, of SST
OK -, CPU board defect

NG -, DCISD board or wiring defect
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (DRIVE SYSTEM)
1. The vehicle does not move at all. (The multi-display is kept off even when the key
switch is turned ON.)
r-~; I
- I
SWKY
0 0
CN102-1 (43 K36V)
CN101-22 (41 B36V)

DCISDD board
A
CN101-3.4 (15 +30V)
CN101-14 (11 GND)
I
CN103-8 (11 GND)
CPU board
CN103-5 (1 5 + 30V)
///
~ s t i m a t
@ The battery voltage is not applied.
@ No voltage is applied to the key switch.
@ 25 V is not supplied to DCISDD.
lnspection 1 0 Battery connector defect

CN101-22 (41 B30V) 0 Blown fuse F5
5 voltage check 0 Internal open circuit in battery
CN101-20 (N1 GND)
I OK (battery voltage)
lnspection 2
CN102-1 (43 K36V) Key switch defect
5 voltage check Wiring defect
CN102-9 (N1 GND)
DCISDD 0
Inspection 5 defect
Inspection 3 Inspection 4 0 Wiring
Disconnect CN1 0 3
CN103-5 Disconnect CN107 from CPU defect
(15 +30V) CN103-5 NG CN103-5 NG,(short
$ voltage check
NG (15 +30V) (OV) (15 +30V) ( 0 V) circuit)
CN103-8 (OV) $ voltage check 5 voltage check between
(N11 GND) CN103-8 CN103-8 CNlOl
(N11 GND) (N11 GND). and
CN103
OK OK OK 0 CPU
(approx. 25 V) (approx. 25 V) (approx. 25 V) board
1 1 defect
0 CPU board defect 0 Display defect 0 CPU board defect 0 Display
0 Defective wiring (short circuit) defect
between CN107 and display
0 CPU board defect
lnspection 1. Battery voltage measurement
Battery plug ON
Measurement terminals CN101-22 ( 4 1 1 0 - CN101-20 ( ~ 1 1 0
Circuit tester range DC 5 0 V

OK (battery voltage) -, To inspection 2

NG (0 V ) + Battery connector defect, blown F5 fuse, or battery internal wiring disconnection
lnspection 2. Voltage measurement after SWKY

Battery plug ON, SWKYON
Measurement terminals @I
~ N 1 0 2 ( 1 ) 4 3 @- C N I O ~ ( ~ ) N
Circuit tester range DC 5 0 V
OK (battery voltage) + To inspection 3

NG (0 V ) + SWk defect, or wiring defect
lnspection 3. DCISDD supply voltage measurement
Battery plug ON, SWKYON
Measurement terminals CN103(5)15@ - CN103(3)110

Standard Approx. 25 V
-
OK (approx. 25 V) + CPU board defect

NG ( 0 V ) + To inspection 4
lnspection 4. DCISDD Supply voltage measurement

Battery plug ON, SWKYON, CN107 connector disconnection
Measurement terminals ~ ~ 1 0 3 ( 5 ) 1 5-@CN103(3)11@

OK (approx. 25 V ) + Display defect, or CN107- display

wiring defect (short circuit)
NG (0 V) + To inspection 5
Inspection 5. DCISDD supply voltage measurement
Battery plug ON, SWKYON, CN104 CPU board side connector disconnection
Measurement terminals ~ ~ 1 0 3 ( 5 ) 1 5-@CN103(3)N11@

OK (approx. 25 V ) 4 CPU board defect

NG (0 V ) + DCISD defect, or CN101 -CN104 wiring defect
(short circuit)
2 . The vehicle does not move at all. (The MF(MR) contactor is not closed when the
direction lever is set to the forword (or reverse) position or when the accelerator
is depressed. 1
CN9
CN106-6 (46 DSR)
CN106-5 (45 DSF) Direction

switch DS
CN106-13 (51 GND)
CN106-13 (51 GND) Accel
CN106-12 (67 LSD) -

CN22
Deadman switch
CN106-13 (51 GND) LSD
CN104-14 (1 M + )
.- T
-
T
CPU board CN104-1 (4 MFR) ---

-
Connector MFR
CN104-3 (2 MFL)
-
Connector MFL
I
CN104-2 (5 MRR) ---
1.
Connector MFR
CN104-4 (3 MRL)
Connector MRL
Estimated causes
@ Battery overdischarge
I @ No input direction switch signal
I @ No input of deadman switch signal
@ Open circuit in MF or MR contactor coil
@ CPU board defect

Inspection 1
voltage check 0 Battery overdischarge
OK (15 V or more)
Is the deadman switch turned NO -0 Deadman switch defect

ON and OFF when the
deadman switch actuator is
(not turned 0 LSD - CN106 wiring defect
ON and OFF)
YES
(turned ON and OFF)

Is the direction switch turned 0 Direction switch defect
ON and OFF when the (not turned 0 -
DSF-DSR CN106 wiring defect
direction lever is operated? ON and OFF)
I S
: ned ON and OFF)

Is the accelerator switch Accelerator switch defect
turned ON and OFF when the 0 -
SWAC CN106 wiring defect
accelerator is operated? ON and OFF)
II
YES
(Turned ON and OFF)
MFR
0
replacement
Not Inspection 2 NG O MFL
Are the MFR, MFL, MRRand MRL
contactors closed? Close, Contactor coil continuity meas-
urement
-
replacement
(* I' o MRR
replacement
Closed OK (approx. 2 0 8) 0 MRL
replacement
I
0 CPU bo&d defect
0 CPU board defect
o Open circuit between CPU board and contactor coil
lnspection 1. Battery voltage measurement
Battery plug ON
Measurement terminals ~ 2 @- NI@

OK (15 V battery voltage or more)

+ ANL31: Switch input test
NG ( 0 V) + Battery overdischarge
Inspection 2. MFR-MF,.MRRmMRL contactor coil continuity check

Battery plug OFF, MF,.MF,.MR,-MR, connector disconnection
Measurement terminals Both terminals of MFR.MFL.MRR.MRL

connector
Standard Approx. 2 0 Q (at 20°C)
OK (approx. 2 0 Q) -, CPU board defect, wiring disconnection (between CPU board and
MFR.MFL.MRR.MRL contactor)
NG (00 Q) + MFR.MFL.MRR.MRL contactor replacement
4. The vehicle does not move at all. (The MFR*MF~.MR~
and MRLcontactors are
closed. 1
Related portion
. I CN106-18 (52 VRAD)
1-1 I
.
CPU board
I I CN 106-1 4 (51 GND)

potentionmeter
VRAD
Estimated causes
@ The acceleration potentiometer signal is not input.
@ CPU board defect
@ Motor circuit abnormality
ANL12: Test operation (No. 5)

voltage check
-no"
(apprOxm
0
0
Acceleration potentiometer defect
Disconnection of wiring between
acceleration potentiometer and C N1 0 6
or less at full
acceleration)
OK
(approx. 1.0 V or more
, at full acceleration)
Inspection 1
Disconnect wiring of
P4, P5, P6, P7, P41, P51 and
P61. NG o Open circuit in armature coil
P 4 P 6 P41 P61 continuity (00 Q) o Open circuit in field coil
5 5 5 5 check
P5 P 7 P51 P 7
*
OK (approx. 0 Q)
* Approx. 0 Q is the motor
I coil resistance very close to
0 CPU board defect 0 Q.
Inspection 1. Drive motor continuity check
Battery plug OFF, cable disconnection from P4 to P7 . P41 to P61
Armature coil: P4- P5, P 4 1 -P51
Field coil: P6- P7, P 6 1 - P7
Standard Approx. 0 Q
(approx. 0 Q ) + CPU board defect

(00 Q )+ Armature coil disconnection or field coil disconnection
-
5. Normal speed control fails. (Acceleration failure)
CN6
CN106-17 (65 LSB)
Brake switch
CN106-13 (51 GND) LSB
CN 106-8 (53 VRAD +)

CPU
board CN 106-1 8 (52 VRAD) Acceleration
potentio-
CN106-14 (51 GND)
meter
CN 106-7 (64 SWAc) VRAD
CN25 - I
@ Insufficient acceleration potentiometer signal
@ Low drive OCL velue
@) Brake switch defect
NG
(Less than 1.3 V in
- 0
0
Acceleration potentiometer defect
Disconnection of wiring between ac-
full acceleration state) celeration potentiometer and CN 106
OK (Approx. 1.3 V or more in

full acceleration state)
t
0 To A on next page
ANL31: Switch input test Pull the brake pedal
Is the brake switch turned OFF 0 Pedal return
when the brake pedal is not failure
depressed?
Not lit
(switch OFF)
Inspection 2 0 Switch
Brake switch (OFF state: replacement
individual check
I OK (OFF state: Q)
~ r a ' k eswitch instal-

lation adjustment
check P- o Installation read-
justment
I 0
OK
Connector contact defect
Wiring disconnection
c
0
I
Display mask func- I
Inspection 1 NG tion check NG
I P Set correctly.
Drive circuit OCL value (outsidew S 36Vl48V selec-
measurement the tion set as
dard range) specified?
I I
0
1 OK (within the standard range)
CPU beard defect 0

1 OK
Drive circuit current sensor defect
0 Drive motor defect 0 CPU board defect
lnspection 1. Drive circuit OCL value measurement
See the OCL value measurement (page 2-35) in the controller section.
lnspection 2. Individual brake switch check

Battery plug OFF Brake switch removal
Measurement terminals Both terminals of brake switch connector

Standard Switch OFF: oo 0
OK (switch OFF: co Q) -+ To inspection 3

NG (switch OFF: 0 Q) -+ Brake switch replacement
lnspection 3. Brake switch installation adjustment check

See the brake switch adjustment (page 2-38) in the controller section.
6. The maximum traveling speed is not attained.
CN26
CN25, -
CN106-8 (53 VRAD+)
CN106-18 (52 VRAD) Acceleration

potentio-
CN106-14 (51 GND) meter
VRAD
CPU CN 106-7 (64 SWAc)
board
-
CN106-15 (77 SWsc)
Speed control
CN106-13 (51 GND) switch SWSc
-
CN1
4Estimated causes I
@ No speed control switch signal input
@ Wheel diameter setting error
The maximum traveling speed is not attained when the speed control switch is ON or the
maximum speed limiter (display mask function tuning mode: C5) is set to enable. (In this
state, the turtose mark is displayed.)
ANL12: Test operation (No. 5) NG 0 Acceleration potentiometer defect

wiring defect (acceleration poten-
full acceleration state)
than
tiometer -CN106)
1
OK (1.3 V or more in full
acceleration state)
0 To A on next page
1 ANL31: Switch input test
Speed control switch ON-OFF
check
lp*(switch OFF)
0
0
Speed control switch defect
-
Wiring
CN106-CN105)
defect (speed control switch
] OK (switch ON)
Tire wheel diameter check (See - NG -0 Traveling test after wheel diameter
the mask function) setting (The maximum speed may
not be attained depending on the
/OK tire material and running resistance.)
0 CPU board defect
0 Drive motor defect
7. Excessive braking in switch back operation.
Related portion
Speed sensor
CN106-1 (82 SSR-) SSR
-
-
-- -
CN20
CN106-4 (83 SSL-1 - '
CPU board Speed sensor

CN106-3 (83 SSL+ )
SSL
-
CN106-10 (P6 VBP6) CN1 16-1 (P6) -
CN116
-0 P6
CNIO6-11 (Pel VBP61) CN116-2 (P61)
-0 P61
L
Estimated causes
@ Speed sensor defect, momentary disconnection or short-circuit in speed sensor harness
@ Momentary disconnection or short circuit in P6.P61 voltage detection harness
@ DF2R or DF2L open
@ CPU board defect
ANL13: Test operation (No. 1)

Check normal speed detection
during wheel rotation at each
14 NG
Speed sensor har-
continuity
check on defective
1 NG -0 Speed sensor har-
ness defect
1'r'
of speed sensor RH and LH.
Speed sensor defect
Harness continuity check

P6- CN106-10
P61 -CN106-11 P- o Harness disconnection
Inspection 1. 1 ~ - DF2R
0 or DF2L defect
DF2R.DF2L individual check
k- CPU board defect

Inspection 1. DF2L-DF2R individual check
Battery plug OFF, DF2L.DF2R wiring disconnection

8
Forward: Anode -
Reverse: Anode +
dlx I
8
- Cathode +
- Cathode -
Forward: Approx. 3 kfl

Standard
Reverse: a
62
OK -+ CPU board defect

NG -+ DF2L-DF2R defect
8 . The vehicle travels only in the forward or reverse direction.
-
CN9
CN106-6 (46 DSR)
CN106-5 (45 DSF) Direction switch

CPU board
DS
CN106-13 (51 GND)
-
I
Estimated causes
@ No direction switch signal input
@ Open circuit in MFR.MFL.MRR-MR,contactor coil
1 ANL31: Switch input test 1

Is DSFIDSRturned ON and Not turned 0 Direction switch defect
OFF when the direction lever
is operated to the forward
Wiring defect (DSFIDSR -
CN106)
and reverse positions
Turned ON and OFF
ANL1 1: ESY-22 Inspection 1

MFR-MFL-MRR.MRL
operation check
contactor NG
- MFR.MFL.MRR.MRL contactor
coil continuity check
N G - ~~ontacter
(a0) defect
1 oK 1
I
OK (approx. 20 0)
CPU board defect 0 CPU board defect

- CN104)
0
0 Wiring defect (MFIMR
Inspection 1. MFR. MFL or MRR.MRLcontactor coil continuity check
Battery plug OFF
Measurement terminals Both terminals of MFR.MFL.MRR.MRL

connector

Standard Approx. 20 Q (at 20°C)
OK (approx. 20 Q) + CPU board defect, or wiring disconnection (between CPU board and
contactor coil)
NG (00 Q) + MFR-MFLorMRR.MRLcontactor replacement
4-85
9 . The speed limiter is ineffective.

(1 The vehicle speed rises to the maximum speed.
7
CN106-15 (77 SWSc)
Speed control
CN106-13 (51 GND) CN 1
CN106-2 (81 SSR+)

- switch SWsc
Speed sensor RH
CN106-1 (82 SSR-)
SSR
CN106-4 (83 SSL+)

Speed sensor LH
CN106-3 (84 SSL- ) -CN20
- SSL
@ No speed control switch signal input
@ Speed sensor signal defect
ANL31: Switch input test 0 Speed control switch defect

0 Wiring defect (speed control switch -
CN106)
OK (ON)
0 Traveling test after wheel diameter

(not regular setting
tire size)
ANI-13: Test operation (No. 1 ) NG 0 Speed sensor defect

Speed indication check (great flue: 0 Wiring defect (speed sensor -
I tuation of CN106)
0
1 oK
CPU board defect
speed indi-
cation dur-
ing
traveling at
a constant
speed)
(2) The limited speed is abnormal.
CN21
CN106-2 (81 SSR+)
Speed sensor RH
CN106-1 ( 8 2 SSR-1 SSR
CPU .-
board
CN106-4 (83 SSL + )
Speed sensor LH
CN 106-3 ( 8 4 SSL-) - SSL
L
CN20
Estimated causes
@ Speed sensor signal defect
NG -0 Traveling test after wheel diameter

(not regular setting.
tire size)
0 Speed sensor defect
ANL 1 3: Test operation (No. 1 ) NG 0 Wiring defect (speed sensor -
Speed indication check (great fluc - 0
CN105)
CPU board defect
tuation of
0
l oK
CPU board defect
speed indi-
cation dur-
ing traveling
at a cons-
tant speed.)
4-87
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED

(MATERIAL HANDLING SYSTEM)
1 . The pump motor does not run.
(1) When material handling chopper is provided. (Option)
-
CN11
CN 105-6 (63 LSAnI) -
CN105-1 (60 LSL) -
CN105-3 (61 LST) -
Lift tilt
CN106-13 (51 GND) - attachment
switch
1
CPU
board
-
CN39
-
CN105-2 (68 LSL2)
CN104-15 (1 M + )
CN104-5 (7 MP)
Connector MP
@ F2 fuse open
@ Display mask function setting error
@ Material handling switch defect
@ MP contactor coil defect
@ Pump motor abnormality
@ Disconnection of motor wiring
@ CPU or DCISDP board defect
0 F2 fuse replacement
0 To A on next page
'-
A
- Turned OFF in ap-
Is the MP contactor closed Is it turned on immediately prox 2.5 seconds
when the matenal handling
lever is pulled?
Closed when the material handling
lever is release?
-
To B on this
0
page
I
I I
Not closed
0
1 Turned OFF immediately
Display mask function is not set to "Materi-

al handling chopper" by option input setting.
ANL31: Switch input test NG 0 Material handling switch defect

-0 Wiring defect (each material handling
Check ONIOFF of each
material handling system
switch - CN 105lCN106)
switch.
OK
Inspection 2
ANL 1 1: ESY-22
MP contactor operation check
NG - MP contactor coil continuity
NG-o MP contactor
(aQ) coil
check
1
OK
1
I
OK (approx. 20 Q)
replacement
0 CPU board defect 0 CPU board defect

0 Wiring defect (MP contactor - CN115)
lnspection 3
Remove P12-P13 (motor w i r i n g j k o Disconnection in motor coil
and check continuity
1 OK (approx o
0 CPU board defect * Approx 0 Q is the motor coil resistance very

0 DCISDP board defect close to 0 Q
lnspection 1. F2 fuse continuity check
Battery plug OFF
Measurement terminals Both terminals of F 2 fuse

Standard 0 61
OK (0Q) + MP closing check at SWKYON

NG (a Q) + F2 fuse replacement
lnspection 2. MP contactor coil continuity check

Battery plug OFF
Measurement terminals Both terminals of MP connector

Standard Approx. 2 0 0 (at 20°C)
OK (approx. 20 Q) -+ CPU board defect, or wiring disconnection (between CPU board and contactor)
NG (aQ) -, MP contactor coil replacement
Inspection 3. Pump motor continuity check
Battery plug OFF, P12-PI3 motor cable disconnection
Measurement terminals Motor coil P I 2 - PI3

Circuit tester range nxl
OK (approx. 0 Q) -, CPU board deftce or DCISDP board defect

NG (ooQ) -, Motor coil disconnection
4-9 1
(2) When the material handling chopper is not provided. (Standard)
CNll
CN105-6 ( 6 3 LSATTI) -
CN 105-1 ( 6 0 LSJ -
CN105-3 (61 LST) -
Lift tilt
attachment
CN106-13 (51 GND) - switch
d
CPU
board
-
CN115
CN104-15 (1 M + )
-
CN 104-5 (7 MP)
L
MP Connector
@ F2 fuse open
@ Pump motor defect
@) Material handling switch defect
@ MP contactor coil defect
Inspection 1
F2 fuse continuity check
NG
(00
- 0 F2 fuse replacement
OK (0Q,
Is the MP contactor closed when the Closed 0 Pump motor defect
material handling lever is pulled? 0 Pump motor cable disconnection
Not closed
1
0 To A on next page
P-
ANL31: Switch input test o Material handling switch defect
Check ONIOFF of each
0 Wiring defect (each material handling switch -
CN 105lCN106)
material handling switch
Inspection 2
ANL11: ESY-22 MP contactor
MP contactor coil continuity 0
MP contactor operation check check
I
OK OK (Approx. 20 Q)
1
0 CPU board defect 0 CPU board defect
0 Wiring defect (MP contactor coil - CN110)
Caution:
Never touch the material handling lever during MP contactor operation check.
Otherwise, the pump motor starte to move the mast and fork when the MP contactor is closed.
lnspection 1. F 2 fuse continuity check
Battery plug OFF
Measurement terminals Both terminals of F 2

Standard 0 62
OK (0 Q) -+ Check MP closing at SWKYON

NG ( a Q) -+ F2 fuse replacement
Inspection 2. MP contactor coil continuity check

Battery plug OFF
Measurement terminals Both terminals of MP connector

Standard Approx. 2 0 62 (at 20°C)
OK (approx. 2 0 Q) CPU board defect, or wiring disconnection between CPU board and contac-
-+
tor coil
NG (a Q) -, MP contactor replacement
TROUBLESHOOTING - OTHERS
Battery capacity is not indicated correctly.
1 Display mask function check

,
Is the 36 V l 4 8 V selection set t o the cor-
rect battery voltage?
p-. s e t it correctly.
Display mask function check NO

Is "the standard battery"m"battery-less" = 0 Set t o battery-less.
selection set t o "battery-less"?
YES
Is the speed control switch setting

NO
correct? -0 Set it correctly.
USA: Invalid
Others: Valid
YES
The charge indicator The charge indicator

is lit although the bat- is off although the
tery has been dis- battery charge still
charged. remains.
0
Adjustment of tuning Adjustment of tuning
mode C 4 mode C 4
0 Adjust toward level 0 Adjust toward level
8. 1.
TROUBLESHOOTING RELATED TO MULTI-DISPLAY AND MCS
COMMUNICATION SYSTEM
ERROR CODE F1: FAILURE IN COMMUNICATION BETWEEN MULTI-DISPLAY AND MCS
Check CN 107 harness and the rnulti-

display connector harness.
NG - Retest after repair
I I I
I
I
OK
1
0 CPU board defect
0 Multi-display board defect* * Multi-display board: CPU board for
display
ERROR CODE F2: FAILURE IN COMMUNICATION BETWEEN MULTI-DISPLAY AND MCS

s
W
Check CN107 harness and the rnulti-
display connector harness. Retest after repair
0 CPU board defect

t
0 Multi-display board defect
ERROR CODE F3: POWER CONTROLLER MEMORY VALUE INCONSISTENCY

I y
W
Check CN107 and harness and the rnulti-
display connector harness. Retest after repair
I I I I
OK
0 CPU board defect

ERROR CODE F4: POWER CONTROLER MEMORY VALUE ABNORMALITY

ERROR CODE F5: CHARGING TIMER MEMORY ABNORMALITY
This error occurs when the AC power

supply is connected.
OK
Note
Even if error code F5 is displayed when the AC power is connected, charging is possible by pressing
the CHARGE switch. As the count memory for automatic equalized charging is abnomal, automatic equal-
ized charging fails.
ERROR CODE F6: CHARGING SAFETY TIMER OPERATION
AC power is input check. NG
Error
- 0
0
Power service interruption
AC power cable defect
display
OK (200 V)
Tap changer voltage check

NG -0 Tap adjustment defect
OK (200 V)
Charger timer test Take a corrective action accord-
NG - ing to the timer test and
troubleshooting.
OK
Fuse (Fch) continuity check NG
0 Blown fuse (Fch)
(00 Q)
- - -
Magnet switch check

I= 0 Magnet switch defect
P-
ANL11: ESY-12
CPU port defect
Charging voltage check
'1
0 Transformer defect
ERROR CODE F7: CHARGING START FAILURE
Continue charging as it is. YES Tap changer voltage check
+Charging completed? -
NO (error code F6 display)

Check in the same way as for
error code F6 No abnormality (error occurrence
due to temporary voltage drop)
ERROR CODE F8: CHARGING NOT COMPLETED

Magnet switch (Mch) drive YES- Signal check (21 magnet switch
signal check (1 )
NG (OV)
(Mch) drive
OK (5 V)
! I
OK (5 V ) 0 Timer unit defect 0 Display board defect
0 Harness defect
Extract the charging power sup-

ply plug and check if MSch is
opened.
- 0 Magnet switch defect (foreign mat-
ter trapped at contact portion)
I
0
I O
pened
Timer unit defect

STEERING SYSTEM TROUBLES
DIAGNOSIS ERRORS
ERROR CODE FO: STD (WITH CONTACTOR)
FO is not displayed for a trouble on the PS side because the standard PS system is not prourded with
the diagnostic junction.
@ Display subharness defect
@ Display board defect
ERROR CODE: FO (WITH EHPS)
---
>
ex
e
P22
I
b
(U
g-
53
TMps
-
-
I 1
BATT
-
4b
CN27-4 (151. LISFi
- cs, 3ISP
41
PBEHPS i
-
1
@ PS board defect
( @ Display board defect
I @ Connector and wiring defect

I
I @ TMps defect
Check connector and wiring connections. 1 4 NG Recheck by operation after correction.

1
Does the PS motor keep running when
the SWKYis turned t o OFF?
IYES-O TMps defect lshon circuit)
0
1
To A on next page
Does the PS motor run when the steering
PS board defect
wheel is not operated after SWKYON?
NO
I Inspection 1.
H
(SWKYON)
Does the PS motor run when the steering
CN27(4)151 (harness side-board side)
wheel is operated after SWKYON?
$ Voltage measurement
CN27(5)163
0 V on both harness
side and board side
0
i
J
Display board defect

I
5 V on harness
side and 0 V on
board side
I
5 V on both harness
side and board side
0 Wiring
disconnection 0
I
CN27 defect 0
t
PS board defect
1
Inspection 2.
SWKYON
CN27(1 )43 (harness side.board side)
$ voltage measurement
CSPSN1
Battery voltage on both

1
NG
Battery voltage on harness
'YG
0 V on both harness side
harness side and board side side and 0 V on board side and board side
0
I
CN41 C N 4 3 defect 0
I
CN27 defect 0
t
0 PS controller internal
wiring defect
0 PS board defect
lnspection 1. Display signal voltage check
Battery plug ON, SWKYON, CN27 connection
Measurement terminals CN27(4)151 - CN27(5)163

Standard 0 V on both harness side and board side
OK (0 V on both harness side and board side) + Display board defect

NG (5 V on harness side and 0 V on board side) CN27 defect
+
NG (5 V on both harness side and board side) PS board defect

-+
lnspection 2. PB board signal voltage check

Battery plug ON, SWKYON, CN27, CN41 and CN43 in connected state
Measurement terminals CN27(1)43 - CSpsN1

Standard Battery voltage on both harness side and board side
C27
(C2E1terminal)
OK (battery voltage on both harness side and board side) CN41 C N 4 3 defect, PS controller in-
+
ternal wiring defect, or PS board

defect
NG (battery voltage on harness side and 0 V on board side) CN27 defect
-+
NG (0 V on both harness side and board side) + wiring disconnection

WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (STDI
1. The steering wheel is heavy. (The PS motor does not run when the direction switch
is closed and the parking brake is released after SWKYis turned to ON.)
Estimated causes
@ CPU board defect
I @ Direction switch defect I
I @ Mps contactor defect I
I @ Connector and Wiring defect I
@ Parking switch defect
Check connector and wiring NG Recheck operation after

connections. correction.
Is the PS contactor closed Blown F 3

Inspection 1. 0
when the direction switch is P22 NG Cable defect
YES 0
closed and the parking brake t
$ voltage measurement 0 Contactor
is released after the SWKYis contact
N1
turned to ON?
NO I OK (battery voltage)
defect
0 Motor cable or connector defect

I 0 Motor defect
lnspection 2
MPScontactor coil continuity
NG
- o Mps contactor coil defect
check (.on)
0
0
oK (llon)l
CN42 defect
0 Direction switch defect
0 CPU board defect
0 Parking switch defect
lnspection 1. Main PS circuit voltage measurement
Measurement terminals ~ 2 2 -0 NIB

OK (Battery voltage) -, Motor cable or connector defect, or motor defect

NG (0 V ) -, F 3 fuse defect, wiring disconnection, or contactor contact defect
lnspection 2. Mps contactor coil continuity check

Battery plug OFF
-
Measurement terminals Both terminals of MPs conector CN42

Standard Approx 1 1 0 (at 20°C)
OK (appro~.1 1 0 Q) + CN42 defect, wiring disconnection, direction switch defect, CPU board
defect, or parking switch defect.
NG (co Q) -, Mps contactor defect
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (WIEHPS)
1. The steering wheel is heavy. (The PS motor does not run when the steering wheel
is operated after the SWKYis turned to ON.)
p22
TM,s
ii
+I
CN27-l(43 SWKY)
-CN27-3(161 SSP)
- CN27-2(162 SSP)
- SSP
CN27-5(163 SSP)
&
-
-BATT PB~HP~
7
CN27-4(151 DISP)
CSPS
DISP
b
-
A
@ F3 open
@ PS controller internal wiring defect
@ PS motor defect
@ PS pump defect
@ PS board defect
@ Steering pressure switch defect
@ TMps defect
@ Wiring disconnection
7
Check connector and wiring connections.
NG
%
Recheck by operation after correction.
11
OK
Inspection 1.
NG - 0 Blown F3
CN41 defect
voltage measurement
0 PS controller internal wiring defect
CSpsN1
I 1
0 To A on next page
Inspection 2. 0 CN41-43 defect
Release the steering wheel. NG 0 PS controller internal wiring defect
TMpsC2E1 - 0 Motor cable connector defect
$ voltage measurement 0 Motor defect (The motor circuit is
CSPSN1 open if the measured voltage is 0 V.)
I OK (battery voltage)
lnspection 3.
Operate the steering wheel t o the stroke
end.
TMpsC2E1
$
CSPSN1
voltage measurement
1 Battery voltage
tLess
than
battery
voltage
0
Motor defect
PS pump defect (The pump or motor
may be seized if the measured voltage
is about half of the battery voltage.)
I
lnspection 4.
CN27(3)161
CN27(5)163 t-
I
o
0
CN27 defect
PS board defect
r-
Inspection 5.
CN27(2)1 6 2
0 Steering pressure switch defect
CN27(5)163
OK (Variation at 2.0 V or less or at 1 0 V or more)
wheel is released
I 1 0 V or more: Voltage when the steering
0 PS circuit TMps defect wheel is operated
0 PS circuit current sensor defect
0 PS board defect
lnspection 1. Main PS circuit voltage measurement (1
Battery plug ON, SWKYON, CN41 C N 4 3 connection
Measurement terminals TMP~C-

I CSPSNI
C27
(C2E1 terminal)

NG (0V ) + F3 fuse defect, CN41 defect, PS controller internal wiring defect
lnspection 2. Main PS circuit voltage measurement (2)

Battery plug ON, SWKYON, CN41 C N 4 3 connection, steering wheel in non-operated
position
Measurement terminals TMwC2EI - CSwNl
C27
(C2E1 terminal)
Battery voltage + To inspection 3

Less than battery voltage -,CN41.43 defect, CPU board defect, motor or cable connector defect
lnspection 3: Main PS circuit voltage measurement (3)
Battery plug ON, SWKYON, CN41.43 connection, steering wheel in operated state
Measurement terminals TMpsC2EI - CSpsNl

C27
(C2E1terminal)

NG (about half of battery voltage) -, Motor defect or PS pump defect
lnspection 4. Steering pressure switch operating voltage measurement (1)

Measurement terminals CN27(3)161 - CN27(5)1 6 3

Standard Approx. 1 2 V
OK (approx. 1 2 V) To inspection 5
NG (0V ) + CN27 defect or PS board defect
Inspection 5. Steering pressure switch operating voltage measurement (2)
Battery plug ON, SWKYON, CN27 connection, with steering wheel rotation

Steering wheel not operated: 2 V or less
Standard
Steering wheel operted 10 V or more
OK (2 V or less when the steering wheel is not operated, and 10 V or more when the steering wheel
is operted) -+PS circuit TMps defect, PS circuit current sensor defect, or PS board defect
NG -+Steering pressure switch
4-108
2. The PS motor keeps running after SWKYON. (STD with contactor)

~ s t i m
@ PS contact welding
@ 0 CPU board defect
04
Does the motor stop upon SWKYOFF? No Welding of contactor contact.
YES
0 CPU board defect
The PS motor keeps running after SWKYON. (with EHPS)

Related portion
7
CN27-3061 SSP)
~ ~ 2 7 - 2 ( 1 6 SSP)
2
PBEHPS SSP
CN27-5(163 SSP)
Estimated causes
@ PS board defect
@ Steering pressure switch
Check steering pressure switch connec-

tor and wiring connection.
NG - Recheck operation after repair.
NG
OK =
Inspection 1.
CN27(2)162 NG 0 Steering pressure sensor
$ voltage measurement - 0 Wiring defect
CN27(5)163
OK (2 V or less when the steering wheel is

not operated and 1 0 V or more when the
steering wheel is is operated)
I
0 PS board defect
Inspection 1. Steering pressure switch operating voltage measurement (2)

Steering wheel not operated: 2 V or less
Standard
Steering wheel operated: 1 0 V or more
OK ( 2 V or less when the steering wheel is not operated, and 10 V or more when the steering wheel
is operated) + PS board defect
NG -, Steering pressure switch defect, or wiring defect
ELECTRICAL SYSTEM TROUBLESHOOTING
[FOR OTHER THAN U.S.A.l(l998.9 - )
Page
GENERAL .................................. 4A-2
TROUBLESHOOTING EXPLANATION ........... 4A-2
LOCATIONS OF TERMINALS AND
CONNECTORS ............................ 4A-3
BEFORE TROUBLESHOOTING ............... 4A-4
DRIVE SYSTEM-MATERIAL HANDLING
SYSTEM TROUBLES ...................... 4A-5
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED ... 4A-5 Em
DISPLAYED (DRIVE SYSTEM) .................... 4A-70
DISPLAYED (MATERIAL HANDLING SYSTEM) ..... 4A-81
TROUBLESHOOTING RELATED TO STEERING
SYSTEM..... ............................. 4A-86
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED ... 4A-86
GENERAL
Only the following items, which have changed due t o use of the MOS controller, are explained here.
DRIVE SYSTEM-MATERIAL HANDLING SYSTEM MALFUNCTION

STEERING SYSTEM MALFUNCTION

For items other than the above, see chapter 4, ELECTRICAL SYSTEM TROUBLESHOOTING, in the
5FBE Repair Manual (CE306).
TROUBLESHOOTING EXPLANATION
Inspection 1 NG
F1 check
C F1 defect
(-Q)
OK (0 s2)
7
Inspection 2 NG
CN101-9 (43)
C
SWKYdefect
$ Voltage check
CN103-2 (N1)
Measure with a circuit tester.
OK (48 V)
1
CPU board defect
\ Repair or replace.
Potential level
/
Tester probe (+)

Voltage check
Tester probe (-)
\ Pin No.
I
Connector No.
LOCATIONS OF TERMINALS AND CONNECTORS
Main measurement terminals referred to in this troubleshooting chapter are located as shown below.
PI2
Provided for models
with a material
handling chopper.
P13
Provided for models
with a material
handling chopper.
Provided for models
without a material
handling chopper.
Provided for models

with a charger.
N1
DFI, CSD, TMD, STH, and snubber board are mounted on

the reverse side of the CPU board. In the case of models with
an optional material handling chopper, DFI, CSD, TMD,
STH, snubber board, DF3, CSP, and TMP are mounted on the
reverse side of the CPU board.
BEFORE TROUBLESHOOTING
Be sure to connect a discharge resistor (220 - 330 Q 2W) between TP9 on the snubber board and N1
before troubleshooting because the voltage at terminal TP9 is not be promptly discharged due to CA
= 8100 pF.
Battery plug OFF

Discharge terminals TP9 (on snubber board) and N1
DRIVE SYSTEM-MATERIAL HANDLING SYSTEM TROUBLES
ERROR CODE AO: MCS MAIN CIRCUIT OVERHEAT
CN
- TH Temperature sensa
CN101-24(76,THCD)
CPU
board CN101-1(75,THC+) STH

@ Temperature sensor defect
@ Defective contact or disconnection between CNlOl and temperature sensor
@ CPU board defect
Stop the vehicle and restart traveling

with normal load 30 minutes later to
run a confirmation test.
Inspection 1
Disconnect connector CN TH Temperature sensor defect
and measure the resistance of
temperature sensor. (2.2 kQ or more)
1
s:P than 2.2 kQ)
Defective contact or disconnection between CNlOl and temperature sensor
CPU board defect
Inspection 1. Temperature sensor resistance check
Battery plug OFF, connector TH disconnection
Measurement terminals Both terminals of connector TH (STH side)

Circuit tester range Q x Ik
Standard Less than 2.2 kQ
OK (less than 2.2 kQ) +CPU board defect, or defective contact or disconnection between C N l O l
and temperature sensor
NG (2.2 kQ or more) + Temperature sensor defect
ERROR CODE A2: CPU BOARD ABNORMAL TEMPERATURE RISE
-
Related portion 1
CPU board temperature sensor

(THAI
fO,
- Estimated causes
a Ambient temperature of CPU board being 80°C or more

@) CPU board temperature sensor defect (CPU board defect)
80°C or more
Temperature measurement + Leave the vehicle unoperated for some
time (about 30 minutes)
Less than 80°C

1
Continued use of the vehicle YES C

Restart traveling for confirmation under
with overload normal load after stopping for 30 minutes.
NO
1
CPU board defect
The CPU board temperature sensor is included on the CPU board. CPU board defect is
conceivable when this error code (A2: CPU board abnormal temperature rise) is displayed.
ERROR CODE A3: ABNORMALLY HIGH BATTERY VOLTAGE
Related portion
CPU
board
I CN102-11(P2.VBP2) P2
0
~ s t
@ Connection of other than specified battery voltage to battery plug

@ Misconnection of charger plug to the controller
@ CPU board defect
The charger plug is connected YES * Start charging after connecting the charger
to the controller. plug to the battery side.
NO
YES
The mounted battery is other w Mount the specified battery.
than the specified one.
NO
7
CPU board defect
ERROR CODE A4: ACCELERATION POTENTIOMETER INSTALLATION DEFECT
Acceleration
potentiometer
CN25 CN26.
CN105-6(50,POT-)
CPU
board CN105-l(64,LSAC) VRAD
- -
E s t i
@ Acceleration potentiometer defect (between 64 and 50)

@ Acceleration potentiometer installation adjustment defect
@) Accelerator switch wiring short circuit (between 64 and 50)
@ CPU board defect
Is the battery plug connected YES c IS the normal state recovered YES
while the accelerator pedal is when the accelerator pedal is Normal
depressed? released?
I I

ON or OFF when the accelerator
pedal is not depressed?
k* CPU board defect
(Not lit) I
Inspection 1
I
I ON (Lit)
Carry out ANL31:Switch input test again

after disconnecting the acceleration
I
Individual acceleration
potentiometer
inspection
nv
I
Acceleration
potentiometer connector (CN26).
1 potentiometer
defect
rANL31: Switch input test

ON or OFF? I-
OFF (Not lit)
0 Q in operated]
t
Accelerator switch wiring short circuit (short circuit between 64 and 50)
Inspection 1. Individual acceleration potentiometer inspection
Battery plug OFF, CN26 removal
Measurement terminals CN26-1 (50) [TAB] - CN26-2 (64) [TAB]

standard Normal state: 042 Operated state: 0 Q
OK (Normal state: 4 2 Operated state: 0 Q) + Installation adjustment defect

NG (always 0 Q) + Acceleration potentiometer defect
ERROR CODE A6: MATERIAL HANDLING SWITCH INSTALLATION ABNORMALITY
Related portion Ii
CNll
CN103-lO(60,LSL)
CN103-6(61,LST)
Lift switch
Tilt switch
CN103-5(63,LSATl) Attachment 1 switch
CPU
board
CN103-11(68,LSL2) CN39 --,
Lift 2 switch
2 -
Estimated causes
a Defect of each material handling limit switch

@ Installation adjustment defect of each material handling limit switch
@ Short circuit of each material handling limit switch wiring
@ CPU board defect
Is the battery plug connecte while YES Recovered to the normal state YES
any material handling lever is when the material handling lever Normal
operated? is released.

Is each material handling switch ON or OFF
CPlJ board defect
when the corresponding material handling (Not lit)
lever is not pulled?
ON (Lit) ON (Lit) Remove CN39.

ILSL2] Wiring
L
ANL31: Switch input test ON D short
Is LSL2switch ON or OFF? (Lit) circuit
I I .. .TJII
L ~. A
4 OFF (Not lit)
Remove CN 1 1.
-
1
Inspection 2 NG LSL2defect
LSL2individual check
(always 0 Q)
OFF NO^ lit) 1
(Lit) I
OK
Wiring short circuit (Normal state: WQ
of the switch in the Operated state: 0 Q)
Inspection 1 ON position
Individual check on LSL, LST, and Installation adjustment defect
I
NG Each material handling
OK 1
(always 0 Q) limit switch defect
(Normal state: -Q Operated state: 0 Q)
1
Inspection 1. LSL, LST, and LSAT1individual check
Battery plug OFF, LSL, LST, and LSATl individual removal
Measurement terminals Both terminals [COM-NO] of LSL, LST, and LSATl

Standard Normal state: -Q Operated state: 0 Q
OK (Normal state: 042 Operated state: 0 Q) -+ Installation adjustment defect

NG (always 0 Q) 4 Defects i n LSL, LST, and LSATl
lnspection 2. LSL2individual check (only when the material handling chopper is provided.)
Battery plug OFF, LSL2individual removal
Measurement terminals Both terminals [COM-NO1 of LSL2

Circuit tester range Q x lk
Standard Normal state: -Q Operated state: 0 Q
OK (Normal state: -Q Operated state: 0 Q) 4 lnstallation adjustment defect

NG (always 0 Q) 4 LSL2defect
ERROR CODE A7: PARKING BRAKE ALARM (For UL-USA-CANADA)
Parking brake switch

CN15
CN103-3(66,LSPB) -
LSPB
CPU
-
board Deadman switch
CN22 CN28
CN103-4(67,LSD)
- -
LSD
- -
Estimated causes
@ Parking brake switch defect
@ Parking brake switch installation adjustment defect

@ Parking brake switch wiring shortcircuit
@ Deadman switch installation adjustment defect
@ Deadman switch wiring short circuit o r disconnection

a CPU board defect
.
Is the error reset
when the parking
brake lever is pulled
or the operator sits
on the seat?
Occurrence of A7 error while
the parking brake is pulled?
Occurrence of A7 error while

the operator sits on the seat?
0
t
Normal
ANL3 1: Switch input test
Is the switch turned ON or OFF
when the parking brake lever is
pulled?
I Lit (switch ON)

I- N~~ lit
(switch OFF)
0 CPU board
defect
After opening the parking brake

switch (CN1 5) Lit
ANL31: Switch input test -0 Wiring shortcir
Is parking brake switch turned (switch ON) cuit (between
ON or OFF? 66 and 51
I Not lit (switch OFF)
lnspection 1
0 Switch
check replacement
OK (a,Q at switch ON)

1 0 ~ e f e c t i d einstallation
adjustment
t
Lit
Is the deadman switch turned 0 Defective CPU board
ON or OFF when the operator (switch ON)
sits on the seat?
Not lit o Wiring disconnection

ANL31: Switch input test Connector contact
-0
(switch OFF) defect
Is the deadman switch turned
0 CPU board defect
Lit (switch ON)

Inspection 2 NG
Deadman switch individual -0 Switch replacement
(a,Q at
check switch OF,F)
-
OK
(0Q at switch ON)
0 Deadman ;witch installation defect
lnspection 1. Parking brake switch individual check
Parking brake switch individual removal
Measurement terminals Both terminals of parking brake switch connector

Standard ao Q at switch OFF
OK (ao Q at switch OFF) 4 Installation readjustment

NG (0Q at switch OFF) -* Switch replacement

Measurement terminals Both terminals of deadman switch

Standard 0 Q at switch ON
OK (0D at switch ON) 4 Installation adjustment defect

NG (aQ at switch ON) Switch replacement
ERROR CODE A8: TRAVELING FUSE ABNORMALITY
F5
CN104-3(41,VBBT) P1
CPU F1
board CN102-11(P2,VBP2) P2
V
Estimated causes
a Drive fuse (FI) open
@ Wiring disconnection between CN102 and P2

@ Short circuit between P2 and N1
@ CPU board defect
1 ,
Inspection 1
Drive fuse (FI) check
p-(other than R)F l defect
OK (0 Q)
Voltage measurement at OK
terminals VBBT and VBP2 CPU board defect
(a= VBBT - VBP2) (a = 15 V or less)
Voltage calculation
I (NaG= 15 v or more)
Inspection 2
P2
$ continuity check
CN102-11 (P2) b- Disconnection between CN102 and P2
1 OK (0 Q)
Short circuit between P2 wiring and N1

lnspection 1. Drive fuse (F1) check
Battery plug OFF, fuse (F1) individual removal

Standard OQ
OK (0 Q) + ANL 12: Test operation (No. 2,4)

NG ( 4 2 ) + F1 defect
Inspection 2. Wiring continuity check

Measurement terminals P2 - CN102-11 (P2) [RECI

Standard 0Q
OK (0 Q) + Short circuit between P2 wiring and N1

NG (-Q) + Disconnection in wiring between CN102 and P2
4A-18
ERROR CODE A9: PUMP FUSE ABNORMALITY

P
Related portion
F5
-
CN104-3(41,VBBT) P1
CPU
board CN102-2(P11,VBP11)
-
- Estimated causes
@ Pump fuse (F2) open

@ Wiring disconnection between CN102 and P I1
@ Short circuit between P2 and N1
@ CPU board defect
Inspection 1 NG
F2 defect
Pump fuse (F2) check
(Any value other than 0 Q)
OK
-
(p = 15 V or less)
CPU board defect
NG
(p = 15 V or more)
1
Inspection 2
P2 NG
c Disconnection between CN102 and P I1
$ continuity check
CN102-2 (PI I) (-Q)
OK (0 Q)
7
Short circuit between P I1 and N1
lnspection 1. Pump fuse (F2) check
Battery plug OFF, fuse (F2) individual removal

Standard 0 52
OK (0 Q) + ANL 12: Test operation (Nos. 2,6)

NG (-0) + F2 defect
lnspection 2. Wiring continuity check

Measurement terminals PI1 - CN102-2 ( P I 1) [RECI

Standard OQ
OK (0 9)+ Short circuit in wiring between PI1 wiring and N1

NG (-52) + Disconnection in wiring between CN102 and PI1
--
ERROR CODE AA: CPU BOARD TEMPERATURE SENSOR OUTPUT ABNORMALITY
CPU board temperature sensor

(TH1)
ro,
Estimated causes
@ CPU board defect
CPU board replacement for AA display
ERROR CODE AE: EXCESSIVE A I D PROCESSING TIME
@ CPU board defect
CPU board replacement for AE display
ERROR CODE AF: CPU PROCESSED DATA ABNORMALITY
@ CPU board defect
CPU board replacement for AF display

4A-21
ERROR CODE CO: MAIN DRIVE CIRCUIT ABNORMALITY
P8 P1
0
RA
____
I TP9
DAD
TDADo ! LI
n
..
" I I
CN101-14(P8,TMD-D) 0 I
t-
-
TMD l-
C PU CN101-16(92,TMD-G)
I1 CA
board
I- Snubber board
'----------------------------------l,---;
- TN1
CN101-22(N2,TMD-S)
i1
0
N1
a TMD defect (Be sure to check DFI, DF2R, DF2L, snubber board (CAI DAD),
and RA because a defect in any of these may be primary cause of a defective TMD.)
a
@ CPU board-TMD wiring disconnection
@) P8-TDAD wiring disconnection
@ CPU board defect
(If error codes CO and FA are displayed at the same time, give priority to FA.)
CO and C1 displayed
in traveling stop state? P- See the section of troubleshooting of C1
Check TMD wiring and

snubber board for loosened Correct the problem and recheck.
connector
lnspection 1
Remove TDAD round terminals of snubber
board and turn on battery plug. Snubber board defect
TDAD (P8) (less than 15 V or less)
$ voltage check
TNI (NI)
v lnspection 2
(15 V or more)
Continuity check between Wiring disconnection between P8 and TDAD

P8 and TDAD.
lnspection 3
Remove CNlOl and TMD wiring- and check
continuity between: NG Wiring disconnection between CPU
(A) CN101-14 - TMD-D
board and TMD
(B) CN101-16 - TMD-G
(C) CN101-22 -TMD-S
(D) CN101-16 - CN101-22
OK
I 1
I
lnspection 4
TMD individual check after
disconnecting TMD wiring
copper bar
OK
I
CPU board defect
I
TMD defect
Conduct inspections 5-10 below the heading "A" on the next page as a defect in DFl1DFZR,
snubber board (CAI DAD), and RA may be a primary cause of a defective TMD.
. .
Inspection 5 NG + DFI defect

DFI individual check
OK
t
lnspection 6
(perform this check only when NG rn SN1 individual check
CO and C9 are simultaneously
displayed.)
OK
1
lnspection 7 NG
DF2Rand DF2Lindividual C DF2 individual check
check
OK .
Inspection 8 NG C
CA individual check
OK
1
Inspection 9 NG C
DAD individual check
Snubber board defect
4
OK
Inspection 10 NG C RA individual check
RA individual check
OK
1
Driving confirmation test
lnspection 1. TDAD-TN1 voltage check
Snubber board TDAD round terminal disconnection, battery plug ON, key switch ON
--
TDAD (P8) @[wiring side] - T N I ( N I ) @

[on snubber board]
Circuit tester range DC50V
Standard 15 V or more
Snubber board
TN1
TDAD
OK (15 V or more) 4 To inspection 2

NG (15 V or less) + Snubber board defect
lnspection 2. P8-TDAD continuity check

Battery plug OFF, P8-TDAD wiring individual removal
Measurement terminals Both terminals of wiring between P8-TDAD

Standard OQ
OK (0 C2)+ To inspection 3
NG ( 4 2 ) -+ Wiring disconnection between P8-TDAD
lnspection 3. Between CPU board-TMD wiring continuity check
Battery plug OFF, CN101-TMD wiring disconnection
A: CN101-14 (P8) [RECI -TMD-D [wiring sidel
B: CN101-16 (92) IRECI - TMD-G [wiring sidel
Measurement terminals C: CN101-22 (N2) [RECI - TMD-S [wiring side1
D: CNIOI-I6 (92) [RECI - CN101-22 (N2) [RECI
A: 0 R
1 Standard
OK (standard) 4 To inspection 4
NG (other than standard) 4 CPU board-TMD wiring defect
lnspection 4. TMD individual check

Battery plug OFF, TMD wiring and copper bar removal, a short between source and
gate before measurement
A: Source O - Drain O
B: Drain O - Source O
C: Gate O - Drain O
Measurement terminals D: Drain O - Gate O
E: Source O - Gate O
F: Gate O - Source O
Circuit tester range R x lk
A: WR
Standard
Source
OK (standard) 4 CPU board defect

NG (other than standard) -c TMD defect, to inspection 5
lnspection 5. DF1 individual check
Battery plug OFF, DF1 wiring and copper bar removal
Forward: cathode@ - Anode @

Reverse: node @ - Cathode @
Forward: approx. 3 kQ
Standard
Reverse: 4 2
OK (standard) + To inspection 6
NG (other than standard) + DFI defect
lnspection 6. SN1 individual check (Conduct this inspection only when CO and C9 are displayed si-
multaneously.)
Battery plug OFF, SN1 wiring disconnection

Circuit tester range 0 x lk
The pointer initially moves toward 0 0 and eventually
Standard
indicates 4.
NG (other than standard) + SN1 defect
Inspection 7. DF2R-DF2L individual check
Battery plug OFF, each DF2 wiring and copper bar removal
Forward: Cathode @ -Anode @

Reverse: Anode @ - Cathode @
Circuit tester range S2x l k
Standard Forward: approx. 3 kS2

Reverse: 4 2
NG (other than standard) -+ DF2 defect
Inspection 8. CA individual check

Battery plug OFF, snubber board wiring disconnection
Measurement terminals TP9 - TNI [on snubber board]

Circuit tester range S2 x l k
Standard The pointer initially moves toward 0 S2 and eventually

indicates 42.
NG (other than standard) + Snubber board defect, to inspection 10
lnspection 9. DAD individual check
Measurement terminals Forward: TDAD @ - TP9G [on snubber board]

Reverse: TP9 @ - TDAD [on snubber board]
Circuit tester range O x Ik
Standard Forward: approx. 2.5 kS1

Reverse: approx. 10 kS1
NG (other than standard) + Snubber board defect, to inspection 10
lnspection 10. RA individual check

Battery removal, CN118 disconnection
Measurement terminals CN118-1 (PI) -CN118-3 (P9)

Standard Approx. 0.8 S1
OK (approx. 0.8 S1) + Drive confirmation test

NG ( 4 2 ) + RA defect
ERROR CODE C1: DRIVE CIRCUIT CURRENT SENSOR ABNORMALITY
elated portion
CN CSD Drive current sensor

CN101-7(73,CSD+)
CPU CN101-9(71,CSD) CSD

board
CN101-ll(74,CSD-)
Estimated causes
@ Drive current sensor defect

@ Disconnection or a short between CNlOl and drive current sensor
@ Contact defect between CNlOl and CN CSD
@) Drive contactor defect
@ Drive contactor coil wiring defect
@ Drive main circuit connection defect
a Drive motor defect
@ CPU board defect
Is C1 displayed with battery plug

ON, key switch ON, and the
vehicle in stop state? (C1 is displayed upon start)
1 YES
~ a i t eplug
r ~ ON, Key switch ON
CSD output voltage check
CPU board defect
CN101-9 (71) (0.86 V or more
$ voltage check and 2.5 V or less)
CN101-I 1 (74)
NG (0.85 V or less and 2.6 V or more)
Inspection 2
Remove CNlOl and CN CSD. Wire continuity
check: OK c CSD defect
between CN101-7 and CN CSD (wire color: W) (0 Q)
between CN101-9 and CN CSD (wire color: 0)
between CN101-11 and CN CSD (wire color: B)
NG c-Q)
Wiring defect between CN101 and drive current sensor
ANL 11: ESY 21-24 NG
Drive contactor ONIOFF check (not turned ON and OFF)
I
OK (turned ON and OFF)

I I
lnspection 3
ANL 11: ESY 21-24
Check voltage between: NG
o P41-N1 with MFRcontactor ON * B
o P51-N1 with MRRcontactor ON (other than
o P4-N1 with MFL contactor ON battery voltage)
o P5-N1 with MRL contactor ON Drive motor defect
1 OK (battery voltage)
Drive motor wiring defect
lnspection 4 lnspection 5
A N L I I : ESY 21,23 Remove P4, P41, P5, P51, P6, P61,
Check voltage between: and P7 and check continuity of
o P7-N1 with MFRcontactor ON (other than drive motor between:
1 o P7-N1 with M Fcontactor
I
~ ON battery voltage)
I P4 - P5
P41 - P51
CPU board defect 1 OK (approx. 0 9)
Copper bar mounting defect

R
lnspection 6 NG Inspection 7
Remove CN102 and check NG Contactor
Individual check of
resistance of NG contactor (other than (other than defect
contactor judged NG
MFR... CN102-3 (4) approx. 20 9) - approx. 20 9)
MRR... CN102-5 (5) OK
MFL... CN102-4 (2) (approx. 20 9)
MRL... CN102-6 (3)
T I Main drive circuit connection defect
CN102-1 (1)
_I
(approx. 20 RYI Inspection
Remove CNlOl Drive main
circuit connec-
I $
N1
continuity check
1 OK (0 9)
(42) tion defect
CPU board defect

lnspection 1. CSD output voltage measurement
Battery plug ON, key switch ON
Measurement terminals CN101-9 (71)@- CN101-11 (74) @

Circuit tester range DClOV
Standard 0.86 V or more and 2.5 V or less
OK (0.86 V or more and 2.5 V or less) + CPU board defect

NG (0.85 V or less and 2.6 V or more) + To inspection 2
Inspection 2. Wiring continuity check between CNlOl - drive current sensor

Battery plug OFF, CN1O1.CN CSD disconnection
CN101-7 (73) [REC] - CN CSD (Wire color: W)

Measurement terminals CN101-9 (71) [REC] - CN CSD (Wire color: 0)
CN101-11 (74) [REC] - CN CSD (Wire color: B)
Standard OQ
OK (0 9 )+ CSD defect
NG (4-2) +Wiring defect between CNlOl and drive current sensor
lnspection 3. Drive contactor voltage measurement
Battery plug ON, key switch ON, each contactor ON in ANLI 1: ESY 21-24
P41 @ - N 1 with MFRcontactor ON
P51 @ - N1 @ with MRRcontactor ON
Measurement terminals P4 @ - N1 @ with MFL contactor ON
P5 @ - N1 @with MRLcontactor ON
Circuit tester range DC5OV

NG (other than battery voltage) 4 To inspection 6
lnspection 4. Drive main circuit voltage measurement

Battery plug ON, key switch ON, each contactor ON in ANLI 1: ESY 21,23
P7 @- N1 @ with MFRcontactor ON
P7 @- N1 @ w i t h MFL contactor ON
OK (battery voltage) + CPU board defect

NG (other than battery voltage) + To inspection 5
lnspection 5. Drive motor continuity check
Battery plug OFF, P4, P41, P5, P51, P6, P61, and P7 disconnection
P4 - P5
P41 - P51
Measurement terminals [Wiring side]
P6 - P7
P61 - P7
Circuit tester range R x l
Standard Approx. 0 R
OK (approx. 0 Q) -c Copper bar installation defect

NG (042) -+ Drive motor defect, drive motor wiring defect
Inspection 6. Contactor resistance measurement (to be performed on defective contactors only)

MFR:CN102-3 (4) [REC] - CN102-1 (1) [REC]

MRR:CN102-5 (5) [REC] - CN102-1 (1) [REC]
MFL: CNI02-4 (2) [REC] - CN102-1 (1) [REC]
MRL: CN102-6 (3) [REC] - CN102-1 (1) [REC]
OK (approx. 20 Q) + To inspection 8
NG (other than approx. 20 R) 4 To inspection 7
lnspection 7. Contactor individual check (to be performed on defective contactors only)
Battery plug OFF, each contactor wiring and copper bar disconnection
Measurement terminals Both terminals of each contactor coil

OK (approx. 20 Q) + Main drive circuit connection defect

NG (other than approx. 20 a) 4 Contactor defect
lnspection 8. Drive main circuit continuity check

Battery plug OFF, CNlOl disconnection
Measurement terminals CN101-25 (N2) [RECI - N I

Standard OQ
OK (0 52) -+ CPU board defect

NG (42)4 Drive main circuit connection defect
ERROR CODE C3: CONTROLLER TEMPERATURE SENSOR ABNORMALITY
CN
- TH Temperature sensc
CN101-24(76,THCD)
CPU
board CN101-1(75,THC+) STH
Estimated causes
a Temperature sensor defect
@ Defective connector contact between CNlOl and CN TH

@ Disconnection in wiring between CNlOl and temperature sensor
@ CPU board defect
ANL 12: Test operation (No. 9) NG

Temperature sensor (STH) CPU board defect
voltage check (0.3 V or more)
Check CNlOl and CN TH for

disconnected connector. t"- Correct the problem and recheck.
Inspection 1
Disconnect CN TH and measure
the resistance of the temperature
sensor.
I NG - Temperature sensor defect
I OK (0 52)
(Less than 2.2 k52)
Wiring defect between CNlOl and temperature sensor
Inspection 1. Temperature sensor resistance measurement
Battery plug OFF, CN TH disconnection
Measurement terminals Both terminals of CN TH [STH side]

Circuit tester range Q x 1k
Standard Less than 2.2 kQ
OK (less than 2.2 kQ) +Wiring defect between CNlOl and temperature sensor
NG (2.2 kQ or more) -+ Temperature sensor defect
ERROR CODE C4: TRAVELING ACCELERATOR ABNORMALITY
Acceleration
CN25 CN26 - potentiometer

-
CN105-2(53,POTA+)
CN105-3(52,POTA)
CPU VRAD
board CN105-6(50,POT-)
CN105-l(64,LSAC) --
Estimated causes
@ Acceleration potentiometer defect

@ Short circuit or open circuit in wiring between CN105 and acceleration potentiometer
@ Defective contact of CN105, CN25, and CN26
@ CPU board defect
ANL12: Test Operation (No. 7)

Check the potentiometer
voltage when the accelerator
pedal is not depressed.
NG
- Inspection 1
Does the acceleration potentiom- NG
eter resistance vary from approx.
CN26
0 SZ to disconnected?
4 kSZ when it is turned, with
- Acceleration
potentio-
meter defect
- - or less)
I OK (0.3 V or more) I
I YES
I
t t
Mounting adjustment defect
Check the potentiometer Wiring defect between CPU board
and acceleration potentiometer
OK (4.5 V or less)
(4'6
NG
Inspection 2
CN105-6 (50)
$ continuity check
CN26-1 (50)
- Wiring defect
NG between
CN105 and
(42) acceleration
or more) pottiometer
1 OK (0 SZ)
ANL12: Test Operation (No. 7)

I Check the potentiometer volt-
age when the accelerator switch & II
ssed. turned
Or
or more.)
" is turned from OFF t o ON while
depressing the accelerator pedal (4m6 or more)
OK (1.3 V or less) gradually.

t OK (4.5 V or less)
CPU board defect
lnspection 1
I:@ Not turned ON: disconnection in wiring between CN105-1 and acceleration potentiometer or
acceleration potentiometer defect
@ 1.4 V or more when turned ON: acceleration potentiometer installation adjustment defect
II: Short circuit between CN105-2 and CN105-3
lnspection 1. Individual acceleration potentiometer measurement
Battery plug OFF, acceleration potentiometer individual removal

Circuit tester range SZ x 1k
Variation from 0 SZ to about 2 - 4 kSZ when turning
Standard
acceleration potentiometer
OK (standard) 4 Mounting adjustment defect, Wiring defect between CPU board and
acceleration potentiometer
NG (other than standard) + Acceleration potentiometer defect
lnspection 2. Continuity check between CN105 and acceleration potentiometer
Battery plug OFF, disconnection between CN26 and CN105
Measurement terminals CN105-6 (50) [REC] - CN26-1 (50) [RECI

Standard 0 SZ
OK (0 Q) + ANL12: To operation test (No. 7)

NG (042) -+ Wiring defect between CN105 and acceleration potentiometer
ERROR CODE C7: DIRECTION SWITCH ABNORMALITY
Related portion
CN9 Direction switch

CN103-7(45,DSF')
CPU CN103-B(46,DSR)
board DS
CN103-17(51,LS-)
- P
Estimated causes
@ Direction switch abnormality

@ Short circuit between CN103 and direction switch
@ CPU board defect
When the direction lever is

operated to the forward or Direction switch defect
reverse position, is the opposite Short circuit between CN103 and direction
direction also set t o ON? switch
NO
1
CPU board defect
4A-40
ERROR CODE C8: SPEED SENSOR ABNORMALITY

- Related portion
-
1 , CN104-l(81,SSR-k)
CN2 1 Speed sensor (right)
SSR
CN104-2(82,SSR-)
i
-
CPU
board CN20 Speed sensor (left)
CN104-6(83,SSL+)
SsL
--
Estimated causes
a Speed sensor defect

@ Disconnection in wiring between CN104 and speed sensor
@ Contact defect of CN104, CN20, CN21
@ CPU board defect
Disconnection check of CN104,

CN20, and CN21 connectors P- Correct the problem and recheck
ANL13: Test operation (vehicle traveling

speed display)
Run the wheels by floating tires above the I
ground and check whether the abnormality
lies in the left side or right side.
1 0 kmlh on right side 1 0 kmlh on left side

Individual speed
sensor (RI check after
disconnecting CN21
NG
(other -
Speed sensor Individual speed sensor
(right)defect (LI check after
than approx.
disconnecting CN20
NG, Speed sensor
(other
(left) defect
than approx.
600 SZ) 600 Q)
OK (approx. 600 SZ) OK (approx. 600 SZ)
1
Inspection 2 Inspection 4 Disconnection

Disconnection
Remove CN104 and
CN21 and continuity
NG in wiring
* between
Remove CN104 and CN20
and continuity check NG_ FeE:~
CN104 and
check between CN104 ( 4 2 ) CN104 between CN104 and CN20 CN20
and CN21. and CN21 I
CPU board defect

1OK (O ")
CPU board defect
lnspection 1. Individual speed sensor (R) measurement

OK (approx. 600 Q) -t To inspection 2

NG (other than approx. 600 Q) -c Speed sensor (R) defect
lnspection 2. Continuity check between CN104 and speed sensor (R)

Battery plug OFF, disconnection of CN104 and CN21
CN104-I (81) [REC] - CN21-2 (81) [REC]

Measurement terminals CN104-2 (82) [REC] - CN21-1 (82) [REC]
Standard 0Q
OK (0 R ) -+CPU board defect

NG ( 4 2 ) -+ Disconnection in wiring between CN104 and CN21
lnspection 3. Individual speed sensor (L) measurement

OK (approx. 600 SZ) + To inspection 4

NG (other than 600 SZ) -+ Speed sensor (L) defect
Inspection 4. Continuity check between CN104 and speed sensor (L)

Battery plug OFF, disconnection between CN104 and CN20
CN104-6 (83) [REC] - CN20-2 (83) [REC]

Standard OSZ
OK (0 Q) -c CPU board defect

NG (42) Disconnection in wiring between CN104 and CN20
ERROR CODE C9: M F - M R DRIVE CONTACTOR ABNORMALITY
Related portion
I
CPU
board
@ Drive contactor defect

@ Defective components (SNI, DFI, DF2R, DF2L, snubber board (DAD)) in the main circuit
@ Disconnection i n wiring between CN101 and TMD (TMD-G wiring disconnection)
@ CPU board defect
refer to CO Troubleshooting
+
ANL 11: ESY21-24 NG Replace welded contactor
Check ONIOFF of drive contactors
(Not turned ON and OFF)
I OK (Turned ON and OFF)
lnspection 1
Disconnect CN101
CN101-16 (92)
1 ~ -
Disconnection in wiring between CNlOl and TMD
(-42)
$ continuity check
TMD-G
lnspection 2
Individual SN1 check ING S N l defect
lnspection 3 NG
lndividual DF1 check DFl defect
lnspection 4
lndividual snubber
board check
TDAD - TP9
ke Snubber board defect
OK (standard)
lnspection 5
Individual DF2R, DF2 defect
1OK
CPU board defect
lnspection 1. Continuity check between CNlOl and TMD
Measurement terminals CN101-16 (92) [REC] - TMD-G

Standard 0 SZ
OK (0 SZ) -+ To inspection 2
NG ( 4 2 ) -+ Disconnection in wiring between CNlOl and TMD
lnspection 2. Individual SN1 check

Battery plug OFF, SN1 wiring disconnection

Circuit tester range SZ x I k
Standard The pointer initially moves toward 0 S1 and eventually

indicates -0.
NG (other than standard) -+ SN1 defect
Forward: cathode @ - Anode @

Circuit tester range R x Ik
Forward: Approx. 3 kR
Standard
Reverse: 4 2
OK (standard) -+ To inspection 4
lnspection 4. Individual snubber board check

Forward: TP9 @ - TDAD @ [On snubber board]

Reverse: TDAD @ - TP9@ [On snubber board]
Circuit tester range 52 x 1k
Forward: several kR
Standard
Reverse: 10 kR
OK (forward: several kR reverse: 10 kR) -+ To inspection 5

NG (0 R) -c Snubber board defect
Inspection 5. Individual DF2R, DF2L check
Battery plug OFF, each DF2 wiring and copper bar removal
Forward: Cathode @- Anode @

, Reverse: Anode @ - Cathode -
Standard
Reverse: 4 2
OK (standard) -+ CPU board defect

NG (other than standard) DF2 defect
4A-48
ERROR CODE CA: MF-MR CONTACTOR DRIVE CIRCUIT ABNORMALITY
Related portion
CN102-3(4,MFR+) cN"6 CNMFn--

MFR
- CONTACTOR
--
CN102-5(5,MRR+) CN MRR -
M RR
- CONTACTOR
--
CN102-4(2,MFL+) CN MFL F- -
MFL
--- CONTACTOR
CN102-6(3,MRL+) CN MRL---
MRL
- CONTACTOR
--
CN102-12(7,MP+) CN MP ---
MP
-
CN103-2(6,MPS+)
- CONTACTOR
-
CN103-l(1,MPS-) - MOPS
C NTACTOR (without EHPS)
k
SWKY
CN103-14(43,VBKY2) I
0 0
CN104-5(94,PSH) CN1-9- CN2-2

-
CN37-15 CN1-5
- - (with EHPS)
@ Contactor coil defect

@ Disconnection in wiring between CPU board and contactor coil
@ Disconnection in wiring between CPU board and key switch
@ Disconnection in wiring from CPU board to CN1 and to CN37.
@ Contact failure of CN102, CN103, and contactor connectors
@ Contact failure of CN104, CNl, and CN37
a Snubber board defect (DAD, DAP)
@ CPU board defect
I
lnspection 1
CN103-14 (43)
$ voltage check
CN101-3 (N2)
1
I
;:lneco
tin in wiring between CPU board and key
II
AN L11: ESY21-26
Check each contactor turns ONIOFF I(
OK
(Turned ON and OFF)
- A
NG (MPSdoes not turn

NG ON and OFF)
(MFR,MFL, and B
MP do not turn NG (MRRand MRLdo not turns ON and OFF)
I I
lnspection 2
ON and OFF)
Remove contactor Disconnection

lnspection 4
Remove CN116 and check
- NG
(ma)
Disconnection
in wiring
in wiring continuity between: between
connectors (MFR,
between CN102-5(5)- CN116-7(5) CPU board
MFL, and MP), CN102
and check continuity CPU board CN102-6(3)- CN116-9(3) and CN116
between contactor and contactor CN102-1(1)- CN116-3(1)
connector and connector
lnspection 5
Remove contactor
connectors (MRRand
-
NG
(mQ)
Disconnection
in wiring
MRL)and CN116 and between
lnspection 3 CN116 and
lndividual contactor Contactor check continuity
between contactor contactor
(MFR,MFL, MP, MRR, defect connector
and MRL)check connector and CN116
IOK
CPU board defect
I OK (0 R)
Inspection 6 NG Inspection 8 NG
Disconnection Disconnection
(applicableto models (applicable to models
(mQ) in wiring in wiring
with EHPS) without EHPS)
between CPU between CPU
Remove CN104 and Remove CN103 and
board and board and
CN37 and check CN42 and check
CN37 CN42
continuity between continuity between
CN104 and CN37. CN103 and CN42.
OK (0 R) OK (0 R)
Inspection 7 NG Inspection 9 NG
C Snubber MPSdefect
Individual snubber (applicable to models (mR)
board check (0 R) board defect without EHPS)
TDAD - TP9 lndividual MpScheck
OK (standard) OK (approx. 68 R)
CPU board defect CPU board defect
X 1 Applicable to models without EHPS.

lnspection 1. Voltage measurement between CPU board and key switch
Measurement terminals CNIO3-I4 (43)@ - CNIOI-3 ( ~ 2 ) @

OK (battery voltage) + ANLI 1: ESY21-26

NG (0 V) + Disconnection in wiring between key switch and CPU board
lnspection 2. Continuity check between CPU board and contactor connectors (MFR,MFL, and MP)
Battery plug OFF, contactor connectors (MFR,MFL,and MP) and CN102 disconnection
MFR:CN102-3 (4) [REC] - CN MFR-2(Wire color: W)
MFL: CN102-4 (2) [REC] - CN MFL-2(Wire color: 0)
Measurement terminals MP: CN102-12 (7) [RECI- CN MP-2 (Wire color: Y)
MFR.MFL.MP:CN102-1 (1) [REC] - Each contactor connector-I
(Wire color: R)
Standard 0 i2
OK (0 i2) + To inspection 3
NG (42) + Disconnection in wiring between CPU board and contactor connectors (MFR,MFL,
and MP)
lnspection 3. Individual contactor (MFR,MFL, MP, MRR,and MRL)continuity check
Battery plug OFF, disconnection of each contactor wiring and copper bar

OK (approx. 20 Sl) + CPU board defect

NG (other than 20 52) + Contactor defect
Inspection 4. Continuity check between CPU board and CN116

CN102-5 (5) [REC] - CN116-7 (5) [REC]

Measurement terminals CN102-6 (3) [RECI - CN116-9 (3) [RECI
CN102-1 (1) [REC] - CN115-3 (1) [RECI
Standard OSl
OK (0 Sl) + To inspection 5
NG ( 4 2 ) + Disconnection in wiring between CPU board and CN116
lnspection 5. Continuity check between contactor connectors (MRRand MRL)and CN116
Battery plug OFF, disconnection of contactor connectors (MRRand MRL)and CN116
MRR: CN116-7 (5) [TAB] - CN MRR-2(Wire color: BR)

MRL: CN116-9 (3) [TAB] - CN MRL-2(Wire color: GR)
MRR.MRL:CN116-5 (1) [TAB] - Each contactor connector-I
(Wire color: R)
Standard OQ
OK (0 Q) + To inspection 3
NG ( 4 2 ) -t Disconnection in wiring between CN116 and contactor connector (MRRand MRL)
lnspection 6. Continuity check between CPU board and CN37 (applicable to models with EHPS)

Standard OQ
NG (ooQ) + Disconnection in wiring between CPU board and CN37
lnspection 7. Individual snubber board check
Battery plug OFF, disconnection of snubber board wiring
Forward: TP9 @ - TDAD @

Reverse: TDAD @ - TP9 @
Measurement terminals ~ - TDAP @
Forward: T P @
Reverse: TDAP @ - TP9 @
(Applicable to models with material handling chopper)
Forward: several kQ
Standard
Reverse: 10 kQ
OK (forward: several ki2 reverse: 10 kQ) + CPU board defect

NG (0 Q) + snubber board defect
Inspection 8. Wiring check between CPU board and CN42 (applicable to models without EHPS)

CN103-2 (6) [REC] - CN42-2 (6) [REC]
Standard OQ
OK (0 0)+ To inspection 9
NG (-Q) + Disconnection in wiring between CPU board and CN42
Inspection 9. Individual MpScheck (applicable t o models without EHPS)
Battery plug OFF, disconnection of CN42

OK (approx. 68 R) 4 CPU board defect

NG (-R) -t MPSdefect
ERROR CODE CE: ROM ABNORMALITY IN CPU
- Estimated causes
a CPU board defect
Replace t h e CPU board w h e n CE is displayed.
ERROR CODE CF: RAM ABNORMALITY IN CPU
- Estimated causes
CPU board defect
Replace the CPU board w h e n CF is displayed.

4A-56
ERROR CODE EO: MAIN MATERIAL HANDLING CIRCUIT ABNORMALITY
Related portion
PI4 P1
0
RA
, ----- - --- - -- -- - -__--- - - --- - -- - -- - -
''---I TP9
DAP
L I .. 'I I
CN101-15(P14,TMP-D)
t-
CPU CN101-4(93,TMP-G)
I1 CA
board
I-- Snubber board

-
'----------------------------------,I---;
TN1
CN101-23(N2,TMP-S)
4I
0
N1
-
P
Estimated causes
a TMP defect (Be sure to check DF3, snubber board (CA, DAP), and RA because a defect in any
of these may be a primary cause of a defective TMP.)
@ Snubber board defect
@ Wiring defect between CPU board and TMP
@ Wiring defect between PI4 and TDAP
@ CPU board defect
It is possible that "WJmaterial handling chopper" is selected in the display option setting although
the vehicle is not provided with a material handling chopper. Change the display option setting to
"Without material handling chopper".
(IfEO and FA are displayed at the same time, give priority to FA.)
Check if the snubber board NG
Correct the problem and recheck
and TMP connection wiring
I is loosened.
I
1
Inspection 1 NG
board defect
Remove TDAP round terminal v or les>)
'(i5
of snubber board and turn on
battery plug.
TDAP (PI4)
$ voltage check
TNI ( N I )
I OK (15 V or more)
v l e m
lnspection 2
and TDAP
Wiring defect between PI4 and TDAP
lnspection 3
Remove CNlOl and TMP wiring and check NG Wiring defect between
continuity between:
* CPU board and TMP
(A) CN101-15 and TMP-D
(B) CN101-4 and TMP-G
(C) CN101-23 and TMP-S
(Dl CN101-4 and CN101-23
(D) 0 0
lnspection 4
Remove TMP wiring CPU board defect
copper bar and check
I TMP individually. I
1
NG
TMP defect
Conduct inspections 5-8 below the heading "A" on the next page, as a defect in TMP, DF3, snubber
board (CAI DAD), and RA may be a primary cause of a defective TMP.
lnspection 5
Individual DF3 check 1~ DF3 defect
lnspection 6
lndividual CA check
lnspection 7
lndividual DAP check
lnspection 8
Individual RA check 1 ~ RA defect -
I oK
Material handling confirmation test
lnspection 1. TDAP - TN1 voltage measurement
Disconnection of TDAP round terminals on snubber board, Battery plug ON, key
switch ON
TDAP (P14) @[wiring side] - TN1 (N1)0
[on snubber board]
Standard 15 V or more
OK (15 V or more) -+ To lnspection 2

NG (15 V or less) -+ Snubber board defect
lnspection 2. PI4 - TDAP continuity check

Battery plug OFF, PI4 - TDAP wiring individual removal
Measurement terminals Both terminals of wiring between P14-TDAP

Standard 0 C2.
OK (0 Q) -+ To lnspection 3
NG ( 4 2 ) -+ P14 - TDAP wiring defect
lnspection 3. CPU board - TMP continuity check
Battery plug OFF, CN101.TMP wiring disconnection
A: CN101-15 (P14) [RECI -TMP-D [wiring sidel
B: CN101-4 (93) [REC] - TMP-G [wiring sidel
Measurement terminals C: CN101-23 (N2) [RECI -TMP-S [wiring sidel
D: CN101-4 (93) [REC] - CN101-23 (N2) [REC]
A: 0 R
B:OR
standard C: 0 Q
D:R
..
OK (standard) -+ To lnspection 4
NG (other than standard) + CPU board - TMP wiring defect
lnspection 4. TMP individual check

Battery plug OFF, TMP wiring and copper bar removal, short-circuiting of sources and
gates before measurement
A: source O - drain O
B: drain O -source O
C: gate O - drain O
Measurement terminals D: drain O -gate O
E: source O - gate O
F: gate O - source O
Circuit tester range R x Ik
A: WR
B: 3 k!2
Standard C: 4 2
D:R..
E: =R
F: Q
..
Source
OK (standard) + CPU board defect

NG (other than standard) -+ TMP defect or to lnspection 5
Forward: Cathode @ - Anode @

Standard
Reverse: WQ
lnspection 6. CA individual check

Measurement terminals TP9 - TN1 [on snubber board1

Circuit tester range Q x lk
Standard The pointer initially moves toward 0 Q and eventually

indicates 42.
NG (other than standard) -+ Snubber board defect, to lnspection 8
lnspection 7. Individual DAP check
Forward: TDAP @ - T P ~[on

O snubber board]
Reverse: TP9 @ - TDAP @ [on snubber board]
Circuit tester range 9 x 1k
Forward: approx. 2.5 k 9
Standard
Reverse: approx. 20 k 9
OK (standard) -t To lnspection 8
NG (other than standard) -t Snubber board defect, to lnspection 8
lnspection 8. Individual RA check

Measurement terminals CN118-1 (PI)- CN118-3 (P9)

Standard Approx. 0.8 9
OK (approx. 0.8 9)-t Material handling operation confirmation test

NG (-9) + RA defect
ERROR CODE E l : MATERIAL HANDLING CIRCUIT CURRENT SENSOR ABNORMALITY
pi&zq
I I
Material handling
CN CSP current sensor
CN101-8(73,CSP+)
CPU CN101-lO(72,CSP)
board CSP
CN101-12(74,CSP-)
Estimated causes
@ Material handling current sensor defect

@ Disconnection in wiring or short circuit between CNlOl and material handling current sensor
@) Defective contact between CNlOl and connector CSP
@ Material handling contactor defect
@ Wiring defect of material handling contactor coil
@ Defective wire connection of material handling main circuit
a Pump motor defect
@ CPU board defect
It is possible that "WJmaterial handling chopper" is selected in the display option setting although
the vehicle is not provided with a material handling chopper. Change the display option setting to
"Without material handling chopper".
Is E l displayed while material handling

is in state with battery plug ON, material handling is
switch ON?
performed.)
1 YES
Inspection 1 OK
Battery plug ON, key switch ON rn CPU board defect
CSP output voltage check (0.86 V or
CN101-10 (72) more and 2.5
$ voltage check V or less)
CN101-12 (74)
NG (0.85 V or less, or 2.6 V or more)
Inspection 2 OK_ CSP defect

Remove CN101 and CN CSP and (0 a)
check wiring continuity between:
CN101-8 - CN CSP (wiring color: G) NGrn Wiring defect between CNlOl and material handling
CN101-10 - CN CSP (wiring color: R) (ma) current sensor
CN101-12 - CN CSP (wiring color: L)
ANLI 1: ESY-25
Check ONIOFF of MP contactor.
B-
NG (not opened and closed)
I
OK (opened and closed)
lnspection 3
ANLI 1: ESY-25 - B
PI2 - N1 voltage check with MP contactor NG (other than battery voltage)
closed
Pump motor defect
I
T
lnspection 4
pump motor wiring defect
t
lnspection 5
NG (-a)
ANLI 1: ESY-25 PI2 - P I 3 pump motor continuity

PI3 - N1 voltage check with MP contactor NG (other check with P12.PI3 removed
closed than battery
voltage)
CPU board defect

4
OK (approx. 0 R )
Copper bar installation defect
B
lnspection 6 lnspection 7
Remove CN102 and MP contactor Contactor defect
check resistance of (other than
MP contactor approx. 20 R) approx. 20 R )
CN 102-12 (7)
resistance
-
measurement OK (approx. 20 R)
CNI02-1 (1)
I OK (approx. 20 R) Defective wire connection of material handling main circuit
lnspection 8
Remove CNlOl
CN101-25 (N2)
$ continuity check
-NG
(-R)
Defective wire connection of material handling main circuit
N1
I OK (approx. O R )
CPU board defect

lnspection 1. CPS output voltage measurement
Measurement terminals CN101-10 ( 7 2 1 0- CN101-12 (74)@

Standard 0.86 V or more and 2.5 V or less
OK (0.86 V or more and 2.5 V or less) -t CPU board defect

NG (0.85 V or less, or 2.6 V or more) -t To lnspection 2
lnspection 2. Wiring continuity check between CNlOl and material handling current sensor
Battery plug OFF, CN CSP-CN101disconnection
CN101-8 (73) [RECI - CN CSP (wiring color: G)

Measurement terminals CN101-10 (72) [REC] - CN CSP (wiring color: R )
CN101-12 (74) [REC] - CN CSP (wiring color: L)
Standard 0Q
OK (0 Q) + CSP defect
NG (42)-t Wiring defect between CNlOl and material handling current sensor
lnspection 3. Material handling contactor voltage measurement
Battery plug ON, key switch ON, closing of MP contactor in ANLI 1: ESY-25
Measurement terminals PI2 - N1 voltage check with MP contactor closed

OK (battery voltage) + To lnspection 4

NG (other than battery voltage) +To lnspection 6
lnspection 4. Material handling main circuit voltage measurement

Battery plug ON, key switch ON, closing of MP contactor in ANLI 1: ESY-25
Measurement terminals PI3 - N1 voltage check with MP contactor closed


NG (other than battery voltage) + To lnspection 5
lnspection 5. Pump motor wiring continuity check
Battery plug OFF, P12mP13 disconnection
Measurement terminals PI2 - PI3

Standard Approx. 0 52
OK (approx. 0 52) -+ Copper bar installation defect

NG (-52) 4 Material handling motor defect or material handling motor wiring defect
lnspection 6. MP contactor individual check


Standard Approx. 20 52
OK (approx. 20 52) + To lnspection 8

NG (other than approx. 20 52) -+ To lnspection 7
Inspection 7. MP contactor individual check
Battery plug OFF, MP contactor wiring and copper bar disconnection
Measurement terminals Both terminals of MP contactor coil

OK (approx. 20 Q) + Defective wire connection of material handling main circuit

NG (other than approx. 20 Q) + Contactor defect
Inspection 8. Material handling main circuit continuity check

Measurement terminals CN101-25 (N2) [REC] - N1

Standard 09
OK (0 Q) -+ CPU board defect

NG (042)+ Material handling main circuit connection defect
4A-69
ERROR CODE E3: RETURN TO NEUTRAL (For UL-USASCANADA)
Related portion
Direction switch
Estimated causes
@ Momentary disconnection of battery plug power supply line

@ Direction switch defect
@ Direction switch wiring short-ci
@ Accelerator switch defect
@ Accelerator switch short-circuit
a Deadman switch wiring defect
@ CPU board defect
Occurrence during traveling YES CN106-12.13
$
CN22
wiring check -
NG
Deadman
switch wiring
defect
NO OK
No error display in normal No error Inspection 1

NG-o Deadman
traveling operation after acceler- display Deadman switch in-
switch defect
ation switch OFF with direction dividual check
switch in neutral position
/ OK
Error display 0 Normal I
I
0 ~omentary disconnection in the line between
ANL31: Switch input test CN106 and CN22
DSFand DSRcheck with direc- 0 Momentary disconnection in battery plug
tion switch in neutral positior power supply line VBBT-VBKY
0 CPU board defect
Lit Inspection 2
'- OK
Direction switch in-
- -0 Short-circuit
(switch ON)
dividual check in wiring
ING
Not lit between
(switch OFF) CN106 and
CN9
0 Direction switch defect 0 CPU board
1 defect
SWACcheck with accelerator
Not lit
(switch OFF)
0
t
CPU board defect
Inspection 3
Accelerator switch Short circuit
(switch ON) in wiring
individual check
0
7
Acceleration circuit
defect
0
between
CN106 and
CN25
CPU board
defect
Measurement terminals Deadman switch (CN22)
Circuit tester range ox I

Standard Normal: ao Q actuated state: 0
OK -+ Momentary disconnection of the line between CN106 and CN22, momentary disconnec-
tion of the BIT plug power supply line, CPU board defect
NG --+ Deadman switch defect
lnspection 2. Direction switch individual check

Direction switch removal
Measurement terminals Direction switch (CN9)

Circuit tester range nxl
In neutral state
Standard (46DSR)- (51.GND): co !2
(45.DSF)- (51.GND): m !2
OK + CN106-CN9 wiring short-circuit or CPU board defect

NG + Direction switch defect
Inspection 3. Accelerator switch individual check
Accelerator switch removal
Measurement terminals Accelerator switch SWnc (64) - GND (51)
Circuit tester range Qxl
Standard Normal: oo Q Actuated state: 0Q
OK -, Momentary interruption between CN106 and CN25, or CPU board defect

NG -, Accelerator switch defect
ERROR CODE E6: MATERIAL HANDLING SWITCH ABNORMALITY
CNll
CN103-lO(60,LSL)
Lift switch
CN103-17(51,LS
CPU
board
CN103-11(68,LSL2) CN39
--
Lift 2 switch
-
a Material handling limit switch LSL defect (open)

@ Material handling limit switch LSL wiring disconnection or LSL2wiring short circuit
@ Installation adjustment defect of material handling limit switch LSL or LSL2
@ CPU board defect
CNl I connector
disconnection check P- Correct the problem and recheck
OK
Is LSL set to ON with LSL2kept

at OFF when material handling
NO
- LSLopen
LSL wiring disconnection or LSL2wiring short circuit
LSL.LSL2installation adjustment defect
lever is pulled slightly?
1
CPU board defect
4A-74
ERROR CODE EE: MCS RECEIVING DATA ABNORMALITY
Related portion
Multi-display
CN1 CN120
CN105-12(143,SDTMQ
CPU
board CN105-13(142,SDTMA) DISP
L -
-
- Estimated c a u s e s s
a Multi-display defect
@ Disconnection in wiring between CN105 and multi-display

@ CN105, CNI, or CN120 contact defect
@ CPU board defect
NG
CN105, CN 1, and CN120 disconnection check t Correct the problem and recheck
OK
T
Inspection 1 NG t Wiring disconnection between CPU
CN105 and CN120 removal and (-Q) board and multi-display
CN105 - CN120 wiring continuity check
-
OK (0 SZ)
7
CPU board defect
Multi-display defect
Inspection 1. Disconnection in wiring between CPU board and multi-display
Battery plug OFF, CN 105.CN120 disconnection
CN105-12 (143) [REC] - CN120-1 (143) [REC]

CN105-13 (142) [REC] - CN120-11 (142) [REC]
Standard 0R
OK (0 R ) -t CPU board defect or multi-display defect

NG (04) + Disconnection in wiring between CPU board and multi-display
ERROR CODE EF: CPU PROCESSING TIME ABNORMALITY
@ CPU board defect
Replace the CPU board when EF is displayed.

WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (DRIVE SYSTEM)
1. The vehicle does not move at all. (The multi-display remains off even when the key switch is
turned ON.)
CN 104-3(41,VBBT)
CN103-16(41,VBBT2)
4P
SWKY
CPU F5
board CN104-4(43,VBKY) I PI
0 0- 0
CN103-14(43,VBKY2)
CN101-3(N2,N2)
I N2
0
- Estimated causes
Battery voltage is not applied.

@ No voltage is applied across key switch and CPU board.
@ CPU board defect
NG
Battery check Correct the problem and recheck
, 1 OK (battery voltage)
lnspection 1 Wiring disconnection between battery and CPU board

CN104-3 (41)
Blown fuse F5
$ voltage check
1
1
NG NG Key switch defect

lnspection 2 lnspection 3 Wiring
CN104-4 (43) Remove CN 1 and measure voltage (0 V) * disconnection
(0 V) *
$ voltage check CN104-4 (43) between key
CN101-3 (N2) $ voltage check switch and CPU
CN101-3 (N2)
1I OK
board
I
(battery voltage)
Display defect
lnspection 4
Wiring disconnection between key switch and CPU board
CN103-14 (43)
either connector pair)
CN103-16 (41)
voltage check
both connector pairs)

CPU board defect
lnspection 1. Wiring check between battery and CPU board
Battery plug ON
Measurement terminals CN104-3 (4110 - CN101-3 (N2) 0

NG (0 V) Wiring defect between battery and CPU board
lnspection 2. Applied voltage measurement after turning key switch ON

Measurement terminals CN104-4 (4310 - CN101-3 (N2) 0


NG (0 V) + To lnspection 3
lnspection 3. Applied voltage measurement after turning key switch ON
Battery plug ON, key switch ON, CN1 disconnection
Measurement terminals CNI04-4 (43)@ - CNIOI-3 (N2)@

OK (battery voltage) -+ Display defect

NG (0 V) -+ key switch defect or wiring disconnection between key switch and CPU board
lnspection 4. Wiring check between key switch and CPU board

CNIO3-14 (43)@ - CN101-3 ( ~ 2 1 0

CNIO3-I6 (41)@ - CN101-3 ( ~ 2 1 0

NG (0 V) -+ Wiring disconnection between key switch and CPU board
2. The vehicle does not move at all. (The MF (MR) contactor is not closed when the direction lever
is set to the forward (or reverse) position or when the accelerator is depressed.)
CN9 Direction switch

CN103-7(45,DSF)
CN103-8(46,DSR)
DS
CN103-17(51,LS
CN103-4(67,LSD) -
CN22
-
Deadman switch
IF
--
CN6 Brake switch
CPU
board
CN103-13(65,LSB)
LSB
-
Y-
Acceleration
potentiometer
CN105-2(53,POTA+)
CN105-3(52,POTA)
CN105-6(51,POT-) VRAD
CN105-l(64,SWAC)
h -
Estimated causes
@ No input of direction switch signal
@ No input of deadman switch signal
@ Accelerator switch defect or wiring disconnection between accelerator switch and CPU board
@ Brake switch defect or wiring disconnection between brake switch and CPU board
@ CPU board defect
ANL2: AID test NG * Battery overdischarge
VBP2 voltage measurement
I
(less than 20 V)
OK (20 V or more)
ANLI 1: Simplified test (ESY - 21-24) OK

* A
Check ONIOFF of each contactor (opened and closed)
NG (MFR.MFL NG (MRR.MRLcontactors are not opened and closed)
contactors are not
1
opened and closed)
I
-
I
*r
lnspection 1 NG lnspection 3
Remove contactor Wiring Remove CN102 and CN116 CPU board
connectors (MFR.MFL) disco~ection and check continuity -CN116
and CN102 Contactor between CPU between: wiring
connectors - CN102 board and CN102-5 (5) - CN116-7 (5) disconnection
wiring continuity contactor CN102-6 (3) - CN116-9 (3)
check connectors CN102-1 (1) - CN116-3 (1)
I
lnspection 2 NG lnspection 4 NG
Contactors (MRR contactor Remove contactor -Wiring
MFL.MRR.MRL) (-a defect connectors (MRRMRL)and (-0) disconnection
individual check CN116 Wiring continuity between
check between CN116 and
contactor connectors contactor
and CN116 connectors
4
CPU board defect
ANL31: Switch input test Wiring disconnection between

Is the Deadman switch turned ON? Deadman switch and CPU board
+I YES Direction switch defect

ANL31: Switch input test NO
Wiring disconnection between
ISthe direction switch turned ON and OFF (not turned direction and c p u board
when the direction lever is operated? ON and OFF )
I YES (turned ON and OFF)
I
+ Accelerator switch defect

ANL31: Switch input test NO Wiring disconnection between
Is the accelerator switch turned ON and turned * acceleration potentiometer and
OFF when the accelerator is operated? ON and OFF ) CPU board
I CN25 and CN26 connection check
YES (turned ON and OFF)
NO Brake switch defect

ANL31: Switch input test * Wiring disconnection between
Is the brake switch turned ON and OFF (not turned brake switch and CPU boarn
when the brake pedal is operated? ON and OFF ) CN6 connection check
1
I
YES (turned ON and OFF)
CPU board defect

lnspection 1. Wiring continuity check between CPU board and MFR.MFLcontactor connectors
Battery plug OFF, MFR.MFLcontactor connectors and CN102 disconnection
MFR:CN102-3 (4) [REC] - CN MFR-2(wire color: W)

MFL: CN102-4 (2) [RECI - CN MFL-2(wire color: 0)
MFR.MFL:CN102-1 (1) [REC] - Each contactor connector-1
(wire color: R)
Standard OQ
OK (0 Q) -t To lnspection 2
NG (42) -c Wiring disconnection between CPU board and MFR.MFLcontactor connectors
lnspection 2. Contactors (MFR.MFL.MRR.MRL) individual check

Battery plug OFF, each contactor wiring and copper bar disconnection

-
OK (approx. 20 Q) -t CPU board defect

NG (042) -t Contactor defect
lnspection 3. Wiring continuity check between CPU board and CN116
Battery plug OFF, CN102-CN116disconnection
CN102-5 (5) [REC] - CN116-7 (5) [REC]

CN102-1 (1) [REC] - CN116-3 (1) [REC]
Standard OQ
OK (0 Q) -+ To lnspection 4
NG ( 4 2 ) -+ Wiring disconnection between CPU board and CN116
lnspection 4. Wiring continuity check between CN116 and MRR.MRLcontactor connectors

Battery plug OFF, MRR.MRLcontactor connectors and CN116 disconnection
MRR:CN116-7 (5) [TAB] - CN MRR-2(Wire color: BR)

MRL: CN116-9 (3) [TAB] - CN MRL-2(Wire color: GR)
MRR.MRL: CN116-5 (1) [TAB] - Each contactor connector-1
(Wire color: R)
Standard OQ
OK (0 Q) + To lnspection 2
NG ( 4 2 ) + Wiring disconnection between CN116 and MRR.MRLcontactor connectors
3. Normal speed control fails.
(The vehicle does not accelerate, attain the maximum traveling speed, or move.
(MFR.MFL.MRR.MRL contactors can be closed.))
o The maximum traveling speed is not attained unless the power control value of the display
mask function tuning mode C5 is set to "8". If the traveling speed control setting indicator for
2-speed appears on the display, the vehicle also does not achieve its maximum traveling
speed.
o The indication on the speedometer depends on the wheel diameter setting. Make sure that the
tire size setting matches the actual wheel diameter of the vehicle.
CN104-1(81,SSR+)
~
-~ 2Speed
1 sensor (right)
CN104-2(82,SSR-) SSR
L
CN20 Speed sensor (left)

CN104-6(83,SSL+) - *
SSL
CPU
board
- CNlO3-13(65,LSB)
CN6 Brake switch +
LSB
- CN103-17(51,LS-)
LU u
Acceleration
- CN105-2(53,POTA+)
potentiometer
CN105-3(52,POTA)
CN105-6(60,POT-) VRAD
---
CNI05-l(64,LSAC)

@ Low drive OCL value
@ Traveling current sensor defect
@ Drive motor defect
@ Brake switch defect, brake switch installation adjustment defect, or wiring defect between
brake switch and CPU board
a Speed sensor defect
@ CPU board defect
Is voltage selection made as specified in
Set correct voltage.
setting option input of the display mask
function?
1 YES
I
-
ANL2: A I D test NG Acceleration potentiometer defect
Acceleration potentiometer voltage fiWiring defect between
measurement ( X C < = 1.3 V) acceleration potentiometer and
CPU board
I
ANL5: Switch input test NO Brake switch defect

fi Wiring defect between brake
Is brake switch turned ONJOFF when (neither ON switch and CPU board
the brake pedal is operated? nor OFF) Brake switch installation
adjustment defect
YES (ON or OFF)
1
ANL13: Test drive NG Speed sensor defect

Speed indication check fi Wiring defect between speed
'1 sensor and CPU board

Wheel diameter setting error
Drive circuit OCL value

measurement
P- Drive current sensor defect
CPU board defect
Drive motor defect

CPU board defect
X Calculate an acceleration potentiometer voltage C as per B - A = C where A is the acceleration

potentiometer voltage when the acceleration switch is turned ON; B is the acceleration poten-
tiometer voltage when the accelerator pedal is depressed to its stroke end.
4A-86
4. Excessive braking in switch back operation
- Related portion
CN102-8(P6,VBP6) CN116-1(P6,VBP6) O
- CN102-g(P61,VBP 7
LA
P61
0
CPU
- CN104-l(81,SSR-t) -
CN21 Speed sensor (right)
board CN104-2(82,SSR-) SSR

-L
CN104-6(83,SSL+) -
CN20 Speed sensor (left)
CN104-7(84,SSL-) SSL
7-
Estimated causes
a Speed sensor defect (coil disconnection)

@ Wiring defect between CN104 and speed sensor
@ D F ~ or
R D F ~ open
L
@ CPU board defect
ANL13: Test operation

Speed indication check
NG
- Speed sensor defect
Wiring defect between speed sensor and
CPU board
lnspection 1
Remove CN102, P6, and P61 CN 102 - P6 wiring disconnection
Checkwiring continuity between: CN102 - P61 wiring disconnection
CN 102 - P6
CN102 - P61
Inspection 2
DF~L.DF~R D F ~ L . D F defect
~R
individual check
D F ~ or
L D F ~ installation
R adjustment defect
CPU board defect
lnspection 1. CPU board - P6aP61 wiring continuity check
Battery plug OFF, CN102*P6.P61disconnection
CN102-8 (P6) [REC] - P6 [wiring sidel

CN102-9 (P61) [REC] - P61 [wiring sidel
Circuit tester range R x 1
Standard 0R
OK (0 R ) -+ To lnspection 2
NG (042) + CN102.P6.P61 wiring disconnection
lnspection 2. D F ~ R . Dindividual
F~~ check
Battery plug OFF, DF2R.DF2Lindividual wiring disconnection
Forward: Cathode @ - Anode @

Circuit tester range R x lk
Forward: approx. 3 kR
Standard
Reverse: 4 2
OK (standard) -+ D F ~ R . Dinstallation
F~~ defect, CPU board defect
NG (other than standard) + D F ~ R . Ddefect
F~~
(MATERIAL HANDLING SYSTEM)
1. The pump motor does not run.
(1) When material handling chopper is provided (option)
-
Related portion
CN103-lO(60,LSL)
CN103-6(61,LST)
CN103-5(63,LSATl)
CNll
Lift switch
Tilt switch
Attachment 1 switch
CPU
board
--
L
,
CN103-1l(68,LSLZ) CN39
Lift 2 switch
I
@ Each material handling limit switch defect

@ lnstallation adjustment defect in each material handling limit switch
@ Wiring defect between CPU board and each material handling limit switch
@ Pump motor defect
@ CPU board defect
It is possible that "Wlmaterial handling chopper" is selected in the display option setting al-
though the vehicle is not provided with a material handling chopper. Change the display option
setting to "Without material handling chopper".
Each material handling limit switch defect

NG Installation adjustment defect in each
Check ONIOFF of each +
(neither ONIOFF) material handling limit switch
Wiring defect between CPU board and each
material handling limit switch
, OK
(ONIOFF)
Pump motor defect
CPU board defect
4A-89
(2) When material handling chopper is not provided (option)
GN 11
CN103-lO(60,LSL) -
CN103-6(61,LST)
Lift switch
CN103-5(63,LSATl) Tilt switch
Attachment 1 switch
CN103-17(51,LS-)
C PU
board --
CNMP' -
MP contactor
-
- Estimated causes.
@ Each material handling limit switch defect

@ Installation adjustment defect in each material handling limit switch
@ Wiring defect between CPU board and each material handling limit switch
@ Pump motor defect
@ Defective wire connection of main material handling circuit
@ CPU board defect
Each material handling system switch
0
Check ONIOFF of each Installation adjustment defect in each
defect
material handling switch.
OK
(neither ON/OFF) material handling switch
Wiring defect between CPU board and
each material handling switch
Is MP contactor closed when

the material handling lever is Closed Pump motor defect
pulled with battery plug ON Material handling main circuit wire
and key switch turned ON? connection defect
I
A
Not closed
A
Inspection 1
Remove CN102
CN102-12 (7)
NG
(other
- Inspection 2
MP contactor
individual check
NG
(other than
- MP contactor defect
resistance than approx. 20 Q)

measurement approx.
OK
CN102-1 (1) 20 Q)
(approx. 20 Q)
1
I OK Wiring defect between CPU board and MP contactor
t
I Inspection 3
Remove CNlOl
CN101-25 (N2) Defective wire connection of material handling main
$ continuity check circuit
N1
1 OK (0 a)
CPU board defect

lnspection 1. MP contactor resistance measurement

OK (approx. 20 Q) + To lnspection 3
NG (other than approx. 20 Q) + To lnspection 2
lnspection 2. MP contactor individual check

Battery plug OFF, MP contactor wiring and copper bar disconnection
Measurement terminals Both terminals of MP contactor coil

OK (approx. 20 Q) + Wiring defect between CPU board and MP contactor

NG (other than approx. 20 Q) + MP contactor defect
Inspection 3. Material handling main circuit continuity check
Battery plug OFF, C N l O l disconnection
Measurement terminals CN101-25 (N2) [RECI - N1

Standard on
OK (0 9 )4 CPU board defect

NG (42) 4 Defective wire connection of material handling main circuit
TROUBLESHOOTING RELATED TO STEERING SYSTEM
ERROR CODE FO (DISPLAYED ONLY WHEN EHPS IS INSTALLED):
MAIN EHPS CIRCUIT ABNORMALITY
-7
TMPS
-
CN1
CN120
-
1
-I
-I
- -
DlSP
PBEHPS
- P23
O
N1
a P B Edefect
~ ~ ~
@ Multi-display defect
@ CNI, CN27, CN41, CN43, CN120 connection defect
@ TMps defect
CNI, CN27, CN41, CN43,

CN120 disconnection check 1 ~ -
Correct the problem and recheck
Is PS motor running when

TMps defect
battery plug is ON and key
switch is turned OFF?
Is PS motor running when

steering wheel is not operated
with battery plug ON and key
1 PBEHPs
defect
switch turned ON?

Does PS motor run Inspection 2
Display defect
when steering wheel Battery plug ON, PS main circuit defect
is o ~ e r a t e dwith kev switch ON
~ ~ 2 7 (151)
- 4
voltage check
CN27-5 (163)
1
lnspection 1
PBEMPsdefect
Battery plug ON, DMps defect

key switch ON PBEHPsdefect
CN27-1 (43) TMPSdefect
voltage check (battery CSps defect
CSps N 1 terminal
I NG (0V)
PS main circuit defect

lnspection 1. key switch - CSps voltage check
Measurement terminals CN27-1 (43) @ - CSps N 1 terminal@

OK (battery voltage) + DMps defect, PBEHPSdefect, TMps defect, or CSps defect

NG (other than battery voltage) key switch - CSps wiring defect
lnspection 2. Voltage check between PBEHPsand display

Measurement terminals CN27-4 (151)@ - CN27-5 (16310

Standard 0V
OK (0 V) + Display defect or main PS circuit defect

NG (5 V) + PBEHPSdefect
ERROR CODE F9: STEERING POTENTIOMETER ABNORMALITY
CN32
- Steering potentiometer
CN1054(55,POTST+)
CPU CN105-5(56,POTST)
board VRSP
CN103-17(51,LS-)
-
a Steering potentiometer defect
@ Open or short circuit of wiring between CPU board and steering potentiometer
@ CN103, CN105, or CN32 connection defect
@ CPU board defect
lnspection 1
Remove CN103, CN105, and CN32 and check wiring continuity of
(A) CN105-4 -CN32-1,
(B) CN105-5 - CN32-2,
(C)CN105-5 - CN103-17,
(D)CN105-4 - CN103-17,
(El CN105-4 - CN105-5,
(F)CN103-17 - CN32-3.
(B) -m
-m
1
1 Wiring defect between CPU board and steering potentiometer
lnspection 2
Steering NG
D Steering potentiometer defect
potentiometer
individual check
! oK
CPU board defect
lnspection 1. Wiring continuity check between CPU board and steering potentiometer
Battery plug OFF, CN103.CN105.CN32 disconnection
A: CN105-4 (55) [REC] - CN32-1 (55) [REC]

B: CN105-5 (56) [REC] - CN32-2 (56) [RECI
C: CN105-5 (56) [REC] - CN103-17 (51) [RECI
Measurement terminals D: CN105-4 (55) [REC] - CN103-17 (51) [REC]
E: CN105-4 (55) [REC] - CN105-5 (56) [REC]
F: CN103-17 (51) [REC] - CN32-3 (51) [REC]
A: 052
B: 0 0
C: -52
Standard D: 5.2
E: .o52
F: 052
Steering potentiometer
OK (standard) + To lnspection 2
NG (other than standard) -+Wiring defect between CPU board and steering potentiometer
lnspection 2. Steering potentiometer individual check

Battery plug OFF, steering potentiometer individual removal
A: CN32-1 (55) [TAB] - CN32-3 (51) [TAB]

Measurement terminals B: CN32-1 (55) [TAB] - CN32-2 (56) [TAB]
C: CN32-2 (56) [TAB] - CN32-3 (51) [TAB]
A: Approx. 2 k52
Standard B: Variation from 0 52 to about 0 - 2 k52
C: Variation from 0 52 to about 0 - 2 k52
OK (standard) -+ CPU board defect

NG (other than standard) -+ Steering potentiometer defect
4A-98
ERROR CODE FA: RA DISCONNECTION
Related portion
CPU
board
--
imated causes
@ RA defect
@ P I - RA - CN100 - P9 - CPU board wiring disconnection
@ CN100, CN118 connector connection defect
@ CPU board defect
@ Snubber board defect
lnspection 1
Remove CNlOl Wiring disconnection between CPU board and P9
P9 (TP9 located at the
upper part of T N I )
$ continuity check
CN101-26 (P9)
Inspection 2 RA defect
Remove P I round terminal (other than P I - RA - CNlOO wiring defect
and CNlOO 0.8 52)
P1
$ continuity check
CN100-2 (P9)
OK (approx. 0.8 R)
A
Inspection 3 Snubber board defect
Individual snubber
board inspection
TP@ - TDAD @ : Approx. 2.5 kQ

T P 9 0 - TDAD@ : Approx. 10 kQ
CPU board defect.

lnspection 1. CPU board - P9 wiring continuity check
Measurement terminals TP9 (TNl upper portion) - CN101-26 (P9) [RECI

Standard On
OK (0 Q) -t To lnspection 2
NG (-& 4 CPU
#I ) - P9 wiring disconnection
board
lnspection 2. PI - RA - CNlOO wiring continuity check

Battery plug OFF, PI round terminal and CNlOO disconnection
Measurement terminals PI [wiring side] - CN100-2 (P9) [RECI

Circuit tester range Q x 1
Standard Approx. 0.8 i2
OK (approx. 0.8 Q) + CPU board defect

NG (other than approx. 0.8 Q) -t RA defect or PI - CN100 wiring defect
4A-101
Inspection 3. Individual snubber board inspection
Forward direction TP9 @ - TDAD

Reverse direction TP9@ - TDAD @
Forward direction: Approx. 2.5 kQ
Standard
Reverse direction: Approx. 10 kQ
OK (Standard) + CPU board defect

NG (0Q) -+ Snubber board defect
MOTOR
Page
DRIVE MOTOR ................................................... 5-2
GENERAL ........................................................... 5-2
SPECIFICATIONS ................................................ 5-2
COMPONENTS ................................................... 5-3
REMOVAL.INSTALLATION ................................... 5-4
DlSASSEMBLY.INSPECTI0N.REASSEMBLY ............ 5-6
PUMP MOTOR ................................................... 5-9
GENERAL ........................................................... 5-9
SPECIFICATIONS ................................................ 5-9
COMPONENTS ................................................... 5-10
DISASSEMBLY.INSPECTION.REASSEMBLY ............ 5-13
POWER STEERING MOTOR ............................... 5-16
GENERAL ......................................................... 5-16
SPECIFICATIONS ................................................ 5-16
COMPONENTS ................................................... 5-17
REMOVAL-INSTALLATION ................................... 5-18
DISASSEMBLY .INSPECT10NmREASSEMBLY ............ 5-19
DRIVE MOTOR
GENERAL
SPECIFICATIONS
Vehicle type
48V specification vehicle 36V specification vehicle
Item
TYpe DC series-wound open type 4-
Nominal voltage V 48 36
Rated output kw 3.3 x 2 e
Insulation class F H
Brush size mm 1 4 x 40 x 32 e
(width x length x thickness) (in) (0.55 x 1.57 x 1.26)
Number of brushes 4 c
COMPONENTS
Removal Procedure
1 Remove the battery ASSY.
(See page 1-5 "Battery Assy Removal.lnstallation".)
2 Remove the rear toe board and front toe board.
3 Remove the steering wheel.

(See 8-1 1 in the "Steering Wheel Removal - Installation" section on page 1-3.)
4 Drain the brake fluid.
5 Remove the disc brake LH.
6 Disconnect the drive motor LH wiring.
7 Remove the drive motor LH. [Point 11
8 Remove the disc brake RH.
9 Disconnect the inlet hose and high pressure hose from the control valve.
1 0 Disconnect the drive motor RH wiring.
11 Remove the drive motor RH. [Point 21
Point Operation
[Point 1I
Removal-Installation: SST 0901 0-10260-71
[Point 21
Removal.Installation: SST 09010-10200-71

Note:
Measure the insulation resistance of each motor cable and motor unit before starting disassembly.
Standard: 3 MQ or more
1 Remove the disc brake.
2 Remove the brush cover.
3 Free the brushs.
4 Remove the bracket, No. 1.
5 Remove the armature coil. [Point 11
6 Remove the commutator frame. [Point 21
7 Remove two brushes from the commutator frame. [Point 31
8 Remove the brush holders from the commutator frame.
9 Remove the field coil. [Point 41
Note:
Measure the insulation resistance between each motor cable and motor case.
Field coil continuity inspection. Terminals to be measured: E and F
Standard: 0 Q (circuit tester range: 0)
5-7
Point Operations
[Point 1 I
Removal: SST 09950-2001 7
Inspection: If the commutator surface is roughened, cor-

rect it with sandpaper (around # 600) and
clean it carefully. If heavily roughened, correct
it with a lathe.
Commutator outside diameter
mm (in) rnrn (in)
Inspection: Carry out undercutting of mica when the com-

mutator is corrected.
Undercut depth
Standard: 1.0 mm (0.039 in)

Limit: 0.3 mm (0.012 in)
Inspection: Measure the insulation resistance of the arma-

ture coil.
Standard: 1 MQor more
[Point 21
Inspection: Install the armature and brushes. Attach a
spring scale to the brush spring and measure
the spring force on the instant when the spring
departs from the brush.
Spring force
5FBE10,13 5FBE15,18,20
Standard 11.8 N (1.2 kg) 12.6 Ibl t
Inspection: Measure the insulation resistance between the
brush holder and bracket.
[Point 31
Inspection: Inspect the brush wear and contact states.
Standard: 32 mm (1.26 in)

Limit: 1 4 mm (0.55 in)
[Point 41
Inspection: Inspect the continuity of the field coil.
Measurement terminals: E-F

Standard: 0 Q (circuit tester range: Q)
Inspection: Measure the insulation resistance of the field

coil
Measurement position: Between E-F terminal

and yoke
5-9
PUMP MOTOR
GENERAL
SPECIFICATIONS
Vehicle type
48V specification vehicle 36V specification vehicle
TYpe DC series-wound open type 4-
Nominal voltage V 48 36
Rated output kw 8 6.1
Insulation class F H
Brush size rnm 14 x 4 0 x 32
4-
(width x length x thickness) (in) (0.55 x 1.57 x 1.26)
Number of brushes 4 c
COMPONENTS
Removal Procedure
1 Remove the battery hood.
2 Remove the rear panel.
3 Remove the panel.
4 Disconnect the inlet hose and high pressure hose.
5 Disconnect the motor wiring.
6 Slightly hoist the motor. [Point 11
7 Remove the motor Wloil pump.
8 Disassemble the motor and oil pump.
Point Operations
[Point 1I
Removal: SST 09010-10260-71

Note:
2 Brushes
1 Raise the brush cover.
2 Free the brushes.
3 Remove the bracket No. I .
5 Remove the commutator frame. [Point 21
6 Remove t w o brushes from the commutator frame. [Point 31
7 Remove the brush holders from the commutator frame.
8 Remove the yoke ASSY. [Point 41
Note:
Field coil continuity inspection. Terminals to be measured: E and F
Standard: 0 Q
5-14
Point Operation
[Point 1I
Disassembly: SST 09950-2001 7

rect it with sandpaper (around # 600) and clean
it carefully. If heavily roughened, correct it with
a lathe.
Commutator outside diameter
1 Standard
5FBE10,13
80 mm (3.15 in)
5FBE15,18,20
t
Mica
Limit 75 mm (2.95 in) t
Inspection: Carry out undercutting of mica when the com-

mutator is corrected.

Limit: 0.3 mm (0.012 in)

ture coil.
[Point 21
spring scale to the brush spring and measure
the force on the instant when the spring de-
parts from the brush.
Spring force
5FBE10,13 5FBE15,18,20
Standard 11.8 N (1.2 kg) i2.6 Ibl t
-
Inspection: Measure the insulation resistance between the
brush holder and bracket.
[Point 31
Standard: 3 2 mm (1.26 in)

Limit: 1 4 mm (0.55 in)
[Point 41
Installation: Field coil continuity inspection.
Measurement terminals: Between E and F

Standard: 0 Q (circuit tester range: Q)
Installation: Measure the insulation resistance of the field

coil.
Measurement position: Between E-F terminal

and yoke
5-16
POWER STEERING MOTOR

GENERAL
SPECIFICATIONS
Vehicle type 48V specification 36V specification EHPS specification
vehicle vehicle vehicle
Permanent magnet +
Type C
type enclosed motor
Nominal voltage V 48 4- 36/48
Rated output kw 0.75 0.66 0.710.9
Insulation class F c c
Brush size mm 8 x 3 0 x 25 C 4-
(width X thickness x length) (in) (0.31 x 1.18 x 0.98)
Number of brushes 2 c c
Removal Procedure
1 Remove the side cover RH.
3 Disconnect the power steering motor wiring.
4 Disconnect the power steerig pump piping.
5 Remove the power steering motor ASSY wlpower steering pump.
6 Disconnect the power steering pump.
7 Remove the bracket.
8 Remove the power steering pump mounting.
9 Disconnect the power steering motor ASSY.
Note:
Standard: 1 Ma or more
_..
....//
. ...._. /'
3 Raise the brush
1 Remove the PS contactor.
2 Remove the brush cover.
3 Raise the brush.
4 Remove the bracket.
6 Remove the commutator frame ASSY. [Point 21
7 Remove the brush holders ASSY. [Point 31
Note:
Point Operations
[Point 1I

rect with sandpaper (around #600)and clean it
carefully.
If heavily roughened, correct it with a lathe.
Commutator outside diameter.

Limit: 45 mm (1.77 in)
Mica
Inspection: When the commutator is corrected, undercut

the mica.

Limit: 0.3 mm (0.012 in)

ture coil.
[Point 21

spring scale t o the brush holder, and measure
the force when the spring departs from the
brush.
Standard: 5.59 N (0.57 kg) 11.26 lbl

Limit: 2.75 N (0.28 kg) r0.617 Ibl
[Point 31

Limit: 14 mm (0.55 in)
Inspection: Insulation resistance between the holder and
bracket.
Standard: 1 M!J or more

FRONT AXLE & TRANSMISSSION
(1993.1.1998.1)
Page
GENERAL ............................................................. 6-2
SPECIFICATIONS ................................................. 6-3
COMPONENTS ..................................................... 6-3
TRANSMISSION .................................................. 6-4
REMOVAL.INSTALLATI0N ..................................... 6-4
DISASSEMBLY .INSPECTION.REASSEMBLY ............. 6-6
FRONT AXLE ........................................................ 6-9
DlSASSEMBLY.INSPECTl0N.REASSEMBLY ............. 6-9
GENERAL
SPECIFICATIONS
Item 5FBElO 5FBE13 5FBE15 5FBE18
Overall gear ratio 17,48 4- 4- 4-
Front tire size 1 8 x 7 - IOPR 1 8 x 7 - 14PR 1 8 x 7 - 14PR 1 8 x 7 - 16PR

Front tire inflation pressure
780(8)[1101 880(9)[1301 c t
kPa (kgf/cm2) [psi]
Front tire rim size 4.25 - 8 c c c
COMPONENTS
TRANSMISSION
I 1 Transmission oil
I
Removal Procedure
1 Drain transmission oil.
2 Remove mast ASSY. (See Mast ASSY Removal on page 12-5.)
3 Remove drive motors LH and RH. (See Drive Motor Removal on page 5-4.)
4 Jack up the frame and remove front wheels.
5 Remove transmission case LH.[Point 11
6 Remove transmission case RH.[Point 21
Note:
Fill transmission oil to the level plug position
Right side: 1.7 Q (0.45 USgall
Left side: 1.8 Q (0.47 USgal)
Standard vehicle: Hypoid gear oil SAE 85W-90
Insulated vehicle: Hypoid gear oil SAE 75W-80W
Front wheel hub nut tightening torque: 107.87-147.10 N.m (1100-1500 kgf-cm)
179.59-108.53 ft-lbfl
Point Operations
[Point 1 I
Removal.lnstallation: Install shackles at drive motor instal-

lation holes and hoist with a wire
rope.
Removal-Installation: Install shackles at drive motor instal-

lation holes and hoist with a wire
rope.
1 Remove the front axle hub. [Point 11
2 Remove the transmission cover.
3 Remove the gears (63T and 16Tl. [Point 21
4 Remove the front axle shaft. [Point 31
5 Remove the gears (74T and 25T). [Point 41
6 Remove the gear (22T). [Point 51
7. Remove the oil seal.
Note:
Coat liquid gasket (Three Bond 1215 or equivalent) on the transmission cover mating face before
reassembly.
Fill MP grease 0.490N (50 g) [O. 110 Ib] in the hub cap. Use MIL-G-3278-A only in the case of insu-
lated model 45s.
Transmission cover set bolt tightening torque: 29.42-44.13 N.m (300-450 kgf-cm) [21.71-32.56 ft-
Ibf]
Check the clearance between the tip end of the speed sensor and the gear. If it is not within the
standard, adjust it by changing the washer.
Standard: 0.5-2.5 mm (0.020-0.098 in)
Point Operations
[Point 1 I
Disassembly: SST 09950-20017
Inspection: Inspect the front axle hub preload.
Standard: 59-88 N (6-9 kg) [13-20 Ibl
[Point 21
[Point 31
[Point 41

[Point 51

FRONT AXLE
1 Jack up the vehicle and remove the front wheels.
2 Remove the front axle hub. [Point 11
Note:
Fill MP grease 0.490N (50 g) [0.110 Ib] in the hub cap. Use MIL-G-3278-A only in the case of insu-
lated model 45s.
Front wheel hub nut tightening torque: 107.87-147.10 N-m (1100-1500 kgf-cm) 179.59-108.53 ft-
Ibf]
Point Operations
[Point 1I
Inspection: Inspect the front axle hub preload.

\
Standard: 59-88 N (6-9 kg) [13-20 Ibl

FRONT AXLE & DRIVE UNlT
(1998.2 - 1
Page
GENERAL .......................................................................... 6 ~ - 2
SPECIFICATIONS ............................................................ 6 ~ - 2
COMPONENTS ................................................................6 ~ - 3
FRONT AXLE & DRIVE UNIT ..................................... 6 ~ - 4
REMOVAL.INSTALLATION ............................................. 6A-4
DISASSEMBLY.REASSEMBLY ........................................ 6A-6
6A-2
GENERAL
SPECIFICATIONS
Item 5FBE 10 5FBE13 5FBE15 5FBE18 5FBE20
Overall gear ratio 17.48 + + + +
Tire size 18x7-10PR 18x7-14PR C 18 X 7 - 16PR 18 X 7 - 12 118

l i r e inflation pressure
780 (8) [ I 101 880 (9) [130] c c
kPa (kgf/cm2)[psi]
6A-4
FRONT AXLE & DRIVE UNIT

T = N-m (kgf-cm) [ft-lbf]
6A-5
Removal Procedure
1 Remove the mast ASSY.
2 Drain drive unit oil.
3 Remove the drive motor LH and RH.
4 Jack up the frame and remove the front wheels.
5 Remove the through bolt. [Point 11
6 Remove the front axle & drive unit LH and RH.
Point Operations
[Point 11
Installation: Install the weld nut on the left of the vehi-

cle.
6A-6
DISASSEMBLY.REASSEMBLY
T = N.m (kgf-cm) [ft-lbfl
1 Remove the speed sensor.
' 2 Remove the transmission cover. [Point 11
3 Remove the gears (33T and 63T-16T) and axle shaft. [Point 21
4 Remove the gear (74T.25T). [Point 31

,
5 Remove the gear (22T). [Point 41
6 Remove the oil seals and bearing outer races. [Point 51
Point Operations
[Point 11
Reassembly: Apply 08826-00100 or equivalent t o the

mating surfaces of the case before assem-
bly.
[Point 21
Disassembly: Remove the gears (33T and 63T.16T)

and axle shaft ASSY.
1. Remove the adjust nut lock bolt.
2. Using SST, loosen the adjust nut.

SST 09420-12240-71
3. Remove the SST, than remove the adjust nut and

axle shaft ASSY.
4. Remove the gears (33T and 63T-16T).
Reassembly: Install the gear (33T) and axle shaft ASSY.
I
*
Grease
I
1.
2.
Fill grease to the transmission case as shown.
STD model: MP grease No. 2

45s model: MIL-G-3278-A
Capacity: 70 - 100 g (0.15 - 0.22 Ib)
Install the bearing (16T gear side).
3. Install the axle shaft ASSY, 33T gear and adjust nut.
4. Adjust the axle shaft preload by tightening the adjust
nut.
Standard: 110-150N(11-15kgf)[24-33lbfl
Note:
See that the adjust nut lock bolt hole aligns with the
33T gear lock hole. If not, adjust at the minimum
tightening side.
w 5.
6.
Install a new lock bolt.
Using SST, install the 16T. 63T gear.

SST 09950-60010
09950-70010
SST
Disassembly: Using SST, remove the bearing (33T gear

side).
SST 09950-40010
09950-60010
Reassembly: Using SST, install the bearing (33T gear

side).
SST 09316-12010
Disassembly: Using SST, remove t h e bearing (axle

shaft side).
SST 09950-40010
Reassembly: Using SST, install the bearing (axle shaft
side).
SST 09316-12010
Disassembly: Using SST, remove the bearings (63T.16T

gear).
SST 09950-40010
Reassembly: Using SST, install the bearing (63T gear

side).
SST 09950-60010
09950-70010
Note:
Install the 16T gear side bearing when installing
the 16T gear to the transmission case.
I [Point 31
SST I
Disassembly: Using SST, remove the bearings.
SST 09950-40010
Reassembly: Using SST, install the bearings.

SST 09950-60010
09950-70010
[Point 41
Disassembly: Using SST, remove the bearing.

SST 09950-40010
09950-60010
Reassembly: Using SST, install the bearing.

SST 09950-60010
09950-70010
[Point 51
Reassembly: Install the bearing outer races and oil

seals.
1. Using SST, install a new inside oil seal.

SST 09950-60010
09950-70010
2. Apply MP grease to the oil seal lip.
Using SST, install the bearing outer races.

SST 09527-1701 I
09950-60020
09950-70010
Using SST, install a new outside oil seal.

SST 09550-5501 1
09550-70010
Apply MP grease to the oil seal lip.

REAR AXLE
(1993.1.1998.1)
Page
REAR AXLE ASSY .............................................. 7-2
GENERAL ........................................................... 7-2
SPECIFICATIONS ................................................ 7-4
COMPONENTS ................................................... 7-4
DISASSEMBLY .INSPECT10NmREASSEMBLY ............ 7-7
REAR AXLE HUB ................................................ 7-9
REAR AXLE ASSY
GENERAL
1.0 and 1.3 ton series, and cushion vehicles of 1.O, 1.3, 1.5 and 1.8 ton series
7-3
1.5 and 1.8 ton series

SPECIFICATIONS
Item 5FBElO 5FBE13 5FBE15 5FBE18
TYpe Full floating type t t c
Rear tire inflation pressure

780 (8) [ I 101 880 (9)11301 780 (8) 11101 t
kPa (kgf/cm2) [psi]
COMPONENTS
Removal Procedure
1 Remove the battery hood.
2 Remove the weight.
3 Jack up the vehicle and remove the rear wheel.
4 Remove the cylinder. (See Steering Cylinder ASSY Removal on page 8-1 5 . )
5 Remove the rear axle ASSY. [Point 1I
Note:
Rear wheel hub nut tightening torque: 107.87-147.10 N-m (1100 - 1500 kgf-cm)
-
[79.59 108.53 ft-lbf]
Point Operations
[Point 1 I
Inspection: Inspect the rear axle ASSY preload.
Standard
1 tonseries: 69 - 1 3 7 N ( 7 - 1 4 k g ) [ 1 5 - 3 1 Ibl
1.5 ton series: 7 8 - 147 N (8 - 15 kg) [ I8 - 33 Ibl
In case of 1 ton series Measure at the center of the rear axle in the 1 ton se-
ries, and at the hub bolt in the 1.5 ton series.
1 Remove the hub cap.
2 Remove the rear axle hub. [Point 11
3 Remove the axle shaft bearing. [Point 21
4 Remove the bearing on the axle shaft wheel side. [Point 31
Note:
Fill MP grease in the hub cap. Use MIL-G-3278-A only in the case of the insulated model 45s.
Axle shaft side: 0.785 N (80 g) t0.176 Ibl
Axle shaft wheel side cap: 0.2452 N (25 g) [0.0551 Ibl
Rear wheel hub nut tightening torque: 107.87 - 147.10 N.m (1100 -
1500 kgf-cm)
[79.59- 108.53 ft-lbfl
7-8
Point Operations
[Point 1I
Inspection: Inspect the rear axle hub preload.
Standard: 49 - 7 8 N ( 5 - 8 kg) [11 - 18 Ibl
[Point 21
[Point 21

REAR AXLE HUB
Removal Procedure
1 Jack up the vehicle and remove the rear wheel.
2 Remove the hub cap.
4 Remove the bearing on the axle shaft wheel side. [Point 21
Note:
Fill MP grease in the hub cap. USE MIL-G-3278-A only in the case of the insulated model 45s.
Axle shaft side: 0.785 N (80 g) [O. 176 Ibl
Axle shaft wheel side cap: 0.2452 N (25 g) [0.0551 Ibl
Rear wheel hub nut tightening torque: 107.87-147.10 N m (1100-1500 kgf-cm)
179.59-108.53 ft-lbf]
7-10
Point Operations
[Point 1 I
Inspection: Inspect the rear axle hub preload.
Standard: 49 - 78 N (5 - 8 kg) [I1 - 18 Ibl
[Point 21

REAR AXLE
(1998.2 - 1
Page
GENERAL ........................................................................ 7 ~ - 2
SPECIFICATIONS ............................................................7A-3
COMPONENTS ............................................................ 7A-4
REAR AXLE HUB ........................................................7A-5
REMOVAL-INSTALLATION ............................................ 7A-5
REAR AXLE ASSY .......................................................... 7 ~ - 8
REMOVAL.INSTALLATION ..............................................7A-8
7A-2
GENERAL
Pneumatic single tire
-.. -.. -..
-. . .
Pneumatic double tire

Cushion double tire
-- -
--- -- -
--- ..
SPECIFICATIONS
Item 5FBE10 5FBE13 5FBE15 5FBE18 5FBE20
TYpe Full floating C C t C
Tire size 18 X7-8 10PR 18 X 7-8 14PR 16X 6-8 10PR C 16 X 5-10 112
Tire inflation pressure
780 (8) [1101 880 (9)[1301 780 (8) [1101 +
kPa (kgf/cm2)[psi]
COMPONENTS
REAR AXLE HUB
T = N-m (kgf-cm) [ft-lbfl
Removal Procedure
1 Jack up the vehicle and support it by wooden supports.
2 Remove the rear wheels. (Except cushion tire)
3 Remove the hub cap. [Point 11
5 Remove the bearing outer lace from the rear axle hub. [Point 31
6 Remove the inner bearing and oil seal. [Point 41
Point Operations
[Point 11
Installation: Install the hub cap.

1. Fill grease t o the h u b cap as shown.
STD model: MP Grease No.2

Capacity: 20 to 30 g (0.044 to 0.066 Ib)
2. Tap the flange of hub cap t o assemble.
[Point 21
Disassembly: Using SST, remove the rear axle hub.

SST 09950-40010
Reassembly: Install the rear axle hub.

1. Using SST, install the rear axle hub.
SST 09316-00011
2. Install the washer and castle nut.
3. Adjust the starting force of the rear axle hub.

Standard: 50 to 80 N (5 to 8 kgf) [ I1 to 18 Ibfl
4. Install the cotter pin.
[Point 31
Disassembly: Using a brass bar, remove t h e bearing

outer lace.
Reassembly: Using SST, install the bearing outer lace.
SST 09950-60020
09950-70010
Reassembly: Fill grease to the axle hub as shown.
STD model: MP Grease No.2

Capacity: 25 g (0.055 Ib)
Grease
[Point 41
Disassembly: Using SST, remove the inner bearing and

oil seal.
SST 09950-40010
Reassembly: Install the oil seal and inner bearing.

1. Using SST, install the oil seal.
SST 09370-10410-7 1
2. Using SST, install the inner bearing.

SST 09523-360 10
7A-8
REAR AXLE ASSY

I:Reuse prohibited parts
Removal Procedure
1 Remove the counter weight.
2 Remove the rear axle hub. (See page 7A-5)
3 Remove the steering potentiometer with bracket.
4 Set the rear axle t o straight ahead condition, remove the steering cylinder set bolt, and slide the
cylinder. (See Section 8.)
5 Remove the lock nut. [Point 11
6 Remove the rear axle ASSY. [Point 21
7 Remove the upper and lower oil seals. [Point 31
8 Remove the upper and lower bearing outer laces. [Point 41
9 Remove the lower bearing. [Point 51
Point Operations
[Point 1I
Disassembly-reassembly: H o l d t h e rear a x l e ASSY

i m m o v a b l e w i t h a monkey
wrench when removing or
installing the lock nut.
Reassembly: Adjust the rear axle starting force.
- -
Standard: 10 20 N-m (100 200 kgf-
cm) [7.2 14.5 ft-lbf]
-
After adjustment, firmly stake the lock nut
with a punch. (2 places)
[Point 21
Disassembly: Remove the rear axle ASSY.

1. Install t h e lock n u t as s h o w n f o r protecting t h e
threaded portion.
2. Disengage the upper bearing using a copper ham-

mer.
3. Support the rear axle ASSY using a jack.
4. Remove the lock nut, gear, washer, bearing spacer

and upper bearing.
5. Remove the rear axle ASSY.
Reassembly: Install the rear axle ASSY.

1. Fill grease t o the bearing housing as shown.
Grease
STD model: MP Grease No. 2
Capacity: 80 g (0.176 Ib)
7A-10
2. Set the rear axle ASSY i n position using a jack.
3. Using SST, install the upper bearing.

SST 09370-10410-71
4. Install the bearing spacer and washer.
5. Install the gear b y aligning the pin w i t h the punch

mark.
[Point 31
Disassembly: Using a screwdriver, remove the oil seal.
Reassembly: Using SST, install a new oil seal.

SST 09340-10410-71
09950-70010
After installation, apply a small amount
o f MP Grease No.2 t o the oil seal lip.
[Point 41
Disassembly: Using a brass bar, remove the upper and

lower bearing outer laces.
Reassembly: U s i n g SST, i n s t a l l t h e u p p e r b e a r i n g
outer lace.
SST 09130-30200-71
Reassembly: Using SST, install the lower bearing outer

lace.
SST 09320-10410-7 1
09950-70010
[Point 51
Disassembly: Remove the lower bearing.
Note:
Be careful so as not to damage the rear axle ASSY.
1. Grind a part of the cage with the disc grinder. Then,

remove the cage and roller.
2. Grind a part of bearing cone with the disc grinder.

3. Break the bearing cone with a chisel and then
remove the bearing cone.
Reassembly: Using SST, install the lower bearing.

SST 09430-12240-71
STEERING
Page
GENERAL ......................................................... 8-2
COMPONENTS ................................................... 8-3
SPECIFICATIONS ............................................... 8-6
H Y D R O S T A T I C S STEERING VALVE ASSY ........ 8-7
DlSASSEMBLY.INSPECTI0N.REASSEMBLY ............ 8-8
STEERING WHEEL .............................................. 8-11
MAST JACKET ASSY ........................................ 8-13
REMOVAL.INSTALLATION .................................. 8-13
DISASSEMBLY *INSPECTION.REASSEMBLY ............ 8-14
STEERING CYLINDER ASSY .............................. 8-15
DISASSEMBLY mlNSPECTlON.REASSEMBLY ............ 8-17
8-2
GENERAL
Tilt steering
-
Operating range ( 6 O )
Full forward tilt
Full backward tilt
Stroke: 82 mm (3.23 in)
Steering valve
8-3
COMPONENTS
Steering wheel
Steering post
Hydrostatic steering valve
Drag link & steering piping
Steering cylinder
I I
SPECIFICATIONS
Vehicle model
5FBE10,13,15,18,20
Item - -
Diameter mm (in) 380 (14.96)
Steering wheel
Play mm (in) 20 - 4 0 (0.78 - 1.57)
Power steering type Hydrostatic power steering
Delivery cclrev (cu-in) 6 9 (4.21)
Hydrostatic
Relief valve set pressure
kPa (kgf/cm 2 ) [psi]
7850 - 8530 (80 - 87) [ I140 - 12401
steering valve
Maximum input torque
1 18 (12) 1871
N.m (kgf-cm) Ift-lbfl
Relief valve type Built-in type
-
HYDROSTATIC STEERING VALVE ASSY
REMOVAL.lNSTALLATlON
Removal Procedure
1 Remove the rear toe board.
2 Remove the front toe board.
3 Disconnect the piping.
4 Remove the hydrostatic steering valve ASSY.
1 Remove the fitting. [Point 11
2 Remove the screw. [Point 21
3 Remove the end cap and O-ring. [Point 31
4 Remove the rotor set, spacer and O-ring. [Point 41
5 Remove the drive, spacer, plate and O-ring. [Point 51
6 Remove the retaining ring and gland bush seal. [Point 61
7 Remove the needle bearing and bearing race.
8 Remove the spool and sleeve ASSY.
9 Remove the centering spring. [Point 71
Point Operations
[Point 11
Reassembly: Set the fitting in the correct position.
One way fitting
[Point 21
Reassembly: Tighten the screws in the sequence illus-

trated at left.
[Point 31
Port face
Drive Reassembly: Set the concave portion of the rotor set star
in parallel.
Pin '\
Concave portions in [Point 41

rotor set star
Reassembly: Insert the drive. For accurate positioning by
fitting the yoke and pin, mark a line with a
felt pin.
Reassembly: Confirm that A, B, C and D portions are par-

allel as illustrated at left.
[Point 51
Disassembly: Remove the retaining ring with a straight-

edge screwdriver.
8-10
[Point 61
Reassembly: Set springs back to back with the notched

portions at both ends facing downward.
8-11
STEERING WHEEL
Removal Procedure
1 Remove the horn button.
2 Remove the set screws, plate and spring.
3 Remove the steering wheel. [Point 11
8-12
Point Operation
[Point 1I
Removal: SST 09609-2001 1

MAST JACKET ASSY
REMOVAL*INSTALLATION
Removal Procedure
1 Remove the steering wheel. (See Steering Wheel Removal-Installation on page 8-11 .)
2 Remove the cover.
3 Remove the turn signal switch.
4 Remove the tilt lock lever.
5 Remove the combination meter.
6 Remove the direction switch.
7 Remove the tilt lock parts.
8 Remove the mast jacket ASSY.
1 Remove the snap ring.
2 Extract the main shaft.
3 Remove the snap ring.
4 Remove the steering post.
5 Remove the steering bracket.
8-15
STEERING CYLINDER ASSY

Removal Procedure
1 Remove the rear panel.
2 Remove the weight.
3 Remove the steering angle sensor. [Point 11
5 Remove the steering cylinder ASSY.
Point Operation
Front
[Point 1I
t
Installation: Install and adjust the steering potentio. See
I Steering potentio
page 2-50 for the adjustment method.
[Point 21
Installation: Install and adjust the steering sensor.
1. While pushing the cylinder with a force of 98 N (10 kg) [22 Ibl in the direction of G, eliminate the
backlash between the rack and pinion to 0.
2. While keeping the state above unchanged, temporarily tighten bolts (to about a half of the spec-
ified torque) in the order of A to D. Then retighten them to the specified torque.
(1) Tightening torque for set blots A, B, C and D:

14710 t o 16691 N.m (1500 t o 1700 kgf-cm) (10853 t o 12300 ft-l bf)
3. Finally, tighten bolts E and F.

(2) Method for tightening set bolts E and F:
Tighten each bolt by a half turn after it comes into contact with the boss end face on the
frame side.
Set by aligning the spring pin (on pinion side) and the punch mark (on rack side). (To obtain the tire
neutral position).
Spring pin
F
Punch mark
Eliminate the backlash t o 0.

/
DISASSEMBLY-INSPECTION-REASSEMBLY
1 Remove the steering cylinder end.
2 Remove the piston.
3 Remove the bushing.
4 Remove the rack. [Point 1I
5 Remove the steering cylinder.
Note:
Coat hydraulic oil on each part before reassembly.
Use new O-rings, U-packings and dust seals at the time of reassembly.
Point Operation
[Point 1 I
Inspection: Measure the steering cylinder bore.

Standard steering cylinder bore:
55 mm (2.17 in)
Steering cylinder bore wear limit:
55.35 mm (2.1791 in)
BRAKE
(1993.1.1998.1)
Page
GENERAL ........................................................... 9-2
SPECIFICATIONS ............................................... 9-3
COMPONENTS ................................................... 9-3
DISC BRAKE ....................................................... 9-7
DISASSEMBLY.INSPECTION.REASSEMBLY ............ 9-8
DISC BRAKE ADJUSTMENT ................................. 9-10
BRAKE PEDAL .................................................... 9-11
REMOVAL-INSTALLATION ................................... 9-11
BRAKE PEDAL ADJUSTMENT .............................. 9-12
MASTER CYLINDER ........................................... 9-13
DISASSEMBLY.INSPECTI0N.REASSEMBLY ............ 9-14
PARKING BRAKE ................................................ 9-15
AIR BLEEDING FROM BRAKE SYSTEM ............. 9-17
9-2
GENERAL
Disc brake
Brake master cylinder

9-3
SPECIFICATIONS
Item 5FBE10-18
Foot brake type Hydraulic disc brake
Parking brake type Lever type
Diameter 200 (7.87)
Brake wheel mm (in)
Thickness 9.5 (0.374)
2
Area cm 28.8 x 2
Brake pad
Thickness mm (in) 5 (0.197)
Wheel cylinder inside diameter mm (in) 19.05 (0.75)
Master cylinder inside diameter mm (in) 19.05 (0.75)
COMPONENTS
Parking brake
9-4
Brake pedal
9-5
Brake pipe
9-6
Disc brake
9-7
DISC BRAKE
REMOVAL.INSTALLATI0N
Removal Procedure
1 Remove the RR toe board and FR toe board.
2 Drain brake fluid.
3 Remove the disc brake LH.
4 Remove the steering wheel.

(See "Steering Wheel Removal.lnstallation" on page 8-11 .I
5 Disconnect the drive motor LH wiring.
6 Remove the drive motor LH.

(See "Drive Motor Removal.lnstallation" on page 5-4.)
7 Remove the disc brake RH.
Note:
Bleed air from the brake system.
Check the brake fluid quantity and never fail to add if insufficient.
3
4 No. 1 and No.2 separation

6 High pressure hose
7 Cap
8 Boot, piston
1 Remove the spring. [Point 11
2 Remove the cotter pin, pin, lever ASSY No. 3 and lever ASSY No. 4.
3 Remove the pad. [Point 21
4 Separate lever ASSY No. 1 and lever ASSY No.2.
5 Remove the wheel cylinder.
6 Disconnect the high pressure hose.
7 Remove the wheel cylinder cap.
8 Remove the piston boot.
9 Remove the spring from the lever ASSY No.2.
9-9
SST Point Operations

[Point 1 I
Disassembly: SST 0971 7-20010
[Point 21
Inspection: Inspect the pad thickness.
Standard: 5 m m (0.197 in)
Wear limit: 1.0 m m (0.039 in)

DISC BRAKE ADJUSTMENT
1. Adjust the distance between pads by turning adjusting bolt @.
Distance between pads (c): Between 1 1 mm (0.433 in) and 12.2 m m (0.480 in) at the ends of
pads
2. Adjust the clearance between the brake wheel and each pad equally on the (a) and (b) sides by
turning adjusting bolt @I.
Clearance: Between 0.4 m m (0.01 57 in) and 1.1 m m (0.0433 in) at the ends of pads
3. Coat thread tightener at A portions after the end of adjustment.
A A
a 0.4 - 1.1 mm (0.0157 - 0.0433 in)

b 0.4 - 1.1 mm (0.0157 - 0.0433 in)
c 11 - 12.2 mm (0.433 - 0.480 in)
9-11
BRAKE PEDAL
REMOVAL.INSTALLATION
Removal Procedure
1 Remove the master cylinder pin.
2 Remove the set bolt.
3 Remove the brake pedal.
9-12
BRAKE PEDAL ADJUSTMENT
Adjust bolt
1 Adjust the brake pedal height by turning the adjusting bolt.
Brake pedal play (A): 135 - 1 4 0 mm (5.31 - 5.51 in)

2 Adjust the brake pedal play by means of the the master cylinder clevis.
Brake pedal play (B): 1 0 f 3 mm (0.39 f 0 . 1 2 in)

MASTER CYLINDER
REMOVAL.INSTALLATION
Removal Procedure
1 Drain brake fluid from the reservoir tank.
2 Disconnect the brake pipe and reservoir pipe.
3 Remove the cotter pin and washer pin.
4 Remove the master cylinder.
Note:
Check the brake fluid quantity, and add without fail if insufficient.
9-14
DISASSEMBLY-INSPECTION-REASSEMBLY
1 Remove the clevis.
2 Remove the boot.
3 Remove the snap ring, push rod and piston stop plate.
4 Remove the piston and spring.
5 Remove the master cylinder body.
PARKING BRAKE
REMOVAL.INSTALLATI0N
Removal Procedure
1 Disconnect the parking brake wire. [Point 11
2 Remove the parking brake ASSY.
9-16
Point Operations
[Point 1 I
Adjustment: Adjust to 4 to 6 notches at the center of the lever when operated with a force of 294 N
(30 kg) 166 Ibl.
Check if the displacement of the A portion is within 3 mm (0.12 in), and make adjustment by means of
@ and @ if the standard is not satisfied.
AIR BLEEDING FROM BRAKE SYSTEM
1. Bleed air from the master cylinder.
2 Bleed air from the wheel cylinder.
Note:
While bleeding air from the brake system, be careful not to let the brake fluid in the reservoir tank
become insufficient.
Always use genuine brake fluid (SAEJ-1703 DOT-3).
While one person pumps the brake pedal several times and keeps it in the depressed state, another
person should loosen the breather plug for air bleeding until no bubble is seen in the discharged
brake fluid.
BRAKE
(1998.2 - )
Page
GENERAL ..........................................................................9 ~ - 2
SPECIFICATIONS ............................................................9 ~ - 3
COMPONENTS................................................................9A-4
DISC BRAKE .....................................................................9 ~ - 7
REMOVAL-INSTALLATION.............................................. 9A-7
DISASSEMBLY.INSPECTI0N . REASSEMBLY ............... 9A-8
DISC BRAKE WHEEL INSPECTION ...........................9 ~ - g
BRAKE ADJUSTMENT..................................................g ~ - l o
AIR BLEEDING FROM BRAKE SYSTEM ..................g ~ - 1I
BRAKING FORCE INSPECTION.................................. ~ A - I I
MASTER CYLINDER (1998.2 - 2000.3) ..................9 ~ - 1 2
REMOVAL-INSTALLATION.............................................. 9A-12
DISASSEMBLY-INSPECTION-REASSEMBLY ................. 9A-13
MASTER CYLINDER (2000.4 - 1 ................................9 ~ - 1 4
REMOVAL.INSTALLATION............................................. 9A-14
DISASSEMBLY.INSPECTION .REASSEMBLY ................ 9A-15
PARKING BRAKE ............................................................9A-17
REMOVAL-INSTALLATION............................................9A-17
BRAKE PEDAL .................................................................9A-19
REMOVAL.INSTALLATI0N..............................................9A-19
ADJUSTMENT .................................................................9A-20
GENERAL
Disc brake
Brake master cylinder (1998.2 - 2000.3)

9A-3
Brake master cylinder (2000.4 -
SPECIFICATIONS
Item 5FBE10-20
Foot brake type Hydraulic disc brake
Parking brake type Lever type
Diameter 200 (7.87)
Brake wheel m m (in)
Thickness 9.5 (0.374)
Area cm2 28.8 X 2
Brake pad
Thickness m m (in) 5 (0.197)
Wheel cylinder inside diameter m m (in) 19.05 (0.75)
Master cylinder inside diameter m m (in) 19.05 (0.75)
COMPONENTS
Parking brake
Brake pedal
Brake pipe
9A-6
Disc brake
DISC BRAKE
Removal Procedure
1 Remove the rear and front toe boards.
2 Drain the brake fluid.
3 Disconnect the left piping.
4 Remove the left parking brake wire.
5 Remove the left disc brake ASSY.
6 Disconnect the right piping.
7 Disconnect the right parking brake wire.
8 Remove the right disc brake ASSY.
Note:
After installation, adjust the disc brake (see page 9A-10) and the parking brake (see 9A-18).
1 Remove the springs. [Point 11
2 Remove the cotter pin, pin, lever ASSY No. 3 and No. 4.
3 Remove the pads. [Point 21
4 Disconnect lever ASSY No. 1 and No. 2.
5 Remove the wheel cylinder.
6 Remove the high-pressure hose.
7 Remove the wheel cylinder cap.
8 Remove the boot and piston.
9 Remove the spring from lever ASSY No. 2.
Note:
After installation, bleed air (see page 9A-11) and adjust the brake (see 9A-10).
9A-9
SST Point Operations

[Point 1I
Disassembly: SST 097 17-20010
[Point 21
Inspection: lnspect the pad thickness.
Limit: 1.0 m m (0.039 in)
DISC BRAKE WHEEL INSPECTION

1. lnspect the disc brake wheel thickness.
Limit: 8.5 m m (0.035 in)
2. lnspect the disc brake wheel runout.

Limit: 0.12 m m (0.0047 in)
BRAKE ADJUSTMENT
1. Release the parking brake.
2. Loosen lock nuts @ and @ and then .adjust bolts @

and @.
3. Tighten adjust bolt @ until the disc brake does not

move.
Be careful not to over-tighten the bolt.
4. Gradually loosen adjust bolt a w h i l e checking move-

ment of the disc brake manually and fix the bolt by
lock nut at a position 45 to 90 degrees loosened
from position A where the disc brake begins to move
smoothly.
5. Pull the disc brake ASSY in the direction of C.

Tighten adjust bolt @, maintaining the outside pad
surface without any gap with the disc brake wheel
surface and then fix the bolt by lock nut @ at a posi-
tion where gaps "a" and "b" on both sides between
the pad and disc brake wheel are equal.
6. Operate the parking brake and foot brake, and then

check the disc brake and wheel for any trace of drag-
ging.
7. After adjustment, apply thread tightener at portions

D.
AIR BLEEDING FROM BRAKE SYSTEM
Note:
Bleed air while adding the brake fluid so that the fluid
level in the reservoir tank will not become low.
1. Bleed air from the brake master cylinder.

(1) Press down the brake pedal several times to com-
press the air in the piping and maintain that condi-
tion.
(2) Loosen the breather plug to purge the air from the
piping together with the brake fluid. Tighten the
plug immediately before flow-out will be stopped.
(3) Repeat operations in (1) and (2) above until no air
bubble is seen in the flowing out brake fluid.
2. Bleed air from both left disc brake ASSY RH and LH.
(1) Bleed air, one side at a time, in the same manner
as above.
3. Add the brake fluid to the specified level.
STD model: SAE J-1703 DOT-3

45s model: Brake fluid arctic S
BRAKING FORCE INSPECTION

1. Inspect the braking force using the brake tester or by driving test.
Braking distance (no-load condition)
5FBE10 5FBE13 5FBE15 5FBE18 5FBE20

Initial speed of braking km/h (mph) 15.0 (9.32) 14.5 (9.01) 14.0 (8.70) 13.5 (8.39) 13.0 (8.08)
I Stopping distance 1
(ft) 5.0 (16.4)
or less
1 + I C I + I e I
2. If the braking force is insufficient, check for poor pad contact, contamination of pad or rotor by
foreign matter, leakage of brake fluid and invasion of air.
9A-12
MASTER CYLINDER (1998.2 - 2000.3)

Removal Procedure
1 Drain brake fluid from the reservoir tank.
3 Remove the cotter pin and the washer pin.
4 Remove the master cylinder.
Note:
1 Remove the clevis. [Point 11
2 Remove the boot.
3 Remove the snap ring, push rod and piston stop plate.
4 Remove the piston spring.
5 Remove the master cylinder body.
Point Operation
[Point 1 I
Reassembly: Tentatively set the push rod length as

shown and adjust the installed length.
Reference value: 108 mm (4.25in)

9A-14
MASTER CYLINDER (2000.4 - 1

Removal Procedure
1 Drain brake fluid f r o m the reservoir tank.
3 Remove the push rod clevis pin.
4 Remove the brake master cylinder.
Note:
DISASSEMBLY-INSPECTION-REASSEMBLY(2000.4 - )
1 Turn the boot up and remove the snap ring.
2 Remove the push rod. [Point 11
3 Remove the piston. [Point 21
4 Remove the pin and the fluid inlet elbow.
5 Remove the outlet plug and valve.
Point Operations
[Point 11
Installation:
Temporarily set the push rod length to the illustrated dimen-
sion, and make readjustment after installation.
[Point 21
Installation:
Apply rubber grease on the piston cup and whole periphery
of the cup before reassembly.
9A-17
PARKING BRAKE
Removal Procedure
1 Remove the spring.
2 Disconnect the parking brake wire. [Point 11
3 Remove the parking brake ASSY.
Point Operations
L
I
[Point 11
Inspection: 1. Check the parking lever moving distance when an operation force of 294 N (30
kgf) [66 Ibf] is applied to the center of the parking lever knob.
Standard: 4 - 6 notches
If the standard is not satisfied, adjust by adjust nut 0.

2. With the above condition satisfying the standard, measure deviation A of the
cable fixture.
Limit: 3 m m (0.12 in)
If the limit is not satisfied, adjust by adjust nuts @ and 0.

BRAKE PEDAL
Removal Procedure
1. Remove the master cylinder pin.
2. Remove the set bolt.
3. Remove the brake pedal.
9A-20
ADJUSTMENT
1. Adjust the brake pedal height.
Standard: 135 - -
140 mm (5.31 5.51 in)
If the standard is not satisfied, adjust b y the adjust bolt.
2. Adjust play of the brake pedal.
Standard: 10 f3 mm (0.39 f0.12 in)

If the standard is not satisfied, adjust the length of the master cylinder push rod so that the
play is within the specified range.
BODY
Page
BODY FRAME ................................................... 10-2
COMPONENTS ................................................. 10-2
BATTERY HOOD .............................................. 10-5
BALANCE W E I G H T .......................................... 10-6
C O M B I N A T I O N METER .................................... 10-7
DISASSEMBLY *INSPECTION.REASSEMBLY .......... 10-8
10-2
BODY FRAME
COMPONENTS
Frame & Weight
Battery hood
5201
(EC SPEC ORS U.S.A)
91651-41026
FL
Instrument panel & floor
BATTERY HOOD
I
Removal Procedure
1. Release the battery hood catch.
2. Disconnect the battery hood damper.
3. Remove the battery hood set bolts.
4. Remove the battery hood Wiseat.
BALANCE WEIGHT
Removal Procedure
1. Remove the rear cover.
2. Temporarily hoist the balance weight with a wire rope.
3. Remove the set bolts.
4. Remove the balance weight.
COMBINATION METER
The combination meter has the diagnostic (self-diagnosis) function and analyzer (fault analysis) func-
tion in addition t o general display such as the traveling speed, battery charge and hour meter indica-
tions.
Vehicle speed limiter set indicator

Battery electrolyte level warning I Parking brake application indicator
Battery charge meter Speedometer
\ \ I
I
I
I I
Multiway power
control level
gauge
\
Multiway hour meter
I I
Display
Level setting switches

Switch panel
I I
1. Remove the cover sheet.
2. Remove the meter board.
3. Remove the panel ASSY.
4. Remove the window plate and glass.
Page
NATURAL DROP TEST ..................................... I1-2
NATURAL FORWARD TILT TEST .................... I 1-2
OIL LEAK TEST ................................................. I1-3
NATURAL DROP TEST
1. Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 to 1.5 m (40 to 6 0
in), and stop the motor.
2. Draw datum lines on the inner and outer masts, and

measure the drop in 15 minutes.
Vehicle model Natural drop amount

5FBE10,13 90 mm (3.54 in) or less
5FBE15,18,20 t
NATURAL FORWARD TILT TEST

load on the fork. Lift the fork about 50 cm (20 in) and
turn the key switch off.
2. Measure the tilt cylinder rod extension in 15 minutes.

Vehicle model Natural forward tilt amount
5FBE10,13 30 mm (1.18 in) or less
5FBE 15,18,20 t
OIL LEAK TEST
LIFT CYLINDER
load on the fork. Lift the fork by 1 to 1.5 m (40 to 6 0
in) and turn the key switch off.
2. Gently tilt the mast fully forward and turn the key switch
off. After 5 minutes, disconnect the oil control valve and
return hose. Measure the oil leakage amount in one
minute by placing a measuring cylinder at the fitting.
Standard oil leakage amount

(at lift port): 6 -
16 cc (0.37 - 0.98 in )3
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
TILT CYLINDER
load on the fork. Lift the fork by about 50 cm (20 in)
and turn the key switch off.
2. After 5 minutes, disconnect the oil control valve and

return hose. Measure the oil leakage amount in 1 minute
by placing a measuring cylinder at the fitting.
Standard oil leakage amount

-
(total of lift and tilt): 1 4 3 4 cc (0.85 - 2.07 in )3
3. The leakage amount at the tilt port is the total leakage

at the lift port.
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
MAST (1993.1 -- 1994.1)
Page
V MAST ASSY ................................................. 12-2
COMPONENTS .................................................. 12-2
REMOVAL . INSTALLATION ................................ 12-5
DISASSEMBLY . INSPECTION . REASSEMBLY ..... 12-6
LIFT BRACKET .................................................. 12-7
DISASSEMBLY . INSPECTION . REASSEMBLY ...... 12-8
CHAIN ............................................................... 12-9
CHAIN INSPECTION ........................................... 12-1 1
CHAIN ADJUSTMENT ........................................ 12-1 1
FORK ................................................................. 12-12
REMOVAL ......................................................... 12- 1 2
INSTALLATION .................................................. 12- 1 2
INSPECTION ...................................................... 12-1 2
MAST ADJUSTMENT ....................................... 12-13
V-SV MAST ...................................................... 1 2- 1 3
FV MAST .......................................................... 12-19
FSV MAST .................................................... 12-25
LlFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) ............ 12-31
MAST (1994.1 ^. 1
Page
V MAST ASSY ................................................. 12-32
COMPONENTS ................................................. 12-32
MAST DISASSEMBLY.
1NSPECTION.REASSEMBLY ............................. 12-38
LlFT BRACKET DISASSEMBLY .
lNSPECTlON.REASSEMBLY (1994.1 - 2000.5) .. 1 2-40
LlFT BRACKET DISASSEMBLY
INSPECTION .REASSEMBLY (2000.6 - ) ........... 1 2-42
MAST ADJUSTMENT ........................................ 12-44
CHAIN .............................................................. 12-54
INSPECTION ..................................................... 12-54
REASSEMBLY .................................................. 12-54
ADJUSTMENT .................................................. 12-55
FORK ................................................................ 12-55
..................................................... 12-55
INSPECTION
SV MAST ASSY ........................................ I2-56
COMPONENTS .............................................. 12-56
MAST ADJUSTMENT ........................................ 12-58
FV MAST ASSY ........................................ I2-62
COMPONENTS ............................................. I2-62
MAST ADJUSTMENT ........................................ 12-64
FSV MAST ASSY ............................................. 12-68
COMPONENTS ................................................ 12-68
MAST ADJUSTMENT ........................................ 12-70
LlFT CYLINDER ROD SHIM
ADJUSTMENT ............................................... 12-74
12-2
V MAST ASSY
COMPONENTS
REMOVAL . INSTALLATION
Removal Procedure
1 Disconnect the chain.
2 Remove the lift bracket.
3 Remove the hose cover.
4 Disconnect the overflow hose and high pressure hose.
5 Slightly suspend the mast with a hoist.
6 Remove the mast support cap.
7 Remove the tilt cylinder front pin. [Point 11
8 Remove the V mast ASSY.
Note:
Coat MP grease on the inner surfaces of the bushing and cap at the mast support and on the tilt
cylinder front pin before reassembly.
It is necessary to inspect uneven motion of lift cylinders and make necessary adjustment when
any of the mast ASSY, outer mast, inner mast and lift cylinders is replaced (See page 12-31).
Install the mast support bushing with the greasing port facing upward.
12-6
Point Operations
[Point 1 I
Removal: SST 09810-201 72-71
DISASSEMBLY . INSPECTION . REASSEMBLY
1 Hose cover ..a[

3 Disconnect the lift cylinder rod end.
4 Remove the lift cylinder.
5 Remove the lift roller.
6 Remove the mast strip.
7 Pull out the outer mast from the bottom side of the inner mast.
LIFT BRACKET
Note:
Remove the lift bracket before lift bracket roller replacement or shim adjustment.
I
1 Mast and fork

4 Inner mast
Removal Procedure
1 Set the mast in the neutral position and fully lower the fork.
2 Remove the lift bracket cotter pin.
3 Remove the nuts.
4 Lift the inner mast.
DISASSEMBLY INSPECTION REASSEMBLY
1 Remove the backrest.
2 Remove the lift rollers. [Point I ]
3 Remove the side rollers.
4 Remove the fork.
Point Operations
[Point 1I

12-9
CHAIN
Removal Procedure
1 Remove the adjusting nut and nut on the mast side.
2 Remove the chain wheel and chain.
3 Remove the cotter pin on the lift bracket side.
4 Remove the chain.
The installation procedure in the reverse of the removal procedure.
Note:
Tighten (in parallel) to prevent twisting as against the chain wheel.
12-10
Point Operation T = N.m (kgf-cm) [ft-lbf]
V.SV Mast FSV Mast FV Mast
0
0
0
0
Outer mast Front lift cylinder Outer mast Front lift cylinder Front lift cylinder
8) T=63.74614.71 (65061501 147.036 10.851
[Point 1I
Installation:
1 Tighten adjusting nuts @ and 0.

2 Tighten adjusting nut 0.
CHAIN INSPECTION
1. Chain inspection
(1) Elongation
SST 09631 -22000-71
Note:
When inspecting the chain elongation, use the SST
above and inspect without removal from the vehicle.
CHAIN ADJUSTMENT
1. Place the vehicle on a flat ground and set the mast in
the vertical position.
2. After moving the fork up and down several times without

.a load, check that the chain tensions on the left and right
sides are equal.
3. Turn the adjusting nut (on the lift cylinder side) so that
the fork bottom surface is about t o come into contact
with the ground surface without slackening the chain.
4. Check that the chain tensions are equal on the left and
right sides.
5. Check that the fork height is as specified.

12-12
FORK
REMOVAL
1. Raise the fork approximately 2 0 0 mm (7.88 in).
2. Place wooden stand under the fork rail slot.
3. Move each fork t o the center.

4. Lower the fork t o remove.
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1. Fork inspection points
(1) Bending, crack, misaligned fork tips

Bending limit: 15 mm (0.59 in)
Fork end unevenness limit: 1 0 mm (0.39 in)
Note:
If the fork tips misalignment exceeds the maximum al-
lowance, check individual fork for bending, play at the
mounting section, and the warping of the lift bracket finger
bar.
MAST ADJUSTMENT
V-SV MAST
Mast Lift Roller Adjustment (V-SV)
lnner mast
$J
Outer mast
Measure with this rolling face
in close contact.
These -rollers
Bring into contact
.8mm(0-0.031 in)
ere the roller is
closest)
1. Measure the gap with the mast overlap at near 500 mm (19.69 in).
2. Shift the inner mast to one side to bring the roller into contact with the outer mast. The gap on
the opposite side between the inner mast and the side of the roller at the position where they are
the closest shall be 0 to 0.8 mm (0 to 0.031 in).
3. See the table below for roller selection.

As a rule, use oversize rollers (No.2). Use No.1 rollers only when the mast inside width is small.
The roller size may be different between the left and right sides.
4. After the adjustment, the inner mast shall move smoothly in the outer mast.
Mast roller list
Outside diameter
Mast roller Seal color Remarks
m m (in)
0 0
Outer mast 94.5 -0.2 (3.720 -0.007) Black
0 0
114.5 -0.2 (4.508 -0.007) Black
Inner mast o o
11 5.1 -0.2 (4.531 -0.007] Blue Oversize
in close contact.
0.8 mm(0-0.031 in)

ere the roller is
closest)
1. Measure the gap with the mast overlap at near 500 mm (19.69 in)
2. Shift the inner mast to one side t o bring the roller into contact with the outer mast, and adjust the
clearance between the roller and mast on the opposite side at the closest position to 0 to 0.8 mm
( 0 to 0.031 in)
3. See the preceding page for the rollers to be used.
4. After the adjustment, check if the inner mast moves smoothly in the outer mast.
Lift Bracket Lift Roller Adjustment (V.SV1
Front
1
Middlellower lift roller
100 mm (3.93 in)
Upper side roller ring into contact

in close contact.
Bring into conta

!'
Lift bracket
Outer mast
m (0-0.031 in) Inner mast

I
here the roller is
1. Make adjustment where the center of the side roller in the upper part of the lift bracket is 100 mm
(3.93 in) above the top end of the inner mast.
2. Upper lift rollers need no adjustment as they are fixed in position by snap rings.
3. For the center and lower lift rollers, shift the lift bracket to one side t o bring the rollers into contact
with the mast, and adjust the clearance between the roller and mast on the opposite side to 0 to
0.8 mm ( 0 to 0.031 in) at the position where the roller is the closest to the mast.
4. Adjust the upper side rollers after adjusting the middle and lower rollers. Bring the side roller into
contact with the mast on one side, and adjust the clearance between the side roller and inner mast
to 0 to 0.6 mm (0 to 0.024 in).
5. After the end of adjustment steps 3 and 4, the lift bracket shall move smoothly along the overall
length of the mast.
12-16
Mast Strip Adjustment (V-SV)
The roller must contact the inner mast. .-c
1. Make adjustment when the inner mast is fully lowered.
2. With the inner mast in contact with the outer mast roller, adjust the clearance between the mast
strip and mast to 0.5 to 1.0 mm (0.020 to 0.039 in)
3. After the adjustment, check if the mast moves smoothly.

12-17
SV Mast Assy
Components
12-19
FV MAST
Components
Outer Mast and lnner Mast Roller Adjustment (FV)
@
in close contact.
Outer mast Inner mast
Bring into contact

These rollers
the closest)
1. Shift the inner mast to one side to bring the roller into contact with the outer mast. The gap on
the opposite side between the roller and outer mast at the position where they are the closest shall
be 0 to 0.5 mm ( 0 to 0.020 in).
2. Turn the bolt for adjustment, and lock the bolt by the nut when the gap is adjusted to an appropri-
ate level. The mast gap, however, shall be even on the left and right sides.
3. See the roller list for roller selection. As a rule use oversize rollers (No.2). Use No.1 rollers only
when the mast inside width is small.
5. See the table below for the mast overlap at the time of adjustment.
FV mast mm (in) lnner mast roller list
Maximum fork height Overlap

3500 or less 400 (15.75)
3700 500 (19.69) Blue
4000 or more 600 (23.62)
12-22
Inner Mast and Outer Mast Roller Adjustment (FV)
These rollers

in close contact
Outer m
Bring into contact
here the roller is

w
1. See the table on the preceding page for the mast overlap at the time of adjustment.
2. Shift the inner mast to one side to bring the roller into contact with the mast. The gap on the oppo-
site side between the roller side face and mast at the position where they are the closest shall be
0 to 0.5 mm ( 0 to 0.020 in).
3. Turn the bolt for adjustment. When the appropriate gap is obtained, lock the bolt by the nut.
4. See the list below for the roller to be used.
Outer mast roller list
Outside diameter mm (in) Seal color

0 0
94-5-0.2 ( 3.720-0.007 ) Black
Bottom recessed roller adjustment
If the bottom recessed roller bolt is overtightened to obstruct smooth mast or lift bracket movement,
loosen the nut and return the bolt a little.
Make readjustment after moving the mast or lift bracket a few times.
As the roller does not retract by loosening of the bolt only, always move the mast or lift bracket a few
times before making readjustment.
12-23
Lift Bracket Roller Adjustment (FV)
100 rnrn (3.9 in)

Lower lift roller
Bring into contact

in close contact. bracket
Bring into contact
1. Make adjustment with the center of the lift bracket upper side roller at 100 mm (3.9 in) from the
top of the inner mast.
2. The upper and center lift rollers need no adjustment because they are stopped by snap rings.
3. For the lower lift rollers and side rollers, shift the lift bracket to one side to bring the roller into
contact with the mast, and make shim adjustment for a clearance of 0 to 0.5 mm (0 to 0.020 in)
between the mast and the roller on the opposite side where the roller is the closest.
4. After the adjustment, check for smooth movement of the lift bracket.
12-24
Mast Strip Adjustment (FV)
.-C
The roller must contact the inner mast

12-25
FSV MAST
Components
12-27
Outer Mast and Middle Mast Lower Roller Adjustment (FSV)

Middle Mast and lnner Mast Adjustment (FSV)
easure with this rolling face

close contact. Outer mas
Bring into contact
here the roller is
1. Shift the middle mast to one side to bring the roller into contact with the mast. The gap on the
opposite side between the roller side face and mast at the position where they are the closest shall
be 0 to 0.5 mm (0 to 0.020 in).
The mast gap, however, shall be even on the left and right sides.
3. See the roller list for roller selection.

As a rule, use oversize (No.2) rollers. Use No.1 rollers only when the mast inside width is small.
4. After the adjustment, the inner mast shall move smoothly in the middle mast.
5. See the table below for the mast overlap at the time of adjustment.
FSV mast mm (in) lnner mast roller list
Maximum fork height Overlap No. Outside diameter mm (in) Seal color
5500 or less 450 (17.72)
6000 500 (19.69) 11 5.1 -0.2 4.531 -0.007 Blue
6500 or more 600 (23.62)
Middle Mast and Outer Mast Rollers Adjustment (FSV)
lnner Mast and Middle Mast Upper Rollers Adjustment (FSV)
These roller

in close contact.
Outer
Middle mast
Bring into c
re the roller is
1. See page 12-27 for the mast overlap at the time of adjustment.
2. Shift the middle mast to one side to bring the roller into contact with the mast. The gap on the
opposite side between the mast roller side face and mast at the position where they are the closest
shall be 0 to 0.5 mm (0 to 0.020 in).
The mast gap, however, shall be even on the left and right sides.
4. See the table below for the roller to be used.
Outer mast upper roller
Outside diameter m m (in) Seal color

0 0
94-5-02 (3.720-0.007) Black
Bottom recessed roller adjustment

if the bottom recessed roller bolt is overtightened to obstruct smooth mast or lift bracket movement,
loosen the nut and return the bolt a little.
Make readjustment after moving the mast or lift bracket a few times.
As the roller does not retract by loosening of the bolt only, always move the mast or list bracket a few
times before making readjustment.
12-29
Lift Bracket Lift Roller Adjustment (FSV)
Lower lift roller
Bring into contact
Measure with this rolling face in

close contact.
Bring into contac
0.5 m m
-0.020 in)
here the roller is
e closest)
1. Make adjustment with the lift bracket fully raised.
2. Upper lift rollers need no adjustment as they are stopped by snap rings.
3. For lower lift rollers and side rollers, shift the lift bracket to one side to bring the roller into contact
with the mast, and make shim adjustment for a clearance of 0 to 0.5 mm (0t o 0.020 in) between
the roller and mast on the opposite side where the roller is the closest.
4. After the adjustment, check for smooth movement of the lift bracket.
12-30
Mast Strip Adjustment (FSV)
The roller must contact the inner mast

-.-
C
Q)

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left
and right sides due to tolerances of parts.
The inspection and adjustment must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-
ASSY, and inner mast SUB-ASSY.
1. Inspection
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with alomost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast, Set the SST to the outer mast
tie beam, and lower the inner mast until it reaches the
SST.
SST 096 10-22000-7 1
(2) Remove the set bolt of the cylinder rod end on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7)Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 mm (0.020 in)
1.0 mm (0.039 in)
12-32
V MAST ASSY
COMPONENTS
12-35
1 Mast in vertical position and fork at the lowermost position

5 Hose
Removal Procedure
1 Set the mast vertical and lower the fork to the bottom position.
2 Disconnect the chain.
3 Remove the chain wheel. [Point 11
4 Remove the lift bracket. (Raise the inner mast until it comes off from the lift bracket, and slowly
move the vehicle in the reverse direction to depart from the lift bracket. Then stop the engine.)
[Point 21
5 Disconnect the overflow hose and high pressure hose. (Lower the inner mast to the bottom posi-
tion and operate the lift lever several times to release the residual pressure in the lift cylinder be-
fore disconnecting the hoses.)
6 Slightly hoist the mast.
7 Remove the mast support caps.
8 Remove the tilt cylinder front pin. [Point 31
9 Remove the mast ASSY.

Note:
Apply MP grease on the interior surface of the mast support bushing, inner surface of the mast sup-
port cap and tilt cylinder front pin.
Mast support cap set bolt tightening torque:
T = 68.65 - -
107.87 N.m (700 1100 kgf-cm) [50.65 - 79.59 ft-lbf]
If any of the mast ASSY, outer mast, inner mast and lift cylinder is replaced, it is necessary t o in-
spect and adjust uneven motion of the lift cylinder. See the lift cylinder rod shim adjustment section
(on page 12-74) for the inspection and adjustment method.
Adjust the chain tension. (See page 12-55.)
Point Operations
[Point 1I
Removal: Use the SST for removal if the fitting is tight.

SST 09950-2001 7
Installation: Install the chain wheel with its side having

greater radius at the periphery of its hole fac-
ing the boss of the mast side pin.
[Point 21
Installation: Adjust the eccentric roller (OPT) after lift

bracket installation. (Common to the V and
SV masts.)
1. Turn the eccentric roller pin in the direction shown in

the illustration, and lock with the set nut at the posi-
tion where the roller comes into contact with the inner
mast.
The direction for turning the pins on the left and right
sides are the same as illustrated.
2. The pin on the right side is punched with punched "R"
mark while the one on the left side has no mark.
3. As the pin on the right and left sides use lefthand

screw and righthand screw, respectively, the set nut
tightening direction is the same as the roller pin turning
direction in step 1 above.
12-37
[Point 31
Removal: SST 09810-201 72-71

MAST DISASSEMBLY-INSPECTION-REASSEMBLY
2 Disconnect the overflow hose and high pressure hose.
3 Remove the cylinder rod end set bolt and disconnect the rod end. [Point 11
4 Remove the cylinder support. [Point 21
5 Remove the cylinder bottom set bolts and remove the lift cylinder.
6 Slide the inner mast in the lowering direction and remove the lift rollers.
7 Remove the mast strip. [Point 31
8 Remove the outer mast.
Point Operations
[Point 1I
Disassembly: Shim adjustment has been made at the lift

cylinder rod end for prevention of cylinder
uneven motion between the left and right
sides. Take a note on which side the shim
adjustment is made and the number of
shims used.
[Point 21
Shim
Disassembly: Take a note on the number of cylinder sup-
port shims used.
Reassembly: When the mast or cylinder is replaced, make

shim adjustment at the cylinder support.
With the cylinder rod end inserted t o the in-
ner mast, eliminate the clearance between
the cylinder support and outer mast by in-
serting shims. The shim thickness should be
slightly thicker.
[Point 31
Inspection: Measure the mast strip thickness.
Thickness limit: 1.5 mm (0.059 in)

LIFT BRACKET DISASSEMBLY.INSPECTI0N.REASSEMBLY(1994.1 - 2000.5)
1 Remove the lift rollers. [Point 11
2 Remove the side rollers. [Point 21
3 Remove the eccentric rollers (OPT). [Point 31
4 Remove the back rest.
Note:
Back rest set bolt tightening torque T = 99.54 - 184.86 N-rn(1015 - 1885 kgf-crn) [73.44 -
136.38 ft-lbf]
12-41
Point Operations
[Point 1I
[Point 21
Reassembly: Do not mistake the side roller mounting di-

rection.
The side where the chamfering radius of the
roller outer circumference shall face the
front side.
[Point 31
Disassembly: The eccentric roller pin set nuts use

lefthand screw on the right side and right-
hand screw on the right side.
Reassembly: Install the eccentric roller pin punched with

the "R" mark on the right side and the one
without a punch mark on the left side.
Reassembly: Keep the eccentric roller pin set nuts not

tightened here and adjust the eccentric roll-
ers after installing the lift bracket on the ve-
hicle.
LIFT BRACKET DISASSEMBLY.INSPECTI0N.REASSEMBLY (2000.6 -)
T = N-m (kgf-cm) [ft-lbfl
Uside roller (STD)
Wls~deroller
1 Remove lift rollers. [Point 11
2 Remove side rollers. (Vehicle W/side rollers) [Point 21
3 Remove the back rest.
Point Operations
[Point 1 I
Disassembly:
SST 09950-40011
Vehicle without side rollers:
Disassembly:
Remove upper roller after removing the roller stop plate.
Reassembly:
Install each roller with the side chamfered with greater ra-
dius facing outward.
Reassembly:
Bring the stop plate into contact with the roller inner ring.
Minimize the clearance between the plate and pin by shim
insertion.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
[Point 21
Reassembly:
Install the side roller in the correct direction.
The side chamfered with a greater radius of the roller shall
be on the front side of the vehicle.
12-44
MAST ADJUSTMENT (V MAST)

Mast Lift Roller Adjustment
lnner
Outer mast
mast
This roller
Bring into contac
1. lnner mast roller clearance adjustment

(1 ) Measure the clearance with the mast overlap at near
450 m m (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller
into contact with the outer mast, and adjust the
clearance between the roller side face and mast at
the closest position on the opposite side t o the fol-
lowing value by inserting the inner mast roller shim.
Standard clearance A = 0 -
0.8 mm
-
(0 0.031 in)
Shim thickness: 0.5 and 1.O mm
(0.020 and 0.039 in)
I
Shim (3) Distribute the shim thickness equally t o the left and
right rollers. (See the "mast roller removal.installa-
tion" section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
This roller
6-Zr
Outer mast
Inner mast
1 2. Outer mast roller clearance adjustment

(1) Measure the clearance with the mast overlap at near
450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller
into contact with the outer mast, and adjust the
clearance between the roller side face and mast at
the closest position on the opposite side t o the fol-
lowing value by inserting the outer mast roller shim:
Standard clearance B = 0 -
0.8 mm
I I
-
(0 0.031 in)
Shim thickness: 0.5-and 1.0 mm
(0.020 and 0.039 in)
I (3) Distribute the shim thickness equally to the left and
right sides. (See the "mast roller removal.installa-
tion" section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
Mast Roller Removal.lnstallation
1. Remove the lift bracket. (See the mast ASSY removal

procedure steps 1 t o 4 on page 12-35.)
2. Jack up the vehicle and support the tires with wooden

blocks. Lock the front and rear tires to prevent rota-
tion.
3. Tilt the lift cylinder.

(1) Remove the hose cover at the bottom of the mast
and disconnect the lift cylinder hose on the LH side.
(2) Remove the lift cylinder bottom set bolts.
(3) Sling the inner mast upper tie beam with a wire and
slightly hoist it.
(4) Remove the lift cylinder rod end set bolts, and dis-
connect the rod end by hoisting the inner mast.
(5) Remove the lift cylinder support.
(6) Tile the lift cylinders LH and RH and tie them with
ropes to the outer mast tie beam.
4. Remove the mast rollers.

I (1) Lower the hoisted inner mast slowly until mast roll-
Shim
ers are visible, and support the bottom with wooden
blocks.
(2) Remove the inner mast rollers and shims.
(3) Remove the outer mast rollers and shims.
5. The installation procedure is the reverse of the removal

procedure.
Shim
Lift Bracket Roller Adjustment (1994.1 - 2000.5)
Bring into contact

11
Outer mast
100 rnm (3.94 in)
bracke;
Inner mast
1. Lift roller and side roller clearance adjustment

( 1 ) Measure the clearance when the center of the lift
bracket upper side roller is 1 0 0 m m (3.93 in) from
the top of the inner mast.
(2) The upper lift rollers need no adjustment because
they are fixed by snap rings.
(3) Measure the clearances at the middle and lower lift
rollers after removing the side rollers.
Shift the lift bracket t o one side t o bring the roller
into contact with the inner mast, and measure the
clearance between the roller side face and the mast
at the closest position on the opposite side t o the
following value by inserting the lift roller shim.
Standard clearance C = 0 -
0.8 mm
-
(0 0.031 in)
(0.020 and 0.039 in)
(4) Distribute the shim thickness equally to the left
and right sides. (For the shim replacement pro-
cedure, see the lift bracket disassembly section
on page 12-40.)
(5) Install the side rollers.
(6) Side roller adjustment shall be made after adjusting

the middle and lower lift rollers.
Bring the side roller on one side into contact with the
mast side surface, and make adjustment by shim in-
sertion to make the clearance between the side
roller and inner mast side surface on the opposite
side satisfy the following standard.
Standard clearace D = 0 -0.6 mm

-
(0 0.024 in)
(0.020 and 0.039 in)
(7) The shim thickness shall be distributed equally in-
to the left and right sides. (Shim replacement is
possible on the vehicle. For the side roller installa-
tion, see the lift bracket disassembly section on
page 12-40.)
2. After the adjustment, the lift bracket should move

smoothly along the overall mast length.
Shim
Lift Bracket Roller Adjustment (Vehicle Without Side Roller) (2000.6 - )
1. Lift roller clearance adjustment
100 mm (3.94 in)
Outer mast
lnner mast
Lift bracket
Other than 1.0 ton
Upperlmiddle lift roller

100 mm (3.94 in)
:,!: 1.0 ton

Outer mast
Inner mast
Lower lift roller
(1) Bring the center of the lift roller in the upper part of the lift
bracket to 100 mm (3.94 in) from the top of the inner
mast.
(2) Adjust the middle and lower rollers.

Shift the lift bracket to one side to bring the roller into
contact with the inner mast and inspect the lift roller clear-
ance at the position on the opposite side where the roller
side is closest to the mast.
Standard
- -
Lower lift roller: C = 0 0.8 mm (0 0.031 in)
- -
Middle lift roller: D = 0 0.8 mm (0 0.032 in)

changing the lift roller shim thickness.

12-50
Distribute shims equally to the left and right rollers.
Middle lift roller
Lower lift roller
(3) Adjust the upper lift rollers after adjusting the middle and
lower lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect the lift roller
clearance on the opposite side where the roller side face
is closest to the mast.
Standard
Upper lift roller: D = 0 - 0.6 mm (0 - 0.024 in)

Shims
Distribute shims equally to the rollers on the right and
left sides.
(See "Lift Bracket Disassembly~Inspection~Reassembly"
for the roller installation.)
(4) After the adjustment, see that the lift bracket moves
smoothly along the overall length of the mast.
, Upper lift roller
12-51
Lift Bracket Roller Adjustment (Vehicle With Side Rollers) (2000.6 - )
1. Middlellower lift roller and side roller clearance adjustment
Inner
::s;lt
mast bracket
1 ton series (exclusive 40-7FB15)

40-7FB20.25
3.J3.5 ton
( i b i
lnner
mast bracket
2 ton series (exclusive 40-7FB20-25)

40-7FB15
(1) 1 ton series (exclusive 40-7FB15), 40-7FB20-25, 3.J3.5

ton:
Bring the center of the side roller in the upper part of the
lift bracket to approx. 100 mm (3.94 in) from the top of
the inner mast.
2 ton series (exclusive 40-7FB20.25), 40-7FB15:
Bring the center of the lift roller in the upper part of the lift
bracket to approx. 100 mm (3.94 in) from the top of the
inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect on the opposite
side the clearance between the roller side face and the
mast where they are the closest. (No adjustment is nec-
essary for the upper lift rollers since they are fastened
by snap rings.)
Standard:
-
C = 0 0.8 mm (0 - 0.031 in)

(4) Distribute shims equally to the left and right side
(5) Install side rollers.
(6) After adjusting the middle and lower lift rollers, bring the
side roller on one side into contact with the outer mast
and measure on the opposite side the clearance between
the side roller and inner mast surface.
Standard:
-
D = 0 0.6 mm (0 - 0.024 in)
changing the side roller shim thickness.
(7) Distribute shims equally to the left and right side. (See
Lift Bracket Disassembly-lnspection-Reassembly sec-
tion for the side roller installation method. Shim replace-
ment is possible on the vehicle.)
(8) After the adjustment, see that the lift bracket moves
smoothly over the entire length of the mast.
Mast Strip Adjustment
Bring into contact
1. Mast strip clearance adjustment

( 1 ) Measure the clearance with the inner mast at the
bottom position.
(2) With the inner mast i n contact w i t h the outer mast
roller, adjust the clearance between the mast strip
and inner mast t o the following value b y inserting
the mast strip shim. (The shim replacement pro-
cedure is the same as that described i n the "mast
roller removal~installation"section on page 12-
46.)
Standard clearance E = 0.5 -

1.0 mm
(0.020 -
0.039 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and
0.039 in)
(3) After the adjustment, the mast should move

smoothly.
CHAIN
INSPECTION
1. Inspect the chain elongation.
SST 09631 -22000-7 1
Note:
When inspecting the chain elongation, use the SST
above and inspect without removal from the vehicle.
Standard chain link pitch
15.88 mm (0.6252 in) (Type: BL534)
REASSEMBLY
V: Lift bracket FV: Lift bracket

and FSV: Inner mast
SV: Lift bracket FSV: Lift bracket
portion
Center of 0 Outside of C] Rear of C]

vehicle
Cot
Sketch
Pin
Install with the cotter pin on the Install with the cotter pin on the Install with the cotter pin on the
vehicle center side. vehicle center side. vehicle front side.
Chain Adjusting Nut Tightening Sequence
1 Tighten nuts @ and a.Tightening torque T = 49.03 - 78.45 (500 - 800 kgf-cm)
-
i36.18 57.88 ft-lbf]
2 Tighten nut @
FV: Front cylinder

Applicable FSV: Front cylinder FSV: Outer mast
mast and V: Outer mast SV: Outer mast (maximum SV: Outer mast (maximum
portion fork height at 2700 mrn fork height at 3000 m m (118
(106 in) or less) in) or more)
Cram Clamp
Sketch
0 0
0
0 0
The clamp is used only for the SV
mast.
12-55
ADJUSTMENT
1 Place the vehicle on a flat ground, and set the mast in the vertical position.
2 After moving the fork up and down several times without a load, check that the chain tension on
the left and right sides are equal.
3 Turn the adjusting nut so that the fork bottom surface is about to come into contact with the
ground surface without slackening the chain.
4 Check the chains for equal tension on the left and right sides.
5 Check that the chains are not twisted.
6 Check that the maximum fork height is as specified.
REMOVAL
1. Loosen the set bolts (OPT) for preventing the fork from
loosening.
Note:
Always set the lever for preventing the fork from loosening
in the horizontal position after it is used.
2. Position the fork at 20 cm (7.9 in) above the ground.

3. Place a wooden block under the notched portiori of the
fork rail.
4. Unlock after lifting the fork stopper pin, and shift the
fork blades one by one to the center.
5. Gradually lower the fork and remove it.

INSTALLATION
The installation procedure is the reverse of the removal pro-
cedure.
INSPECTION
1. Inspect the fork.
Fork tip end limit misalignment: 10 mm (0.39 in)
Note:
If the tip end limit misalignment is exceeded, inspect the
bend, fork mounting looseness and lift bracket finger bar
distortion for each blade.
12-56
SV MAST ASSY
COMPONENTS
12-58
MAST ADJUSTMENT (SV MAST)

Mast Lift Roller Adjustment (SV)
lnner
Outer
mast

(1) Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust
the clearance between the roller and mast at the closest position on the opposite side to the
following value by inserting the inner mast roller shim.
Standard clearance A = 0 - -
0.8 mm (0 0.031 in)
Shim thickness: 0.5 and 1.0 mm ( 0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast move smoothly in the outer mast.
This roller
Inner mast
2. Outer mast roller clearance adjustment

( 1) Measure the clearance with the mast overlap at near 4 5 0 m m (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the outer mast, and adjust
the clearance between the roller side face and mast at the closest position on the opposite side
t o the following value by inserting the outer mast roller shim.
Standard clearance B = 0 - -
0 . 8 mm (0 0.031 in)
(3) Distribute the shim thickness equally t o the left and right sides. (See the mast roller removal.
installation section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
12-60
Lift Bracket Roller Adjustment (SV)
Lower side roller
Middle lift roller
k't
into contact
Outer mast
Inner mast

(1) Measure the clearance when the center of the lift bracket upper side roller is 100 mm (3.94 in)
from the top of the inner mast.
(2) The upper and lower lift rollers need no adjustment because they are fixed by snap rings.
(3) Adjust the clearances at the middle lift rollers as follows: Shift the lift bracket to one side t o
bring the roller into contact with the inner mast, and adjust the clearance between the roller
side face and the mast at the closest position on the opposite side to the following value by
inserting the lift roller shim.
0.8 mm (0 0.031 in) -
(4) Distribute the shim thickness equally to the left and right sides.
(5) Adjust the upper and lower side rollers after adjusting the middle lift rollers. Bring the side roller
on one side into contact with the mast side surface and adjust the clearance between the side
roller and inner mast surface to the following value by inserting the side roller shim.
Standard clearance D = 0 -
0.6 mm (0 0.024 in) -
( 6 ) Distribute the shim thickness equally to the left and right side rollers.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
Mast Strip Adjustment (SV)
Bring into contact

(1 Measure the clearance with the inner mast at the bottom position.
(2) With the inner mast in contact with the outer mast roller, adjust the clearance between the
mast strip and inner mast to the following value by inserting the mast strip shim.
Standard clearance E = 0.5 -1 .O mm (0.020 -

0.039 in)
(3) After the adjustment, the mast should move smoothly.

12-62
FV MAST ASSY
COMPONENTS
12-64
MAST ADJUSTMENT (FV MAST)

Mast Lift Roller Adjustment (FV)
lnner
Outer mast
mast
This roller

(1) Measure the clearance with the mast overlap at near 450 m m ( 17.72 in).
( 2 ) Shift the inner mast t o one side t o bring the roller into contact with the outer mast, and adjust
t o the following value by inserting the inner mast roller shim.
0.8 mm (0 0.031 in)
(3) Distribute the shim thickness equally t o the left and right rollers.
This roller
fi
Outer mast
Inner mast
2. Outer mast roller clearance adjustment

( 1 ) Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust
to the following value by inserting the outer mast roller shim:
0.8 mm (0 0.031 in)
(3) Distribute the shim thickness equally to the left and right rollers.
12-66
Lift Bracket Roller Adjustment (FV)
Lower lift roller
100 m m (3.94 in)
bracket

(1) Measure the clearance when the center of the lift bracket upper side roller is 1 0 0 m m (3.94 in)
from the top of the inner mast.
(2) The upper and middle lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift roller, shift the lift bracket t o one side t o bring the roller into contact w i t h the
inner mast, and adjust the clearance between the roller side face and the mast at the closest
position on the opposite side t o the following value by inserting the lift roller shim.
0.5 mrn (0 0.020 in) -
(4) Distribute the shim thickness equally t o the left and right sides.
(5) Adjust the side rollers after adjusting the lower lift rollers. Bring the side roller on one side into
contact with the mast side surface and adjust the clearance between the side roller and inner
mast on the opposite side t o the following value by inserting the side roller shim:
0.6 mm (0 0.024 in) -
Shim thickness: 0 . 5 and 1.0 mm (0.020 and 0.039 in)
(6) Distribute the shim thickness equally t o the left and right side rollers.
12-67
Mast Strip Adjustment (FV)
Bring into contact

(11 Measure the clearance with the inner mast at the bottom position.
(2) With the inner mast in contact with the outer mast roller, adjust the clearance between the
mast strip and inner mast to the following value by inserting the mast strip shim.

1.0 mm (0.020 -
0.039 in)

12-68
FSV MAST ASSY

COMPONENTS
12-70
MAST ADJUSTMENT (FSV MAST)

Mast Lift Roller Adjustment (FSV)
F
Outer mast
Middle mast
lnner mast
This ioller
1. lnner mast roller and middle mast lower roller clearance adjustment
(1) Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast and the mid-
dle mast, and adjust the clearance between the roller side face and mast at the closest position
on the opposite side to the following value by inserting the inner mast roller shim and middle
mast lower roller shim, respectively.
0.8 mm (0 0.031 in)
(3)Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
For the lift bracket roller adjustment procedure on trucks without side rollers, see pages 12-49
to 12-50.
This roller
2. Outer mast roller and middle mast upper roller clearance adjustment
(1 Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the inner mast and middle
mast, and adjust the clearance between the roller and mast at the closest position on the op-
posite side t o the following value by inserting the outer mast roller shim and middle mast upper
roller shim respectively.
0.8 mm (0 0.031 in)
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast and the
middle mast moves smoothly in the outer mast.
12-72
Lift Bracket Roller Adjustment (FSV)
Lower lift roller
Lift bracket

(1) Measure the clearance with the lift bracket at the uppermost position.
(2) The upper lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift rollers, shift the lift bracket t o one side t o bring the roller into contact with the
inner mast, and measure the clearance between the roller side face and the mast at the closest
position on the opposite side t o the following value by inserting the lift roller shim.
0.5 mm (0 0.020 in) -
(4) Distribute the shim thickness equally t o the left and right rollers.
(5) Adjust the side rollers after adjusting the lower lift rollers.
Bring the side roller on one side into contact with the mast side surface, and adjust the clear-
ance between the side roller and inner mast side surface t o the following value by inserting the
side roller shim:
0.6 mm (0 - 0.024 in)
Shim thickness: 0.5 and 1.0 mm (0.020 - 0.039 in)
12-73
Mast Strip Adjustment (FSV)
Bring into contact

( 1 1 Measure the clearance with the inner mast or middle mast at the bottom position.
(2) With the inner mast in contact with the middle mast upper roller, adjust the clearance between
the mast strip and inner mast to the value shown below by inserting the mast strip shim.
Then, with the middle mast in contact with the outer mast roller, adjust the clearance between
the mast strip and the middle mast to the value shown below by inserting the mast strip shim.

1.0 mm (0.020 -
0.039 in)
Shim thickness: 0.5 and 1.0 mm (0.020 -
0.039 in)

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left
and right sides due to tolerances of parts, etc.
The inspection and adjustments must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY, and inner mast SUB-ASSY
1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simulta-
neously with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of
the inner mast shakes at the time of stopping. To
correct this, add shims to the cylinder that stops
first.
2. Adjustment method
(1 Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches
the SST.
SST 09610-22000-7 1
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)
CYLINDERS
Page
LIFT CYLINDER ASSY (1993.1 ^. 1994.1) ..... 13-2
GENERAL .......................................................... 13-2
SPECIFICATIONS ............................................... 13-2
COMPONENTS .................................................. 13-3
TILT CYLINDER ................................................. 13-8
GENERAL .......................................................... 13-8
SPECIFICATIONS ............................................... 13-8
COMPONENTS .................................................. 13-9
LIFT CYLINDER ASSY (1994.1 ^. ) ............... 13-14
GENERAL .......................................................13-14
SPECIFICATIONS ............................................... 13-14
COMPONENTS .................................................. 13-15
REMOVAL.INSTALLATION .................................. 13-16
DISASSEMBLY INSPECTION-REASSEMBLY
(1994.1.2000.1) ........................................ 13-18
13-2
LIFT CYLINDER ASSY (1993.1 - 1994.1)

GENERAL
SPECIFICATIONS
Cylinder type Single-acting type
Cylinder bore m m (in) 45 (1.77)
Piston rod outside diameter mm (in) 35 (1.38)
Piston stroke m m (in) 1 5 0 0 (59.06)
Piston seal type U packing
Rod seal type U packing
13-3
COMPONENTS
6501
CB
p r m r
I 02 K Al
I
m i
91611-41040
01 (RH)
6501 -038C
13-4
Removal Procedure
1 Remove the chain and chain wheel.
3 Disconnect the cylinder rod end, and set the SST. [Point 11
5 Remove the lift cylinder ASSY.
Note:
Adjust the lift chain tension equally on the left and right sides.
Repeat full stroke lifting and lowering without any load to bleed the air and check if movements are
normal.
After the movement check, inspect the hydraulic oil level.
If a part of the lift cylinder ASSY, etc. is replaced, it is necessary to check and adjust uneven move-
ments of lift cylinders. See page 12-31 for the inspection and adjustment methods.
13-5
Point Operations
[Point 1I
Removal: SST 09610-22000-71

DISASSEMBLY . INSPECTION . REASSEMBLY
2 2
3 8 3
1 Overflow hose
LH RH
1 Remove the overflow hose.
2 Remove the lift cylinder cover.
3 Remove the cylinder rod. [Point 11
4 Remove the rod guide.
5 Remove the wear ring, back up ring and U packing.
6 Remove the flow regulator valve ASSY.
7 Remove the safety down valve ASSY.
8 Remove the lift cylinder. [Point 21
The reassembly procedure is the reverse of the disassmbly procedure.
Note:
Before reassembly, coat hydraulic oil on each part.
Replace O-rings, U-packing and dust seals with new ones at the time of reassembly.
Coat liquid packing (08833-00080) on the threaded portion of the cylinder cover before reassembly.
Point Operations
[Point 1I
Inspection: Measure the piston rod outside diameter.

Standard outside diameter: 3 5 mm (1.38 in)
Wear limit: 34.92 mm (1.3748 in)
Inspection: Measure the bend of the piston rod.

Piston rod bend limit: 2.0 mm (0.079 in)
[Point 21
Inspection: Measure the tilt cylinder bore.

Standard bore: 4 5 mm (1.77 in)
13-8
TILT CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double acting
Cylinder bore mm (in) 7 0 (2.76)
Piston rod outside diameter mm (in) 3 0 (1.18)

Piston stroke mm (in) 6 6 (2.60)
Piston rod seal type U packing
COMPONENTS
13-10
Removal Procedure
1 Slightly hoist the mast.
2 Remove the front pin [Point 1I
3 Disconnect the hose.
4 Remove the rear pin.
5 Remove the tilt cylinder.

Note:
Check if the rod joint length is the same as that at the time of removal.
Raise the fork by approx. 200 mm (7.87 in). Inspect and adjust the forwardlbackward tilt angle.
Put a match mark (with red paint) on the joint and rod.
Slowly tilt the mast a few times to check movement.
Check the hydraulic oil level, and add if insufficient.
Coat MP grease where the front and rear pins are inserted.
Tilt the mast fully forward and backward to confirm no uneven movements between the left and right
sides.
Point Operations
[Point 1I
Removal: SST 09810-201 72-71

13-12
DISASSEMBLY . INSPECTION . REASSEMBLY T= N.m (kgf-cm)[ft-lbf]
1 Remove the rod joint.
2 Remove the top cover, and extract the rod wlpiston. [Point 11
3 Remove the guide. [Point 21
4 Remove the piston wlpiston rod.
5 Remove the rod. [Point 31
6 Remove the cylinder. [Point 41

Note:
Coat hydraulic oil on each part before reassembly.
Replace O-rings, U-packings and dust seals with new ones at the time of reassembly.
Coat liquid packing (08833-00080) on the threaded portion of the cylinder cover.
when installing the rod guide, wrap the threaded portion of the piston rod thinly with vinyl tape and
slowly insert the rod to prevent sealing parts from being damaged.
Point Operations
[Point 11(1993.1 - 2000.1)
Disassembly.Reassembly: SST 09620-10110-71
[Point 21 (2000.2 - )
Disassembly Reassembly: SST 09620-10110-71
[Point 31

Standard piston rod outside diameter:
30.00 mm(1.1811 in)
Piston rod wear limit:
29.92 mm (1.I780 in)

Piston rod bend limit:
1.0 mm (0.039 in)
[Point 41

Standard tilt cylinder bore:
70.0 mm (2.756 in)
Tilt cylinder bore wear limit:
70.35 mm (2.7697 in)
13-14
LIFT CYLINDER ASSY

GENERAL (1994.1 - )
SPECIFICATIONS
Cylinder type Single-acting type
Cylinder bore mm (in) 4 5 (1.77)
Piston rod outside diameter mm (in) 35 (1.38)
Rod seal type U packing
With flow regulator valve (RH)
Others
With safety down valve (LH)
13-15
COMPONENTS
13-16
1 Lift bracket
Removal Procedure
1 Remove the lift bracket. (See removal procedure steps 1 t o 4 in mast removal-installation section
on page 12-35.)
2 Remove the cylinder rod end set bolt and cylinder bottom set bolt.
3 Disconnect the cylinder rod end. [Point 11
5 Disconnect the hose.
6 Remove the lift cylinder support. [Point 21
7 Remove the lift cylinder ASSY.
Note:
Perform the following operations after installing the lift cylinder:
Repeat lifting and lowering to stroke ends without load to bleed the air and t o check normal opera-
tion.
After the operation check, check the hydraulic oil level and add oil if insufficient.
Inspect t h e lift cylinders for uneven movements and make adjustment if necessary. (See t h e lift
cylinder r o d shim adjustment section on page 12-74.)
Point Operations
[Point 1I
Removal: Hoist the inner mast (middle mast) and set the
SST to the inner mast (middle mast) tie beam.
SST 09610-22000-71
Removal: Shim adjustment is made at the lift cylinder rod

end to prevent uneven movements of the lift
cvlinders RH and LH. Take a note on which side
the adjustment is made and the number of
shims used.
[Point 21
Installation: The cylinder support shall be tightened tem-

porarily here and make shim adjustment after
rod end connection.
Adjustment: With the rod end connected, insert shims be-

tween the cylinder support and outer mast to
eliminate the clearance. The shim thickness
shall be slightly on the thicker side.
13-18
DISASSEMBLY-INSPECTION-REASSEMBLY (1994.1 - )
Note:
Oil will leak if the U packing or dust seal at the rod guide portion is defective.
Natural drop will occur if the U packing at the piston portion is defective.
1 Remove the cylinder cover.
2 Remove the rod guide.
3 Remove the piston rod. [Point 11
4 Remove seals from the piston side.
5 Remove the flow regulator valve or safety down valve.
6 Remove the lift cylinder. [Point 21
Note:
Do not install dry parts but apply hydraulic oil before reassembly.
Apply liquid packing (08833-00080) on the threaded portion of the cylinder cover before tightening.
Cylinder cover tightening torque T = 284.39 - -
421.69 N.m (2900 4300 kgf-cm) [209.82 - 311.11
ft-lbf]
Point Operations
[Point 1I

Standard outside diameter: 35 mm (1.38 in)

Piston rod bend limit: 2.0 mm (0.079 in)
[Point 21

Standard bore: 45 mm (1.77 in)
OIL PUMP
Page
OIL PUMP ASSY ............................................... 14-2
GENERAL .......................................................... 14-2
SPECIFICATIONS ........................................ 14-2
COMPONENTS ................................................. 14-3
TEST PROCEDURE ............................................ 14-8
POWER STEERING PUMP ASSY ...................... 14-9
GENERAL .......................................................... 14-9
SPECIFICATIONS ........................................... 14-9
COMPONENTS .................................................. 14-9
14-2
OIL PUMP ASSY

GENERAL
112 pitch
-- --
Displacement between front
and rear gears
SPECIFICATIONS
Vehicle type
5FBE10.13-15 5FBE18.20
Item
Oil pump type DGP4-16C DGP4-14C
Discharge (1500 rpm) &'/min (USgalImin) 22.0 (5.81) 19.6 (5.17)
Theoretical discharge cc (in3)/rev 16.0 (0.976) 14.2 (0.867)

Driving by direct coupling e
Drive method with the motor
COMPONENTS
Removal Procedure
Remove the battery hood.

Remove the RR panel.
Remove the panel.
Disconnect the inlet hose and high pressure hose.
Disconnect the motor wiring.
Hoist the motor slightly. [Point 1I
Remove the motor wloil pump.
Disconnect the motor and oil pump.
Note:
Coat paste lubricant containing molybdenum disulfide on the pump spline before installation.
Clean the surface for mounting the fitting to prevent damage on the O-ring.
Point Operations
[Point 1I
Removal: SST 09090-10260-7 1

DISASSEMBLY . INSPECTION - REASSEMBLY
1 Remove the cover. [Point 11
2 Remove the mounting flange.
3 Remove the backing ring, bushing seal and body seal.
4 Remove the gear & bushing set. [Point 21
5 Remove the oil seal.
6 Remove the body. [Point 31
Note:
Wash the parts, blow them with compressed air and reassemble them after applying hydraulic oil.
Always use new seals after disassembly.
14-6
Point Operations
[Point 1 I
Disassembly: Put a match mark.
[Point 21
Inspection: Measure the body bore.
Limit: 39.180 mm (1.54252 in)

-To outlet
Inspection: Measure the flaw on the body inside surface.
Flaw depth limit: 0.1 mm (0.004 in)
Longitudinal Inspection: Measure the side bushing bore.

bushing length
Limit: 19.123 mm (0.75287 in)
Inspection: Measure the bushing length in axial direction.
Inside Limit: 14.77 mm (0.5815 in)

diameter
Inspection: Measure the center bushing bore.
Limit: 19.123 mm (0.75287 in)
Inspection: Measure the center bushing length in axial

direction.
Limit: 29.68 mm (1 . I 6 8 5 in)
Inspection: Measure the gear shaft outside diameter
Limit: 18.935 mm (0.74547 in)

[Point 31
Inspection: Measure the gear contact trace on the suction

side body inner surface.
Limit:
Contact trace exceeding half of the circum-
ference
TEST PROCEDURE
Note:
A bench test is required for a strict inspection, but it is impossible in an actual service. Install the oil
pump on the actual vehicle and judge the properness of the oil pump state by checking the cylinder
operation.
1. Check on the display if the battery charge is sufficient.
2. Check if the oil control valve relief pressure is as specified.
3. Raise the hydraulic oil temperature t o 50-55OC (122-1 3 1 OF), and measure the lift cylinder full stroke
operation time calculate the lifting speed.
Lifting Speed Table

V-SV Masts Unit : mmlsec (fpm)
Lifting speed mm/s

Vehicle model
No load Loaded
5FBE10 500 (99) 320 (63)
5FBE13 500 (99) 300 (59)
5FBE15 500 (99) 280 (55)
5FBE18 480 (91 250 (49)
5FBE20 480 (91 250 (49)
FV.FSV Masts
Lifting speed mm/s
Vehicle model No load Loaded
FV FSV FV FSV
5FBE10 390 (77) 460 (91) 240 (49) 280 (55)
5FBE13 390 (77) 460 (91) 230 (45) 260 (51)
5FBE15 390 (77) 460 (91) 220 (43) 240 (47)
5FBE18 350 (69) 410 (81) 190 (37) 220 (43)
5FBE20 350 (69) 410 (81) 190 (37) 220 (43)
POWER STEERING PUMP ASSY
GENERAL
SPECIFICATIONS
Pump type TCP-031 -C
Discharge (1500 rpm) elmin (USgalImin) Approx. 5.5 (1.45)
Theoretical discharge cc (in3)/rev 4.0 (0.244)
COMPONENTS
Rear tor board . front
Removal Procedure
1 Remove the side cover RH.
2 Remove the rear tor board and front tor board.
3 Disconnect the power steering motor wiring.
4 Disconnect the suction hose.
6 Remove the power steering motor Wlpower steering pump.
7 Disassemble the power steering motor and power steering pump.
Note:
Coat paste lubricant containing molybdenum disulfide on the oldham joint before installation.
OIL CONTROL VALVE
Page
GENERAL ........................................................... 15-2
SPECIFICATIONS ................................................ 15-3
HYDRAULIC CIRCUIT ......................................... 15-3
COMPONENTS .................................................... 15-4
OIL CONTROL VALVE ASSY ............................. 15-5
REMOVAL.INSTALLATION .................................... 15-5
DISASSEMBLY.INSPECTION.REASSEMBLY ............. 15-6
RELIEF PRESSURE ADJUSTMENT ..................... 15-8
OIL CONTROL VALVE LINK ............................... 15-9
COMPONENTS .................................................... 15-9
15-2
GENERAL
Oil Control Valve Sectional View (in Neutral State)
Body Check valve
Relief Valve Sectional View
Lift relief valve
Tilt relief valve

SPECIFICATIONS
Outside diameter mm (in) 16
Spool
Surface treatment Hard chromium plating
Spool stroke mm (in) 7
Lift 17160 (175) [2490]

Relief pressure Tilt 13730 (140) [I9901
kPa (kglcmz) Ipsil
-
3-~p00l CSPOOI 13730 (140) 119901
HYDRAULIC CIRCUIT
Steering oil pump
Steering pump motor

15-4
COMPONENTS
15-5
OIL CONTROL VALVE ASSY

REMOVAL INSTALLATION
Removal Procedure
3 Remove the pin.
4 Remove the oil control valve ASSY.
Note:
Check the hydraulic oil level, and add oil to the specified level if insufficient.
Coat grease on the oil control valve lever link.
DISASSEMBLY INSPECTION REASSEMBLY
Note:
Select a clean location for operation.
As every component part is finished with high precision, carefully operate during disassembly to pre-
vent any damage.
T=N.m (kgf-cm) [ft-lbfl
1 Remove the seal holder.
2 Remove the spring cover.
3 Remove the lift spool and tilt spool.
4 Disassembly the lift spool and tilt spool. [Point 11
5 Remove the tilt relief valve.
6 Remove the lift relief valve.
7 Remove the check plunger.
8 Remove the outlet housing.
9 Remove the valve seat.
Note:
Before reassembly, thoroughly wash each part, blow compressed air and coat hydraulic oil.
15-7
Point Operations
[Point 1I
Disassembly: SST 0961 0-1 01 60-71

RELIEF PRESSURE ADJUSTMENT
Note:
Always make adjustment according to the following procedure. Random adjustment may generate
a high pressure to damage the oil pump and other hydraulic equipment.
No adjustment is required when the relief valve is not disassembled or is replaced with a new one.
1 Remove the plug (9116- 18UNF-2B)on top of the oil control valve, and install an oil pressure gauge.
Oil pressure gauge: Pressure resistance at 19610 kPa (200 kgf/cm2, 2840 psi) or more.
2 Loosen the lift relief valve adjusting screw.

Loosen the lock nut, and loosen the adjusting screw to a degree not coming off from the body.
3 Adjust the hydraulic pressure.

(1) Turn the key switch to ON.
(2) Set the lift lever slowly to the lift position, and tighten the adjusting screw gradually before the
fork starts to rise.
(3) Lift the fork fully t o the maximum height, and read the hydraulic pressure at the position. Tight-
en the adjusting screw so that the pressure at the time becomes normal.
(4) Tighten the lock nut and check the hydraulic pressure again.
4 Adjust the tilt relief valve hydraulic pressure.
Note:
Follow the same procedure as that for lifting.
Tilt the mast fully backward when measuring the hydraulic pressure.
Tilt relief valve
Pressure check plug
Relief Pressure Table kPa (kgf/cm2) [psi]

5FBE 10,13,15,18,20
Lift 17160 (175) I24901
Relief pressure
Tilt 13730 (140) [I9901
OIL CONTROL VALVE LINK
COMPONENTS
APPENDIX
Page
SST LIST ........................................ 16-2
SERVICE STANDARDS LIST .................... 16-4
CONNECTOR DRAWING
[FOR OTHER THAN U.S.A.] ................... 16-12
CONNECTOR DRAWING
[FOR U.S.A.] .................................. 16-30
CPU BOARD & DC/SD BOARD
CONNECTOR DRAWING (Harness side) ..... 16-47
CONNECTING DIAGRAM
CONNECTING DIAGRAM
[FOR U.S.A.] .................................. 16-58
WIRING DIAGRAM
WIRING DIAGRAM [FOR U.S.A.] ............... 16-63
16-2
SST LIST
Section
Part Name
2 2A 4 5 6 6A 7 7A 8 9 9A 12 13 15
Part No.
Illustration
09316-00011 Pipe replacer 0
Transfer bearing
09316-12010
replacer
0
L) ., , ,, 09523-36010
Rear axle hub
guide tool
0
0 09527-17011
Rear axle shaft
bearing remover
0
Differential
09550-5501 1
replacer set
0
Steering wheel
09609-20011 0
puller
4 09717-20010
09950-40011
Brake shoe
return spring
remover
Universal
0 0
(09950-40010)
puller
0 0 0 0
&@ p o : .
(09950-20017)
/ \
*$5 09950-40010 Puller B set 0 0
lsbe*%d*
09950-60010 Replacer A set 0
@ OOQO,,
09950-60020 Replacer B set 0 0
&/ 09950-70010 Steering

wheel set
0 0
4 09010-10260-71 Motor hook 0

Section
Part Name
2 2A 4 5 6 6A 7 7A 8 9 9A 12 13 15
Part No.
Front axle hub

09340-10410-71
oil seal replacer
09370-10410-71
nut remover
s* 09430-12240-71
Rear axle shaft
bearing replacer
0
09610-10160-71
09610-22000-71
3" q~mF- ''a Chain wear

O
""..-
09631-22000-71
.' >7'-77-, scale
Joint pin
09810-20172-71 0 0
remover
16-4
SERVICE STANDARDS LIST

BATTERY
Specific gravity full discharge (at 20°C) (68OF) 1.280
Specific gravity at the end of discharge (at 20°C) (68OF) 1.150
Insulation resistance 1 MQ or more
*
CONTROLLER
@ and @ represent the positive (red) probe and negative (black) porbe of the circuit tester
All models from January 1993 to August 1998
U.S.A. specifications as from September 1998
CPU board & DC-SD board See text (page 2-1 8)
PS controller See text (page 2-47)
Display See text (page 2-28)
F1 (Drive fuse) A 225 (48 V spec.) 275 (36 V spec.)
F2 (Pump fuse) A 225 (48 V spec.) 275 (36 V spec.)
F3 (Power steering fuse). A 50
F4 (Lamp fuse) . A 10
F5 (Control circuit fuse) A 10
D O s@ 00
TM-TMP - 0 0 So 00
conduction Q Do GO 00
Tester range 0 0 G@ Conduction

( QxlK ) GO s@ Conduction
G O SQ 00
DF 1 -DF2,.DF2, Foward Anode @ probe - Cathode @ probe : About 3

conduction KQ
(Tester range Q x 1 K) Reverse Anode @ probe - Cathode @ probe : 00
DF3 (with material handling Foward Anode @ probe - Cathode @ probe : About 3
chopper) conduction Kfl
(Tester range Qx IK) Reverse Anode @ probe - Cathode @ probe : 00
DAD-DAP Foward Anode @ probe - Cathode @ probe : About 6
conduction KQ
(Tester range Q x IK) Reverse Anode @ probe - Cathode @ probe : a,
When the tester probes are brought into contact with the
CADCAP conduction Q CAD and CAP terminals, the pointer initially diflects, then
(Tester range Qx IK) gradually returns until it finally indicates co.
(As CAD and CAP is charged by the current from the tester.)
MFR.MFL.MRR.MRL.MP
Coil resistance n 20 (20°C) (68OF)
(Tester range Qx 1)
RADaRAP resistance
(Tester range Qx 1)
n 1.5~
A ~ O U
OCL value 4 6 0 2 7,: (48 V Spec.)

(Drive circuit)
A
610 * 6 0 (36 V Spec.)
Tightening torque N.m (kgf-cm) [ft-lbfl
Control panel
M5 2.16 - 2.75 (22 - 28) 11.59 - 2.031
1.18 - 1.77 (12 - 18) 10.87 - 1.301
For harness set
TMmTMP M4
For mounting M5 2.16 - 2.75 (22 - 28) [ I.59 - 2.031
For harness set M6 3.14 - 3.73 (32 - 38) 12.32 - 2.751
5.10 - 5.69 (52 - 58) 13.76 - 4.201
DFI
For mounting M6
For harness set M6 2.1 6 - 2.75 (22 - 28) 11.59 - 2.031
13.44 - 14.02 (137 - 143) 19.91 - 10.351
DF3
For mounting MI2
DAD -DAP For mounting M6 2.16 - 2.75 (22 - 28) 11.59 - 2.031
Heat sink For mounting M5 2.16 - 2.75 (22 - 28) [ I.59 - 2.031
Set nut for external connection terminal M8 7.85 - 11.77 (80 - 120) 15.79 - 8.681
Contactor panel N.m (kgf-cm) [ft-lbfl

MFL.MFR Terminal set nut M8 7.85 - 11.77 (80 - 120) 15.79 - 8.681
MRL.MRR
MP For mounting M5 2.16 - 2.75 (22 - 28) 11.59 - 2.031
For harness set M6 2.16 - 2.75 (22 - 28) 11.59 - 2.031
21.28 - 21.87 (217 - 223) 115.70 - 16.131
DF2,-DF2,
For mounting M 20
Heat sink For mounting M5 2.16 - 2.75 (22 - 28) 11.59 - 2.031
Set nut for external connection terminal M8 7.85 - 11.77 (80 - 120) 15.79 - 8.681
Power steering circuit
For harness set M5 1.96 - 2.94 (20 - 30) [ I.45 - 2.171
1.96 - 2.94 (20 - 30) 11.45 - 2.171
TMps
For mounting M5
-
For other than U .S.A. specifications as from September 1998

(models with power MOS FET)
CPU board See text (page 2A-30)
PS controller See text (page 2-47)
Display See text (page 2-28)
F1 (Drive circuit fuse) A 225
F2 (Material handling circuit fuse) A 225
F3 (Power steering fuse) A 50
F4 (Lamp fuse) A 10
F5 (Control circuit fuse) A 10
DO-S@ ca
DO-S@ 3
.=a
TM D.TMP kR D@-G@
[Tester range: R x 1kl DO-G@ Ca
oo
GO-S@
GO-S@ m
Forward
Cathode @ - Anode @ : Approx. 3
DFI.DF~R.DF~~.DF~ kR direction
[Tester range: 52 x Ik l Reverse
cathode @ - node @ : 00
direction
When the tester probes are brought into contact with
On the CA terminals, the pointer initially deflects,
CA kR
snubber board then gradually returns until it finally indicates R.
[Tester range: R x Ik] (The pointer indicates m R because the capacitor
TP9-TN1
is charged by the current from the tester.)
Forward TP9 (Cathode)@ probe - TDAD (Anode)@ probe:
DAD kR direction Approx. 2.5
[Tester range: R x 1kl Reverse TP9 (Cathode)@ probe - TDAD (Anode) @ probe:
direction Approx. 10
Forward TP9 (cathode)@ probe - TDAD (Anode) @ probe:
DAP kR direction Approx. 2.5
[Tester range: R x Ik l Reverse TP9 (Cathode)@ probe - TDAD (Anode) @ probe:
direction Approx. 20
MFR.MFL.MRR.MRL.MPcoil resistance R
[Tester range: 52 x Ikl Approx. 20 (20°C)
RA kR
Approx. 0.8
[Tester range: R x Ik l
OCL value (Drive circuit) A 460
Tightening torque N.m(kgf-cm) [ft-lbfl
Control panel
M5: 2.5 f 0.5 (25 f 5) i1.8 f 0.41
Main terminal -
TM D.TMP M4: 1.5 f 0.5 (15 + 5) i1.1 f 0.41
For mounting M5: 2.5 + 0.5 (25 f 5) [ I .8 + 0.41
Main terminal M5: 2.5 f 0.5 (25 f 5) [1.8 f 0.41
DF1 . DF3
For mounting M5: 2.5 f 0.5 (25 f 5) [1.8 f 0.41
Heat sink For mounting M5: 2.5 f 0.5 (25 f 5) [ I .8 f 0.41
Set nut for external connection terminal M8: 9.8 f 2 (100 f 20) [7.23 f 1.41
Controler panel
Main terminal M5: 2.5 f 0.5 (25 f 5) 11.8 f 0.41
DF~R.DF~~
For mounting M5: 2.5 f 0.5 (25 f 5) 11.8 f 0.41
MFR.MFL. Main terminal M8: 9.8 f 2 (100 f 20) l7.23 f 1.41

MRR.MRL.MP For mounting M5: 2.5 f 0.5 (25 f 5) [1.8 f 0.41
Heat sink For mounting M5: 2.5 f 0.5 (25 f 5) 11.8 f 0.41
Set nut for external connection terminal M8: 9.8 f 2 (100 f 20) 17.23 f 1.41
Accelerator Potentio-Meter
Clearance between accelerator link 1.0 mm (0.039 in) Switch must be turned off.
stopper and bracket 2.0 mm (0.079 in) Switch must be turned on.
Tightening torque for set-screw N.m(kgf-cm)[ft-lbf] 1.57 - 2.35(16- 2 4 ) [ 1 . 1 6 - 1.741
Brake Switch (LS,)

,
I Switch roller end projection out of switch bracket

mm (in)
1 26 (1.02)
1
Non-manipulation 0
Switch ON, OFF (Continuity) Q
With manipulation 00
Brake pedal depression and switch ON-OFF

Q 1 0 mm (0.39 in) O-rw
(Conduction)
Parking Brake Switch (SW,,)

Non-manipulation 0
Switch ON, OFF (Continuity)
With manipulation Q
*
MOTOR
)rive Motor
Armature coil insulation resistance More than 1 MQ
Commutator outside Standard 8 0 (3.15)
diameter mm (in) Limit 7 5 (2.95)
Standard 1 .O (0.09)
Undercut mm (in)
Limit 0.3 (0.01 2)
1
Field coil conduction Q
E- F 0
(Tester range Q x 1K)
Field coil insulation
Yoke E-F More than 1 MQ
resistance
Standard 32 (1.26)
Brush length mm (in)
Limit 1 4 (0.55)
Brush pressure N (kg) [Ibl 11.8 (1.2) i2.61
I Brush holder insulation resistance 1 More than 1 MQ I
Pump Motor
Armature coil insulation resistance More than 1 Mi2
Commutator outside Standard 8 0 (3.1 5)
diameter mm (in) Limit 7 5 (2.95)
Standard 1.O (0.039)
Undercut mm (in)
Limit 0.3 (0.01 2)
Field coil conduction 62
E- F 0
(Tester range 62 x 1K)
I Field coil insulation

Resistance
I
I
I
Yoke * E-F More than 1 M62
Standard 3 2 (1.26)
Limit 1 4 (0.55)
I Brush ~ressure N (ka) llbl I 11.8 (1.2) 12.61
Brush holder insulation resistance More than 1 M62
Power Steering Motor

Armature coil insulation resistance More than 1 MQ
Commutator outside Standard 50 (1.97)
diameter mm (in) Limit 45 (1.77)
Standard 0.8 (0.031
Undercut mm (in)
Limit 0.3 (0.01 2)
Standard 25 (0.98)
Limit 1 4 (0.55)
Standard 5.59 (0.57) I1.261
Brush pressure N (kg) [Ibl -
Limit 2.75 (0.28) [0.6171
Brush holder insulation resistance More than 1 M62
FRONT AXLE & TRANSMISSION

735 (7.5) [I071 (1.0 ton) (1993.1 -1998.1)
Front tire air pressure kPa (kgf/cm2) [psi] 780 (8) [I101 (1.0 ton) (1998.2 -1
880 (9) 11301(1.3, 1.5, 1.8, 2.0 ton)
Front axle hub stating force N (kg) [Ibl 59 - 8 8 ( 6 - 9) t13 - 201
Clearance between speed sensor and gear mm (in) 0.5 - 2.5 (0.020 - 0.098)
Tightening torque' N.m (kgf-cm) [ft-lbfl
Front wheel hub nut 107.87- 147.10 (1100 - 1500) [79.59 - 108.531
Divided rim set nut 78.45 - 117.68 (800 - 1200) [57.88 - 86.821
Mission cover set bolt 29.42 - 44.13 (300 - 450) [21.71 - 32-56]
16-9
REAR AXLE
735 (7.5) [I071 (1.O ton) (1993.1 1998.1) -
780 (8) [I 101 (1.0 ton) (1998.2 -1
Rear tire air pressure kPa (kgf/cm2) [psi] 880 (9) [I301 (1.3 ton)
834 (8.5) I1211 (1.5, 1.8 ton) (1993.1 -
1998.1)
780 (8) [I101 (1.5, 1.8, 2.0 ton) (1998.2 -1
69 -
137 (7 -
14) [15 - 311 (5FBE10, 13)
Rear axle ASSY starting force N (kg) [Ibl 78 - 147 (8 - -
15) 118 331 (5FBE15, 18,201
Rear axle hub starting force N (kg) [Ibl 49 - 7 8 ( 5 - 8) [ I 1 - 181
Tightening torque N.m (kgf-cm) Ift-lbfl
Rear wheel hub nut 1 107.87 - 147.10 (1100 - 1500) 179.59 - 108. 531
STEERING
Play of steering wheel mm (in) 20 - 4 0 (0.79 - 1.57)
Relief valve set pressure kPa (kgf/cm2) [psi] 7850 - 8530 (80 - 87) [ I140 - 12401
Steering valve screw 254.97 - 284.39 (2600 - 2900) i188.11 - 209.821
Steering Cylinder
Standard 55 (2.17)
Steering cylinder bore mm (in)
Limit 55.35 (2.1791)
BRAKE
Foot Brake
Standard 5 (0.197)
Brake pad thickness m m (in)
Limit 1 .O (0.039)
Disk brake wheel
m m (in) Limit 8.5 (0.335)
thickness
Disk brake wheel runout m m (in) Limit 0.12 (0.0047)
Brake Pedal
Brake pedal height (without pad) mm (in) 135 - 140 (5.31 - 5.51
Brake pedal play mm (in) 10 * 3 (0.39 * 0.12)
Parking Brake
Number of parking brake lever notches 4- 6
(operating force) (294 N (30 kg) [66 Ibl)
Deviation of cable fixture m m (in) Within 3 (0.12) (1998.2 -1
Natural drop mm (in)/15 min 90 (3.54)
Natural forward tilt mm (in)/15 min 30 (1.18)
Lift cylinder oil
leak amount
(all lift port)
6 - 16 (0.37 - 0.98)
Oil leak cc (cu-in)/min
test Tilt cylinder oil
leak amount
(total of lift and tilt)
14 - 34 (0.85 - 2.07)
cc (cu-in)/min
MAST
Fork
-
Individual fork bending limit mm (in) 15 (0.59)

Fork tip misalignment limit mm (in) 10 (0.39)
CYLINDER
Lift Cylinder
Standard 45 (1.77)
Lift cylinder bore mm (in) V mast
Limit 45.20 (1.7795)
Lift cylinder rod Standard 35 (1.38)
V mast
diameter mm (in) Limit 34.92 (1.3748)
Lift cylinder rod bending limit mm (in) 2.0 (0.079)
Tilt Cylinder
?
Standard 70 (2.26)
Tilt cylinder bore mm (in)
Limit 70.35 (2.7697)
Standard 30 (1.18)
Tilt cylinder rod diameter mm (in)
Limit 29.92 (1.1780)
Tilt cylinder rod bending limit mm (in) 1 .O (0.039)
Tilt cylinder cover 219.67 - 407.96 (2240 - 4160) f162.06 - 300.981
Piston rod joint set bolt 60.90 - 1 13.17 (621 - 1 1 54) i44.93 - 83.491
Castle nut 225.55 - 284.39 12300 - 2900) I1 66.41 - 209.821
OIL PUMP
Body inside diameter mm (in) Limit 39.180 (1-54252)
Body interior surface damage depth
Limit 0.1 (0.004)
mm (in)
Side bush inside diameter mm (in) Limit 19.123 (0.75287)
Side bush axial length mm (in) Limit 14.77 (0.581 5)
Center bush inside diameter mm (in) Limit 19.123 (0.75287)
Center bush axial length mm (in) Limit 29.68 ( 1 .I
685)
Gear shaft diameter mm (in) Limit 18.935 (0.74547)
Lifting Speed (V mast)
- 5FBE10 5FBE13 5FBE15 5FBE18 5FBE20

Lifting speed (48 V) Full load 320 (63) 300 (59) 280 (55) 250 (49) 250 (49)
mm/sec (fpm) NO load 500 (99) 500 (99) 500 (99) 480 (91) 480 (91)
Lifting speed (36 V) Full load 290 (57) 270 (53) 260 (51) 210 (41) 210 (41)
mm/sec (fpm) No load 480 (94) 480 (94) 480 (94) 440 (87) 440 (87)
OIL CONTROL VALVE

Relief set pressure Lifting 17160 (175) I24901
kPa (kgf/cm2) [psi] Tilting 13730 (140) [I9901
Tightening torque N.m (kgf-crn) [ft-lbfl
Outlet housing 34.32 - 44.13 (350 - 450) [25.32 - 32-56]
CONNECTOR DRAWING [FOR OTHER THAN 1J.S.A.] (1993.1 - 1998.1
TAB
TAB REC
-
TAB REC
43
REC
TAB REC
TAB REC
aCN
TAB
-
TA B REC
TAB REC
--
TAB REC
Ct'
TAB REC TAB REC
TAB REC
N O P C J N O P C J .
1161G-R .I5V I161G-RCN27-3
2 162 G-Y SSP 2 162 G-Y CN27-2 TAB REC
3 163 G-8 GNO 3 163 G-8 CN27-5
N22-
CN20
TAB REC
TAB REC
O l P I C I J I ~ N O ~ P I C JI
I 11071 B 1 PL. 1 1 1 11071R-B-7.
CN22 &
TAB REC
TAB REC
TAB REC
2 NI 2 NI Y-8 UlM
TAB REC
a TAB
cN
REC
TAB REC
TAB REC
TAB REC
2 5 6 Y
3 51
CN4 1
Il
N O P
iP2li G
TAB
C
2 1 N I l B I
J
FET
sM
] 2 N 1
REC
B BATTB
-
TAB RE
TAB REC 2 1 ps 2 1 NI 15-1
TAB REC
TAB REC
TAB REC
TAB REC
I152 B 1 I52 B CNI-12
CN37
(Joint connector)
1121/11415~61711819110
1111211311141151l6117118119~~0l/l~
REC TAB REC
m]
2 T B T m k l
P C
21TlBlAKRw
J
p s l R I A K R w l
TAB REC
2 V R 7-4
-
-
TAB REC
3 R
TAB REC
2 V B FAN 2 V W 1-1
TAB REC
TAB REC
CN 1 00
TAB REC
El
TAB REC TAB REC
3 P9 RAD
lCN
l8
TAB REC
TAB
laCN1l9
2 PI5
TAB
W
lN: rREC
I s I-;.I
RAP 2 1 PI5 1 G ~ C N17-1
I
LF-LR CN31-I CN12-1
CN3 -2 h N 3 3 - 2
CN3 1-6 N30-I 0 ~ ~ 3 0 - 2
N34-5 CN30-5 CN34-2
m w w (Nl. W)
CN30-8
A3
cN30-9
"J",P cN30-1
( i o a BR)
LF+
( 1 10.
CN34- 3
CN12-2
GR)
CN34-4
( J 11. st)
1 -4
JOINT PORTION OF. REAR HARNESS
CN13-1 CNI 7-1 CNI 4-1 CN 14-2
CN18-3 CN52-2 0413-4 LF-R CN13-5 LF-R

(N1. W l (N1. W l (108- BR) ( 1 10. GR)
CN18-I CN 1 8- 2 CNl-1
sCN120-19 cFCN120-9
0417-5 LF-L 0465-7 CN65-2
( 109. BR) (110. GR) (17.BR) u&H
JOINT PORTION OF FR PILLAR HARNESS Display, charge panel joint
CN4-I CNI 7-5
A
CN30-5
CN30-9N&- 13-5
cN23-2% N24- 2
CN1 6- 4 CN7-1 CN 00-3 CNI- 14
(41. Y ) (N1. W - 8 ) (N1. W - B ) ( 110.R
CN3-1 CN35- 2 P 1 Terminal
CN16-3
A
CN5-I
(101. R)
CN32-2 A N I05-9
( 5 6 R-G) f!lAl
JOINT PORTION OF MAIN HARNESS
CONNECTOR DRAWING [FOR OTHER THAN U.S.A.] (1998.2 - 1998.8)
TAB REC
TAB REC
TAB REC
77 G-Y CNl-8
TAB REC
TAB REC
N O P C J
1 1 60 1 G-W I LS r
2 1 61 1 G-R I LS r
REC
1 N1 W J14
FRY 2 110 GR J15
FRY 3 43 L CN304
TAB REC
TAB REC
8.W LS Y.G CN106-17
2 51 R-L LS s 2 51 R.L CN37-16
TAB REC
TAB REC SSL
TAB REC
SSR
TAR REC
B CN106-16
2 51 B SW ?. 51 R-L CN37-7
REC
- JL
TAB REC
TAB REC
TAB REC
TAR REC
TAB REC
4 1 104 1 R I LC-L I 1 1 104 1

4 G I CN17.2
TAR REC
9 M ACCEL
TAB REC
REC
- SWn
2 162 - SSP
3 161 - SSP OUT CN105-9
51 8 GND
SSP
CN33
TAB REC
TAB REC
107
TAB REC
104 LT-R 104 CN30-2
2 N1 B GND
TAB REC
~ N O ~ P ~ J C 1I
1 108 R-Y CN8-2
2 104 G-R CN37-20
R-G
4 43 BY CN1W-2
51 R-L CN37.19
6 120 Y.R CN24.1

7 107 R-8 CN29-1
8 111 R-L CN5-2
9 110 GR CN17.5
10 109 G.Y CN8.3
TAB REC
152 SLL 152 CN1-12
TAB REC
CN37
(JOINT CONNECTOR)
TAB REC
P21 DM P21 FET
P22 W FET
REC
TAB REC
102 LH-R
TAB REC
102 LH-L 102 CN17.3
TAB REC TAB REC

CN105-2
CN67.1
TAB REC
P21 FET
TAB REC
TRANS
TAB REC
TAB REC
TAB REC
l 1 132 1 V-R I TU I 1 4 1 132 1 Y-R ICN120-5 AC7i.7 CNW-1
2 95 L THR
REC
TAB REC
TAB REC
TAB REC
NO[ P I C I J
1 I 1 I V 1 MrlMPSI
TAB REC
P I 1 7-ZfJ
TAB REC
CN12-1
CN316ECN30-3
CN31.2 f i C N 3 3 . 2
CN31.6 CN30-10 CN30.2 CN34-1 CN333 CN34-5
CN30-5 CN34-2
(1W.P) (104.G) (1M.O) (N1.W
cN34-6'A
Lf.RR CN3D1
CN30.9
LF.LR
LF-RR
CN31.3
CN34.3
CN12-2 CN3M
ACN3O-8
CN31-4
(1MI.0R) (11O.GR) (1 11,SL)
JOINT PORTION OF REAR HARNESS
CN13.1 CN17-1 CN14-1 CN14-2
CN14.3
b CN51-2 CN18.3
b CNU-2 CN13-4 LF-R CN13-5
( I 1O.GR)
LF-R
IN1.W) (N1.W) (1OB.BR)
($
CNl8-1 CN18-2 CN1-1 CNl-l
@ CNlm-19 CNlm-9
CNi7-4 LF-L CN17-5 LF-L

CN657 CN652
(1W.BR) (11O.GR) (17.0R) (16.R)
JOINT PORTION OF FR PILLAR HARNESS DISPLAY.CHARGE PANEL JOlNT PORTION
CN41 CN17-5
CN16-4
A (41.Y)
CN7.1
C N 2 3 . 2 S
CNI
(N1.W-0)
CN17.1 &'cw.2 CN24-2
C~13.1
CN1-14
(NI.W-0)
CN30-9-&CNl3.5
(1 10.GR)
CN35-2 P I TERMINAL
-&
CN3-1
CN16-3
A CN51
(1Ot.R)
CN32-2 A
(56.R-G)
CN1059
CN16.1
(Pl.0)
CNl6.2
JOINT PORTION OF MAIN HARNESS

CONNECTOR DRAWING [FOR OTHER THAN U.S.A.] (1998.9 -)
CN8
REC
TAB REC
NO P C J lc8 SW F 108 R-Y CN13-4.CN301
3 108 G SWF 109 G-Y CN17d.CNS10
Wl R-L CNZ-2 RFEqzj

REC
2 120 B DSFO
3 103 G DSBU
4 40 W-0 DSR CN103.0
5 45 W-BR DSF CN103-7
6 43 R DSFO.DSBU
REC
IUI U
REC
77 G-Y CN1.8
TAB REC
TAB REC
N O P C J
1 60 G-W LS L 1 60 G.W CN103-10
2 61 GR LS T 2 61 G-R CNlOJs
3 1)3 GY LS ~ r r 3 -
63 -
0-0 -
CN103-5
4 51 R-L COM -
4 51 R-L CN37-5
TAB REC
NO P C J
REC
2 110 GR CN10-2 2 110 GR J15
REC
REC
TAB REC 2 104 G CEil4-4 2 101 GR CN37-9
BW LS.
2 51 R-L LS
TAB REC
NO P I C 1 J I INO I P I C I J
TAB REC
TAB REC
N O P
i ;i
1 1 ~ 1 0 3
C J
LF-R 1NO P
1 1 ~ 1 0 8~
I C
~
1
~ C
J
N l 1 3 4
SSR
2 110
1 ;1 1 ;1
NI
104
LF-R
LC-R
LGR 1 1 1 1 1
2 110
Nl
104
CN13-5
cN13-1
CN13-2
1
TAB REC
TAB REC 2 51 R-L CN37-17
51 B SW, 51 R-L CN37-7
TAB REC
103 R-W CN309.CNg-3
TAB REC 8Z 2 N1 W-8 CNlW-1
NO P C J
1 101 R CN5-1
F4 2 P1 B
4 41 Y CUC1,CUlW-16
TAB REC
N O P C J NO1 P 1 C J
TAB REC
NO1 P C J
TAB REC
N O P C J NO P C J
CN261 R-L CN1058

64 GR CN262 €4 YO CN105.1
REC
TAB REC
TAB REC
TAB REC
TAB REC
TAB REC
TAB REC
2 51 - Ls cs
W
2
I N1 0 GND
5 103 LEU-R
6 108 G LF-RR
TAB REC
TAB REC
J
2 56 R-6 J6
51 IWP 3 51 R-L CW7-19
TAB REC
TAB REC
152 SLL 152 CN1-12
TAB REC
TAB REC
56 OVT 56 CN105-5
51 8 GND
TAB REC
J
W{ TAB REC
120 G-Y C.. 2 1 51 I R-L I LSU

TAB REC TAB REC
NOIP c J NO P c J
NO P C J NO P C J
1 95 L N 1 95 L CN68-2
2 S R TU 2 s R
3 R W TU
-
3 R W
TAB REC
WlW-1
TAB REC
NO P C J
TAB REC
2 PU W DM-
TAB REC TAB REC

NO P C J
2 1 N1 W LH-R 95 THR
TAB REC
TAB REC
102 W-L 102 CN17-3 NO P I C ] J I NO P C J
2 N1 W LH-L N1 W JO
TAB REC
TAB REC
CN61-1
CNS1
2 95 L CN€€-2 TU
TAB REC
NO P C J
TAB REC
NO P C J
1 U W
2 V R TRANS
4 W B 4 W TRANS
TAB REC
NO P I C / J N O P C J
TAB REC TAB REC

INO~P I C I J I !NO! P ! C J
TAB REC
I . o ~ P-
I -C I J I h o l P / C / J ]
1 143 - SDTMK 1 143 R-Y CNl-6
TAB REC
1 - I C / 0 / P l C I J 1
12 1U SMTDK 144 RO CNl-S

13 135 CLK 13 135 Y-B C m
TAB REC
CONNECTOR DRAWING [FOR U.S.A.] (1993.1 - 1998.11
TAB REC
@JJ
CN -
TAB REC
TAB REC
TAB REC
N O I P I C I J
11411 - 1 An TAB REC
TAB REC
@CN15 &
TAB REC
2 51 SW 2 51 R CN37-7
TAB REC
TAB REC
2 108 Y
3 109 0
25 @
REC
TAB REC
TAB REC
TAB REC
-
-
TAB REC
- -
TAB REC
TAB
TAB REC
TAB REC
TAB REC
TAB REC
REC
TAB REC
TAB REC
N O I P I C ( J
2 1 ~ l1 e l cur
32
TAB REC
2 56 Y
3 51
@j
REC
TAB REC
TAB REC
TAB REC
N O j P I C I J N O I P I C I J
I 11021 Y I CN17-3
CN37 111021 W 1
2 1 N l l U I
LK
LK 2 1 N l l U 1 J9
(Joint connector)
CN
@g
TAB REC
TAB REC
TAB REC
TAB REC
2 51 LSL2 2 51 R CN37-6
CN4 1
TAB REC
N O I P I C I J
2 1 NI I B 1 Shunt
TAB REC TAB REC
TAB
TAB REC
E P C J ycP C J
I P I 5 GP Ullt? I P I 5 GR RAP
2 P 2 GR 01118-1 2 P 2 GR RAD
3 P 9 GR UllCl 5 P9 GR PAD
mlpt REC
2 P9
TAB
l E kNl:7-2]
W PAD 2 I P9 1 GI) ICNI 17-3
TAB REC
CN13-1 CN17-I CN14-1 CN 1 4-2
-2 CN 1 8-3 CN52-2 CN13-4 LF-R CN 1 3-5 LF-R

(Nl. W l N l . W) (108. BR) ( 1 10. GR)
CN18-I CN 1 8-2
LF-L C N 7-5
~ LF-L
( 109. BR) ( I 10, GR)
FR pillar harness joint
LF-LR CN31-1 CN12-1

CN31-5gN30-3
-2 &N33-2
CN31-6 CN30-I 0 CN30-24N34- 1 CN33-3 N34-5 CN3
CN30-5 CN34-2
( 109. P )
CN34-6
LF-R BcN30-1
( 104. G )
g3
~ ~ 3 0 - 9
LF-
-'
( 103. 0)
CN34-3
CN12-2
CN30-8
(N1. W )
(108. BR) ( 1 10. GR) (111.1

Rear pillar harness joint
CN 1 7-4 CN30-4
N37-1
(109. P ) (43.L)
CN 1 00-4
CNI-lfiC~7-I
JI
CN13-1
CN10 0 - w 2 4 - 2 ~ ~ 1 3 - 1 R~~ CN 17-5
CN3O-lI&N13-5
CN3- 1
CN 1 6-4 CN 1 00- 1 CN23- N30-5 CN1-14 CN17-1

H
(41. Y ) (N1. W ) (N1. W) ( 1 10. GR) (101. R)
PI9-it& CN9-2 CN9-3 CN 1 3-4 CN 1 7-3
CN24- 1 N30-6 CN23-1 AN30-3 N8-2 CN3-3 CN13-3

( P I . 01 ( 120. G - Y ) ( 103. 0) ( 108. BR) (102. Y )
Main harness joint
16-35
CONNECTOR DRAWING [FOR U.S.A.] (1998.2 - 1999.1)
TAB REC
N o I P I C I J
BR CN120.19 l 1 17 1 BR I CN107.6
2 104 G-R CN120.10 CN8
3 144 R.G CN120.12
R CN120.9
5 51 R.L CN2.2
6 143 R.Y CN120.1
REC
Wl
N O P C J
7 141 R.W CN120-2
1 43 L CN37-11
8 77 G.Y CN2.3
2 108 2 108 BR CN30.1
3 109 SWr 3 109 P CN30.10
W-B CNl20-20
TAB REC
TAB REC
TAB REC
2 110 FRY
FRY
CN
TAB REC
TAB REC
l N O l INOI
P I c l J I
1 108 BR J25
2 110 GR J26
3 N1 W CN13-1
G
*I
LC-R 4 104 CN13-2
TAB REC
1101 P l c l J 1
2 51 B sw,
TAR RFC
TAB REC
TAB
REC
1 ~ 0 1P I C I J 1
TAB REC
TAB REC
120 R-W CHI
N1 B CHI
TAB REC
NO^ P I C I J I I N OP~I C I J I
TAB REC
TAB REC
TAB REC
OUT CN105-9
51 B GND 51 CN37-18
TAB REC
107 Lw 107 CN30-7
N1 W L w L a.B z
N O P
1 1 67
TAB
C
1 . I
J
LSar I!%E~ 3 103 0 B,
TAB REC
104 CN30.2
REC
CN37
(JOINT CONNECTOR)
TAB REG
TAB REC
TAR RFC
LSU CN105.2
2 51 R LSL2
TAB REC
P21 FET F3ta-
TAB REC
TAB REC
TAB REC
102 LH a 102 CN13-3
2 N1 W LH a
TAB REC
102 LH L 102 CN17-3
2 N1 W LH
TAB REC
SDTMK
GND
1-
TAR REC
2 141 - SMTOA
MRR
. MFL
- MRL
10 . MP
TAB REC
RAP
CN13-1 CN17-1 CN14.1 CN14.2
CN14-3
d.2 CN51-2 C~(8.3 CN52.2 CN13.4 LF-R ~~13.5
95 LF.R
( N l .W) (N1.W) , (108.BR) (11O.GR)
CN18-1 CNl8-2
J2-j
CN17-4
(109.BR)
LF-L CN17-5 95
(1 1O.GR)
LF-L
JOINT PORTION OF FR PILLAR HARNESS
CN31-6
5 CN30.10 CN302
5 CN34-1
CN3l.5
CN33-3
CN30.3
CN2d-5
CN31-2
CN30.5
CN12-1
CN33.2
CN34-2
(109.P) (104.G) (103.01 (N1.W)
N c
LF-RR
~~30.1
CN30-9
LF-LR
'fc
LF-RR
CN31-3
CN3-3
CN12-2 CN24.4
A
CN30-8
CN31-4
(108.BR) (11O.GR) (11l.SL)
J O l M PORTION OF REAR HARNESS
4
CN17-4
CN30-6 -&
CN30.4
CN1.2
CN37-1
CNB-3 CN30-10 CN1W-2
(1OO.P) (43.L)
cN13.n
CN1W.4 CN13-1 CN17-5
$
CN3.1
CN4-1 CN7-1 c~lw.3 CN24-2
CN16-4
?I
(41.Y)
CN1W-1
CNZ3.2
(N1.W)
CN30-5
CNl-1
IN1.W)
"
CN17-1
1&cN13-5
(11 O.GR)
CN16-3
A(101.R)
CN51
P 1 TERMINAL
cN16.1& cN16-2
CN23.1
5 CN303
CN30-1
ACN13-4
CNB-2 CN3-3A
CN17-3
CN13-3
(P1.0) (103.0) (108,BR) (102.Y)
JOINT PORTION OF MAIN HRNESS

CONNECTOR DRAWING [FOR U.S.A. UL. CANADA] (1999.2 - )
TAB REC
TAB REC
NO P C J NO P C J
1 17 BR CN120-19 1 17 BR CNlE-18
2 104 G CN120-10 2 4 3 L .I8
3 144 GR CN120-12 3 144 GR CNlE-11
TAB REC
N O P C J
TAB REC
NO P C J NO P C J
TAB REC 2 120 B DSFO

3 103 G DSW
J5
4 48 W-0 DSR CNlW-8
5 45 W-BR DSF 45 SL CNlW-7
6 43 R DSFO.DSBU 43 CN37-13
TAB REC TAB REC

NO P C J
TAB REC
TAB REC
2 111 SL CN3C-E
TAB REC
TAB REC
[ N O ~ P I C IJ I [ N O ! P I C I J 1
TAB REC TAB REC
NO P C J
162 G-Y SSP

3 163 G-8 GND
TAB REC
SSL CN104-7
2 83 B SSL 2 83 0 CN1046
TAB REC
1 NO
1 ~108
2
P
110
1 1
C J
LF-R
LF-R
1E
NO
2
P
110
C J
CN13-5
l
IN,OI~; 1
TAB
SSR
J 1 1~ ~ 1 1 REC
c
GR CN104-2
1
TAB REC
NO P C J NO P C J
TAB REC
~NOIPIC! J ~NOIPICI J
TAB REC
2 PI 0 F5
TAB REC
~ N 103
, O R-W
I P ~ C ~ I ~ N
103
, O ~ P
CN30-3
I ; J~ 1
TAB REC
REC
TAB REC
NO P C J NO P C J
TAB REC
NO P C J NO P C J
1 1 1 1
Nl
104
LGL
LGL
1 1 1 1 1
Nl
104
CNl7-1
CN17-2
1
TAB REC TAB REC
NO P C J
TAB REC TAB REC

NO P C J
1 55 G VCC
4 1 53 1 - I ACCEL
CN33
TAB REC
2 162
TAB
- SSP 2 162
REC
CN19-2
I
mi 120 G-Y CN30-6
1 1 I-I 1 1 ;I I I
3 161 - SSP 3 161 R CN19-1
DISP CN1-11
163 SSP 163 CN19-3
151 151
I W I 1 4 1 5 1 6 /
TAB REC
TAB REC
110 LF-RR 110 GR CN30-9

111 SL CN30-8
TAB REC
TAB REC
56 IWP 58 G 514
3 51 B IWP 51 R CN37-19
TAB REC
1 1 2 1 3 1 1 4 1 5 1 0 1 [ 6 1 7 1 [ / I 9 I 10 CN103-1
11 12 13 14 15 16 17 18 19 20
REC
TAB REC
N P J
P21 DM P21 FET
2 P22 W DM n 2 P22 W FET
TAB REC
N O P C I J N O I P ~ C I J
TAB REC
NO P C J J
TAB REC
1 51 B LSD
2 67 Y LSD CN22-2
TAB REC
TAB REC
BW EL2 CN103-11
2 51 R-L EL2 2 51 R CN37-6
TAB REC
NO P C J
TAB REC
P21 FET F21
TAB REC
3 P B 8 R4
CNtlJ
a v mrls
, * m CNW
TAB REC
~ N ~ ~ P IJ C ]I ) d o I P I C I J 1
TAB REC
WI
11 142 - SDTMA
CN105
TAB REC
TAB REC
h 0 l P / C / J 1 I N O ~ P I C / J 1
DIRECTIONALCONTROL PEDAL
DEAD MAN BRAKE BACK-UP BUZR
wrm FR OPTIONAL LESS FR OPTIONAL

FORWARD AND BACK-UP CHIME
NO
CN9 CN9
CN22
TAB TAB
CHI-F&R
CN1-5 CN13-1 CN17-1
CN1-9 CN2-2 CN14-3 CN51-2 CN~W CN52-2
(51.R) {NI,WI (N1-W)
JOINT PORTION OF DISPLAY SUB HARNESS JOINT PORTION OF FR PILLAR HARNESS
CN31-1
Ecm CN12-1
q A
CN30-E
A.
CN31-5 CW-2 ~ c w 2 CN31-3
cN304 CN34-3
c m 2 CN34-1 CN12-2 CN34-4 CN31-4
CN33-3 CN344 CN30-5 CN34-2
(104.G) (103.0) (N1,W (110,GR) (H1.SL)
JOINT PORTION OF REAR HARNESS
CN7-1 CN24-2 CNI-14 CN17-5 CNSl

CN103-18
044-1
%
(41,Y)
cN1w3
CN1W CN1OO-l
& H
(N1 .W)
CN30-5
'323-2
CN13-1
H
(N1,w
CN17-1
J2
Cbi30.9 &CNw
l
(ll0,QR)
CN16-4 A
(101,R)
CN51
CN1-2 CNB-3
CNl6-I +cN16-2
CN103-14
CNE-1 @:z CNBl 4 CN30-4
CN30-1
CN13-4
CN8-2
CN8-3
4
CN17-4
CNYJ-10
CN118-I CN104-4 CN37-1
(103.0) (108.BR) (109.P)
143.L)
IP1.O)
CN17-3 CN352
J
+
J
,
CN3-3 CNl3-3 CN105.5 CN32-2
(102.Y) 156.6)
JOINT PORTION OF MAIN HRNESS

CPU BOARD & DCISD BOARD CONNECTOR DRAWING
(Harness side) (1993.1 - 1998.1)
CNlOl CN102
No. P No. P
MCS-Ill A CHECK SUB-HARNESS (SST 09240-12240-71)
CONNECTOR DRAWING ON INSPECTION SIDE.
CNlOl CN102
CNlll CN112
CPU BOARD & DC/SD BOARD CONNECTOR DRAWING (Harness side)
[FOR OTHER THAN U.S.A.] (1998.2 - 1998.8)
-
[FOR U.S.A.] (1998.2 1999.1)
CNlOl CN102
No. P No. P
1 - 12 -
2 - 13 -
3 15 14 11
4 15 15 -
5 10 16 11
6 32 17 33
7 30 18 31
8 - 19 -
43 22
CNlll
No. P No. P No. P No. P
1 35 9 36 1 4 11 P2
2 37 10 38 2 5 12 6
3 11 11 11 3 2 13 1
4 10 12 13 4 3 14 1
5 15 13 14 5 7 15 1
6 30 14 31 6 75 16 76
7 32 15 33 7 - 17 P9
8 11 16 11 8 74 18 74
9 71 19 72
10 73 20 73
No. P No. P
1 82 . 11 P61
2 81 12 67
3 84 13 51
4 83 14 51
5 45 15 77
6 46 16 66
7 64 17 65
8 53 18 52
MCS-Ill A CHECK SUB-HARNESS (SST 09240-12240-71)
CONNECTOR DRAWING ON INSPECTION SIDE.
CN 101 CN102
CNlll CN112
CPU BOARD CONNECTOR DRAWING (Harness side)
[FOR OTHER THAN U.S.A.] (1998.9 - )
[FOR USA- UL- CANADA 1 (1999.2 - )
CONNECTING DIAGRAM [FOR OTHER THAN U.S.A.] (
CNI 1
CN29
warnicg chime
Contactor panel
Main hamesl Contactor PS

CN42
Joint
..,.-
111 111 111
laa
CNI 1 8 I _.__ I
CONNECTING DIAGRAM [FOR OTHER THAN U.S
CNl l
CNI
AC PLUG
CONTACTOR PANEL
CHI-FBR
FORWARD AND
BACK.UP CHIME
CONTROL PANEL
-
--
CN107 CN105
CONNECTING DIAGRAM [FOR OTHER THAN U.S.A. UL. CANADA] (1998.9 - )
U i L Y FOR C W A S P E C SW 0
CNl
CNll
CN52
(EnPSl (EMPSI DM 0s
CONT CN43
BAT
CONTROLPANEL
16-58
CONNECTING DIAGRAM [FOR U.S.A.] (1993.1 - 1998.1)
CNI I
CN3
C
-- - - --- - - -- -
, When EHPS ia not provided
P21 h 1
Contactor PS
CN42
Joint connector
CONNECTING DIAGRAM [FOR U.S.A.] (1998.2 - 1999.1)
.--
I I I FOR LOkD WNDLNG
CHWPEII I @ CN13
(EHPS) IEHPS) DM .,
CONT ,
BATT IEHPSI
SEAT
I STD Veh~cle
i
CONNECTING DIAGRAM [FOR U.S.A. UL. CANADA] (1999.2 - )
ONLY FOR W I S P E C .
9 CNl
f
CN1
CNll
COKIACTOR PANEL
1 STD
F?
WIRING DIAGRAM [FOR OTHER THAN U.S.A.] (1993.1 - 1998.1)
WIRING DIAGRAM [FOR OTHER THAN U.S.A.] (1998.2 - 1998.8)
pe CP"
NOTE THIS DRAWING SHOWS

FULL OPTION
FOR EHPS LESS

WIRING DIAGRAM [FOR OTHER THAN'U.S.A. UL. CANADA] (1998.9 - )
CII CHARGER DS D l R M O N SWITCH. FORWARDOPTIONAL
TF TRWORMER DS -
- OIRECSION SWITCH, s*CK.UP
iJ TIMER UNIT -
W A D-
VARI-OHM. ACCEL. D R M 3
-
-
lR LIMITSWITCH.LIFT NO.1R
MS IAGNETSWITCH.WARGER
THR RELAY,WERMAL DF~R DIODE FLYWHEEL NO in

-
-
OF3 DIODE. FLYWHEEL NO3 LS Am, UMTTSWITW.AlTACHMWT1
Dm DIODE.CHARGER
F, FUSE. CHARGER OF4 DIODE. FLYWHEEL N0.4 ,

LS LIMITSWlTCH.AlTACHMENIZ
LIMIT%lTCH. STOP LAMP
-
- LS I,
mn - BATTER" DAW DlODE A850RBER. DRIVEPUMP LS LIMITSWITCH, BRME
SW LIMnSWTCH. P A R W N G W E L , I LAMP, STOP LH
F , FUSE. DRIVE
-
-CA
CSM
CAPACITOR. I\BSORBER
CURRENTSENSOR.DRNEPUMP
--
LS
SW
L I M ~ S W I T M . D WMIW
SWITCH ACCEL
L STa LIUIP STOP Fn
F, FUSE.P"MP
F, FUSE. POWER STEERING

F5 MAX 1OAMP
NOTE.
F, FYSE.UMP THIS DRAWINGM O W S
FULLOPTION.
P R I M WARD. COMPUTER
1 FOR EHPSLESS 1
PB PRINT WARD. EHPS SSP SENSOR, SEERING PRESSORE Pt PILOTLIUIP, WORKING WZZER
ST+
YL
SENSOR.THERM0
SENSOR. LEOUlD LEVEL LAMP, HEAD LH

CHI
cn . CHIME FORWARD
CHIME REVERSE
L LAMP. HE40 RH
L LAMP, CLEAMNCI L t
. C.a LAMP, UEAPAW RH

MOTOR, DRlVErPUMP CONTACTOR.REVERSE RIGHl L ,r UMP, TAIL LW SURGE lisSOsER
COWACTOR. REVERSE LEFT L , LANP TAIL RH
L UMP, WOmING INDICATOR.WIIEELPOSlT1~
T W S T O R . MAIN, DRIVE L FF LAMP, FLASHER LI( /@EAR) VRSPI WRI-OHM STERRIL~Gm s l T K X i NO I
.+
TRANSSTOR. MAIN. PUMP L U M P FLASHER RH lRE4Rl RCKIR RESISTOR.CHECK ( R
L LAMP FLASHER LH
L LAMP FLASHER RH SNUBBER RESISTOR. 1R

WIRING DIAGRAM [FOR U.S.A.] (1993.1 - 1998.1)
v
VRAO VARI-OHCC ACCEL DRIVE
OSFO
---"
nspl.
JOIRECTION
-- --
L S I/~~LIMIT
~
--
SWITCH.
SYITCK
-
l n r R r r T r n N SYTTCH.
- -
LIFT.
FORWARO OPTIONAL
- ACK-UP
B
NO. 1 1 2 1 T2+I 1 1
CUL .*"
OISP
.so" W
am
ON
LST+ LAMP. STOP RH

Lp+ LAMP. ROTARY FORWARD
Lp-g LAMP. ROTARY REVERSE
I
C A W I CAPACI TOR ABSORBER. ORIVE/PUMP Lw+ [LAMP. BACK- UP L H
FUSE.
FUSE.
POWER STEERING
LAMP
r+nD I CURRENT S E ~ S O R . ORIVE/PJMP
1
L-
CMIa
ILAMP.
I
CHIME.
BACK-W,RH
REVERSE
FRY IRELAY.
FLASHER
SA ISLIRGE ABSORBER
I I
OISP IDISPLAY LAMP. CLEARANCE L H
I
OMD/P MOTOR. OSIVWPUMP

OMps MOT09 POWER STEERING
MP IC@~TACTOC(. PUMP
ups TACTOR. OR. POWER S T E E R I N G
ITRANSISTOR. MAIN. PUMP
TY- ITRANSISTOR.
MAIN. POWER STEERINC OSF D I R E C T I O N SWITC* FORWAR0
0s. DIRECTION SWITCH REVERSE
WIRING DIAGRAM [FOR U.S.A.] (1998.2 - 1999.1)
I I
TM TRANSISTOR MAlN hlpr CONTACTOR W W E R STEERING
TMP I TIANSISIOR MAIN PUMP I I I 1 I I

TRANSISTOR MAIN POWERSTEERING
16-66
WIRING llAGRAM [FOR U.S.A. UL. CANADA] (1999.2 - )
DS DIRECTIONSWTCK WRtIN7D OPTiONN 1 F4 MAX 10AMP MAX lOAMP 1

DS DIRECTIONswrrm ~*CX.UP
1 -
LS - IR UMITSWTTCH. UFT, K) 1R
LS UMITSWFCH. TILT
OFlR DIODE. FLVWHEEL. NO.1R
DF3 DIODS FLYAWEEL NOS
DM DIODE. FLV.WEEL. NO.4
BIl7 BIlTERV
F, FUSE DRIVE I CA CbPACm3R*8SORBER
F2 1 FUS€PUMP CSW CURRMSENSOR. DRWEFVMP

(USAULCANADASPEC.)
NOTE:
THIS DRAWING SHOWS
,
.
F FUSE. PVWERSTEERINO CS r(l
CURREMSENSOR. P M R SEERING
FUUOPTICU.
SS
SS
SENSOR. SPEED RIGKT
SENSOR. SPEED LEFT L
L-
-. 1 LAMP. BICICUP M
I WP.FUSlsEICON
FOR EHF'S LESS
SSP SENSOR. STEERBE PR-E Sz sUmR 1
STH SPISORTI(ERM0 CHI , CHlMEFO~MD
I CHWRMRSE
W P ,H W M H w
W P , CLEAPANCE Ln m RELAY,iU8HER
SI SUffiE*BSOBER
SN1 SNUBBER.NO.1
MOTOR. WWER STEERING
mP INOIUTOR. WHEEL W m O N
CONTACTOR.PUMP (ONLY M R U W O A SPEC.)
TRANSTOR. WIN. ORNE CONTACTOR. WWER STEERING U P , -HER Ln ( R W )
L q P ( V I R K Y U STERRNO W m O N . N 3 1
TW\HSISXXL WIN, PUMP W P , -HER M (REAR) RCKlR RESISTORCHECK 1R
L
L FL W P , -HER LH W1R SNUBBERCIPACTOR 1R
1 I
DS DIRECTION S M E H . REVERSE

5fbe10-20 Repair Manual Ce306-3

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5fbe10-20 Repair Manual Ce306-3

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FOREWORD

This manual covers the service procedures of the TOYOTA BATTERY

TOYOTA Material Handling Company

CONTROL CIRCUIT [FOR OTHER THAN U.S.A.] (1998.9

ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHERTHAN U.s.Ad(199889 -I A A

1.25 ton 5FBE13 t t t

Upper face of side member

Vehicle model Punching format

Example of description in pattern B

DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T=N.m (kgf-cm)[ft-lbfl

2 Remove the bush [Point 21 Operation explained later

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

3. Matters omitted in this manual

Standard: Values showing allowable range in inspection and adjustment.

3. Grasping the troule state

4. How to treat liquid waste

Hoisting the vehicle

Front jack-up Rear jack-up

(1) Analog circuit tester

(2) Digital circuit tester

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

3. Difference in measurement result by measurement range (analog type)

Always use the range described in the repair manual

1. How to judge tightening torque of a standard bolt.

2. How to judge tightening torque of a standard nut.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

Shape and class Class Hexagon head bolt I

Hexagon Two protruding 5T

TIGHTENING TORQUE TABLE

14 1.5 75 1 760 j 55 83 1850 161

6 1 .O 6.4 1 65 i 56 in-lbf 7.5 1 75 j 65 in-lbf

14 1.5 110 j1100 i 8 0 123 1 1250 j 90

16 1.5 170 11750 1127 191 11950 1141

12 1.25 108 11100 180 123 1 1250 1 90

1. Do not use the precoat bolt as it is in either of the fol-

2. Method for reuse of precoat bolts

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

o0 1.00 time 0 time

60' 1.16 time 0.58 time

Rope Cutting Single-rope Two-rope suspension Four-rope suspension

RECOMMENDED LUBRICANTS AND CAPACITIES

45s: Refrigerator specification vehicle

1. Chain I lnspect every 8 hours (daily)

2. Mast strip I1 lnspect every 40 hours (weekly)

4. Mast support bushing IV lnspect every 1000 hours (6 monthly)

5. Front axle hub V lnspect every 2000 hours (annually)

Transmission housing 0 lnspect and service

Reservoir tank Replace

Oil control valve link pin

Brake pedal link @ Engine oil

Oil tank @ Hypoid gear oil

Rear wheel bearing @ Brake fluid

Rear axle bearing @ Hydraulic oil

Steering rack & pinion

Commutator fouling and damage I c

Brush spring fatigue M

Battery fluid level I t c t

Battery fluid specific gravity M c +- c

Battery Abnormality at top of battery and

Cell voltage measurement after

Charger Operating voltage measurement M t +-

Magnet switch function, contact