DOWNLOAD PDF Toyota Forklift 7FGU15-32 7FDU15-32 & 7FGCU20-32 Repair Manual

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

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

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

(Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 7FGU/7FDU15~32, 7FGCU20~32 REPAIR MANUAL (No. CU027-2) TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE REPAIR MANUAL (No. CE602-2) TOYOTA INDUSTRIAL EQUIPMENT 1DZ-II ENGINE REPAIR MANUAL (No. CE618-2)

SECTION INDEX NAME

SECTION

GENERAL OPS BODY MATERIAL HANDLING SYSTEM OIL CONTROL VALVE SAS APPENDIX

0 1 2 3 4 5 6

0-1

GENERAL Page

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

0

0-2

PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection. Repair or Replacement if required.

M : Measurement. Repair or Adjustment if required.

T : Retightening C : Cleaning L : Lubrication * : For new vehicle *1 : Flaw detector Inspection Period

Every 6 weeks

Every 3 months

Every 6 months

Every 12 months

Every 250 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Loosening and damage of mounting

I

←

←

←

Seatbelt damage and function

I

←

←

←

Seat switch function

I

←

←

←

Functions

I

←

←

←

Item SAFETY DEVICES, ETC. Seat OPS

0-3

OPS SYSTEM General The OPS (Operator Presence Sensing) system is added as standard.

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

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

When the OPS controller detects the seat switch going off, it sounds the OPS buzzer* (bleeping) for about one second and turns the OPS lamp on before OPS activation. Furthermore, the OPS lamp keeps lighting while the seat switch stays off. *: The buzzer sounds only export model.

Only export model: If the seat switch is turned on without returning the forward/reverse lever to the neutral position after drive OPS activation, the newly added return to neutral warning function sounds the buzzer at short intervals (pip-pip) to warn the operator of the unreleased state of the drive OPS. When the OPS controller detects any system malfunction, the OPS lamp blinks to warn the abnormality.

Control block diagram *: Parts added or changed for OPS

* Seat switch

* OPS Key switch

Forward tilt switch

* OPS lamp relay * OPS lamp * OPS buzzer (Export model)

* Plug in analyzer

SAS Controller

Controller

Bakward tilt switch Foward reverse switch

Battery

Tilt cylinder

* Lower limit switch

F N R

* Tilt * Unload control valve valve

* Forward interrupt relay

* Reverse interrupt relay

Forward drive valve

* Oil control valve

Reverse drive valve

T/C

Engine

Oil pump

Oil tank

* Lift lock valve

Lift cylinder

0

0-4

Name of each part (1) (14)

(13)

(2) (7) (8) (9) (10) (11) (12)

(3) (4) (15)

(5) (6) (16)

(1)

OPS controller

(9)

Backward tilt switch

(2)

Seat switch

(10)

Unload valve

(3)

Forward switch

(11)

Lift lock valve

(4)

Reverse switch

(12)

Tilt control valve

(5)

Forward interrupt relay

(13)

OPS lamp

(6)

Reverse interrupt relay

(14)

OPS lamp relay

(7)

Lower switch

(15)

OPS buzzer (Export model)

(8)

Forward tilt switch

(16)

Plug-in analyzer

0-5

Function of each part Input to controller Name

Function

(2)

Seat switch

This switch mounted underneath the seat detects the operator sitting on the seat.

(3)

Forward switch

This switch inputs the voltage branched from the forward drive valve power supply line to the OPS controller that detects the forward drive operation.

(4)

Reverse switch

This switch inputs the voltage branched from the reverse drive valve power supply line to the OPS controller that detects the reverse drive operation.

(7)

Lower switch

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

(8)

Forward tilt switch

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

(9)

Backward tilt switch

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

Output from controller Name

Function

(5)

Forward interrupt relay

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

(6)

Reverse interrupt relay

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

(10)

Unload valve

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

(11)

Lift lock valve

This valve cuts off the oil flow from the lift cylinder to the oil tank according to the instruction from the OPS controller to disable fork lowering.

(12)

Tilt control valve

This valve changes the oil path to the tilt cylinder according to the instruction from the OPS controller to disable forward tilting and to slow down the backward tilting speed.

(13)

OPS lamp

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

(14)

OPS lamp relay

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

(15)

OPS buzzer (Export model)

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

Plug-in analyzer

This new plug-in analyzer is added with the OPS analyzer functions to the service functions of the conventional SAS analyzer. It is connected to the same service connector.

OPS analyzer functions • Diagnostic display (More detailed display than OPS lamp blinking frequency) • I/O monitor display (Shortening the time required for troubleshooting) • Output test (Shortening the troubleshooting time by setting each output on and off according to the instruction from the OPS controller)

(16)

0

0-6

Control specifications 1.

Drive OPS When the OPS controller detects seat switch off state for 2 seconds, the forward/reverse interrupt relay is operated to disconnect the driving power supply to the forward/reverse drive relay in the torque converter.

This drive OPS operation is released when the seat switch is turned on and the forward/reverse shift relay is returned to the neutral position.

2.

Material handling OPS When the OPS controller detects seat switch OFF for 2 seconds, the lift lock valve and tilt control valve are controlled to stop fork lowering and forward tilting. Other material handling operations such as backward tilting, fork lifting and attachment operations are stopped by interrupting the hydraulic oil supply by means of the unload valve. The disabled material handling operations are released upon lapse of 1 second after seat switch ON. Caution: • Backward tilting: If the material handling lever is operated while the OPS is functioning, the mast may be tilted backward because of the weight of the tilted mast or the back pressure at the unload valve.

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

1.

OPS operation notice When the OPS controller detects the seat switch off state, it sounds the OPS buzzer* (bleep) for about one second, and turns the OPS lamp on to warn the operator of the OPS operation. *: The buzzer sounds only export model.

2.

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

3.

Malfunction alarm When the OPS controller detects any malfunction, it blinks the OPS lamp to warm the malfunction. The lamp blinking frequency identifies the defective part.

Seat Every seat has the seat switch for operator detection.

When replacing seat, install a genuine TOYOTA seat designed specifically for this lift truck. (The OPS may fail to operate unless the correct seat is used.)

Combination Meter OPS lamp This lamp indicates OPS operation and warns an OPS error.

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

0-7

Oil Control Valve 1.

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

2.

An electronic hydraulic control mechanism is incorporated in the tilt control circuit for controlling the mast tilting operation.

3.

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

4.

The unload valve provided in the supply circuit.

Unloading solenoid valve Manual downlifting valve Open this valve to forcibly lower the fork with the engine key turned OFF.

Lift lock solenoid valve

Tilt control solenoid valve

Specifications Pn1-ton series

Pn2 · Cu2-ton series

Pn3 · Cu3-ton series

Relief pressure setting MPa (kgf/cm2) [psi]

Lift

18.7 (191) [2720]

←

←

Tilt

15.7 (160) [2280]

←

←

Flow divider flow rate

L/min

13.0 (3.43)

←

Pn: 15.2 (4.01) Cu: 13.0 (3.43)

0-8

SAS Hydraulic circuit diagram The integral control valve has integrated the unload valve (unload SOL), lift lock valve (lift lock SOL) and the tilt control valve (tilt control SOL) with the oil control valve in the previous model. Each solenoid valve (SOL) is normally closed.

T2

R (4) P

(1) OUT

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

C1

(3) C2 C3

C4 C5

T1

0-9

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

Tilt control SOL ON Semi-open circuit

OFF Forward tilt circuit

• High lifting height, backward tilting speed restriction • Low lifting-height, backward tilting speed restriction*

Full open circuit for backward tilting

• Low lifting height, backward tilting

• Forward tilting

Tilt stop circuit • Tilt lever at neutral • Stop with forward tilting angle restriction • Automatic leveling stop with forward tilting

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

1.

Tilt stop circuit The tilt stop circuit refers to the state where the tilting operation is disabled as upon tilt lever setting at the neutral position or upon stopping with forward tilting angle restriction or fork automatic leveling. The tilt cylinder operation is stopped because the tilt control valve in the control valve is closed.

2.

Tilt semi-open circuit The tilt semi-open circuit refers to the state where the tilting operation speed is restricted (slowed down).

The tilting speed is slowed down because the orifice in the tilt control valve is connected to reduce the oil flow to the tilt cylinder.

Tilt Cylinder Tilt Control Valve Pilot Line

Tilt Lever

SOL OFF Tilt Cylinder

Tilt Control Valve (Orifice) Pilot Line

Tilt Lever

SOL ON

0-10 3.

Tilt Cylinder Tilt Control Valve

Tilt full open circuit The tilt full open circuit refers to the state where the tilting speed is not restricted. The forward/backward tilting speed at the low lifting height becomes the normal tilting speed.

The fully opened circuit in the tilting control valve results in normal tilting speed with no restriction.

Pilot Line

Tilt Lever

RR Tilt : SOL OFF FR Tilt : SOL ON

Key-off lift lock 1.

The integral control valve is designed for addition of the OPS system and the lift hydraulic circuit is modified accordingly.

2.

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

3.

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

1-1

OPS Page

GENERAL ............................................................1-2 COMPONENTS ....................................................1-4 OPS CONTROLLER ............................................1-5 REMAVAL · INSTALLATION ..................................1-5

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

OPS TROUBLESHOOTING...............................1-14 DIAGNOSIS........................................................1-14 DIAGNOSIS ERROR CODE LIST ..........................1-15 TROUBLESHOOTING BY ERROR CODE ..............1-18 TROUBLESHOOTING BY PHENOMENON ............1-33 Note: See Section 5 (SAS) for the connector layout, controller sequence and connector diagram.

1

1-2

GENERAL *: Parts added or changed for OPS

* Seat switch

* OPS Key switch

Forward tilt switch

* OPS lamp relay * OPS lamp * OPS buzzer (Export model)

* Plug in analyzer

SAS Controller

Controller

Bakward tilt switch Foward reverse switch

Battery

Tilt cylinder

* Lower limit switch

F N R

* Tilt * Unload control valve valve

* Forward interrupt relay

* Reverse interrupt relay

Forward drive valve

* Oil control valve

Reverse drive valve

T/C

Engine

Oil pump

Oil tank

* Lift lock valve

Lift cylinder

1-3 (1) (14)

1

(13)

(2) (7) (8) (9) (10) (11) (12)

(3) (4) (15)

(5) (6) (16) (1)

OPS controller

(9)

Backward tilting switch

(2)

Seat switch

(10)

Unload valve

(3)

Forward drive switch

(11)

Lift lock valve

(4)

Reverse drive switch

(12)

Tilt control valve

(5)

Forward interrupt relay

(13)

OPS lamp

(6)

Reverse interrupt relay

(14)

OPS lamp relay

(7)

Lift lowering switch

(15)

OPS buzzer (Export model)

(8)

Forward tilting switch

(16)

Plug-in analyzer

1-4

COMPONENTS 1910

4

5701

1

PA 2

36A

VZ

QY

1 4

PA

3

MF WG 36A PG

QY MF WE PG 3

2

LN

WS LN

GU

RQ

RQ

RQ

WS

EP

LY

WE LN GH VZ

GH GU

WA 5701-467

1-5

OPS CONTROLLER REMAVAL · INSTALLATION 4 6

1

5

Removal Procedure 1

Remove the toe board.

2

Remove the lower panel.

3

Remove the instrument panel (RH).

4

Remove the OPS controller set bolts.

5

Disconnect the connector.

6

Remove the OPS controller.

Installation Procedure The installation procedure is the reverse of the removal procedure.

1-6

OPS PLUG-IN ANALYZER For the maintenance and service of OPS functions, a separate type plug-in analyzer is introduced as an SST (Special Tool for Service).

The plug-in analyzer is designed to read the operating state of sensors and actuators used for the OPS functions and the error information detected by the controller. It serves to check on the operating state of OPS functions and shortens the repair time for a problem. Moreover, it is installed with save function to file data displayed on the screen in the SST. SST 09240-23323-71

Content of function

Reference page

DIAG MEMORY

Indication of ten error codes and sub-codes in past.

1-9

IN/OUT MONITOR

Monitoring input voltage value from the sensors and the output signal, etc. to the solenoid, etc.

1-10

ACTIVE TEST

Forced operation of solenoids and warning lamps.

1-11

CONTROLLER DATA

Indication of OPS controller abbreviation number and version

1-11

OPS

Communication function with the OPS controller on the vehicle side

Menu name

SCREEN CONFIGURATION See the SAS section.

Page 1-9 1-10 1-11 1-11 See the SAS section.

1-7

BASIC OPERATION Name of Sections and the Switch Functions Position of indication

Name of section

Mark

Main unit

• Move the cursor to right or left.

<Blank> Connector A

Switch

Switch

• Move the cursor to the above item.

• Move to the preceding page.

A

Screen title

Function

<No function>

• Select the item below.

• Move to the following page.

B <Blank>

Selector switch c

Selector switch d

<No function>

Determine an item for selection.

Menu switch e

C B

C

Switch mark indicator

<Blank>

• Move to MENU screen.

Caution on using: • Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections.

• Operate the switch with finger tip.

• Donít give it strong impact from dropping or collision.

• Donít leave it under the direct rays of the sun for long time.

Connection and Operation of SST 1. Turn the key switch OFF. 2. Open the diagnosis connector cover of the vehicle and properly connect the connector on the SST side.

SST 09240-23323-71

SST

Diagnosis connector

Note: Since the connector has no locking device, securely connect it to prevent contact defect upon closing the engine hood with the connector in connected state.

3. Turn the key switch ON or start engine.

PLUG IN ANALYZER SYSTEM PROG VER 4.00

4. Display of the initialization screen After about 15 seconds of display, "LANGUAGE SET" or "MAIN MENU" screen appears. The screen may be changed during this period by pressing the menu switch e.

1-8 5. "LANGUAGE SET" screen Since this screen appears only when the language is undefined, determine a language to use for display.

(1) Select a display language by pressing selector switch c and d.

• Japanese • English

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

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

6. "MAIN MENU" screen (1) Select the menu using selector switch c and d and determine by pressing menu switch e.

• SAS: Moves to SAS MENU screen. (See the SAS section) • OPS: Moves to OPS ANALYZER MENU Screen.

• TESTER SET: Moves to TESTER SET screen. (See the SAS section)

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

2. Turn the key switch OFF. 3. Disconnect the connector.

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

4. Close the diagnosis connector cover.

1-9

ANALYZER ANALYZER MENU

Display contents and function

Page

1. DIAG MEMORY

Indication of error codes for 10 most recent errors

1-9

2. IN/OUT MONITOR

Indication of operating conditions of vehicle electrical system

1-10

3. ACTIVE TEST

Forced operation signal output to the selected item

1-11

4. CONTROLLER DATA

Indication of the OPS controller part number and version

1-11

Operation Procedure 1. Select and enter "2OPS" on the main menu screen to display the OPS ANALYZER MENU screen.

2. ANALYZER MENU screen (1) Move the cursor to the desired menu by operating selector switch c or d, and enter by operating MENU switch e.

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

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

[Explanation on display contents] (1) Order of error occurrence (2) Error codes [Clear memory]

(1)

(2)

Press selector switch c continuously for 2 seconds.

[End] Press MENU switch e to return to the ANALYZER MENU screen.

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

• If reception has not been completed, only the number appears without "-" indication.

1-10

"2 IN/OUT MONITOR" [Explanation on display contents] (1) SEAT: Seat switch input signal

(1) (2)

(2) DIR: Direction switch input signal

(3)

FWD: Forward direction switch input signal (4)

REV: Reverse direction switch input signal (3) RLY: Output signal to forward/reverse interrupt relay FWD: Output signal to forward interrupt relay REV: Output signal to reverse interrupt relay (4) VOLTAGE: OPS controller power supply voltage

(1) (5) (6) (7) (8)

(5) LIFT LOWER: Lift lowering switch input signal (6) UNLOAD SOL: Output signal to unload solenoid (7) LWR SOL: Output signal to lowering lock solenoid

(4)

(8) TILT SOL: Output signal to tilt solenoid (9) TILT: Tilt lever switch input signal FWD: Forward tilt switch input signal BWD: Backward tilt switch input signal (1) (9)

CONT: SAS tilt control command input signal (10) LSOPT: Reserved.

* (8) (10) (4)

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

Press MENU switch e to return to the ANALYZER MENU screen.

1-11

"3 ACTIVE TEST" (1) (2) (3) (4) (5) (6) (7)

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

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

[Explanation on display contents] (1) RLY FWD Set to ON for forced output of forward interrupt relay activating signal. (Forward traveling disabled state) (2) RLY REV Set to ON for forced output of reverse interrupt relay activating signal. (Reverse traveling disabled state) (3) UNLOAD SOL Set to ON for forced output of unload solenoid activating signal. (Material handling disabled state) (4) LWR SOL Set to ON for forced output of lowering lock solenoid activating signal. (Lowering enabled state) (5) TILT SOL Set to ON for forced output of tilt solenoid activating signal.

(Forward tilting enabled state with backward tilting speed restriction) (6) LAMP Set to ON for forced output of OPS lamp lighting signal.

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

(Continuous OPS buzzer sounding) 2. After resetting all items to OFF, press MENU switch e to return to the ANALYZER MENU screen.

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

[Explanation on display contents] (1) (2)

(1) DATA Controller abbreviation No. (2) VER Version No. [End] Press MENU switch e to return to the ANALYZER MENU screen.

1-12

TROUBLESHOOTING z No display on the screen.

Related Portion

CN44-12 (IG, Power supply)

1

CN44-1

6

CN44-3 (E2, Main GND)

REC TAB

J2

REC TAB

CN45-1

REC TAB

CN46-3 TAB REC

OPS controller

To IG SW

CN6-3 REC TAB

ECU-IG

Analyzer

13 Analyzer CN

Estimated Causes: c Connector contact defect d Analyzer harness (power supply) defect e Plug-in analyzer defect

Check CN44 and analyzer connector for any disconnection.

NG

NG

OK

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

Screen check after correction.

NG

Harness defect on vehicle side

OK

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

NG

Analyzer harness defect

OK

Plug-in analyzer defect

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

Key switch ON (engine in stopped state)

1 2 3 7 8 9

4

5 6

18

10 11 20

19

12 13 14 15 16 17 21 22 23

CN44 (REC)

Standard: CN44-12 (+) ~ CN44-3 (-)

8 to 16 V

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

Key switch ON (engine in stopped state) Analyzer CN (REC)

Standard: Analyzer CN-1(+) ~ analyzer CN-13 (-)

8 to 16 V

1-13

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

CN44-12 (IG, Power supply)

1

CN44-1

6

REC TAB

J2

REC TAB

CN45-1

REC TAB

CN46-3 TAB REC

OPS controller

To IG SW

CN6-3 REC TAB

ECU-IG

Analyzer

13

CN44-3

Analyzer CN

(E2, Main GND)

Estimated Causes: c Connector contact defective d Analyzer harness (communication) defect

e Plug-in analyzer defect f OPS controller defect

Check CN44 and analyzer connector for any disconnection.

NG

Data display check after correction.

NG

OK

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

NG

Harness defect on vehicle side

OK

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

NG

Analyzer harness defect

OK

Check data display by connecting the analyzer to another vehicle.

NG

Plug-in analyzer defect

OK

OPS controller defect

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

Key switch OFF, disconnection between CN44 and CN45.

1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

7 8 9

4

5 6

18

10 11 20

19

12 13 14 15 16 17 21 22 23

Standard: CN44-1 ~ CN45-1

CN45 (REC)

CN44 (REC)

Continuity

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

Key switch OFF, disconnection between analyzer CN and CN44.

Analyzer CN (REC)

Standard: Analyzer CN-6 ~ CN44-1

Continuity

CN44 (TAB)

1-14

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

Note: • The OPS lamp is lit for 1 second upon key switch ON for broken lamp check.

• The OPS lamp comes on when the operator leaves the seat.

• If multiple errors occur at a time, only the lowest error code appears. Upon correction of that error, the next lowest error code appears.

Example: Display example of error code 3

Break point indication

Code indication

ON OFF 2 sec.

Abnormality detection (Code 3)

0.5 sec.

0.5 sec.

0.5 sec.

0.5 sec.

0.5 sec.

0.5 sec.

0.5 sec.

Blinking (four short ON cycles)

Blinking (three short ON cycles)

4-1

3-2

3-1

2-4

2-3

2-2

Lift lowering switch abnormality

Other than mini lever model

2-1

Blinking (two short ON cycles)

Seat switch abnormality

All specifications

1-1

All specifications

All specifications

SAS-less*

Unload solenoid (SOL1) abnormality

Reverse interrupt relay (RYR) abnormality

Forward interrupt relay (RYF) abnormality

Tilting switch abnormality

Dead lamp check

Blinking (one short ON pulse)

—

—

Error description

ON

Vehicle spec.

Error code

Lamp

DIAGNOSIS ERROR CODE LIST

+B shorting

All material handling operations are disabled while OPS is operating.

While OPS is not operating, only lift lowering is possible but other material handling operations are disabled.

All material handling operations are disabled while OPS is operating.

While OPS is not operating, only lift lowering is possible but other material handling operations are disabled.

↑

Discontinuity

↑

Lift lowering and backward tilting are disabled but other material handling operations are possible while OPS is operating

Lift lowering and backward tilting are disabled but other material handling operations are possible while OPS is operating GND fault

Reverse traveling is always disabled.

Reverse traveling is always disabled.

↑

+B shorting

↑

Reverse traveling is possible while OPS is operating.

Reverse traveling is possible while OPS is operating.

Discontinuity GND fault

Forward traveling is always disabled.

Forward traveling is always disabled.

↑

Forward traveling is possible while OPS is operating.

Forward traveling is possible while OPS is operating. ↑

No special change from normal state (Excessive leak during lowering)

No special change from normal state (Excessive leak during lowering)

No special change from normal state (Excessive leak during lowering) —

No OPS functioning

—

SAS-less spec. model

No OPS functioning

—

SAS spec. model

Phenomenon on vehicle

+B shorting

GND fault

Discontinuity

Sticking GND fault

Sticking GND fault

Sticking GND fault

—

Major cause

1-15

1

—

ON

—

All specifications

OPS operation

Low voltage alarm

EEPROM abnormality

EEPROM abnormality

CPU abnormality

Automatic leveling stop is disabled.

GND fault +B shorting

Departure from seat

Low battery voltage

Controller abnormality

—

Alarm before OPS operation, but drive/ material handling OPS does not function, lowering is always disabled.

Alarm before OPS operation, but drive/ material handling OPS does not function, lowering is always disabled.

—

Drive OPS does not function, lowering is always disabled, and material handling OPS does not function.

None in particular

Drive OPS does not function, lowering is always disabled, and material handling OPS does not function.

When OPS is operating, releasing is disabled (locked state by return to neutral function).

Drive OPS does not function, lowering is always disabled, and material handling OPS does not function.

None in particular

Drive OPS does not function, lowering is always disabled, and material handling OPS does not function.

When OPS is operating, releasing is disabled (locked state by return to neutral function).

↑

↑

Discontinuity

+B shorting

While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible.

While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible.

+B shorting

—

While OPS is operating, only lift lowering is possible and all other material handling operations are disabled.

↑

While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible.

While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible. ↑

SAS-less spec. model

SAS spec. model

Phenomenon on vehicle

While OPS is operating, only lift lowering is possible and all other material handling operations are disabled.

GND fault

Discontinuity

Major cause

*: SAS-less spec. model only because of detection by the SAS controller here on the SAS spec. models.

—

7-6

7-5

All specifications

CPU abnormality

7-3

7-4

CPU abnormality

7-2

Shift lever abnormality CPU abnormality

All specifications

Tilt solenoid (SOL3) abnormality

Lowering lock solenoid (SOL2) abnormality

Error description

7-1

5-1

All specifications

All specifications

4-2

4-3

Vehicle spec.

Error code

ON

ON

Blinking (seven short ON cycles)

ON

Blinking (five short ON cycles)

Blinking (four short ON cycles)

Lamp

1-16

1-17

List of Reference Pages for Error Codes and Sub Error Codes Without analyzer (SST) Error code 1

2

3

4

5

7

Error description Seat switch abnormality

Lowering switch abnormality Tilt switch abnormality (L/SAS spec.)

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

Solenoid (SOL) abnormality

T/C shift lever abnormality

OPS controller abnormality

With analyzer (SST) Page

Error code

1-18

1-1

Seat switch abnormality

1-18

2-1

Lowering switch abnormality

1-23

2-2

Tilt lever switch simultaneous ON abnormality

1-24

2-3

Forward tilt switch 2-minute shorting abnormality

1-24

2-4

Backward tilt switch 2-minute shorting abnormality

1-24

3-1

Forward interrupt relay (RYF) abnormality

1-26

3-2

Reverse interrupt relay (RYR) abnormality

1-26

4-1

Unload solenoid (SOL1) abnormality

1-28

4-2

Lowering lock solenoid (SOL2) abnormality

1-28

4-3

Tilt solenoid (SOL3) abnormality

1-28

5-1

T/C shift lever abnormality

1-31

7-1

CPU abnormality

—

7-2

ROM abnormality

—

7-3

RAM abnormality

—

7-4

A/D conversion abnormality

—

7-5

EEPROM data abnormality

—

7-6

EEPROM access abnormality

—

1-21

1-26

1-28

1-30

—

Error description

Page

List of Pages to be Referenced by Phenomenon Pages to be referenced Description

Without analyzer

With analyzer

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

1-33

1-33

The OPS lamp does not come on.

1-37

1-37

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

1-39

1-42

Cannot lower the fork.

1-45

1-48

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

1-50

1-50

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

1-51

1-51

The mast backward tilting speed is always slow or unrestricted.

1-52

1-52

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

1-56

1-56

Mast does not tilt forward.

1-57

1-57

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

1-61

1-61

The drive OPS does not function.

1-63

1-63

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

1-66

1-66

1-18

TROUBLESHOOTING BY ERROR CODE z Error Code 1 · 1-1 (Seat switch abnormality)

CN45-17 (E03, Switch GND)

J1

1

CN50

CN60

1

REC TAB

6

REC TAB

REC TAB

CN45-23 (DMI, Seat SW)

REC TAB

CN4 TAB REC

OPS controller

Related Portion

2

1 Seat switch 2

CN65

Estimated Causes: c Connector contact defect d Seat switch defect

e Harness defect f Controller defect

Error code 1

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

NG

NG

OK

Inspection 1: Check the seat switch individually for continuity.

After correction, check the OPS lamp indication.*

NG

Seat switch defect

OK

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

NG

Harness defect

OK

Controller defect

*: After correction, check the OPS lamp indication.

After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFF again.

After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display error code 1 with blinking.

1-19 Inspection 1: Check the individual seat switch for continuity.

Key switch OFF, CN 60 disconnection.

2

Standard:

1

CN60 (TAB)

CN60-1 ~ CN60-2

Seated

Unseated

Continuity

No continuity

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

Key switch OFF, CN45 disconnection. (CN4, CN50 and CN60 must be connected.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard:

CN45 (REC)

CN45-23 ~ CN45-17

Seated

Unseated

Continuity

No continuity

Error code 1-1

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

NG

NG

OK

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

After correction, check the OPS lamp indication.*

OK

Seat switch defect

NG

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

NG

Harness defect

OK

Controller defect

*: After correction check the OPS lamp indication.

After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFF again.

After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display error code 1 with blinking.

1-20 Inspection 1: With CN60 disconnected, check the input signal to the controller.

CN60 connector disconnection, key switch OFF ⇒ ON Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard: SEAT

Seated

Unseated

OFF

OFF

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

Key switch OFF, CN45 disconnection. (CN4, CN50, CN60 and CN65 must be connected.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

Standard: CN45-23 ~ CN45-17

Seated

Unseated

Continuity

No continuity

1-21

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

Related Portion

REC TAB

CN45-24 (TRI, Backward tilt switch) CN45-26 (DOWN, Lowering switch)

CN34-1 CN34-2

Forward tilt switch

CN34-3 CN34-4

Backward tilt switch

CN49-1

CN45-17 (E03, SW-GND)

J1

REC TAB

TAB REC

OPS controller

CN45-25 (TFI, Forward tilt switch)

CN49-2

Lowering switch

Estimated Causes: c Connector contact defect d Lowering switch defect e Harness defect f Controller defect

g Forward tilt switch defect h Backward tilt switch defect i Tilt switch installation defect j Lowering switch installation defect

Error code 2 Check the CN45, CN34, and CN49 connectors for any disconnection or internal wetting.

NG

After correction check the OPS lamp indication.* NG

OK

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

OK

Controller defect

NG

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

OK

Harness defect

NG

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

NG

Switch defect

OK

Lever switch installation defect

*: After correction check the OPS lamp indication.

After key switch ON, operate the tilt lever forward and backward to check if the OPS lamp blinks.

Or keep the tilt lever in the neutral position for 2 minutes and check if the OPS lamp blinks.

Or keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.

The OPS lamp must not indicate error code 2 with blinking.

1-22 Inspection 1: Check the lift lower lever switch wiring and tilt lever switch wiring for continuity.

Key switch OFF, CN45 disconnection.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard: • Lift lower switch

CN45 (REC)

Lever at neutral position

Lever at up position

Lever at down position

No continuity

No continuity

Continuity

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN45-25 ~ CN45-17

No continuity

Continuity

No continuity

CN45-24 ~ CN45-17

No continuity

No continuity

Continuity

CN45-26 ~ CN45-17 • Tilt switch

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

Key switch OFF, CN34 and CN49 disconnection.

2

1

4

3

2

1

CN34 (TAB) CN49 (TAB)

Standard: • Lift lower switch Lever at neutral position

Lever at up position

Lever at down position

No continuity

No continuity

Continuity

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN34-1 ~ CN34-2

No continuity

Continuity

No continuity

CN34-3 ~ CN34-4

No continuity

No continuity

Continuity

CN49-1 ~ CN49-2 • Tilt switch

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

Key switch OFF, CN34 and CN49 disconnection.

2

1

4

3

2

1

CN34 (TAB) CN49 (TAB)

Standard: • Lift lower switch (switch on the upper side when installed on the vehicle) CN49-1 ~ CN49-2

Switch free

Switch pressed

Continuity

No continuity

• Forward tilt switch (switch on the upper side when installed on the vehicle) CN34-1 ~ CN34-2

Switch free

Switch pressed

Continuity

No continuity

• Backward tilt switch (switch on the lower side when installed on the vehicle) CN34-3 ~ CN34-4

Switch free

Switch pressed

Continuity

No continuity

1-23 Error code 2-1 Check CN45 and CN49 connectors for any disconnection or internal wetting.

After correction, check the OPS lamp indication.*

NG

NG

OK

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

Inspection 4: Check continuity between CN45 and CN49.

NG

OK

NG

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

Harness defect

OK

NG

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

NG

OK

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

Lower switch defect

OK

Lever switch installation defect

*: After correction, check the OPS lamp indication.

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

The OPS lamp must not indicate error code 2 with blinking.

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

Key switch ON (engine in stopped state) Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard: Lift lower switch LIFT LOWER

Lever at neutral position

Lever at up position

Lever at down position

OFF

OFF

OFF

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

Key switch OFF, CN49 disconnection.

Standard: Lift lower switch CN49-1 ~ CN49-2

2

1

CN49 (TAB)

Lever at neutral position

Lever at up position

Lever at down position

No continuity

No continuity

Continuity

1-24 Inspection 3: Check the lift lower lever switch individually (as removed from the vehicle) for continuity.

Key switch OFF, CN49 disconnection.

2

Standard: Lift lower switch (switch on the upper side when installed on the vehicle) CN49-1 ~ CN49-2

1

CN49 (TAB)

Switch free

Switch pressed

Continuity

No continuity

Inspection 4: Check continuity between CN45 and CN49.

Key switch OFF, CN45 and CN49 disconnection.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard:

CN45 (REC)

CN45-26 ~ CN45-17

2

CN49 (REC)

No continuity

Error codes: 2-2, 2-3, and 2-4 Check CN45 and CN34 connectors for any disconnection or internal wetting.

NG

After correction, check the OPS lamp indication.* NG

OK

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

NG

NG

OK

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

OK

NG

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

Inspection 4: Check continuity between CN45 and CN34.

NG

Harness defect

OK

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

Tilt switch defect

OK

Lever switch installation defect

*: After correction, check the OPS lamp indication.

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

1-25 Inspection 1: Check the switch output upon tilting operation after disconnecting CN34.

Key switch ON (engine in stopped state) Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR Standard: Tilt switch Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

TILT FWD

OFF

OFF

OFF

TILT BWD

OFF

OFF

OFF

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

Key switch OFF, CN34 disconnection.

Standard: Tilt switch

2

1

4

3

CN34 (TAB)

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN34-1 ~ CN34-2

No continuity

Continuity

No continuity

CN34-3 ~ CN34-4

No continuity

No continuity

Continuity

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

Key switch OFF, CN34 disconnection.

Standard: • Tilt forward switch (switch on the upper side when installed on the vehicle) CN34-1 ~ CN34-2

2

1

4

3

CN34 (TAB)

Switch free

Switch pressed

Continuity

No continuity

• Tilt backward switch (switch on the lower side when installed on the vehicle) CN34-3 ~ CN34-4

Switch free

Switch pressed

Continuity

No continuity

Inspection 4: Check continuity between CN45 and CN34.

Key switch OFF, CN45 and CN34 disconnection.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard:

CN45 (REC)

CN45-25 ~ CN45-17

No continuity

CN45-24 ~ CN45-17

No continuity

1

2

3

4

CN34 (REC)

1-26

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

CN45-10 (RYF, Forward interrupt relay)

2

CN45-11 (RYR, Reverse interrupt relay)

2

CN45-17, (E03, SW-GND)

TAB REC

TAB REC

OPS controller

T/C relay block Forward interrupt 1 relay Reverse interrupt 1 relay

CN46-6

Estimated Causes: c Connector contact defect d Forward interrupt relay defect e Reverse interrupt relay defect

f Harness defect g Controller defect

Error Codes 3, 3-1, 3-2

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

NG

NG

OK

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

After correction, check the OPS lamp indication.*

NG

Interrupt relay defect

OK

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

NG

Harness defect

OK

Controller defect

*: After correction, check the OPS lamp indication.

After key switch ON, place the shift lever in the forward or reverse position and leave the seat to check if the OPS lamp blinks.

The OPS lamp must not display error code 3 with blinking.

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

1-27 Inspection 1: Check the forward/reverse interrupt relay (on coil side) individually.

Measure the resistance between terminals of each of the forward and reverse interrupt relays.

Key switch OFF, relay disconnection from T/C relay block.

1 4 2 (5) 3

RLY

Standard: Resistance Forward interrupt relay, between terminals 1 and 2

Approx. 90 Ω (20°C)

Reverse interrupt relay, between terminals 1 and 2

Approx. 90 Ω (20°C)

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

Key switch OFF, CN45 disconnection, relay removal from the T/C relay block.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard: • Discontinuity check

CN45 (REC)

CN45-10 ~ Forward interrupt relay terminal 2

Continuity

CN45-11 ~ Reverse interrupt relay terminal 2

Continuity

CN45-17 ~ Forward interrupt relay terminal 1

Continuity

CN45-17 ~ Reverse interrupt relay terminal 1

Continuity

• GND fault check CN45-10 ~ CN45-17

No continuity

CN45-11 ~ CN45-17

No continuity

• +B shorting check CN45-10 ~ CN45-32

No continuity

CN45-11 ~ CN45-32

No continuity

• IG line shorting check CN45-10 ~ CN45-15,-16

No continuity

CN45-11 ~ CN45-15,-16

No continuity

3 5

3 5

1 4 2

1 4 2

T/C FR RLY

T/C RR RLY

1-28

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

W/SPLICE-Z

REC TAB

CN45-13 (SOL2, Lowering lock SOL)

CN45-30 (E3, SOL-GND) CN45-29 (E3, SOL-GND)

REC TAB

CN45-12 (SOL3, Tilt SOL) REC TAB

TAB REC

OPS controller

CN45-14 (SOL1, Unload SOL)

REC TAB

Related Portion

CN46-8 CN46-9

CN47-1

Unload SOL CN47-2 CN48-1 CN48-2 CN12-1

Lowering lock SOL Tilt SOL

CN12-2

(E3, Body GND)

Estimated Causes: c Connector contact defect d Unload solenoid defect e Lowering lock solenoid defect

f Tilt solenoid defect g Controller defect h Harness defect

Error Codes 4, 4-1, 4-2, 4-3 Check the CN45, CN46, CN47, CN48 and CN12 connectors for any disconnection or internal wetting.

NG

NG

OK

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

After correction, check the OPS lamp indication.*

NG

Solenoid defect

OK

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

NG

Harness defect

OK

Controller defect

*: After correction, check the OPS lamp indication.

After starting the engine, operate lift up/down, forward/backward tilt in each of OPS activation and deactivation to check if the OPS lamp blinks.

The OPS lamp must not display error code 4 with blinking.

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

1-29 Inspection 1: Check the resistance of each solenoid (SOL1 to SOL 3).

Key switch OFF, CN47, CN48 and CN12 disconnection.

Standard:

2

2

1

CN47 (TAB)

1

2

CN48 (TAB)

1

CN12 (TAB)

Resistance SOL1 CN47-1 ~ CN47-2

Approx. 9 Ω (20°C)

SOL2 CN48-1 ~ CN48-2

Approx. 9 Ω (20°C)

SOL3 CN12-1 ~ CN12-2

Approx. 9 Ω (20°C)

Inspection 2: Check continuity of the wiring between CN45 and each of solenoids SOL1 to SOL3.

Key switch OFF, CN45, CN47, CN48 and CN12 disconnection.

Standard: • Discontinuity check CN45-14 ~ CN47-1

Continuity

CN45-29 ~ CN47-2

Continuity

CN45-30 ~ CN47-2

Continuity

CN47-2 ~ Frame

Continuity

CN45-13 ~ CN48-1

Continuity

CN45-29 ~ CN48-2

Continuity

CN45-30 ~ CN48-2

Continuity

CN48-2 ~ Frame

Continuity

CN45-12 ~ CN12-1

Continuity

CN45-29 ~ CN12-2

Continuity

CN45-30 ~ CN12-2

Continuity

CN12-2 ~ Frame

Continuity

• GND fault check CN45-14 ~ CN45-29,-30

No continuity

CN45-13 ~ CN45-29,-30

No continuity

CN45-12 ~ CN45-29,-30

No continuity

• +B shorting check CN45-14 ~ CN45-32

No continuity

CN45-13 ~ CN45-32

No continuity

CN45-12 ~ CN45-32

No continuity

• IG line shorting check CN45-14 ~ CN45-15,-16

No continuity

CN45-13 ~ CN45-15,-16

No continuity

CN45-12 ~ CN45-15,-16

No continuity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

1

2

CN47 (REC)

1

2

CN48 (REC)

1

2

CN12 (REC)

1-30

z Error Code 5 · 5-1 (T/C shift lever abnormality) Related Portion REC TAB

SFT To IG1

CN53-6

CN6-8

CN45-3 (DRF, Forward drive SW) CN45-4 (DRR, Reverse drive SW)

TAB REC

Reverse interrupt relay

4

CN46-1 CN46-11

REC

Forward interrupt relay

TAB REC

OPS controller

T/C relay block Shift lever

4 CN53-5 (CN57-3) CN53-1 (CN57-6)

Estimated causes: c Connector contact defect d Shift lever switch defect e Harness defect

f Controller defect g Fuse defect

Error Code 5

Check if the fuse (SFT) is blown.

NG

NG

OK

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

NG

After correction, check the OPS lamp indication.* NG

OK

Inspection 1: Check the shift lever individually for continuity.

After correction, check the OPS lamp indication.*

NG

Shift lever defect

OK

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

NG

Harness defect

OK

Controller defect

*: After correction, check the OPS lamp indication.

After key switch ON, operate the shift lever to forward or reverse position and check if the OPS lamp blinks.

The OPS lamp must not display error code 5 with blinking.

1-31 Inspection 1: Check the T/C shift lever individually for continuity.

Key switch OFF, CN53 disconnection.

9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10

Standard:

DIRECTION SWITCH

Lever at neutral position

Lever at forward traveling position

Lever at reverse traveling position

Between pins 5 and 6 on lever side

No continuity

Continuity

No continuity

Between pins 6 and 1 on lever side

No continuity

No continuity

Continuity

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

Key switch OFF, CN45 and IG SW connectors disconnection.

(CN6, CN46 and CN53 must be connected.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

Standard: • Lever at neutral

2 3 4

CN45-3 ~ IG SW-4

No continuity

CN45-4 ~ IG SW-4

No continuity

IG SW

• +B shorting check CN45-3 ~ CN45-32

No continuity

CN45-4 ~ CN45-32

No continuity

• IG line shorting check CN45-3 ~ CN45-15,-16

No continuity

CN45-4 ~ CN45-15,-16

No continuity

Error code 5-1

Check if the fuse (SFT) is blown.

NG

NG

OK

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

NG

After correction, check the OPS lamp indication.* NG

OK

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

After correction, check the OPS lamp indication.*

OK

Shift lever defect

NG

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

OK

Controller defect

NG

Harness defect

1-32 *: After correction, check the OPS lamp indication.

After key switch ON, operate the shift lever to the forward or reverse position and check if the OPS lamp blinks.

The OPS lamp must not indicate error code 5 with blinking.

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

CN53 disconnection, and key switch ON (engine in stopped state) Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard: Lever at neutral position

Lever at forward traveling position

Lever at reverse traveling position

DIR FWD

OFF

OFF

OFF

DIR REV

OFF

OFF

OFF

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

Key switch OFF, CN45 and IG SW connectors disconnection.

(CN6, CN46 and CN53 must be connected.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

Standard: • Lever at neutral

2 3 4

CN45-3 ~ IG SW-4

No continuity

CN45-4 ~ IG SW-4

No continuity

• +B shorting check CN45-3 ~ CN45-32

No continuity

CN45-4 ~ CN45-32

No continuity

• IG line shorting check CN45-3 ~ CN45-15,-16

No continuity

CN45-4 ~ CN45-15,-16

No continuity

IG SW

1-33

TROUBLESHOOTING BY PHENOMENON z The OPS buzzer does not sound. (Export model) z The OPS buzzer keeps sounding. (Export model) Related Portion ECU-IG

CN45-9 (BZO, OPS buzzer)

REC TAB

CN51-1 TAB REC

OPS controller

To IG SW

OPS buzzer

CN51-2

Estimated Causes: c Connector contact defect d OPS buzzer defect e Harness defect

f Controller defect g Fuse defect

The OPS buzzer does not sound.

Check for blown fuse (ECU-IG).

NG

NG

OK

Check the CN45 and CN51 for any disconnection or internal wetting.

NG

After correction, check the OPS buzzer sound.* NG

OK

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

After correction, check the OPS buzzer sound.*

NG

Harness defect

OK

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

OK

OPS buzzer defect

NG

Controller defect

*: After correction, check the OPS buzzer sound.

After connecting all connectors, turn the key switch ON, and leave the seat to check if the buzzer sounds.

1-34 Inspection 1: Check the continuity between the IG SW and CN51, and between CN45 and CN51.

Key switch OFF, CN45, CN51, IG SW connector disconnection.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard:

CN45 (REC)

IG SW-4 ~ CN51-1

Continuity

CN45-9 ~ CN51-2

Continuity

1

2

CN51 (REC)

Inspection 2:

2 3 4

Check the continuity between CN51-2 and the frame.

IG SW

• Without analyzer Disconnect CN51 and turn the key switch to ON (engine in stopped state).

Standard: Between CN51-2 and the frame

Buzzer ON

Buzzer OFF

Continuity

No continuity

1

2

CN51 (REC)

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

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

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST Standard: Forcibly turn the OPS buzzer ON and OFF, and check the continuity between CN51-1 and CN51-2.

Between CN51-2 and the frame

Buzzer ON

Buzzer OFF

Continuity

No continuity

1

2

CN51 (REC)

1-35 The OPS buzzer keeps sounding.

Check CN45 and CN51 for any disconnection or internal wetting.

NG

After correction, check the OPS buzzer sound.* NG

OK

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

NG

Harness defect

OK

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

OK

OPS buzzer defect

NG

Controller defect

*: After correction, check the OPS buzzer sound.

After connecting all connectors, turn the key switch to ON and leave the seat to check if the buzzer sounds.

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

Key switch OFF, CN45, CN51, IG SW connector disconnection.

Standard: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

IG SW-4 ~ CN51-1

Continuity

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45-9 ~ CN51-2

Continuity

CN45 (REC)

Between CN45-9 and the frame

No continuity 1

2

CN51 (REC) 2 3 4 IG SW

1-36 Inspection 2: Check the continuity between CN51-2 and the frame.

• Without analyzer Disconnect CN51 and turn the key switch to ON (engine in stopped state).

2

CN51 (REC)

Standard: Between CN51-2 and frame

1

Buzzer ON

Buzzer OFF

Continuity

No continuity

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

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

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST Standard: Forcibly turn the OPS buzzer ON and OFF, and check the continuity between CN51-1 and CN51-2.

Between CN51-2 and frame

Buzzer ON

Buzzer OFF

Continuity

No continuity

1

2

CN51 (REC)

1-37

z The OPS lamp does not come on.

Related Portion REC TAB

GAUGE

CN41-12

W/SPLICE-Y

CN6-3

4 2 1

REC TAB

CN45-8 (RYLP, OPS lamp relay) CN8-3

REC TAB

REC TAB

CN58-3

ECU-IG

TAB REC

OPS controller

To IG SW

Combination meter

OPS lamp relay

3 4 SAS lamp relay

CN5-12

Estimated Causes: c Connector contact defect d OPS lamp defect e OPS lamp relay defect

f Harness defect g Controller defect h Fuse defect

Check if the OPS lamp is burnt out.

NG

NG

OK

Check for blown fuse (GAUGE).

NG

NG

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

OK

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

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

OK

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

After bulb replacement, check that the OPS lamp comes on.

NG

Harness defect

OK

Inspection 2: Check the OPS lamp relay.

NG

OPS lamp relay defect

OK

Controller defect

*: After correction, check OPS lamp lighting.

After connecting all connectors, turn the key switch to ON (engine in stopped state) and leave the seat to see that the OPS lamp comes on.

1-38 Inspection 1: Check the continuity between fuse (ECU-IG), CN45, CN41, frame, and OPS lamp relay.

Turn the key switch OFF, disconnect CN45 and CN41, and remove the OPS lamp relay.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Standard:

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

Between fuse (ECU-IG) and relay pin 2

Continuity

Between CN45-8 and relay pin 1

Continuity

Between frame and replay pin 3

Continuity

Between CN41-12 and relay pin 4

Continuity

Between frame and relay pin 1

No continuity

1 2 3 4 5 6

7 8 9 10 11 12 13

CN41 (REC)

3 5

Inspection 2:

1 4 2

OPS LAMP RLY

Check the OPS lamp relay.

• Without analyzer

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

Standard: Between relay pin 1 and frame

Lamp ON

Lamp OFF

No continuity

Continuity

3 5 1 4 2

OPS LAMP RLY

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

Standard: Between relay pins 3 and 4

Lamp ON

Lamp OFF

0V

Approx. 12 V

• With analyzer (1) Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch to ON (engine in stopped state).

Check the continuity between OPS lamp relay block 1 and the frame with no one on the seat.

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST Standard: Forcibly turn the OPS lamp ON and OFF, and check the continuity.

Between relay pin 1 and frame

3 5

Lamp ON signal

Lamp OFF signal

1 4 2

No continuity

Continuity

OPS LAMP RLY

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

Standard: Between relay pins 3 and 4

Lamp ON

Lamp OFF

0V

Approx. 12 V

1-39

z The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled) Related Portion CN58-3 REC TAB

ECU-B

REC TAB

To battery

REC TAB

ECU-IG

CN58-5

4 2 1

TAB REC

W/SPLICE-Y CN46-5 CN46-4 REC TAB REC TAB

6

J1

1

CN45-17 (E03, Switch GND)

3

CN8-3

4

CN5-12

CN50 REC TAB

CN45-23 (DMI, Seat switch)

REC TAB

CN4

1 2

CN60

CN64

Estimated Causes: c Contactor contact defect d OPS lamp defect e OPS lamp relay defect f Harness defect

Combination meter

CN41-12

CN45-8 (RYLP, OPS lamp relay) TAB REC

OPS controller

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

CN6-3

REC TAB

To IG SW

REC TAB

GAUGE

g Controller defect h Fuse defect i Low battery voltage j Seat switch discontinuity

OPS lamp relay

SAS lamp relay

1 Seat switch 2

1-40 Without Analyzer

Check for blown fuse (ECU-B).

NG

NG

OK

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

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

NG

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

OK

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

NG

Harness defect

OK

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

NG

Battery defect (low battery voltage)

OK

Inspection 3: Check the OPS lamp relay.

NG

OPS lamp relay defect

OK NG

Inspection 4: Check the seat switch.

Seat switch defect

OK

Controller defect

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

After connecting all connectors, turn the key switch to ON while staying on the seat (engine in stopped state).

Check that the OPS lamp goes off in 1 second.

1-41 Inspection 1: Check and measure the continuity and voltage between IG SW and CN45, between the battery and CN45, between IG SW and OPS lamp relay, between OPS lamp relay and CN45, and between CN60 and CN45.

Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamp relay.

Standard: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

IG SW-4 ~ CN45-16

Continuity

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

IG SW-4 ~ CN45-15

Continuity

CN45 (REC)

Between IG SW-4 and relay pin 2

Continuity

Between CN45-8 and relay pin 1

Continuity

CN45-23 ~ CN60-1

Continuity

CN45-17 ~ CN60-2

Continuity

CN45-15 ~ CN45-31

No continuity

2 3 4

CN45-16 ~ CN45-31

No continuity

IG SW

Between frame and relay pin 4

No continuity

CN45-32 ~ CN45-31

Approx. 12 V

1

2

CN60 (REC)

3 5 1 4 2

OPS LAMP RLY

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

Disconnect CN45 and turn the key switch to ON. (Connectors other than CN45 must be connected).

Standard: CN45-15 ~ CN45-31

11 V or more

CN45-16 ~ CN45-31

11 V or more

Inspection 3: Check the OPS lamp relay.

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

Standard: Between relay pin 1 and frame

Lamp ON

Lamp OFF

No continuity

Continuity

3 5 1 4 2

OPS LAMP RLY

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

Standard: Between relay pins 3 and 4

Lamp ON

Lamp OFF

0V

Approx. 12 V

1-42 Inspection 4: Check the individual seat switch for continuity.

Turn the key switch to OFF, and disconnect CN60.

2

Standard: CN60-1 ~ CN60-2

Seated

Unseated

Continuity

No continuity

1

CN60 (TAB)

With Analyzer

Check for blown fuse (ECU-B).

NG

NG

OK

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

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

NG

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

OK

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

NG

Harness defect

OK

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

NG

Battery defect (low battery voltage)

OK

Inspection 3: Check the OPS lamp relay.

NG

OPS lamp relay defect

OK OK

Inspection 4: Check the seat switch.

Seat switch defect

NG

Controller defect

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

After connecting all connectors, turn the key switch to ON while staying on the seat (engine in stopped state).

Check that the OPS lamp goes off in 1 second.

1-43 Inspection 1: Check and measure the continuity and voltage between the IG SW and CN45, between the battery and CN45, between the IG SW and the OPS lamp relay, between the OPS lamp relay and CN45, and between CN60 and CN45.

Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamp relay.

Standard: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

IG SW-4 ~ CN45-16

Continuity

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

IG SW-4 ~ CN45-15

Continuity

CN45 (REC)

Between IG SW-4 and relay pin 2

Continuity

Between CN45-8 and relay pin 1

Continuity

CN45-23 ~ CN60-1

Continuity

CN45-17 ~ CN60-2

Continuity

CN45-15 ~ CN45-31

No continuity

CN45-16 ~ CN45-31

No continuity

Between frame and relay pin 4

No continuity

CN45-32 ~ CN45-31

Approx. 12 V

1

2

CN60 (REC)

2 3 4 IG SW

3 5 1 4 2

OPS LAMP RLY

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

After connecting all connectors, turn the key switch to ON (engine in stopped state).

Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR Standard: Key ON VOLTAGE

11 V or more

Inspection 3: Check the OPS lamp relay.

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

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST Standard: Forcibly turn the OPS lamp to on and off, and check the continuity.

Between relay pin 1 and frame

Lamp ON signal

Lamp OFF signal

No continuity

Continuity

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

Standard: Between relay pins 3 and 4

Lamp ON

Lamp OFF

0V

Approx. 12 V

3 5 1 4 2

OPS LAMP RLY

1-44 Inspection 4: Check the seat switch individually.

Turn the key switch to OFF and disconnect CN60.

Standard: CN60-1 ~ CN60-2

2

1

CN60 (TAB)

Seated

Unseated

Continuity

No continuity

1-45

z Cannot lower the fork.

J1

CN45-30 (E3, SOL-GND) CN45-29 (E3, SOL-GND)

REC TAB

CN45-13 (SOL2, Lowering lock solenoid) CN46-8

REC TAB

CN45-17 (E03, SW-GND) TAB REC

OPS controller

CN45-26 (DOWN, Lowering switch)

REC TAB

Related Portion CN49-1 CN49-2 CN48-1 CN48-2

Lowering switch Lowering lock solenoid

W/SPLICE-Z CN46-9

(E3, Body ground)

Estimated Causes: c Connector contact defect d Lowering switch defect e Control valve lowering lock valve sticking defect

f Lowering lever switch installation defect g Controller defect h Harness defect

1-46 Without Analyzer

Is the OPS lamp blinking to indicate an error.

Yes

Perform troubleshooting according to the error code.

No

Perform troubleshooting for "The OPS Lamp keeps lighting".

NG

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

No

Does the OPS lamp go off when seated.

Yes

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

OK

NG

NG

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

Inspection 2: Check the continuity between CN45 and CN49.

OK

NG

Harness defect

OK

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

NG

Lowering switch defect

OK

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

NG

Controller defect

OK

Lowering lock valve sticking

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

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

Turn the key switch to OFF and disconnect CN45.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard: CN45-26 ~ CN45-17

CN45 (REC)

Lever at neutral position

Lever at up position

Lever at lowering position

No continuity

No continuity

Continuity

1-47 Inspection 2: Check the continuity between CN45 and CN49.

Turn the key switch OFF, and disconnect CN45 and CN49.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Standard:

1

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45-26 ~ CN49-1

Continuity

CN45-17 ~ CN49-2

Continuity

CN45 (REC)

CN49 (REC)

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

Turn the key switch OFF, and disconnect CN49.

2

1

CN49 (TAB)

Standard: CN49-1 ~ CN49-2

Free

Pressed

Continuity

No continuity

2

1-48 With Analyzer

Is the OPS lamp blinking to indicate an error?

Yes

Perform troubleshooting according to the error code.

No

Perform troubleshooting for "The OPS Lamp keeps lighting."

NG

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

No

Does the OPS lamp go off when seated.

Yes

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

OK

NG

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

NG

Inspection 2: Check the continuity between CN45 and CN49.

OK

NG

Harness defect

OK

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

NG

Lowering switch defect

OK

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

NG

Controller defect

OK

Lowering lock valve sticking

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

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

Turn the key switch to ON (engine in stopped state).

Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR Standard: LIFT LOWER

Lever at neutral position

Lever at up position

Lever at lowering position

OFF

OFF

ON

1-49 Inspection 2: Check the continuity between CN45 and CN49.

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Standard:

1

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45-26 ~ CN49-1

Continuity

CN45-17 ~ CN49-2

Continuity

CN45 (REC)

CN49 (REC)

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

Turn the key switch to OFF, and disconnect CN49.

Standard: CN49-1 ~ CN49-2

2

1

CN49 (TAB)

Free

Pressed

Continuity

No continuity

2

1-50

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

Related Portion CN47-1

CN45-29 (E3, SOL-GND)

REC TAB

CN45-30 (E3, SOL-GND)

REC TAB

CN45-13 (SOL2, Lowering lock SOL)

REC TAB

W/SPLICE TAB REC

OPS controller

CN45-14 (SOL1, Unload SOL)

CN46-8 CN46-9

CN47-2 CN48-1 CN48-2

Unload SOL

Lowering lock SOL

(E3, Body ground)

Estimated Causes: c Controller defect d Control valve unload valve or lowering lock valve defect

Is the OPS lamp blinking?*1

Yes

Perform troubleshooting according to the error code.

No

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

NG

Controller defect

OK

Sticking unload valve on control valve or lowering lock valve

*1: Check if the OPS lamp is blinking.

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

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

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

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

1-51

z Material handling fails (Including when fork lowering is disabled)

CN45-30 (E3, SOL-GND)

REC TAB

CN45-29 (E3, SOL-GND)

REC TAB

CN45-14 (SOL1, Unload solenoid) TAB REC

OPS controller

Related Portion

CN46-8

CN47-1 CN47-2

Unload solenoid

W/SPLICE-Z

CN46-9

(E3, Body ground)

Estimated Causes: c Sticking unload valve on control valve d Controller defect

Is the OPS lamp blinking to indicate an error?

Yes

Perform troubleshooting according to the error code.

No

Perform troubleshooting for "The OPS lamp keeps lighting".

No

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

Yes

Check the unload solenoid operating sound.*

NG

Controller defect

OK

Sticking unload valve on control valve

*: Check the control valve solenoid operating sound.

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

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

1-52

z The mast backward tilting speed is always slow or unrestricted.

Related Portion CN34 REC TAB

CN45-25 (TFI, Forward tilt switch)

CN46

3 4

J1 CN1-22 CN1-23

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

Backward tilt lever switch

W/SPLICE-A

CN1-10 CN1-9 CN1-13

SAS controller

6

Forward tilt lever switch

REC TAB

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

REC TAB

CN45-17 (E03, SW-GND) TAB REC

OPS controller

CN45-24 (TRI, Backward tilt switch)

1 2

Estimated Causes: c Connector contact defect d Harness defect e Tilt lever switch defect f Tilt lever switch installation defect

g Sticking tilt control valve h OPS controller defect i SAS controller defect

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

OK

Is the OPS lamp blinking?*1

Yes

Perform troubleshooting according to the error code.

NG

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

No

Check CN1, CN34, CN45 and CN46 for any disconnection or internal wetting.

NG

To be continued

1-53 Continued

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

NG

OK

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

OK

Harness defect (between CN34 and CN45)

NG

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

NG

Tilt lever switch defect

OK

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

NG

Inspection 5: Check the continuity between CN45 and CN1.

NG

Harness defect (between CN45 and CN1)

OK

OK

Check the tilt solenoid operating sound.*3

OK

Sticking tilt control valve

NG

Inspection 6: Check tilting control by the OPS controller.

NG

OPS controller defect

OK

SAS controller defect

*1: Check if the OPS lamp is blinking.

Turn the key switch to OFF → ON (2 seconds or more) → ON with no one on the seat. Leave the vehicle as it is for 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink. *2: After correction, check the backward tilting speed while staying on the seat.

After turning the key switch to ON while staying on the seat, check the mast backward tilting speed. *3: Check the tilt solenoid operating sound.

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

Caution: *3: Be careful so as not to get burnt because the solenoid may be hot.

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

Turn the key switch to OFF and disconnect CN45. connected.)

(CN34 and CN46 must be

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

Standard Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN45-25 ~ CN45-17

No continuity

Continuity

No continuity

CN45-24 ~ CN45-17

No continuity

No continuity

Continuity

1-54 Inspection 2: Check the tilt lever switch individually (as installed on the vehicle) for continuity.

Turn the key switch to OFF and disconnect CN34.

Standard: Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN34-1 ~ CN34-2

No continuity

Continuity

No continuity

CN34-3 ~ CN34-4

No continuity

No continuity

Continuity

2

1

4

3

CN34 (TAB)

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

Turn the key switch to OFF and disconnect CN34.

Standard: • Forward tilting switch (upper switch as installed on the vehicle) CN34-1 ~ CN34-2

2

1

4

3

CN34 (TAB)

Free

Pressed

Continuity

No continuity

• Backward tilting switch (lower switch as Installed on the vehicle) CN34-3 ~ CN34-4

Free

Pressed

Continuity

No continuity

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

Disconnect CN1 and turn the key switch to ON (engine in stopped state).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CN1 (REC)

Standard: Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN1-10 (+) ~ CN1-23 (-)

No continuity

Continuity

No continuity

CN1-9 (+) ~ CN1-23 (-)

No continuity

No continuity

Continuity

CN1-10 (-) ~ CN1-23 (+)

No continuity

Continuity

No continuity

CN1-9 (-) ~ CN1-23 (+)

No continuity

No continuity

Continuity

Circuit tester Digital type Analog type

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

1-55 Inspection 5: Check the continuity between CN45 and CN1.

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CN1 (REC)

Standard: CN45-22 ~ CN1-10

Continuity

CN45-21 ~ CN1-9

Continuity

CN45-20 ~ CN1-23

Continuity

Between CN45-22 and frame

No continuity

Between CN45-21 and frame

No continuity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

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

Disconnect CN1 and turn the key switch to ON. (CN34 and CN46 must be connected).

Operate the tilt lever to check the mast movement.

Standard: Lever at neutral position

Mast does not move.

Lever at forward tilt position

Mast tilts forward.

Lever at backward tilt position

Mast tilts backward at the normal speed.

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

1-56

z Slow mast backward tilting speed (SAS-less vehicle)

CN45-29 (E3, SOL-GND)

REC TAB

CN45-30 (E3, SOL-GND)

REC TAB

CN45-12 (SOL3, Tilt SOL) TAB REC

OPS controller

Related Portion

CN46-8

CN12-1 Tilt SOL CN12-2

W/SPLICE-Z

CN46-9

(E3, Body ground)

Estimated Causes: c Controller defect d Sticking tilt control valve

Is the OPS lamp blinking?*1

Yes

Perform troubleshooting according to the error code.

No

Check the tilt solenoid operating sound.*2

OK

Sticking tilt control valve

NG

OPS controller defect

*1: Check if the OPS lamp is blinking.

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

Furthermore, operate the tile lever to the forward position on the operator's seat, make sure that the OPS lamp does not blink. *2: Check the tilt solenoid operating sound.

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

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

1-57

z Mast does not tilt forward.

Related Portion

J1

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

2 CN1-22 CN1-23

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

Forward tilt lever switch

W/SPLICE-A

CN1-10 CN1-13

SAS controller

CN46

REC TAB

6

REC TAB

TAB REC

OPS controller

CN45-17 (E03, SW-GND)

REC TAB

CN34 1

CN45-25 (TFI, Forward tilt switch)

Estimated Causes: c Connector contact defect d Harness defect e Forward tilt lever switch defect f Forward tilt lever switch installation defect

g Sticking tilt control valve h OPS controller defect i SAS controller defect

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

Yes

Perform troubleshooting according to the error code.

No

Perform troubleshooting for Disabled Material Handling error.

NG

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

No Get on the seat and check if the fork can be lifted.

Yes Check CN1, CN34, CN45 and CN46 for any disconnection or internal wetting.

NG

To be continued

1-58 Continued

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

NG

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

OK

OK

Harness defect (between CN34 and CN45)

NG

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

NG

Forward tilt lever switch defect

NG

Harness defect (between CN45 and CN1)

OK

Forward tilt lever switch installation defect

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

NG

Inspection 5: Check continuity between CN45 and CN1.

OK

OK

Check the tilt solenoid operating sound.*2

OK

Sticking tilt control valve

NG

Inspection 6: Check tilt control by the OPS controller.

NG

OPS controller defect

OK

SAS controller defect

*1: Get on the seat and check forward tilting operation: Stay on the seat and turn the key switch to ON. Operate the tilt lever with the unloaded fork at a height of 500 mm (20 inches) to check if the mast can be tilted forward. *2: Check for tilt solenoid operating sound: Stay on the seat and turn the key switch to ON (with the engine in stopped state). Put a hand on the tilt solenoid of the control valve with the unloaded fork at a height of 500 mm (20 inches) to check for solenoid operating sound.

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

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

Key switch OFF, CN45 disconnection. (CN34 and CN46 must be connected.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard: CN45-25 ~ CN45-17

CN45 (REC)

Lever at neutral position

Lever at forward position

Lever at backward position

No continuity

Continuity

No continuity

1-59 Inspection 2: Check the forward tilt lever switch individually (as installed on the vehicle) for continuity.

Key switch OFF, CN34 disconnection.

Standard:

2

1

4

3

CN34 (TAB)

CN34-1 ~ CN34-2

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

No continuity

Continuity

No continuity

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

Key switch OFF, CN34 disconnection Standard: Tilt forward switch (upper switch when installed on the vehicle) CN34-1 ~ CN34-2

2

1

4

3

CN34 (TAB)

Free

Pressed

Continuity

No continuity

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

CN1 disconnection, key switch ON (with the engine in stopped state)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Standard:

CN1 (REC)

Circuit tester

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

Digital type

CN1-10(+) ~ CN1-23(-)

No continuity

Continuity

No continuity

Analog type

CN1-10(-) ~ CN1-23(+)

No continuity

Continuity

No continuity

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

Inspection 5: Check continuity between CN45 and CN1.

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

Standard: CN45-22 ~ CN1-10 CN45-20 ~ CN1-23

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CN1 (REC)

Continuity Continuity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

1-60 Inspection 6: Check tilt control by the OPS controller.

CN1 disconnection, key switch ON. (CN34 and CN46 must be connected.)

Operate the tilt lever and check the mast movement.

Standard: Lever at neutral position

Mast does not move.

Lever at forward tilt position

Mast tilts forward.

Lever at backward tilt position

Mast tilts backward at the normal speed.

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

1-61

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

CN34

CN45-25 (TFI, Forward tilt switch)

1 Forward tilt lever switch

REC TAB

REC TAB

TAB REC

OPS controller

Related Portion

CN45-17 (E03, SW-GND)

2

J1

6 CN46

Estimated Causes: c Connector contact defect d Harness defect e OPS controller defect

f Forward tilt lever switch defect g Forward tilt lever switch installation defect h Sticking tilt control valve

Check if the OPS lamp blinks to indicate an error.

Yes

Perform troubleshooting according to the error code.

No

Perform troubleshooting for Disabled Material Handling error.

NG

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

No Stay on the seat and check if the fork can be lifted.

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

OK

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

NG

NG

OK

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

OK

Forward tilt lever switch installation defect

NG

OPS controller defect

Harness defect

NG

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

Check the tilt solenoid operating sound*2

OK

OK

Sticking tilt control valve

NG

Forward tilt lever switch defect

1-62 *1: Stay on the seat and check the forward tilting operation.

After turning the key switch to ON, operate the tilt lever to check if the mast can be tilted forward. *2: Check the tilt solenoid operating sound.

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

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

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

Key switch OFF, CN45 disconnection. (CN34 and CN46 must be connected).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Standard:

CN45-25 ~ CN45-17

CN45 (REC)

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

No continuity

Continuity

No continuity

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

Key switch OFF, CN34 disconnection.

Standard:

CN34-1 ~ CN34-2

2

1

4

3

CN34 (TAB)

Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

No continuity

Continuity

No continuity

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

Key switch OFF, CN34 disconnection.

Standard: Forward tilt switch (switch on the upper side as installed on the vehicle) CN34-1 ~ CN34-2

2

1

4

3

CN34 (TAB)

Free

Pressed

Continuity

No continuity

1-63

z The drive OPS does not function.

CN6-8

CN53-6 CN53-5

REC

SFT To IG SW

REC TAB

Related portion

Shift lever

T/C relay block

TAB REC

CN45-17 (E03, SW-GND)

CN46-6

2

4

1

3

CN53-1

Forward interrupt relay

CN45-11 (RYR, Reverse interrupt relay)

1

4

2

3 5

Reverse interrupt relay

CN45-3 (DRF, Forward drive switch) CN45-4 (DRR, Reverse drive switch)

TAB REC

TAB REC

OPS controller

CN45-10 (RYF, Forward interrupt relay)

CN46-1

TAB REC

CN52

CN46-11

7

1 CN54

2 REC

Shift SOL

Estimated Causes: c Connector interrupt defect d Forward interrupt relay defect e Reverse interrupt relay defect

f Harness defect g Controller defect

1-64

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

Yes

Perform troubleshooting according to the error code.

NG

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

No

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

NG

OK

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

NG

Harness defect

OK

Inspection 2: Check the forward/reverse interrupt relay.

NG

Interrupt relay defect

OK

Controller defect

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

Without getting on the seat, turn the key switch to OFF → ON (2 seconds or more) → OFF. Leave the vehicle as it is for at least 15 minutes. Then turn the key switch to ON again and make sure that the OPS lamp does not blink. *2: After correction, check if the drive OPS functions normally.

Turn the key switch ON, set the shift lever to either forward or reverse and leave the seat. Check if the drive OPS is activated.

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

Turn the key switch OFF, disconnect CN53 and CN54, and remove the relays from the T/C relay block.

Standard:

1 2 3 4 5 6 7 8 9 10 11 12 14 14 15 16 17 18

CN53 (REC) 1

Between CN53-5 and pin 4 of forward interrupt relay

Continuity

Between CN53-1 and pin 4 of reverse interrupt relay

Continuity

Between CN54-1 and pin 3 of forward interrupt relay

Continuity

Between CN54-2 and pin 3 of reverse interrupt relay

Continuity

CN53-6 ~ IG SW-4

Continuity

2

CN54 (REC) 2 3 4 IG SW

1-65 Inspection 2: Check the forward/reverse interrupt relay individually.

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

Standard:

1 4 2 (5) 3

RLY

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

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

• Without analyzer

1 2 3 4 5 6 7 8 9 10 11 12 14 14 15 16 17 18

CN53 (REC)

Standard:

1

Unseated

Seated

CN53-5 ~ CN54-1

No continuity

Continuity

CN53-1 ~ CN54-2

No continuity

Continuity

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

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST Standard: • Forward interrupt relay (RLY FWD) CN53-5 ~ CN54-1

Relay ON

Relay OFF

No continuity

Continuity

• Reverse interrupt relay (RLY REV) CN53-1 ~ CN54-2

Relay ON

Relay OFF

No continuity

Continuity

2

CN54 (REC)

1-66

z Traveling fails (Including forward traveling only, reverse traveling only, and occasional abnormalities)

CN6-8

CN53-6 CN53-5

REC

SFT To IG SW

REC TAB

Related Portion

Shift lever

T/C relay block

TAB REC

CN45-17 (E03, SW-GND)

CN46-6

2

4

1

3

CN53-1

Forward interrupt relay

CN45-11 (RYR, Reverse interrupt relay)

1

4

2

3 5

Reverse interrupt relay

CN45-3 (DRF, Forward drive switch) CN45-4 (DRR, Reverse drive switch)

TAB REC

TAB REC

OPS controller

CN45-10 (RYF, Forward interrupt relay)

CN46-1

CN52

CN46-11

7 TAB REC

1 CN54

2 REC

Shift SOL

Estimated Causes: c Connector contact defect d Forward interrupt relay defect e Reverse interrupt relay defect f Harness defect

Check if the OPS lamp blinks to indicate an error.

g Controller defect h Shift lever switch defect i Fuse defect

Yes

Perform troubleshooting according to the error code.

No

Perform troubleshooting for "OPS lamp keeps lighting".

NG

After correction, check if the OPS functions normally.*

NG

After correction, check if the OPS functions normally.*

No

Stay on the seat and check if the OPS lamp goes off.

Yes

Check if the fuse (SFT) is blown.

OK

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

OK

To be continued

NG

1-67 Continued

NG

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

Shift lever defect

OK

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

NG

Harness defect

OK

Inspection 3: Check the forward/reverse interrupt relay.

NG

Interrupt relay defect

OK

Controller defect

* After correction, check if the OPS functions normally.

Check that forward traveling is disabled if operator leaves the seat with key switch ON to activate the OPS, sets the shift lever to forward and then sits on the seat again.

Next, check that forward traveling is enabled if the shift lever is set to neutral once and then to forward again.

Inspection 1: Check the T/C shift lever unit individually for continuity.

Key switch OFF, CN53 disconnection.

9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10

Standard:

DIRECTION SWITCH

Lever at neutral

Lever at forward

Lever at reverse

Between pins 6 and 5 on lever side

No continuity

Continuity

No continuity

Between pins 6 and 1 on lever side

No continuity

No continuity

Continuity

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

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

Standard: 1 2 3 4 5 6 7 8 9

Between CN53-5 and pin 4 of forward interrupt relay

Continuity

10 11 12 14 14 15 16 17 18

Between CN53-1 and pin 4 of reverse interrupt relay

Continuity

CN53 (REC)

Between CN54-1 and pin 3 of forward interrupt relay

Continuity

Between CN54-2 and pin 3 of reverse interrupt relay

Continuity

CN53-6 ~ IG SW-4

Continuity

CN45-3 ~ CN53-5

Continuity

CN45-4 ~ CN53-1

Continuity

1

2

CN54 (REC) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

1-68 Inspection 3: Check the forward/reverse interrupt relay individually.

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

1 4 2 (5) 3

Standard:

RLY

Resistance Between forward interrupt relay pins 1 and 2

Approx. 90 Ω (at 20°C)

Between reverse interrupt relay pins 1 and 2

Approx. 90 Ω (at 20°C)

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

• Without analyzer 1 2 3 4 5 6 7 8 9 10 11 12 14 14 15 16 17 18

Standard: Unseated

Seated

CN53-5 ~ CN54-1

No continuity

Continuity

CN53-1 ~ CN54-2

No continuity

Continuity

CN53 (REC)

1

2

CN54 (REC)

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

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST Standard: • RLY FWD CN53-5 ~ CN54-1

Relay ON

Relay OFF

No continuity

Continuity

Relay ON

Relay OFF

No continuity

Continuity

• RLY REV CN53-1 ~ CN54-2

2-1

BODY Page

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

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

2

2-2

COMPONENTS 5701

STD 4

1

PA 2

36A

VZ

QY

1 4

PA

3

MF WG 36A PG

QY MF WE PG 3

2

LN

WS LN

GU

RQ

RQ

RQ

WS

EP

LY

WE LN GH VZ

GH GU

WA 5701-467

5701

UL spec.

4

1

PA 2 VZ

QY

1 36A

4 PA

3

MF WG 36A

PG

QY MF WE PG 3

2 WS RQ

LN LN RQ

RQ

EP

WE TY WS KZ

PN

GU

TZ VZ EP

36 KK

GU WT

VZ

LN FS

KZ

LY LY 5701-468

2-3

RELAY BLOCK Layout

Front

OPS LAMP

2

GOV

OPS lamp relay

Front

T/C FR T/C RR

T/C relay

RELAY INSPECTION Head/tail relay

Individual Relay Continuity Inspection

Measurement state

Measurement positions

Standard

Head/tail relay ST relay

Normal state When the battery voltage is applied to terminals 1 and 2:

1-2

Continuity

3-5

No continuity

3-5

Continuity

1-2

No continuity

3-4

Continuity

1-2

Continuity

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

Normal state When the battery voltage is applied to terminals 3 and 4:

SAS-LAMP relay, OPS lamp relay, T/C FR relay, T/C RR relay Normal state When the battery voltage is applied to terminals 1 and 2:

1-2, 3-4

Continuity

3-4

No continuity

2-4

PORTIONS PROTECTED BY FUSES NO

Name

Capacity

Main protected portions

–

–

–

TWC

7.5A

TWC (3-way catalytic) system

ST (Starting motor)

7.5A

Starting motor relay (IG) and glow plug timer (IG)

SFT (Shift)

7.5A

Electric shift T/C

ECU-IG

7.5A

SAS controller and SAS lamp relay

IGN (Ignition)

7.5A

Alternator, glow plug timer, ignition coil, LPG solenoid, fuel cut and vehicle speed control system

TURN (Turn)

7.5A

Turn signal lamp and flasher relay

GAUGE (Meter)

10A

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

EFI

15A

EFI injector, EFI fuel pump

GOV

15A

Governor ECU, EFI ECU, Electronic throttle body

HORN (Horn)

7.5A

Horn

ALT-S (Alternator sending)

5A

Alternator sending

HEAD (Headlamp)

15A

Headlamp

CHARGE (Charge)

7.5A

Charge lamp, choke and glow plug timer

TAIL (Tail)

7.5A

Tail lamp, clearance lamp and meter illumination

ECU-B

7.5A

OPS controller

STOP (Stop lamp)

7.5A

Stop lamp

Including options Fusible links NO.

Name

Capacity

FL

GOV

30A

FL

AM1

40A

FL

HEAD

40A

FL

GLOW

60A

Type

Cartridge type

Screw-fastened type

FL

ALT

80A

2-5

SEAT SWITCH INSPECTION Push on the seat cushion and check continuity of the seat switch.

Measurement terminals: Seat switch connector terminals CN50-1 and CN50-2 Standards: Not pressed: OFF (∞ Ω) Pressed: ON (0 Ω)

2

3-1

MATERIAL HANDLING SYSTEM Page

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

OIL LEAK TEST ...................................................3-4 LIFT CYLINDER ....................................................3-4 TILT CYLINDER ....................................................3-4

3

3-2

COMPONENTS 6801

3-3

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 59 in), and stop the engine.

2.

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

Limit: W/SAS, L/SAS

45 mm (1.77 in)

NATURAL FORWARD TILT TEST 1.

Set the mast in the vertical position with standard load on the fork. Lift the fork by about 50 cm (19.7 in) and stop the engine.

2.

Measure the tilt cylinder rod extension in 15 minutes.

Vehicle model

Natural forward tilt amount mm (in) W/SAS, L/SAS

Pn1 ton series Pn · Cu2 ton series Pn · Cu3 ton series

W/SAS, L/SAS: 15 (0.59) or less W/SAS, L/SAS: 20 (0.79) or less W/SAS, L/SAS: 25 (0.98) or less

3

3-4

OIL LEAK TEST LIFT CYLINDER 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 59 in).

2.

Slowly tilt the mast fully forward, and stop the engine. After 5 minutes, disconnect the oil control valve to oil tank hose.

Place a measuring cylinder under the elbow and measure the amount of oil leaking in one minute.

Standard (at lift port): W/SAS, L/SAS 8 cm3 (0.49 in3) or less Note: If the natural drop is great even though the oil leak amount is within the standard, the lift cylinder packing is defective.

TILT CYLINDER 1.

Set the mast in the vertical position with standard load on the fork. Lift the fork by about 50 cm (19.7 in) and stop the engine.

2.

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

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

3.

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

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

4-1

OIL CONTROL VALVE Page

GENERAL (W/SAS AND L/SAS).........................4-2 SPECIFICATIONS................................................4-7 COMPONENTS ....................................................4-7 OIL CONTROL VALVE ASSY .............................4-8 REMOVAL · INSTALLATION ..................................4-8 DISASSEMBLY · INSPECTION · REASSEMBLY ......4-9

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

4

4-2

GENERAL (W/SAS AND L/SAS)

X1

T2 X2

OUT

R

X3

X4

C2 C4

P X1

C5 X4

C1 C3 X2

X3

T1

4-3 X1-X1

Flow divider valve

Relief valve

4

Unloading SOL

X2-X2

Lift lock SOL

Manual down valve

Lift spool

Lower limit switch

4-4 X3-X3

Tilt control SOL

Tilt spool

Backward tilt limit switch

Forward tilt limit switch

X4-X4

Attachment spool

4-5

Solenoid Connector

Lift limit switch connector

Lift lock solenoid connector

4 Unload solenoid connector

Tilt control solenoid connector

Tilt limit switch connector

4-6

Hydraulic Circuit Diagram T2

R P

(1)

OUT

(2)

C1

(3)

C2 C3

C4 C5

T1

(1) Unloading SOL (2) Lift lock SOL (3) Tilt control SOL R: Gauge port

4-7

SPECIFICATIONS Vehicle model Item

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

Type

Pn 3 ton series Add-on type

Relief set pressure

Lift

18.7 (191) [2720]

←

MPa (kgf/cm2 [psi])

Tilt

15.7 (160) [2280]

←

13.0 (3.43)

Pn 15.2 (4.02)

Built-in frow divider valve

←

Flow divider valve frow rate l/min (US gal/min) Others

COMPONENTS 6705

4-8

OIL CONTROL VALVE ASSY REMOVAL · INSTALLATION

T=N·m (kgf·cm) [ft·lbf] 6

T=61 (620) [44.9]

5

7 5

5

Removal Procedure 1 2 3 4 5 6 7 8 9

Remove the toe board.

Remove the lower panel.

Remove the instrument panel RH. Disconnect the lever rod.

Disconnect the piping.

Disconnect the connector.

Remove the oil control valve W/bracket.

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

Remove the oil control valve.

Remove the fitting.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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

4-9

DISASSEMBLY · INSPECTION · REASSEMBLY Note: • Select a clean location for operation.

• Since each part is finished with high precision, carefully operate so as not to damage it.

T=N·m (kgf·cm) [ft·lbf]

8

9

8 3

9

7

6

1

10 4 2 4 4

5

11

2

5 10

11

5

T=39.2 (400) [28.9]

Disassembly Procedure 1 2 3 4 5 6 7 8 9 10 11

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

Remove the rod bolt and the housing.

Reassembly Procedure The assembly procedure is the reverse of the disassembly procedure.

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

4-10

Point Operations [Point 1] Disassembly: Provide a match marks on each solenoid to ensure installation in the correct position.

Inspection: Check the lift solenoid for continuity.

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

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

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

[Point 2] Inspection: Check the lift limit switch for continuity.

4-11 [Point 3] Washer

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

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

SST

[Point 4] Inspection: Check the tilt solenoid for continuity.

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

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

Reassembly: Carefully prevent incorrect installation of each solenoid spool.

[Point 5] Inspection: Check the tilt limit switch for continuity.

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

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

Reassembly: Carefully prevent confusion between forward and backward tilt limit switches.

4-12 [Point 6] Washer

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

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

SST

[Point 7] Inspection: Check the unload solenoid for continuity.

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

[Point 8] Inspection: Check the orifice for any clogging and clean it if clogged.

[Point 9] Inspection: Check the filter for any clogging, and clean it if clogged.

4-13 Reassembly: When the relief valve is disassembled, temporarily install it after setting the nuts as illustrated.

a

a = 27.0 mm (0.62 in)

4-14

RELIEF PRESSURE ADJUSTMENT Note: • Since the relief valve is structured in two stages, always adjust the relief pressure in the correct order: the lift (high pressure) side first and the tilt (low pressure) side later. (If the lift side is normal and the tilt side is abnormal as the result of relief pressure inspection, it is allowed to adjust only the tilt side pressure.)

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

• Make sure that the no-load maximum speed is as specified before the adjustment operation.

1.

Install an oil pressure gauge.

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

Plug size: 9/16-18UNF Fitting size: 9/16-18UNF ² PF1/4 Fitting: 90407-13469-71

9/16-18 UNF Fitting

2.

Adjusting screw A Lock nut 1

Set adjusting screw A and adjusting sleeve B of the relief valve as follows: (1)

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

(2)

Loosen lock nut 2, and position adjusting sleeve B to satisfy the following dimension:

a

Adjusting sleeve B Lock nut 2

a = 27 mm (0.62 in)

3.

4.

5.

6.

7.

Start the engine and check for any oil leak or abnormal noise.

Adjust the lift side relief pressure.

(1)

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

(2)

Operate the lift lever to raise the fork to the uppermost position.

(3)

With the engine running at the maximum speed, operate the lift lever to the lift side. Gradually tighten adjusting sleeve B to adjust the oil pressure in the relief state to satisfy the standard below for adjustment, and fix it by turning lock nut 2.

Adjust the tilt side relief pressure.

(1)

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

(2)

Operate the tilt lever to tilt the mast fully backward.

(3)

With engine running at the maximum speed, operate the tilt lever to the backward side. Gradually tighten adjusting screw A to adjust the oil pressure in the relief state to satisfy the standard below. Then fix the position by tightening lock nut 1.

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

4-15

Standards

Unit: MPa (kgf/cm2) [psi]

Standards

All models

Lift side relief pressure

+17 +240 18.7 +1.7 0 (191 0 )[2720 0 ]

Tilt side relief pressure

+17 +240 15.7 +1.7 0 (160 0 )[2280 0 ]

4-16

LIFT LOCK RELEASE BOLT

T=N·m (kgf·cm) [ft·lbf] Lift lock unlocking bolt T = 28.8~35.2 (294~359) [21.3~26.0]

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

After the repair, tighten it appropriately.

5-1

SAS Page

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

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

5

5-2

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

List of Reference Pages for Error Codes and Sub Error Codes Without analyzer (SST) Error code

63

64

Error description

Tilt lever switch abnormality

Tilt solenoid abnormality

With analyzer (SST) Page

5-3

5-5

Error code

Error description

Page

63-1

Tilt lever switch simultaneous ON

5-3

63-2

Forward tilt switch short circuit for 2 minutes

5-3

63-3

Backward tilt switch short circuit for 2 minutes

5-3

64-1

Tilt solenoid abnormality

5-5

List of Pages to be Referenced by Phenomenon

Active mast function controller

Description The active mast rear tilt speed control is not regulated, or the backward tilting speed is always slow.

The mast does not perform front tilt.

Page to be referenced Without analyzer

With analyzer

5-7

5-10

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

5-3

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

CN1-23 (E02, SW-GND)

CN45-20

CN46-10

REC TAB

CN1-9 (MR, Backward tilt switch)

CN45-22 CN45-21 TAB REC

TAB REC

SAS controller

CN1-10 (MF, Forward tilt switch)

CN45-17

J1

CN45-24

OPS controller

Related Portion

CN45-25

REC TAB

CN34-1 CN34-2 CN34-3 CN34-4

Forward tilt switch Backward tilt switch

Estimated Causes: c Connector contact defect d Harness defect e Forward tilt switch defect

f Backward tilt switch defect g Tilt switch installation defect h Controller defect

Error code 63

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

NG

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

OK

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

OK

SAS controller defect

NG

Inspection 2: Check continuity between CN1 and CN45.

NG

Harness defect

OK

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

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

5

5-4 Inspection 1: Check continuity through the tilt lever switch wiring.

Turn the ignition switch OFF and disconnect CN1.

CN1 (REC)

Standard: Lever at neutral position

Lever at forward tilt position

Lever at backward tilt position

CN1-10 (+) ~ CN1-23 (-)

No continuity

Continuity

No continuity

CN1-9 (+) ~ CN1-23 (-)

No continuity

No continuity

Continuity

CN1-10 (-) ~ CN1-23 (+)

No continuity

Continuity

No continuity

CN1-9 (-) ~ CN1-23 (+)

No continuity

No continuity

Continuity

Circuit tester Digital type Analog type

Inspection 2: Check continuity between CN1 and CN45.

Turn the key switch OFF and disconnect CN1 and CN45.

CN1 (REC)

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45 (REC)

5-5

z Error Code 64 · 64-1 (Tilt solenoid abnormality) Related Portion

OPS controller

CN45-29 CN45-30

REC TAB

CN45-5

TAB REC CN1-24 (E1, main GND)

CN46-8

REC TAB

CN45-12

TAB REC

SAS controller

CN1-13 (TILT, Tilt solenoid)

CN12-1 Tilt solenoid CN12-2

CN46-9

5

(E3, body ground)

Estimated Causes: c Connector contact defect d Harness defect

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

f SAS controller defect g OPS controller defect

NG

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

OK

Inspection 1: Check continuity between CN1 and CN45.

NG

Harness defect

OK

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

NG

OPS controller defect

OK

SAS controller defect

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

Start the engine and operate for forward/backward tilting to check if the SAS lamp blinks.

The SAS lamp must not blink.

5-6 Inspection 1: Check continuity between CN1 and CN45.

Key switch OFF, CN1 and CN45 disconnection.

(Keep CN46 connected and also keep the body ground connected to the frame.)

Standard: • Discontinuity check CN1-13 ~ CN45-5: Continuity CN1-24 ~ CN45-29: Continuity CN1-24 ~ CN45-30: Continuity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN1 (REC)

CN45 (REC)

• GND fault check CN1-13 ~ CN1-24: No continuity • +B shorting check CN45-5 ~ CN45-32: No continuity • Ignition line shorting check CN1-13 ~ CN1-11: No continuity Inspection 2: Measure the resistance between input pins of the OPS controller.

Key switch OFF, CN45 disconnection.

16 15 14 13 12 11 10 9

8

7

6

5

4

3

2

1

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

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

CN45 (TAB)

5-7

TROUBLESHOOTING BY PHENOMENON z The mast backward tilting speed is always slow or unrestrected.

Related Portion

Active fork leveling switch

Active fork leveling switch

Controller

(MN Tilt knob SW)

(E02 SW-GND)

Controller

(E02, SW-GND) (MH1, Lifting height sensor 1) (MH21, Lifting height sensor 21)

Lifting height switch

Lifting height switch

5-8 Without analyzer

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

NO

Stopping with automatic leveling occurs upon automatic leveling switch operation when the fork is raised to approx.

500 mm (19.6 in) without a load.

OK

YES

NG

Check connectors CN1 and CN33 for disconnection or internal wetting.

NG

OK

Inspection1 Check the automatic leveling switch wiring for continuity.

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

NG

OK

Controller defect.

NG

Automatic leveling switch defect.

NG

Inspection 2 Check continuity of the automatic leveling switch alone.

OK

Inspection 3 Check continuity between CN1 and CN33.

NG

Harness defect.

OK

CN33 connector defect.

Inspection 4 Check continuity of the fork height switch alone.

NG

Fork height switch abnormality.

OK

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

5-9 Inspection 1: Check continuity of the active fork leveling switch wiring.

Key switch OFF, CN1 disconnection.

CN1 (REC)

Standard: Active fork leveling switch free

Active fork leveling switch depressed

No continuity

Continuity

CN1-8 ~ CN1-23

Inspection 2: Check continuity of the active fork leveling switch only.

Switch OFF, CN33 disconnection.

Standard:

CN33-1 ~ CN33-2

Active fork leveling switch free

Active fork leveling switch depressed

No continuity

Continuity

CN33 (TAB)

Inspection 3: Check continuity between CN1 and CN33.

Turn the key switch OFF and disconnect CN1 and CN33.

CN1 (REC)

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

CN33 (REC)

Inspection 4: Check continuity of the lifting height switch only.

Key switch OFF, CN31 disconnection.

CN31 (REC)

Standard: Low lifting height

High lifting height

CN31-1 ~ CN31-2

Continuity

No continuity

CN31-1 ~ CN31-3

No continuity

Continuity

5-10 With analyzer OK

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

NG

Check for slip off of the CN1 and CN33 connectors.

After correction, check the backward tilting speed.

NG

OK

NG

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

OK

CN1 connector or controller defect

NG

Active fork leveling switch defect

NG

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

OK

Inspection 4 Check continuity between CN1 and CN33.

NG

Harness defect

OK

CN33 connector defect.

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

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

OK

NG

Inspection 6 Check continuity of the individual lifting height switch.

NG

Lifting height switch defect

OK

Controller defect.

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

Turn the key switch ON (with the engine in stopped state).

Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA Standard:

KNOB

Active fork leveling switch free

Active fork leveling switch depressed

OFF

ON

5-11 Inspection 2: Check continuity of the active fork leveling switch wiring.

Key switch OFF, CN1 disconnection.

Standard:

CN1-8 ~ CN1-23

Active fork leveling switch free

Active fork leveling switch depressed

No continuity

Continuity

CN1 (REC)

Inspection 3: Check continuity of the active fork leveling switch only.

Key switch OFF, CN33 disconnection.

Standard:

CN33-1 ~ CN33-2

Active fork leveling switch free

Active fork leveling switch depressed

No continuity

Continuity CN33 (TAB)

Inspection 4: Check continuity between CN1 and CN33.

Key switch OFF, CN1 and CN33 disconnection.

Standard: CN1-8 ~ CN33-1: Continuity

CN1 (REC)

CN1-23 ~ CN33-2: Continuity Inspection 5: CN33 (REC)

Check the output signal of the lifting height switch.

Turn the key switch ON (start the engine).

Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA Standard: When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SW1: ON SW21:OFF SW22:OFF Inspection 6: Check continuity of the lifting height switch only.

Key switch OFF, CN31 disconnection.

Standard: Low lifting height

High lifting height

CN31-1 ~ CN31-2

Continuity

No continuity

CN31-1 ~ CN31-3

No continuity

Continuity

CN31 (REC)

5-12

CONNECTOR LAYOUT (SAS, OPS)

MAST SW1 COMB MET HOUR MET SAS LP SWN LOCP LP

PRES SSR TAB REC

CN31

CN26

SAS BZR OPS BZR (Export model) TAB REC

REC TAB

UNLORD SOL REC TAB CN3 TAB REC

CN51

SPD SSR FPC TAB REC

CN47

CN22 CN41 CN42

TAB REC

TAB REC

SAS CONTROLLER

CN45

CN43

NTRLTILT SW

OPS-LAMP RLY (OPS R/B)

OPS CONTROLLER

CN1

TAB REC

TAB REC

TAB REC

CN33

CN27

CN2

TAB REC

CN46

CN37

REC TAB

CN49

REC TAB

CN48

TAB REC

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

TAB REC

HOUR MET CNN TAB REC

CN35

LIFT SW

DIODE A

SFT SOL

TAB REC

TAB REC

CN55

DOWN LOCK SOL

CN12 REC TAB

TILT SOL

CN54

REC TAB

CN34

TILT SW1 TILT SW2

EZ F/SFT RLY

SAS RE-SETTING CN TAB REC TAB REC

DIAG SW (CHKR)

EZ R/SFT RLY CN52

FR W/H

CN57

CN44 REC TAB

CN4

REC TAB

FR W/H

CN65 CN5

TAB REC

TAB REC

CN6

TAB REC

CN8

TAB REC

CN9

E/G W/H

SIDE W/H

SEAT SW SAS-LAMP RLY (R/B)

TAB REC

BODY EARTH03 SIDE HOOD W/H W/H TAB REC

SIDE W/H

RR LWR W/H

REC TAB

TAB REC

W/H: Wire harness

CN50

CN7

CN11

SWN SOL

CN60

TILT AGL SSR

5-13

W/SPLICE-C

3 CN6

GAUGE (10A)

JOINT3

SEAT SWITCH

2 CN50

JOINT1

14 CN65

JOINT4

SOLENOID RB

SOLENOID FB

7 CN52

TILT SWITCH RB

T/C RR RELAY

TILT SWITCH FB

T/C FR RELAY

EZ PEDAL

(MH1)

(E02)

(MH21)

(MH21)

(MH22)

(MH22)

SAS spec.

SAS less spec.

DIODE A

W/SPLICE-F 1 CN46

DIRECTION SWITCH RR

CN52 8

1 CN50

11 CN46 6 CN46

6 CN4

TILT ANGLE SENSOR

SAS RE-SETTING CONNECTOR DIAG CONNECTOR

MAST SWITCH

3 CN46

-

+

YAW RATE SENSOR +

T

5T

SPD-

SPD+

MA

5MA

SA

5SA

5PRS

PRES

MH22 E01

MH21

SS2

SS1

SSC

SW2

SW1

MN

MR

MF

IG

MH1

SPD

SPDF

TILT

SWN

HRM3

HRM2

HRM1

OUT1

RLY E1

SIL

DIODE A

TRG

SAS CONTROLLER STRG

TGND

TRO

TFO

BZO

RYLP

E2

TCON

SOL3

PRESS SENSOR +

4 7 CN3 CN3

OPS BUZZER (EXPORT MODEL) E02

JOINT3

See Table1.

1 CN3 2 CN3

JOINT2

SHIFT SOLENOID RB

JOINT4

W/SPLICE-A

YB1

7 CN52

W/SPLICE-F 5 CN4

CHKR

OPS CONTROLLER

SPEED SENSOR

TRG SWING SOLENOID

SAS-LAMP RELAY

SIL

11 CN5 10 CN5

PLUG-IN ANALYZER

RYR

RYF

11 CN46 DRR

8 CN52 1 CN46 DRF

IG E0

COMBINATION METER L

3 CN58

SHIFT SOLENOID FB

5 CN52

UNLOAD SOLENOID

TO E03

2 CN46

W/SPLICE-Z

TILT SOLENOID

T/C RR RELAY

DOWN LOCK SOLENOID

T/C FR RELAY

SOL2

9 CN46 8 CN46

SIL

10 CN46

6 CN57

E3

E3

3 CN57

SOL1

BCIN

EZ MAIN RELAY CN52 2

NEUTRAL TILT SWITCH

OPS CONTROLLER

W/SPLICE-Y

IG IG

CN46 5 4 CN46

DMI

DMO

SPI2

TRI

SPI1

DGND

BATT BCON

TFI

DOWN

E03

RYR

EZ RR SFT RELAY

DRR

SAS SYSTEM DRF

CN52 4 EZ FR SFT RELAY

RYF

DIRECTION SWITCH FR

PARKING SWITCH

(MH1)

(E02)

5 CN6

ECU-B(7.5A)

5 CN52

STARTER RELAY

Table 1 A

SHIFT LEVER

ECU-IG (7.5A)

LIFT SWITCH

IG1

10 CN6

BUS BAR

FL AM1 (40A)

6 CN6

SFT (7.5A)

8 CN6

CONTROLLER SEQUENCE (SAS, OPS)

OPS-LAMP RELAY

L

L

OPS SAS LOCK LAMP WARNING INDICATOR LAMP

SPEED CONTROLLER

5-14

CONNECTOR DIAGRAMS (SAS, OPS) CN1 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 REC

TAB No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

C

No. C 1 G2 V 3 L4 L-B 5 L-W 6 LG-B 7 LG 8 P-G 9 Y-B 10 Y 11 B-R 12 13 L14 G-R 15 16 17 Y-G 18 G-Y 19 20 21 22 BR23 BR24 W-B 25 L-B 26 -

J 5PRS SIL MH1 MH21 MH22 SW2 SW1 MN MR MF IG TLT2 TLT1 5MA 5T YR MA PRES T SA E01 E02 E1 SWN STRG

J CN3-1 CN46-3 CN3-7 CN3-4 CN3-5 CN44-23 CN35-1 CN33-1 CN45-21 CN45-22 W/SPLICE-Y(IG) CN45-5 CN27-1 CN27-2 CN3-2 W/SPLICE-A W/SPLICE-A BODY EARTH05 CN4-7 -

CN2 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TAB No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C

J RLY HRM1 SPD+ SPDSS1 SS2 5SA OUT1 SPDF HRM3 HRM2 SPD SSC YB1 TRG

REC No. C 1 L-W 2 3 V-G 4 G-B 5 G-R 6 7 8 9 L-O 10 P-B 11 P-L 12 V-R 13 G-B 14 15 16 L-B

J CN5-11 CN41-4 CN22-1 CN22-2 CN42-9 CN6-5 CN42-12 CN41-3 * CN44-14

5-15

CN3

CN4

4

3

2

1

1

2

3

4

8

7

6

5

5

6

7

8

TAB No. C 1 G 2 G-Y 3 BR 4 L-B BR 5 L-W 6 7 L 8 -

J CN1-1 CN1-18 W/SPLICE-A(E) CN1-4 W/SPLICE-A(E) CN1-5 CN1-3 -

2

1

1

2

3

6

5

4

4

5

6

TAB

REC No. C 1 G 2 G-Y 3 BR-W 4 L-B BR 5 L-W 6 7 L 8 -

3

No. C 1 2 Y 3 Y-G 4 B-L 5 L-B 6 G-W

J CN26-3 CN26-2 CN31-1 CN31-3 CN26-1 * CN31-2 -

REC

J * * * CN7-1 CN50-1

No. C 1 Y-B 2 Y 3 Y-G 4 B-L 5 L-B 6 G-W

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

CN5 4

3

2

1

1

2

3

4

8

7

6

5

5

6

7

8

12 11 10

9

9

10 11 12

TAB No. 1 2 3 4 5 6 7 8 9 10 11

C R-L R-B R-W G-Y R-G W LG-B G G-W P-G L-W

J * * * * * CN45-23

J * * * * * * * BODY EARTH 05 CN45-32 CN41-1 CN2-1 BODY EARTH 02 or 12 W-B or B BODY EARTH 04 or DIODE ST

REC No. C J 1 R-L * 2 R-B * 3 R-W * 4 G-Y * 5 R-Y * 6 W * 7 LG * 8 * 9 * 10 P-G SAS-LAMP RLY(B) 11 L-W SAS-LAMP RLY(+S) 12 W-B ST RYL(-S) or SAS-LAMP RLY(L)

5-16

CN6 3

2

5

CN11

1

1

4

4

5

6

6

8 10

11

7

7

9

9

8 10

11

J * * W/SPLICE-Y (IG) * * * * * * -

C -

REC

J Phorting: (+) Phorting: (-)

No. C 1 L-B 2 W-B

1

1

TAB

No. 1 2

2

J CN7-1 CN7-2

1

TAB

1

2

CN12

CN7

No. C 1 L-B 2 W-B

1

TAB No. 1 2

2

2

1

REC No. C J 1 B* 2 B-W * 3 B-R F=ECU-IG (L) 4 B-W * 5 6 B-Y * 7 8 L * 9 10 W-L * 11 -

TAB No. C 1 B2 B-W 3 B-R 4 B-W 5 R 6 B-Y 7 LG-R 8 L 9 10 W-L 11 -

2

3

2

C R B

2

REC

J Phorting: (+) Phorting: (-)

No. C 1 GR-R 2 W-B

J CN45-12 W/ SPLICE-Z (E)

REC

J CN4-5 BODY EARTH 03

No. C 1 L-B 2 W-B

J CN11-1 CN11-2

CN22 2

CN8

1

1

TAB 3

2

1

1

2

3

6

5

4

4

5

6

TAB No. C 1 P-B 2 R-W 3 W-B 4 Y-B 5 G-B 6 -

J * * OPS LAMP RLY(L) * * -

REC No. C 1 P 2 3 W-B 4 Y-B 5 L 6 -

J * SAS LAMP RLY(L) * * -

No. 1 2

C

2

REC J +S -S

No. C 1 G-B 2 G-R

J CN2-4 CN2-5

5-17

CN26 3

2

CN33 1

1

TAB No. 1 2 3

C -

2

2

3

REC

J GND (Ground) Vout (output) Vcc power supply

No. C 1 BR 2 G-Y 3 G

1

1

TAB

J CN3-5 CN3-2 CN3-1

No. C 1 BR 2 BR

2

REC

J 5V or GND GND or 5V

No. C 1 P-G 2 BR

J CN1-8 W/SPLICE-A

CN34

2

1

1

TAB No. 1 2 3

C -

1

1

2

4

3

3

4

REC

TAB

CN27 3

2

2

3

No. C J 1 R Forward tilt side (+) 2 BR Forward tilt side (-) 3 R Backward tilt side (+) 4 B Backward tilt side (-)

No. C 1 P-G 2 BR-W 3 P-L 4 BR-W

REC

J Power supply Sensor output GND

No. C 1 G 2 Y-G 3 BR

J CN1-14 CN1-17 W/SPLICE-A

CN35 1

1

TAB No. C 1 BR-

CN31 3

2

1

1

TAB No. C 1 BR-W 2 L 3 L-B

J CN45-25 JOINT 1 CN45-24 JOINT 1

J CN3-3 CN3-7 CN3-4

2

3

REC No. C 1 BR 2 W 3 R

J COM NC NO

REC J

No. C 1 LG-

J CN1-7

5-18

CN37 2

1

1

TAB No. C 1 P-G 2 W-B

CN43 2

2

1

1

2

REC

J CN5-10 BODY EARTH02

No. C 1 L-W 2 Y-B

J CN43-1 CN41-6

TAB No. 1 2

C B R

REC

J GND Power supply

No. C 1 L-W 2 R-G

J SAS relay Fuse

CN41 CN44 1 2 3 4 5 6

7 8 9 10 11 12 13 1 2 3 REC

No. C J 1 P-G CN5-10 2 Y-R * 3 V-R CN12-2 4 V-G CN2-3 5 * 6 Y-B CN37-2 7 W-B BODY EARTH02 8 V* 9 10 LG-R * 11 Y-G * 12 G OPS-LAMP RLY (B) 13 Y*

CN42 1 2 3 4 5 6

4

5 6

18

10 11 20

19

12 13 14 15 16 17 21 22 23 REC No. C J 1 V JOINT 2 or CN46-3 2 * 3 BR-W W/SPLICE-B(E) : : : : : 12 B-R W/ SPLICE-Y (IG) 13 * 14 L-B CN2-16 : : 22 BR W/ SPLICE-A (E) 23 LG-B CN1-6

7 8 9 10 11 12 13 REC

No. C 1 V-G 2 LG-B 3 W-B 4 R-W 5 6 R-G 7 Y-B 8 R9 L-O 10 11 R-L 12 P-L 13 W-B

7 8 9

J * * BODY EARTH02 * * * * CN2-9 * CN2-11 BODY EARTH02

SAS Lamp relay (Base side) 3(B) 5 1 4 2 (+S) (L) (-S)

No. C 1 L-W 2 B-R 3 P-G 4 W-B 5 -

J CN5-11 F=ECU-IG CN5-10 CN5-12,CN8-3 -

5-19

CN45

16 15 14 13 12 11 10 9

8

7

6

5

4

3

1

2

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

2

1

3

4

5

6

7

9 10 11 12 13 14 15 16

8

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 REC

TAB No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

J SIL DRF DRR TCON RYLP BZO RYF RYR SOL3 SOL2 SOL1 IG IG2 E03 TGND TRO TFO DMI TRI TFI DOWN E3 E3 E2 BATT

C

J No. C CN46-3 1 V 2 CN46-1 3 G-R CN46-11 4 R CN1-13 5 L 6 7 8 O OPS-LAMP RLY (-S) CN51-2 9 W-G T/C FR RLY (+S) 10 G T/C RR RLY (+S) 11 Y-R CN12-1 12 GR-R CN48-1 13 GR-L CN47-1 14 GR-G CN46-5 15 B-R CN46-4 16 B-R CN46-6 17 BR-W 18 19 CN46-10 20 BR CN1-9 21 Y-B CN1-10 22 Y CN4-6 23 G-W CN34-3 24 P-L CN34-1 25 P-G CN49-1 26 P-B 27 28 29 W-B CN46-9 30 W-B CN46-8 31 W-B CN46-2 32 W-R CN58-9

CN46 5 11 10

3

4 9

2 8

1

1 7

6

6

7

TAB No. C 1 G-R 2 W-B 3 V 4 B-R 5 B-R 6 BR-W 7 8 W-B 9 W-B 10 BR 11 R

J CN45-3 CN45-31 CN45-1 CN45-16 CN45-15 CN45-17 CN45-30 CN45-29 CN45-20 CN45-4

3

2 8

4 9

5 10 11

REC No. C 1 G-R 2 W-B 3 V 4 B-R 5 B-R 6 BR-W 7 8 W-B 9 W-B 10 BR 11 R

J T/C FR RLY (B) BODY EARTH10 CN1-2 or CN44-1 W/SPLICE-Y (IG) W/SPLICE-Y (IG) T/C RR RLY (-S) W/SPLICE-Z (E) W/SPLICE-Z (E) W/SPLICE-A (E) T/C RR RLY (B)

5-20

CN47 2

1

1

2

J -

C W W

No. C 1 GR-G 2 W-B

J CN45-14 W/ SPLICE-Z (E)

CN48 2

1

1

TAB No. 1 2

4

3

2

1

1

2

3

4

8

7

6

5

5

6

7

8

REC

TAB No. 1 2

CN52

TAB No. 1 2 3 4 5 6 7 8

C Y-R G L-B L L-W L-R W-B

J -

No. C 1 GR-L 2 W-B

No. 1 2 3 4 5 6 7 8

C Y-R G R-Y G-W L-W L-R W-B

J * * * * T/C FR RLY (L) T/C RR RLY (L) BODY EARTH02

2

CN53 (LH SHIFT LEVER)

REC

C W W

REC

J * * * * CN54-1 CN54-2 W/SPLICE-F (E)

J CN45-13 W/ SPLICE-Z (E)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CN49 (RH SHIFT LEVER) 2

1

1

9 8 7 6 5 4 3 2 1

2

18 17 16 15 14 13 12 11 10 TAB No. 1 2

REC

C R B

J -

No. C 1 P-B 2 BR-W

REC

J CN45-26 JOINT1

No. C 1 R 2 R-Y 3 B/B-Y 4 5 G-R 6 L 7 B-W 8 R-G 9 10 11 12 13 14 15 16 17 18 -

CN50 2

1

1

TAB No. C 1 G-W 2 BR

2

REC J CN60-1 CN60-2

No. C 1 G-W 2 BR

J CN4-6 CN65-14

J T/C RR RLY (B) * * T/C FR RLY (B) CN6-8 * * -

CN51 2

1

1

TAB No. 1 2

C -

CN54

2

REC J -

No. C 1 B-R 2 W-G

2

J W/SPLICE-Y (IG) CN45-9

1

1

TAB No. 1 2

C -

2

REC J FB RB

No. C 1 L-W 2 L-R

J CN52-5 CN52-7

5-21

CN55

CN65 1 2 3

3 2 1

6 5 4

3 2 1

1 2 3

14 13 12 11 10 9 8 7 TAB No. 1 2 3

REC J + +

C -

No. C 1 L-W 2 W-B 3 L-R

J JOINT4 W/SPLICE-F (E) JOINT3

CN57

No. 1 2 3 4 5 6

3

2

1

1

2

3

6

5

4

4

5

6

TAB C J R-W * B * G-R SFT SOL RLY (FR) (NO) R-G * B-W * R SFT SOL RLY (RR) (NO)

REC No. 1 2 3 4 5 6

C R-W B G-R R-G B-W R

REC

TAB No. C 1 B-O 2 G 3 G-R 4 G-W 5 G-O 6 G-Y 7 G-B 8 B-Y 9 R-Y 10 V 11 V-W 12 B 13 R-G 14 BR

J * * T/C FR RLY (B) * * T/C RR RLY (B)

No. C 1 B-O 2 G 3 G-R 4 G-W 5 G-O 6 G-Y 7 G-B 8 B-Y 9 R-Y 10 V 11 V-W 12 B 13 R-G 14 BR

J * * * * * * * * * * * * * CN50-2

EZ FR SFT RLY 1

2

4

J * * * * * * * * * * * * * JOINT 1

EZ RR SFT RLY

3

1

5

4

REC No. 1 2 3 4 5

CN58 4

3

2 1

1

2

8

7 6 5

5

6 7 8

TAB No. 1 2 3 4 5 6 7 8

No. 1 2 3 4 5 6 7 8

C -

5

No. 1 2 3 4 5

C W-G L-B R W-B G-W

J * * CN57-6 * *

OPS-LAMP RLY (Base side)

J * * * * F=ECU-B * * *

C B-L B-O V-G B W-R B-Y G W-B

1

3 5 1 4

No. C 1 G-W BR 2

J CN45-8 W/SPLICE-Y (IG) CN8-3 CN41-12 -

2

REC J + -

2

REC No. C 1 O 2 B-R 3 W-B 4 G 5 -

1

TAB No. 1 2

3

REC

J * * CN57-3 * *

CN60 2

2

REC

J * * * * CN45-32 * * *

C B-L B-O V-G B W-R B-Y G W-B

3 4

C W-L L-B G-R W-B G-W

4 5 6

7 8 9 10 11 12 13 14

T/C FR RLY (Base side) T/C RR RLY (Base side)

J CN50-1 CN50-2

3

3

5

5

1 4

2

REC No. C 1 BR-W 2 G 3 L-W 4

G-R

5

-

J T/C RR RLY (-S) CN45-10 CN52-5 CN46-1, CN53-5 or CN57-3 -

1 4

2

REC J No. C 1 BR-W T/C FR RLY (-S),CN46-6 CN45-11 2 Y-R CN52-7 3 L-R CN46-11, 4 R CN53-1 or CN57-6 5 -

6-1

APPENDIX Page

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

6

6-2

SST LIST ★ : Newly adopted SST Section Illust.

Part number

Part name

★ 09240-23323-71

Plug-in analyzer

09610-10161-71

Oil control valve spring remover and replacer

1

4

{

{

6-3

SERVICE STANDARDS LIST METERIAL HANDLING SYSTEM Natural drop test Limit

W/SAS, L/SAS: 45 (1.77)

Pn1 ton series

Standard

W/SAS, L/SAS: 15 (0.59) or less

Pn ⋅ Cu2 ton series

Standard

W/SAS, L/SAS: 20 (0.79) or less

Pn ⋅ Cu3 ton series

Standard

W/SAS, L/SAS: 25 (0.98) or less

Natural drop

mm (in)

Natural forward tilt test

Natural forward tilt

mm (in)

Oil leak test Lift cylinder oil leak amount

cm3 (in3)

Standard

W/SAS, L/SAS: 8 (0.49) or less

Tilt cylinder oil leak amount (total for lift and tilt)

cm3 (in3)

Standard

W/SAS, L/SAS: 16 (0.98) or less

OIL CONTROL VALVE OIL CONTROL VALVE Lift Relief set pressure MPa (kgf/cm2)[psi]

Tilt

+1.7

+17

+240

+1.7

+17

+240

+1.7

+17

+240

Standard

18 .7 0 (191 0 )[2720 0 ]

Pn1 ⋅ Pn 2ton series and Cu2 ⋅ Cu 3ton series

Standard

15 .7 0 (160 0 )[2280 0 ]

Pn3ton series

Standard

14 .7 0 (150 0 )[2130 0 ]

6

6-4

WIRING DIAGRAM G

D

LP

G/ LP

GS

DS

LPS

Page

BATTERY, RELAY BOX

{

{

{

{

{

{

{

6-5

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

{

—

{

{

{

—

{

6-6

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

{

—

{

{

{

—

{

6-7

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

—

{

—

—

—

{

—

6-8

SAS AND OPS CONTROLLER

{

{

{

{

{

{

{

5-13

COMBINATION METER

{

{

{

{

{

{

{

6-9

COMBINATION METER (EZ PEDAL)

{

{

{

{

—

—

—

6-10

3-WAY CATALYTIC SYSTEM (G, GS)

{

—

—

—

{

—

—

6-11

3-WAY CATALYTIC SYSTEM (LP, LPS)

—

—

{

—

—

—

{

6-12

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

—

—

{

—

—

—

—

6-13

3-WAY CATALYTIC SYSTEM (G/LP)

—

—

—

{

—

—

—

6-14

NAME

Note: This manual shows only the wiring diagrams revised in August 2005. As for wiring diagrams not shown herein, refer to 7FGU/7FDU15-32 and 7FGCU20-32 Repair Manuals (Pub. Nos. CU027, CU027-1 and CU0272) and Parts & Service News, Ref. No. CB-4006 (issued in February 2004).

DISCONNECT SW (L-GS,DS,LPS)

BATTERY

W

W

V

B-Y

FL ALT 80A

FL AM1 40A W-L

ALT

B S IG L

W

FL GLOW 40A

W-L W-L

FL HEAD 40A

W

BUS BAR

US BAR

(UL-G,LP,G/LP)

RELAY BOX

B-W

B-Y

ST 7.5A

SFT 7.5A

B-W

L

B-R

B-O

IGN 7.5A

B-R

DOUBLE

B-Y

G-W

TURN 7.5A

FUSE IGN

B-Y

ECU-IG 7.5A

B-Y B-W

DOUBLE

R-Y

R-G

B-Y

GAUGE 10A

W-L

B

L-O

B-R

W-R

W

G R-W

G-Y

ALT-S 5A

TWC 7.5A

ECU-B 7.5A

STOP 7.5A

TAIL 7.5A

R-L R-B

DOUBLE HORN 7.5A

STARTER RLY

GLOW RLY

W

TAIL LP RLY

HEAD 15A

FUSE ALT-S

IG SW IG1 AM1 ST1

W-L

W-L

L-B

B

R

HEAD LP RLY

SAS WARNING LAMP RELAY

L-W

STARTER RELAY (COIL)

ELECTRIC SHIFT T/C

SAS ECU

ALTERNATOR, GLOW PLUG TIMER FUEL CUT SOL, GASOLINE SOL, LPG SOL IGNITION COIL, VSCS ECU (OPT)

TURN SIGNAL LAMP (OPT)

T/C OIL TEMPERATURE INDICATOR (OPT)

HOUR METER, WATER TEMP IND, FUEL IND BACK BUZZER (OPT), BACK UP LAMP (OPT)

HORN

ALTERNATOR SENSING

STARTER

THREE WAY CATALYTIC SYSTEM

GLOW PLUG (UL-D, DS)

OPS CONTROLLER

STOP LAMP (OPT)

TAIL LAMP (OPT), CLEARANCE LAMP (OPT)

HEAD LAMP, METER ILLUMINATION

6-5

BATTERY, RELAY BOX

6

B-Y

W

B-R

STARTER

RELAY BOX

FL ALT 80A

FL HEAD 40A

FL AM1 40A

BODY EARTH

B B W-L

B-Y B-Y

B-Y

W-L

W-B RLY2

STARTER RELAY B

B-L

(LP, LPS)

Rr N R

Ra

F1

F2

B N

B-W

B-R

SHIFT CONTROL SW

B

IG1

B

IG2

L

B-W

VF

G-R

SAFETY STARTSW (OPT)

L-W

VF2 ST

R-G

B-W

VR

ST 7.5A

B-W

R

Ra

RELAY BOX

R-Y

L

B-Y

SFT 7.5A

BZ

R-Y

B-Y

L-W

L-R

R

R-G

R-W

IG1

B-R

ST1

B-L

SLOW SOLENOID KEEP RELAY

R

W-B L-R

Y

T/C RR RELAY

W-B

LOCK

IG SW

TWC CONTROLLER

AM1

STARTER KEEP RELAY

W-B LFC

A See pages 6-12 ,13 ,14.

B

STA

W-B

W-B BODY EARTH

T/C FR RELAY

SOLENOID

W-B BODY EARTH

SOLENOID

W-B

GAUGE 10A

MOTION ALARM (OPT) W-B PARKING BRAKE LAMP (OPT)

RELEASE

AM1

EZ PEDAL

STARTER RELAY(+S)

IG1

ST1

IG SW

B-R

B

B-W RELAY BOX

EZ MAIN RELAY

SFT 7.5A

B-Y

PKB SWITCH

B-W

B-W

SAFETY STARTSW (OPT)

B-W

B-W

B-Y

B-W ST 7.5A

B B-R

B-R

STARTER SUB RELAY L

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: 3-WAY CATALYTIC SYSTEM) 6-6

B-Y

W

STARTER

FL ALT 80A

FL HEAD 40A

FL AM1 40A

RELAY BOX

B-R

BODY EARTH

B W-L

B

W-L

W-B

W-L

W-B

STARTER RELAY

AM1

B

IG1

ST1

W-B

B-W

B-R

R

IG SW

W-B BODY EARTH

SOLENOID

L-W

W-B

SOLENOID

B-Y

SAFETY STARTSW (OPT)

W-B

Y

BODY EARTH

L-R Rr

SHIFT CONTROL SW

B

N R

Ra

F1

F2

B-W

N

L-W

IG1 IG2 R-G

L

B-W

VF

B-W

G-R

VF2

T/C FR RELAY

ST

R

VR

L-R

Ra

B-W

RELAY BOX

B-W

R-Y

ST 7.5A

B-Y

T/C RR RELAY

L

W-B

R

BZ

W-B

SFT 7.5A

R-Y

MOTION ALARM (OPT)

R-W

LOCK

GAUGE 10A

R-G

W-B PARKING BRAKE LAMP (OPT)

RELEASE

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: LESS 3-WAY CATALYTIC SYSTEM) 6-7

B-Y

W

B-R

STARTER

RELAY BOX

FL ALT 80A

FL GLOW 60A

FL HEAD 40A

FL AM1 40A

BODY EARTH

B B

B W-B GLOW PLUG G-R

GLOW PLUG TIMER

Y

R

ALT (L)

LG-B

W-B

R

IG SW (IG1)

GLOW RELAY MAIN

IGN 7.5A

B-O W-B

W-B

R-G

R-G

GAUGE 10A

GLOW

WATER TEMP SENSOR

RELAY BOX

W-L

B

W-L

W-B

W-L

W-B

STARTER RELAY

AM1

Rr

SHIFT CONTROL SW

N R

Ra

F1

F2

B

N

B-W

B-R

IG1 IG2

L

B-W

VF

G-R

SAFETY STARTSW (OPT)

L-W

VF2 ST

R-G

B-W

VR

ST 7.5A

B-W

R

B-Y

L-W

L-R

Ra

RELAY BOX

R-Y

L

B-Y

BZ

R

IG1

ST1

W-B R

W-B L-R

Y

T/C RR RELAY

W-B

IG SW

W-B BODY EARTH

T/C FR RELAY

SOLENOID

W-B BODY EARTH

SOLENOID

SFT 7.5A W-B

R-Y

MOTION ALARM (OPT)

LOCK

GAUGE 10A

R-G

R-W

W-B PARKING BRAKE LAMP (OPT)

RELEASE

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (DIESEL ENGINE) 6-8

B-Y

LW

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

W

DISCONNECT SW (UL-G,DS,LPS) P-G

P-G

SAS ECU

FL AM1 40A

SAS WARNING OUT1

HRM1 HRM2

L-O LOCK IND

V-G V-R P-L

W-L

Y-B

W-L

W-B

W-B

SAS WARNING LAMP RELAY

W-B

E1 HRM3

W-B

HOUR METER

RELAY BOX

W-B

W-B

G OPS

UL-G, D, G/LP UL-GS, DS

FUEL SENDER

W-B

IG SW IG1 AM1 ST1

OPS-LAMP RELAY W-B

V

Y-G

V-W

L-Y

V

W-B LG-B W-B

Y

GAUGE 10A

RELAY BOX

Y-R

Y-B SEDIMENTER

R-G

Y-G

B-Y

L

Y

Y-R

Y-B

B

B-Y

LG

W-B

W-B

AIR CLEANER

VACCUM SW (AIR CLEANER) W-B

B

COMBINATION METER

FUEL

BODY EARTH

WATER TEMP SENDER

WATER TEMP

BODY EARTH

CHARGE

ALTERNATOR

W

W-B (UL-D,DS)

LEVEL SW (SEDIMENTER) W-B

Y-G RADIATOR (OPT)

LEVEL SW (OPT) (RADIATOR RESERVOIR TANK) LG-R

BODY EARTH

LG-R

R-G OIL

OIL PRESSURE SW R-W R

B

W-B

R-W

R-W

PARKING BRAKE SW (OPS) W-B G-W

W-B

BRAKE (OPT)

LEVEL WARNING SW (OPT) W-B

R

R

4Y-ECS ECU (OPT)

W-B

W-B

W-B

W-B

CHECK (4Y-ECS) (OPT)

Y-B

Y-B

TWC ECU

(UL-D,DS) BODY EARTH

TWC(STD:2004.1 R

R

GLOW TIMER

GLOW V-G

(UL-G,LP,G/LP)

V-G

WATER TEMP SW (OPT) (UL-G,LP,G/LP) W-B R R R-W (UL-D)

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

VSCS ECU (OPT) W-B

W-B

OVER HEAT (OPT)

CHECK (VSCS) (OPT)

V-W

V-W

LPG WARNING (OPT)

LPG PRESSURE SW (OPT)

COMBINATION METER 6-9

P-G

B-Y

W BATTERY

P-G

SAS ECU

FL AM1 40A

SAS WARNING

HRM1 HRM2

L-O LOCK IND

V-G V-R P-L

W-L

Y-B HOUR METER

W-L

W-B

W-B

SAS WARNING LAMP RELAY OUT1

W-B

E1 HRM3

W-B

RELAY BOX

W-B

W-B

G OPS-LAMP RELAY

UL-G, D, G/LP

FUEL SENDER

V-W

L-Y

W-B

V

W-B LG-B

L

Y

Y

Y-B

GAUGE 10A

RELAY BOX

Y-R

Y-B

B-Y

Y-R

COMBINATION METER

FUEL

W-B

W-B

AIR CLEANER

VACCUM SW (AIR CLEANER) W-B

SEDIMENTER

UL-G, D, LP, G/LP

Y-G

R-G

LEVEL SW (SEDIMENTER) B

B

Y-G

R-G

LG-R OIL

OIL PRESSURE SW G-W R-W

W-B

R-W R-W

BRAKE (OPT)

B-R

B-R

R L

B-Y

V

Y-G

W-B

IG SW IG1 AM1 ST1

OPS

WATER TEMP SENDER LG

BODY EARTH

W-B WATER TEMP

BODY EARTH

CHARGE

ALTERNATOR

W

W-B (UL-D) W-B

RADIATOR (OPT)

LEVEL SW (OPT) (RADIATOR RESERVOIR TANK) LG-R

BODY EARTH

W-B

LEVEL WARNING SW (OPT) LOCK

STARTER RELAY EZ PEDAL RELAY

B

W-B

G-R

RELEASE

PARKING BRAKE SW W-B

R

R

4Y-ECS ECU (OPT)

W-B

W-B

W-B

W-B

CHECK (4Y-ECS) (OPT)

Y-B

Y-B

TWC ECU

TWC(STD:2004.1 R

(UL-D)

R

GLOW TIMER

GLOW

BODY EARTH

V-G

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

V-G

WATER TEMP SW (OPT) W-B V-W

W-B

OVER HEAT (OPT) V-W LPG WARNING (OPT)

LPG PRESSURE SW (OPT)

COMBINATION METER (EZ PEDAL) 6-10

DISCONNECT SW FL W W

B-Y

W (GS)

W (G)

RELAY BOX

FL AM1 40A

FL HEAD 40A

W-L W-L

BUS BAR

AM1

IG SW ST1

IG1

B-W

B-Y

B-W

B-Y

B-Y

B-Y

RELAY BOX

IGN 7.5A

ST 7.5A

GAUGE 10A

TWC 7.5A

BODY EARTH

FUEL CUT SOLENOID GAS RLY B-Y

B-O B-O

B-O

B-W

R-G

G-R SH-LD

GFUL

IIA

B IGW

B-W

VCC

E2

FCM2 R

SEL1

FCM4

B-W

VACUUM SENSOR

R-B FCM1

AIR BLEED CONTROL VALVE

PIM

L-O

L-W

R-W

BR

FCM3 R-G W-B

L-B STARTER SUB RLY

L-B B

EZ PEDAL W-B

W-B

E1

B

B

B-W

B

SH-LD

STA L-B

R

SHIFT CONTROL SW

OX

B-O

R-Y

TWC ECU

W-B

G

OXYGEN SENSOR

W-B

E2

CHECK CONNECTOR

E1

W-B W-B

OXM

W-B

TE2 TE1

G-W G-B

OXM

G-Y

VF

G

L-B

L-O

L-B

L-O

BATT1

L-B

IGB2

BATT2 V-G

L-B L-O

L-O

L-O

THW

R-G W

W-G

TWC RLY

TE2 TE1 IGB

VF

WATER TEMP SENSOR W-G

W-G

Y-B

Y-B

E01 COMBINATION METER (TWC LAMP)

W-G E02

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

DISCONNECT SW FL W W

B-Y

W (LPS)

W (LP)

RELAY BOX

FL AM1 40A W-L W-L

BUS BAR

AM1

IG SW ST1

IG1

B-W

B-Y

B-W

B-Y

B-Y

B-Y

RELAY BOX

IGN 7.5A

ST 7.5A

GAUGE 10A

TWC 7.5A

B-O

B

FL HEAD 40A

B

LPG RLY B

B-O

W-B R-G

B-W

B-O LPG MAIN SOLENOID B V-W LFUL

B-L

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

B

LFC

IG-

IIA

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

SH-LD

LPG SLOW SOLENOID

See page 6-6. A B-L (LP) B-O (LPS)

W

B-W

VCC

VACUUM SENSOR

B-W

PIM

L-O

L-W BR

E2 STARTER SUB RLY

B EZ PEDAL

B

B

B

SH-LD

SHIFT CONTROL SW RESISTER L-R

RES

OX

R-Y

L W-B

CHECK CONNECTOR

E2

TE2 TE1 VF

B-W

STA RLY1 RLY2

B-O

R

TWC ECU

W-B E1

W-B G

OXYGEN SENSOR

L

L INJ E1

W-B W-B

OXM

TWC RLY

L-B

TE2

G-W

LPG INJECTOR

TE1

G-B

L-O IGB

VF

G

IGB2

L-B

L-B L-B

L-B L-O

BATT1 OXM

G-Y W-B

BATT2

WATER TEMP SENSOR

THW

V-G

L-O L-O

L-O

R-G

Y-B W

W-G

Y-B

E01

W-G

COMBINATION METER (TWC LAMP)

W-G

E02

W-G

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

W

RELAY BOX

FL GOV 40A W-L

L-W

W-L

L-W

LG

L-W

AM1

L-W

MAIN RLY L-W

L-B

L-W

L-B

L-R

ST1

W-B

B-O

IG1

THROTTLE BODY

IG RLY IG RLY IN

IG SW

M+ MVC2

B-Y

MOTOR RLY

L-W

LG-R

IG1 IG2

B

IGNITION RLY

EZ PEDAL & E/G SHUT DOWN RLY B-W

B-Y

B

B-O

B

B-O

V-W

L-B

W-B

GOV 15A

IGN 7.5A

ST 7.5A

B-O

GAUGE 10A

TWC 7.5A

W-B CHECK (ECS)

RELAY BOX

ACCELERATOR SENSOR

B-Y

DIAG CHKR

CHECKER SH-LD

IDL

CHECK LP

B-Y

GOVERNOR ECU

B-R

L-W

B-O

B-W

B-Y

B

TPS1 SIN TPS2 SIN SENSOR GND2

FL AM1 40A

MTR RLY IG(MTR) GND1 GND2

R W

R

W

VC1

ACCEL

SENSOR GND1

FL HEAD 40A

W-B W-B SH-LD

M+ MVC VTA1 VTA2 E2 SH-LD

B

R

W

G SH-LD

R

VC SH-LD

ALT

CHARGE Y

R-G

IDLE VOLUME

VC3 Y

ID

B-O

R

COMBINATION METER L

W

R-G

B ID E2

ALT

L-W

SH-LD MEMORY CLEAR

G-O

MEM CLR

B

B-W

ENG REV VSV RLY

G/LP CHG

W-B

V

IIA

B-O

B VSV RLY

SH-LD IG-

B-W

B

W-B

B-L

B-O

VSV SOLENOID

LPG RLY L-O

W VCC

B-W

B-O

PIM E2

B

B

B

B-O

LPG MAIN SOLENOID

BR LFC

SEL1

LPG SLOW SOLENOID

A See page 6-6.

B-L

B-L

STARTER SUB RLY

B

B-L

SEL2

W-B

B

E1

EZ PEDAL

B

SH-LD

B-W

B

B

RESISTER

B-O

TWC ECU

W-B

STA

RES R-Y

INTERNAL WIRING OF COMBI METER

VACUUM SENSOR

V-W LFUL

L-W

W-B BR

BR

B-L

W-B BR

W-B

G

R

OXYGEN SENSOR

SHIFT CONTROL SW

L-R

OX L

CHECK CONNECTOR

E2

W-B

E1

W-B W-B

OXM

TE2 TE1 VF

G-W G-B G G-Y

W-B

WATER TEMP SENSOR

V-G

W-G W-G W-G W-G

TE2

INJ

L

L

TWC RLY

L-B

TE1

LPG INJECTOR

VF

L-O IGB

OXM

IGB2

L-B

L-B L-B

L-B L-O

THW

BATT1 BATT2

E01

W

E02

L-O L-O

L-O

Y-B

Y-B TWC COMBINATION METER

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

B-Y

W

RELAY BOX

FL AM1 40A

FL HEAD 40A

W-L W-L AM1

IG SW ST1

IG1

BUS BAR

B-W

B-Y

B-W

B-Y

B-Y

B-Y

RELAY BOX

IGN 7.5A

ST 7.5A

GAUGE 10A

TWC 7.5A

BODY EARTH

B-O

FUEL CUT SOLENOID

GAS RLY B-O

B-Y

W-B B-Y

B-O

GAS SOLENOID

B-Y B-Y

B

B

B

R

GAS

LPG RLY B

B-O B

G-R

B-R

B-Y

B-R

B-O

B-O

R-G

B-W

B-R

W-B LPG MAIN SOLENOID

LPG L

FUEL CHANGE SW

V-W

B-R

B-L

LPG SLOW SOLENOID GAS

LFUL GFUL

See page 6-6.

LPG

B-L

A

B-Y B-R SH-LD

B-L

LFC

B-L W

VCC B-W

B-W

VACUUM SENSOR

IIA

PIM

L-O

B IG-

L-W

E2

BR

BR

R-B AIR BLEED CONTROL VALVE

FCM1

BR

R R-G FCM4

L-B

B-O

R-W FCM2 FCM3 SEL2

BR

STARTER SUB RLY

L-B B

EZ PEDAL

E1

W-B SH-LD

STA

B

B

B

RESISTER

SHIFT CONTROL SW RES

L-R

OX

R-Y

L W-B

CHECK CONNECTOR

E2

TE2 TE1

L

TWC RLY

L-B

TE2

G-W

LPG INJECTOR

TE1

G-B

VF

B-W

L-B

TWC ECU

W-B

G

R

OXYGEN SENSOR

L INJ E1

W-B W-B

OXM

L-O IGB

VF

G

IGB2

L-B

L-B L-B

L-B L-O

BATT1 OXM

G-Y W-B

WATER TEMP SENSOR

BATT2 THW

V-G

L-O L-O

L-O R-G

W W-G

Y-B

Y-B

E01

W-G

COMBINATION METER (TWC LAMP)

W-G E02

W-G

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

Published by

A 1st Printing: Oct. 2005 Pub. No. CU040 Printed in Japan

C