DOWNLOAD PDF Toyota Forklift 7FGU35-80 7FDU35-80 & 7FGCU35-70 Repair Manual

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 7FGU/ 7FDU35~80 series and 7FGCU35~70 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 September 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/7FDU35~80, 7FGCU35~70 REPAIR MANUAL (No. CU030-1) TOYOTA INDUSTRIAL EQUIPMENT GM6-262 ENGINE REPAIR MANUAL (No. C4630) TOYOTA INDUSTRIAL EQUIPMENT 11Z, 12Z, 13Z, 14Z ENGINE REPAIR MANUAL (No. C4615-2)

Service Information Bulletins affecting Models 7FG(D)U35-80 and 7FGCU35-70 Title 1 SIB MA04-001 Revision of Repair Manual for 7FG/DU35-80 & 7FGCU35-70 2 SIB MA02-001 GM 6-262 Timing & Idle Adjustment Procedure Change 3 SIB FS06-001 13Z Updated Fuel System Components 4 SIB FS06-002 LPG Pre-Filter Service Parts 5 SIB CE05-004 Starter Motor Engagement Delay (All I.C. Units) 6 SIB BR06-001 Stiffer Inching Pedal Spring 7 SIB EN04-004 13Z Injection Pump Changes 8 SIB MA05-003 Change to Periodic Replacement Parts (4Y & GM6-262) 9 SIB EN04-001 EPA Compliant Three Way Catalyst System Identification & New SST 10 SIB EN03-004 Exhaust Y-Pipe Cracking 11 SIB CE01-005 Combination Meter Membrane Grease 12 SIB FA06-001 Changes to Reamer Bolt Torque Specification 13 SIB MA07-001 Caution During Oil Filling 14 SIB FS07-001 New Fuel System for GM6-262 15 SIB MA07-001R Caution During Oil Filling 16 SIB FS07-002 MIL Strategy Change 17 SIB FS07-003 ECM calibration revisions and DTC updates 18 SIB CE07-002 Wiring Diagrams for Spectrum Fuel System 19 SIB ST07-002 Recommended Service Tools for a Field Service Technician 20 SIB FS07-004 New Spectrum DTC 652 and 653 21 SIB FS07-008 New Spectrum DTC 9999 and 1151 22 SIB FS07-005 New Spectrum DTC 627, 628, and 629 23 SIB CE07-006 Introduction of VSCS Vehicle Speed Control System 24 SIB FS07-006 Spectrum Fuel System Relay Change

File ma04-001.pdf ma02-001.pdf fs06-001.pdf fs06-002.pdf ce05-004.pdf br06-001.pdf en04-004.pdf ma05-003.pdf en04-001.pdf en03-004.pdf ce01-005.pdf fa06-001.pdf ma07-001.pdf fs07-001.pdf ma07-001r.pdf fs07-002.pdf fs07-003.pdf ce07-002.pdf st07-002.pdf fs07-004.pdf fs07-008.pdf fs07-005.pdf ce07-006.pdf fs07-006.pdf

REV: 1/31/08 File Size Modified On 2739 KB 4/26/2006 237 KB 5/3/2006 278 KB 5/8/2006 62 KB 5/8/2006 1018 KB 5/25/2006 77 KB 6/1/2006 505 KB 6/7/2006 45 KB 6/7/2006 210 KB 6/7/2006 323 KB 6/7/2006 385 KB 6/8/2006 82 KB 10/18/2006 126 KB 1/31/2007 175 KB 1/31/2007 190 KB 6/27/2007 75 KB 6/27/2007 163 KB 7/12/2007 3247 KB 9/25/2007 84 KB 9/25/2007 87 KB 10/26/2007 53 KB 10/26/2007 141 KB 10/26/2007 741 KB 10/26/2007 77 KB 11/16/2007

Technical New Briefs affecting Models 7FG(D)U35-80 and 7FGCU35-70 1 TNB-2007-08 Troubleshooting 13Z Diesel Exhaust Smoke 2 TNB-2005-04R2 Guidelines for Cleaning a Contaminated Hydraulic System 3 TNB-2007-02 Chassis Lubrication Clarification 4 TNB-2007-01 Use of Torque Adapter for SSC FL06-007 5 TNB-2003-03 7FGU35 – 80, 7FGCU35 – 70 Poor Engine Performance When Cold 6 TNB-2005-03 Quick Reference Sheet for 13Z Diesel Pump Timing

tnb-2007-08.pdf tnb-2005-04-r2.pdf tnb-2007-02.pdf tnb-2007-01.pdf tnb-2003-03.pdf tnb-2005-03.pdf

71 KB 77 KB 71 KB 88 KB 156 KB 294 KB

10/26/2007 10/26/2007 4/9/2007 4/9/2007 11/29/2005 11/29/2005

Hotline Tech Tip Articles affecting Models 7FG(D)U35-80 and 7FGCU35-70 1 HTT-11-2004 - V-6 hard start; Hydraulic valve sticking: Excessive brake wear & noise; Axle plate mounting bolts loose 2 HTT-12-2004 - GMV6 Timing; Strobe Light Failures; V6 hard start; Drive Train Noise; Hydraulic pump failures 3 HTT-1-2005 - Rotten Egg Smell, Retrieving TWC Error Codes, Flame Retardant Hydraulic Oil, GM V-6 Crank Pulley 4 HTT-2-2005 - LP Pre-filter Parts, Retrieving TWC Error Codes, Hydraulic Pump Change 5 HTT-3-2005 - “Rotten Egg” Smell; Driveline Vibration; Aisin LPG Regulator Rich/Lean Air/fuel Ratio; Abnormal Brake Noise; Diesel Engine Smoke; Overheating 6 HTT-4-2005 - Lean LPG Main Path, Engine Compression Check; Key Switch Change 7 HTT-5-2005 - Seat Switch Testing, Premium GM V-6 Engine; GM V-6 Crankshaft Bolt 8 HTT-6-2005 - Injector Harness Test Light; Cascade House Valves 9 HTT-7-2005 - TWC Initial Setting for Injector Period, Improvements to the new key switches, Operator Prescence System 10 HTT-8-2005 - TWC Initial Setting for Injector Period, Improvements To The New Key Switches, Operator Presence System 11 HTT-9-2005 - 13Z Diesel Injection Timing 12 HTT-10-2005 - 13Z Diesel Injection Timing 13 HTT-11-2005 - TWC Analyzer Tips, GM V6 Hot Soak Engine Shut Down 14 HTT-12-2005 - OPSS Component Information 15 HTT-1-2006 - TWC Trouble Shooting Tips, Metal Clad Wiper Seals on Rear Lift Cylinders 16 HTT-2-2006 - O.P.S.S. Error Code 1, TWC Light Strobing & Adjustments, Hood Vents, Replacement Radiators, GM V-6 Y Pipe Update 17 HTT-3-2006 - 7Series Starter Delay Circuit 18 HTT-4-2006 - LPG Regulator Air Testing, Home Depot Options, LPG Pre-Filter Service Parts 19 HTT-5-2006 -7FDU Oil Filing, Cotton Core Radiator, LPG Oil Contamination 20 HTT-6-2006 - V-Mast Rear Cylinders, Wire Harness Repair, SAS Code 63, Axle Mount Bolts 21 HTT-7-2006 - GM6-262 Exhaust Y-Pipe Breaking 22 HTT-8-2006 -Engine Shutdown Option, Extreme Environment Radiator 23 HTT-9-2006 - V-Mast Cylinder Spacer, GM6-262 Timing Chain Tensioner, TWC Tamper Resistant Plug 24 HTT-10-2006 - GM6-262 Hard/Impossible to Start, SAS L-Off 25 HTT-11-2006 - Ultra-Low Sulfur Diesel, 7FGCU35-45 Brake Noise, TWC Emission Warranty 26 HTT-12-2006 - Travel Speed Measurement, Clogged LP injector, New Fuel System SST 27 HTT-1-2007 - GM6-262 Spectrum Fuel System 28 HTT-2-2007 - Spectrum MIL Strategy change, Chassis Lubrication, USB adapter for Spectrum 29 HTT-3-2007 - IC Radiator Offerings 30 HTT-4-2007 - Spectrum Adapter hardware change 31 HTT-5-2007 - Spectrum Fuel System Terminology 32 HTT-6-2007 - New Active Radiator, Troubleshooting Smoke 33 HTT-7-2007 - New Hydraulic Oil, Troubleshooting Overheating, Spectrum III LP and/or Gasoline 34 HTT-9-2007 - Spectrum Fuel System Calibration 35 HTT-10-2007 - LP Lockoff Solenoid Orientation 36 HTT-11-2007 - Spectrum Calibration changes, Spectrum DTC 1152 37 HTT-12-2007 - Spectrum hard start, Engine Block Heaters 38 HTT-1-2008 - Threshold Voltages

hotline tech tips-2004-11.pdf hotline tech tips-2004-12.pdf hotline tech tips-2005-01.pdf hotline tech tips-2005-02.pdf hotline tech tips-2005-03.pdf

REV: 1/31/08 114 KB 2/6/2006 130 KB 2/6/2006 119 KB 7/5/2006 153 KB 2/20/2006 121 KB 2/6/2006

hotline tech tips-2005-04.pdf hotline tech tips-2005-05.pdf hotline tech tips-2005-06.pdf hotline tech tips-2005-07.pdf hotline tech tips-2005-08.pdf hotline tech tips-2005-09.pdf hotline tech tips-2005-10.pdf hotline tech tips-2005-11.pdf hotline tech tips-2005-12.pdf hotline tech tips-2006-01.pdf hotline tech tips-2006-02.pdf hotline tech tips-2006-03.pdf hotline tech tips-2006-04.pdf hotline tech tips-2006-05.pdf hotline tech tips-2006-06.pdf hotline tech tips-2006-07.pdf hotline tech tips-2006-08.pdf hotline tech tips-2006-09.pdf hotline tech tips-2006-10.pdf hotline tech tips-2006-11.pdf hotline tech tips-2006-12.pdf hotline tech tips-2007-01.pdf hotline tech tips-2007-02.pdf hotline tech tips-2007-03.pdf hotline tech tips-2007-04.pdf hotline tech tips-2007-05.pdf hotline tech tips-2007-06.pdf hotline tech tips-2007-07.pdf hotline tech tips-2007-09.pdf hotline tech tips-2007-10.pdf hotline tech tips-2007-11.pdf hotline tech tips-2007-12.pdf hotline tech tips-2008-01.pdf

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2/6/2006 7/5/2006 2/6/2006 3/13/2006 3/13/2006 2/6/2006 2/2/2006 2/6/2006 4/9/2007 2/2/2006 3/2/2006 4/3/2006 4/27/2006 6/20/2006 7/11/2006 4/9/2007 9/6/2006 10/3/2006 4/9/2007 11/27/2006 4/9/2007 4/9/2007 4/9/2007 4/9/2007 5/10/2007 9/24/2007 9/24/2007 9/24/2007 9/24/2007 10/30/2007 11/19/2007 12/12/2007 1/28/2008

SECTION INDEX NAME

GENERAL OPS BODY OIL CONTROL VALVE SAS APPENDIX

SECTION

0 1 2 3 4 5

0-1

GENERAL Page

PERIODIC MAINTENANCE .................................0-2 OPS SYSTEM.......................................................0-3 SAS.......................................................................0-9

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.

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. *: The buzzer sounds only the export model.

Control block diagram *: Parts added or changed for OPS

* Seat switch

* OPS lamp relay * OPS lamp

* Plug in analyzer

* OPS buzzer * OPS Key switch

Forward tilt switch

* SAS Controller

Controller

Bakward tilt switch Foward reverse switch

Battery

Tilt cylinder

F N R

Lift cylinder

* 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

Lift lock valve

Oil tank

Note: • The OPS buzzer is installed only in the export specification model.

• When the OPS system is operating, the hydraulic power supply is interrupted by the unload valve to provide the steering with no power assistance.

0

0-4

Name of each part (1) (12)

(11)

(2) (7) (8) (9)(10)

(3) (4) (13)

(5) (6) (14)

(1)

OPS controller

(8)

Backward tilt switch

(2)

Seat switch

(9)

Unload valve

(3)

Forward switch

(10)

Tilt control valve

(4)

Reverse switch

(11)

OPS lamp

(5)

Forward interrupt relay

(12)

OPS lamp relay

(6)

Reverse interrupt relay

(13)

OPS buzzer (Export model)

(7)

Forward tilt switch

(14)

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 detects inputs the voltage branched from the forward drive valve power supply line of the torque converter to the OPS controller for detecting forward drive operation.

(4)

Reverse switch

This switch detects inputs the voltage branched from the reverse drive valve power supply line of the torque converter to the OPS controller for detecting reverse drive operation.

(7)

Forward tilt switch

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

(8)

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 interrupts 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 interrupts the voltage supply to the reverse drive valve in the torque converter according to the instruction from the OPS controller.

(9)

Unload valve

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

(10)

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.

(11)

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.

(12)

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.

(13)

OPS buzzer

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)

(14)

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 tilt control valve is controlled to disable forward tilting operation. Backward tilting, fork lifting and attachment operations are disabled by interrupting the hydraulic oil supply by means of the unload valve. Fork lowering operation is stopped by interrupting the control hydraulic pressure to the lift lock 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 move because of its own weight when it is in a backward tilted position.

• Attachment: If the material handling lever is operated while the OPS is functioning, the attachment may move because of its own weight.

3.

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 OPS buzzer sounds only on the export specification vehicle.

4.

Return-to-neutral warning (Export specification vehicle only) 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.

5.

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.

The tilt solenoid became one (SOL1: Normally open type) from two units (SOL1, SOL2).

2.

An unload valve (unload SOL) is newly added this time.

3.

Key OFF lift lock: This function prevents the fork from lowering upon lowering operation when the key switch is at the OFF position (engine in stopped state).

4.

There are no change in the specifications (such as relief pressures) and the manner of relief pressure adjustment.

Unloading solenoid valve

0-8

EZ PEDAL While the forward or reverse traveling direction is selected by operating the direction lever at the steering column on the standard model, the EZ pedal model changes the direction by stepping on either the left or right half of the accelerator pedal.

Operation Only when the parking lever is pulled to apply the brake, the T/C is set in the neutral position to enable the engine to be started. According to the addition of the OPS system as a standard feature, the parking brake OFF warning is abolished. When the operator is off the seat (judged by seat switch OFF for 2 seconds or more), the drive power is interrupted (by the drive OPS function) and material handling operations are disabled.

When the drive OPS is operated, pull the parking lever to cancel the drive OPS function to allow traveling.

0-9

SAS Hydraulic Circuit Diagram An unload valve is added a new to the oil control valve on the previous model.

(1)

(4)

(2)

C2 C3

(5) C1 (3)

(7)

SOL

PS

P

T

Gage Port

(6) (1) Flow control valve (2) Tilt select valve

(5) Lift lock check valve (Leak lock valve)

(3) Lift select valve

(6) Unloading valve & solenoid

(4) Tilt lock check valve (Leak lock valve)

(7) Tilt control valve & solenoid

0-10

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 OFF

ON

Full open circuit

Half open circuit • High lifting height and backward tilting speed restriction • Low lifting height and backward tilting speed restriction*

• Low lifting height and backward tilting • Forward tilting

Tilting stop circuit • Tilt lever in neutral position • Stop be forward tilting angle restriction • Forward automatic leveling stop

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

Tilt Cylinder

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.

Pilot Check Valve

Flow Control Valve Orifice Tilt Lever

SOL ON

Pilot Circuit Tilt Cylinder Pilot Check Valve

Flow Control Valve Orifice Tilt Lever

SOL ON

Pilot Circuit

0-11 Tilt Cylinder Pilot Check Valve

Flow Control Valve Orifice Tilt Lever

SOL OFF

Pilot Circuit

3.

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.

1-1

OPS Page

GENERAL ............................................................1-2 COMPONENTS ....................................................1-4 OPS CONTROLLER ............................................1-5 REMOVAL · 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 ..............1-17 TROUBLESHOOTING BY PHENOMENON ............1-28 Note: See Section 4 (SAS) for the connector layout, controller sequence and connector diagram.

1

1-2

GENERAL *: Parts added or changed for OPS

* Seat switch

* OPS lamp relay * OPS lamp

* Plug in analyzer

* OPS buzzer * OPS Key switch

Forward tilt switch

* SAS Controller

Controller

Bakward tilt switch Foward reverse switch

Battery

Tilt cylinder

F N R

Lift cylinder

* 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

Lift lock valve

Oil tank

Note: • The OPS buzzer is installed only in the export specification model.

• When the OPS system is operating, the hydraulic power supply is interruptedby the unload valve to provide the steering with no power assistance.

1-3 (1) (12)

1

(11)

(2) (7) (8) (9)(10)

(3) (4) (13)

(5) (6) (14) (1)

OPS controller

(8)

Backward tilting switch

(2)

Seat switch

(9)

Unload valve

(3)

Forward drive switch

(10)

Tilt control valve

(4)

Reverse drive switch

(11)

OPS lamp

(5)

Forward interrupt relay

(12)

OPS lamp relay

(6)

Reverse interrupt relay

(13)

OPS buzzer

(7)

Forward tilting switch

(14)

Plug-in analyzer

1-4

COMPONENTS 1910

4

5701

1

PA 2 VZ

QY

1 4 MF PG

PA

3 WG MF

QY WE PG 3

2 GU RQ

GM6-262(UL-LPS)

RQ NX

RQ

EP

WE WE

LN LN

VZ GU

LY

EP GU

WT

LN

5701-471

1-5

OPS CONTROLLER REMOVAL · 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 trouble. 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 SAS section of 7FGU35

80 Repair Manual (Pub. No. CU030,-1).

See SAS section of 7FGU35

80 Repair Manual (Pub. No. CU030,-1).

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 Screen title

Switch

Switch

• Move the cursor to the above item.

• Move to the preceding page.

A

A

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.

• OPS: Moves to OPS ANALYZER MENU Screen.

• TESTER SET: Moves to TESTER SET screen.

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) (2)

(1) SEAT: Seat switch input signal (2) DIR: Direction switch input signal

(3)

FWD: Forward direction switch input signal REV: Reverse direction switch input signal

(4)

(3) RLY: Output signal to forward/reverse interrupt relay FWD: Output signal to forward interrupt relay REV: Output signal to reverse interrupt relay (1) (5) (6)

(4) VOLTAGE: OPS controller power supply voltage (5) LIFT LOWER: Unused

(7)

(6) UNLOAD SOL: Output signal to unload solenoid

(4)

(7) TILS SOL: Output signal to tilt solenoid (8) TILT: Tilt lever switch input signal FWD: Forward tilt switch input signal BWD: Backward tilt switch input signal CONT: SAS tilt control command input signal

(1) (8)

(9)

LSOPT: Reserved.

[End] (7) (9) (4)

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

1-11

"3 ACTIVE TEST"

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

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) TILT SOL Set to ON for forced output of tilt solenoid activating signal.

(Forward tilting enabled state with backward tilting speed restriction) (5) LAMP Set to ON for forced output of OPS lamp lighting signal.

(OPS lamp lighting state) (6) 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 OPS 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 6

REC TAB

CN44-1

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.

1-15

DIAGNOSIS ERROR CODE LIST Lamp

Error code

ON

—

Dead lamp check

—

—

Blinking (one short ON pulse)

1-1

Seat switch abnormality

Sticking GND fault

The OPS does not function.

Discontinuity

Forward traveling is possible while OPS is operating.

3-1

Error description

Forward interrupt relay (RYF) abnormality

Blinking (three short ON cycles) 3-2

4-1

Reverse interrupt relay (RYR) abnormality

Unload solenoid (SOL1) abnormality

Blinking (four short ON cycles) 4-3

Blinking (five short ON cycles)

Major cause

Phenomenon on vehicle

↑

GND fault +B shorting

Forward traveling is always disabled.

Discontinuity

Reverse traveling is possible while OPS is operating. ↑

GND fault +B shorting

Reverse traveling is always disabled.

Discontinuity

Forward tilting is disabled but other material handling operations are possible while OPS is operating.

GND fault

↑

+B shorting

All material handling operations are always disabled.

Discontinuity

Automatic stop is disabled.

GND fault

↑

+B shorting

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

+B shorting

Resetting is disabled while OPS is operating (locked state by return to neutral function).

Tilt solenoid (SOL3) abnormality

5-1

Shift lever abnormality

7-1

CPU abnormality

7-2

CPU abnormality

7-3

CPU abnormality

7-4

CPU abnormality

7-5

EEPROM abnormality

7-6

EEPROM abnormality

ON

—

Low voltage alarm

Low battery voltage

Ordinary control (or control failure may arise).

ON

—

OPS operation

Departure from seat

—

ON Blinking (seven short ON cycles) ON

Drive/material handling OPS does not function.

Controller abnormality

None in particular.

The OPS lamp keeps lighting. The drive/ material handling OPS does not function.

1-16

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

Error description

With analyzer (SST) Page

Error code

1-17

1-1

Seat switch abnormality

1-18

3-1

Forward interrupt relay (RYF) abnormality

1-20

3-2

Reverse interrupt relay (RYR) abnormality

1-20

4-1

Unload solenoid (SOL) abnormality

1-22

4-3

Tilt solenoid (SOL) abnormality

1-22

5-1

T/C shift lever abnormality

1-26

7-1

CPU abnormality

—

7-2

CPU abnormality

—

7-3

CPU abnormality

—

7-4

CPU abnormality

—

7-5

EEPROM abnormality

—

7-6

EEPROM abnormality

—

1

Seat switch abnormality

3

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

1-20

4

Solenoid (SOL) abnormality

1-22

5

T/C shift lever abnormality

1-24

7

OPS controller abnormality

—

Error description

Page

List of Pages to be Referenced by Phenomenon Description

Pages to be referenced Without analyzer

With analyzer

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

1-28

1-28

The OPS lamp does not come on.

1-32

1-32

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

1-34

1-37

The material handling OPS does not function. (Including the case where forward tilting is disabled)

1-40

1-40

Material handling fails. (Including the case where only fork lowering is possible)

1-41

1-41

The mast backward tilting speed is always slow or unrestricted.

1-42

1-42

Mast does not tilt forward.

1-46

1-46

The drive OPS does not function.

1-50

1-50

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

1-53

1-53

1-17

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.

1-18 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, 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

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.

1-19 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

1-20

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 page 1-9 "1 DIAG MEMORY" for the error memory check method.

1-21 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

1-22

z Error Code 4 z Error Code 4-1 (Unload solenoid (SOL1) abnormality) z Error Code 4-3 (Tilt solenoid (SOL3) abnormality)

W/SPLICE-Z

CN45-29 (E3, SOL-GND)

REC TAB

CN45-30 (E3, SOL-GND)

REC TAB

CN45-12 (SOL3, Tilt SOL) TAB REC

OPS controller

CN45-14 (SOL1, Unload SOL)

REC TAB

Related Portion

CN46-8

CN47-1 CN47-2

Unload SOL

CN12-1

Tilt SOL CN12-2

CN46-9

(E3, Body GND)

Estimated Causes: c Connector contact defect d Unload solenoid defect e Tilt solenoid defect

f Controller defect g Harness defect

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

NG

NG

OK

Inspection 1: Check the each solenoids (SOL) 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 (SOL) 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 page 1-9 "1 DIAG MEMORY" for the error memory check method.

1-23 Inspection 1: Check the resistance of each solenoid (SOL).

Key switch OFF, CN47 and CN12 disconnection.

Standard:

2

2

1

CN47 (TAB)

1

CN12 (TAB)

Resistance Unload SOL CN47-1 ~ CN47-2

Approx. 9 Ω (20°C)

Tilt SOL CN12-1 ~ CN12-2

Approx. 9 Ω (20°C)

Inspection 2: Check continuity of the wiring between CN45 and each of solenoids (SOL).

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

CN45-12 ~ 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

CN45-12 ~ CN45-29,-30

No continuity

• +B shorting check CN45-14 ~ CN45-32

No continuity

CN45-12 ~ CN45-32

No continuity

• IG line shorting check CN45-14 ~ 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

CN12 (REC)

1-24

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.

1-25 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

• +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

1-26

Error code 5-1

NG

Check if the fuse (SFT) is blown.

After correction, check the OPS lamp indication.* 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.

OK

Shift lever defect

NG

Inspection 2: (For the NG portion in inspection 1) Check the wiring between CN45 and IG SW for continuity.

NG

Harness defect

OK

Controller defect

*: 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

1-27 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

1-28

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.

1-29 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)

1-30 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

1-31 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)

1-32

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.

1-33 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: Lamp ON signal Lamp OFF signal Between relay pin 1 and frame

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

• 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 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 ON and OFF, and check the continuity.

Lamp ON signal Lamp OFF signal Between relay pin 1 and frame

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

1-34

z The OPS lamp keeps lighting. (Including the case where 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

CN65

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

1-35 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.

1-36 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

3 5 1 4 2

OPS LAMP RLY

1-37 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 goes off.

After connecting all connectors, turn the key switch to ON with no one on the seat (engine in stopped state).

Check that the OPS lamp goes off in 1 second.

1-38 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.

Lamp ON signal Lamp OFF signal Between relay pin 1 and frame

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

1-39 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

1-40

z The material handling OPS does not function. (Including the case where forward tilting is disabled)

CN47-1

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

REC TAB

W/SPLICE-Z CN46-8

REC TAB

CN45-14 (SOL1, Unload SOL) TAB REC

OPS controller

Related Portion

Unload SOL CN47-2

CN46-9

(E3, Body GND)

Estimated Causes: c Controller defect d Control valve unload 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

*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.

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

1-41

z Material handling fails. (Including the case where only fork lowering is possible)

REC TAB

CN45-30 (E3, SOL-GND)

REC TAB

CN45-14 (SOL1, Unload SOL) TAB REC

OPS controller

Related Portion

CN45-29 (E3, SOL-GND)

CN46-8

CN47-1 CN47-2

Unload SOL

W/SPLICE-Z

CN46-9

(E3, Body GND)

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.

1-42

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

1-43 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.

Harness defect (between CN45 and CN1)

OK

OK

Check the tilt solenoid operating sound.*3

NG

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.

1-44 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

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.

1-45 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.

1-46

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

1-47 Continued

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

NG

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

OK

OK

Harness defect (between CN34 and CN45)

NG

Inspection 3: Check the forward tilt lever switch (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 tilt position

Lever at backward tilt position

No continuity

Continuity

No continuity

1-48 Inspection 2: Check the forward tilt lever switch (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 (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)

1-49 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.

1-50

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

CN52

CN46-11

7 REC TAB

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

1-51

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.

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

CN53 (REC)

Standard:

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 3 5

3 5

1 4 2

1 4 2

T/C FR RLY

T/C RR RLY

1-52 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 13 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)

1-53

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

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 REC TAB

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.*

No

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

Yes

Check if the fuse (SFT) is blown.

NG

OK

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

OK

To be continued

NG

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

1-54 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 13 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) 3 5

3 5

1 4 2

1 4 2

T/C FR RLY

T/C RR RLY

1-55 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 13 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: • 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

2-1

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 4

1

PA 2 VZ

QY

1 4 MF PG

PA

3 WG MF

QY WE PG 3

2 GU RQ

GM6-262(UL-LPS)

RQ NX

RQ

EP

WE WE

LN LN

VZ GU

LY

EP GU

WT

LN

5701-471

2-3

RELAY BLOCK Layout

Front

OPS LAMP

2

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

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

FUEL

7.5A

Fuel solenoid

TWC

7.5A

TWC (3-way catalytic) system

ST (Starting motor)

7.5A

Starting motor relay (IG) and pre-heating timer (IG)

SFT (Shift)

7.5A

Electric shift T/C

SAS-ECU

7.5A

SAS controller and SAS lamp relay

IGN (Ignition)

7.5A

Alternator, pre-heating timer, ignition coil, LPG main solenoid, LPG slow solenoid and fuel cut

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

–

–

–

–

–

–

HORN (Horn)

7.5A

Horn

ALT-S (Alternator sending)

5A

Alternator sending

HEAD (Headlamp)

15A

Headlamp and meter illumination

–

–

–

TAIL (Tail)

7.5A

Tail lamp and clearance lamp

ECU-B

7.5A

OPS controller

STOP (Stop lamp)

7.5A

Stop lamp

Including options Fusible links NO.

Name

Capacity

FL

–

–

FL

AM1

40A

FL

HEAD

40A

FL

GLOW

120A

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 position: Between seat switch connectors CN50-1 and CN50-2 in LH side of engine room Standards: Not pushed: OFF (∞ Ω) When pushed: ON (0 Ω)

2

3-1

OIL CONTROL VALVE Page

GENERAL ............................................................3-2 SPECIFICATIONS................................................3-8 COMPONENTS ....................................................3-9 OIL CONTROL VALVE ASSY ...........................3-10 REMOVAL · INSTALLATION ................................3-10 DISASSEMBLY · INSPECTION · REASSEMBLY ....3-11

RELIEF PRESSURE ADJUSTMENT (Pn35 ~ 50, Cu35 ~ 55 MODEL) .....................3-15 RELIEF PRESSURE ADJUSTMENT (Pn60 ~ 80, Cu60 · 70 model).........................3-16 LIFT LOCK RELEASE BOLT ............................3-17

3

3-2

GENERAL

(a)

(c) (e)

(f)

T

(b)

(d)

C2 (j)

C4 P

C1 C5

(k) C3

(h)

(i)

(l)

(g)

3-3 Oil Control Valve

Tilt spool

3 Lift spool

k: Lift lock check valve c: Unloading SOL

(a) Tilt control valve & solenoid

(a)

(b)

(b) Unload solenoid

3-4 (c) Filter and Lift Check Valve

Filter

(d) Flow Divider Valve

(e) Relife Valve

3-5 (f) Needle Valve (Manual Down Valve)

(g) Flow Control Valve

(h) Lift Select Valve

(i) Tilt Select Valve

3

3-6 (j) Limit Switch Forward tilt switch

Backward tilt switch

(l) Tilt Lock Check Valve

3-7

Hydraulic Circuit Diagram (1)

(4)

(2)

C2 C3

(5) C1

(3)

(7)

SOL

PS

T

P

Gage Port

(6) (1) Flow control valve

(5) Lift lock check valve (Leak lock valve)

(2) Tilt select valve

(6) Unloading valve & solenoid

(3) Lift select valve

(7) Tilt control valve & solenoid

(4) Tilt lock check valve (Leak lock valve)

3-8

Relief Valve (For Forward Tilt) (Pn60 ~ 80, Cu60 · 70 Model)

B

T

A (C2 por)

B

A (C2 por)

SPECIFICATIONS Model Item

Pn35 ~ 50

Lift Tilt

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

Cu35 ~ 55

Add-on type (1-, 2-spool monoblock)

Oil control valve type Relief set pressure kPa (kgf/cm2) [psi]

Pn60 ~ 80 Cu60 · 70

18140 (185) [2630]

20590 (210) [2990] (Forward tilt: 13240 (135) [1920])*

18140 (185) [2630]

17.0 (4.49)

22.0 (5.81)

←

Built-in flow divider valve

*: The relief set pressure on the forward tilt side is controlled by connecting another relief valve to the C2 port.

3-9

COMPONENTS 6705

3-10

OIL CONTROL VALVE ASSY REMOVAL · INSTALLATION Note: Before disconnecting the lever rod, operate the control levers to bring the mast to the neutral position and fully lower the fork to release the residual pressure in the material handling system piping.

T=N·m (kgf·cm) [ft·lbf]

3 4

6

5

Oil control valve ASSY set bolt: T=39.2 (400) [28.9]

Removal Procedure 1 2 3 4 5 6

Remove the toe board.

Remove the lower panel.

Disconnect the lever rod.

Disconnect the wiring.

Disconnect the piping.

Remove the oil control valve ASSY.

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

Note: • Apply grease (chassis grease) on the oil control valve lever links.

• Inspect the hydraulic oil level, and add if insufficient.

3-11

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

• Since individual parts are finished with high precision, carefully disassemble so as not to damage them.

T=N·m (kgf·cm) [ft·lbf] 2 T=34.3~44.1 (350~450) [25.3~32.6]

14

8

11

10 2 4 1 9

3 12

6

4

1

7 6 T=26.5~32.4 (270~330) [19.5~23.9]

13

5

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

Remove the limit switch and spring cover. [Point 1] Remove the tilt spool.

Remove the solenoid valve. [Point 2] Remove the lift spool. [Point 3] Remove relief valve No.1. [Point 4] Remove the flow divider valve. [Point 5] Remove the filter. [Point 6] Remove the lift select valve. [Point 7] Remove the tilt select valve. [Point 8] Remove the flow control valve. [Point 9] Remove the tilt lock check valve.

Remove the lift lock check valve.

Remove the additional spool.

Remove the unloading SOL. [Point 10] Remove the outlet housing.

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

Note: Wash each part thoroughly, remove dirt by blowing compressed air and apply hydraulic oil before reassembly.

3-12

Point Operations Forward tilt (-)

Forward tilt (+)

[Point 1] Inspection: Check continuity of limit switches.

Backward tilt (-)

Backward tilt (+)

Forward tilt side: No continuity when the switch is pressed.

Backward tilt side: No continuity when the switch is pressed.

Reassembly: Carefully connect the limit switches on the forward and backward tilt sides in correct positions. Install the one for the forward tilt on the upper side. (It is regular that the both switches must be in pressed state when installed.)

[Point 2]

(+)

Inspection: Check continuity of solenoid.

Inspection: Inspect and wash each orifice to eliminate clogging.

(-)

[Point 3]

SST

Disassembly · Reassembly: Remove the compression spring from the lift spool.

SST 09610-10160-71

[Point 4] Inspection: Inspect and wash the orifice to eliminate clogging.

Orifice

3-13 Reassembly: When the relief valve is disassembled, always loosen the adjusting screw fully.

[Point 5] Inspection: Inspect and wash the orifice to eliminate clogging.

[Point 6] Inspection: Inspect and wash the filter to eliminate clogging.

Service nut

[Point 7] Disassembly Use the service bolt and nut to remove the sleeve.

Service bolt size: M10 x 1.25

Service bolt

[Point 8] Inspection: Inspect and wash the filter to eliminate clogging.

3-14 Service nut

Disassembly: Use the service bolt and nut to remove the sleeve.

Service bolt size: M10 x 1.25

Service bolt

Inspection: Inspect and wash the filter to eliminate clogging.

[Point 9] Inspection: Inspect and wash the filter to eliminate clogging.

[Point 10] Inspection: Check the unload SOL for continuity.

3-15

RELIEF PRESSURE ADJUSTMENT (Pn35 ~ 50, Cu35 ~ 55 MODEL) Note: • Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices.

• Always check that the no-load maximum speed is as specified.

1.

Install an oil pressure gauge.

(1)

2.

Remove the oil pressure detection port plug (illustrated) installed on the front side of the oil control valve, and install the oil pressure gauge.

Plug size: 9/16-18UNF

See that the adjusting screw is loosened.

(1)

Remove the cap nut and packing, loosen the lock nut, and loosen the adjusting screw until it is about to come off from the body.

3.

Start the engine, and check no oil leakage and abnormal noise generation.

4.

Adjust the relief pressure.

(1)

Set the seat switch to ON. (Operate by two workers with one sitting on the seat.)

(2)

Operate the tilt lever for backward tilting, and gradually tighten the adjusting screw until the mast starts to be tilted backward.

Tilt the mast fully backward.

(3)

With the engine running at the maximum speed, operate the tilt lever for backward tilting. Gradually tighten the adjusting screw for adjustment of the pressure upon relief to the standard below, and lock the screw by means of the lock nut.

Standards For both tilt and lift

kPa (kgf/cm2) [psi] 181400+490 (185 +50 )[2630 +70 0 ]

5.

After the adjustment, place the packing, tighten the cap nut and check the relief pressure again.

6.

Remove the oil pressure gauge, and tighten the plug.

3-16

RELIEF PRESSURE ADJUSTMENT (Pn60 ~ 80, Cu60 · 70 MODEL) Note: • Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices.

• Always check that the no-load maximum speed is as specified.

1.

Install an oil pressure gauge.

(1)

2.

See that the adjusting screw (A) is loosened.

(1)

3.

A

4.

Remove the oil pressure detection port plug (illustrated) installed on the front side of the oil control valve, and install the oil pressure gauge.

Plug size: 9/16-18UNF Remove the cap nut and packing, loosen the lock nut, and loosen the adjusting screw (A) until it is about to come off from the body.

Start the engine, and check no oil leakage and abnormal noise generation.

Adjust the lift and tilt (backward) relief pressure.

(1)

Set the seat switch to ON. (Operate by two workers with one sitting on the seat.)

(2)

Operate the tilt lever for backward tilting, and gradually tighten the adjusting screw (A) until the mast starts to be tilted backward.

Tilt the mast fully backward.

(3)

With the engine running at the maximum speed, operate the tilt lever for backward tilting. Gradually tighten the adjusting screw (A) for adjustment of the pressure upon relief to the standard below, and lock the screw by means of the lock nut.

Standards For both tilt (backward) and lift

5.

6.

+490

20590 0

+5

+70

(210 0 )[2990 0 ]

See that the adjusting screw (B) is loosened.

(1)

B

kPa (kgf/cm2) [psi]

Remove the cap nut and packing, and loosen the adjusting screw (B) until it is about to come off from the body.

Adjust the tilt (forward) relief pressure.

(1)

Set the seat switch to ON. (Operate by two workers with one sitting on the seat.)

(2)

Operate the tilt lever for forward tilting, and gradually tighten the adjusting screw (B) until the mast starts to be tilted forward.

Tilt the mast fully forward.

(3)

With the engine running at the maximum speed, operate the tilt lever for forward tilting. Gradually tighten the adjusting screw (B) for adjustment of the pressure upon relief to the standard below.

Standards Tilt (forward)

kPa (kgf/cm2) [psi] +490

13240 0

+5

+70

(135 0 )[1920 0 ]

7.

After the adjustment, place the packing, tighten the cap nut and check the relief pressure again.

8.

Remove the oil pressure gauge, and tighten the plug.

3-17

LIFT LOCK RELEASE BOLT

T=N·m (kgf·cm) [ft·lbf] Lift lock unlocking bolt T = 26.5 ~ 32.4 (270 ~ 330) [19.5 ~ 23.9]

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 making repairs, tighten it appropriately.

4-1

SAS Page

TROUBLESHOOTING .........................................4-2 TROUBLESHOOTING BY ERROR CODE ................4-3 TROUBLESHOOTING BY PHENOMENON ..............4-7

CONNECTOR LAYOUT (SAS, OPS).................4-12 CONTROLLER SEQUENCE (SAS, OPS) .........4-13 CONNECTOR DIAGRAMS (SAS, OPS)............4-14

4

4-2

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

4-3

4-5

Error code

Error description

Page

63-1

Tilt lever switch simultaneous ON

4-3

63-2

Forward tilt switch short circuit for 2 minutes

4-3

63-3

Backward tilt switch short circuit for 2 minutes

4-3

64-1

Tilt solenoid abnormality

4-5

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

4-7

4-10

See "Mast dose not tilt forward." section in OPS Troubleshooting.

4-3

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

OK

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

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

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 key 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.

4

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

Turn the key 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)

4-5

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 (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 tilting to check if the SAS lamp blinks.

The SAS lamp must not blink.

4

4-6 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)

4-7

TROUBLESHOOTING BY PHENOMENON z The active mast rear tilt speed control is not regulated, or the backward tilting speed is always slow.

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

4-8 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. 1-42).

4-9 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

4-10 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. 1-42).

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

4-11 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)

4-12

CONNECTOR LAYOUT (SAS, OPS)

MAST SW1 COMB MET HOUR MET SAS LP SWN LOCP LP

PRES SSR TAB REC

CN31

CN26 SHIFT SW

OPS BZR (Export model) TAB REC

CN3

REC TAB

UNLORD SOL REC

SPD SSR TAB REC

TAB REC

CN51

CN47

CN22 CN41 CN42

TAB CN53 REC

TAB REC

CN43

NTRLTILT SW

OPS-LAMP RLY (OPS R/B)

OPS CONTROLLER

TAB REC

FPC

TAB

SAS BZR

SAS CONTROLLER

CN45

CN1

TAB REC

TAB REC

TAB REC

CN33

CN27

CN2

TAB REC

CN12 CN46

CN37

REC TAB

TAB REC

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

TAB REC

HOUR MET CNN TAB REC

CN35

TILT SOL

DIODE A

SFT SOL

TAB REC

TAB REC

CN55

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

CN50

RR LWR W/H

REC TAB

TAB REC

CN7

CN11

SWN SOL

CN60

TILT AGL SSR

4-13

W/SPLICE-C

SHIFT LEVER

ECU-IG (7.5A)

3 CN6

EZ PEDAL

7 CN52

JOINT4

SOLENOID RB

SOLENOID FB

5 CN52

JOINT1

JOINT3

SEAT SWITCH

T/C RR RELAY

2 CN50

T/C FR RELAY

14 CN65

5 CN6

ECU-B (7.5A)

TILT SWITCH RB

GAUGE (10A)

TILT SWITCH FB

IG1

10 CN6

DIODE A

W/SPLICE-F 1 CN46

DIRECTION SWITCH RR

CN52 8

1 CN50

11 CN46 6 CN46

6 CN4

10 CN46

TILT ANGLE SENSOR

MAST SWITCH

SAS RE-SETTING CONNECTOR DIAG CONNECTOR

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

MH1

SPD

SPDF

TILT

SWN

HRM3

HRM2

OUT1

SIL

DIODE A

HRM1

SAS CONTROLLER STRG

TGND

TFO

BZO

RYLP

E2

TCON

TRO

IG

RLY E1

JOINT3

JOINT2

SHIFT SOLENOID RB

JOINT4

-

4 7 CN3 CN3

OPS BUZZER (EXPORT MODEL) MF

7 CN52

PRESS SENSOR +

1 CN3 2 CN3

TRG

5 CN52

UNLOAD SOLENOID

TO E03

2 CN46

W/SPLICE-Z

W/SPLICE-A

E02

T/C RR RELAY

SIL

YB1

T/C FR RELAY

SOL3

9 CN46 8 CN46

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

PARKING SWITCH

6 CN57

TILT SOLENOID

3 CN57

E3

E3

EZ MAIN RELAY CN52 2

SOL1

BCIN

NEUTRAL TILT SWITCH

OPS CONTROLLER STARTER RELAY

W/SPLICE-Y

IG IG

CN46 5 4 CN46

DGND

DMI

DMO

SPI2

TFI

SPI1

BATT BCON

E03

RYR

EZ RR SFT RELAY

TRI

SAS SYSTEM DRF

CN52 4 EZ FR SFT RELAY

RYF

DIRECTION SWITCH FR

DRR

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

4-14

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

4-15

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)

4-16

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

4-17

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

4-18

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 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 -

4-19

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 SOL1 IG IG2 E03 TGND TRO TFO DMI TRI TFI 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 13 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 26 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)

4-20

CN53 (LH SHIFT LEVER)

CN47 2

1

1

1 2 3 4 5 6 7 8 9

2

10 11 12 13 14 15 16 17 18 REC

TAB No. 1 2

C W W

J -

No. C 1 GR-G 2 W-B

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

(RH SHIFT LEVER) 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10

CN50 2

REC

1

1

TAB No. C 1 G-W BR 2

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 -

2

REC

J CN60-1 CN60-2

No. C 1 G-W 2 BR

J CN4-6 CN65-14

CN51 2

1

1

TAB No. 1 2

C -

2

REC No. C 1 B-R 2 W-G

J -

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

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

CN54 CN52 4 8

3 7

2 6

1 5

2

1

2

3

4

5

6

7

8

TAB No. 1 2 3 4 5 6 7 8

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

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

1

1

TAB No. 1 2

REC J FB RB

C -

2

J CN52-5 CN52-7

No. C 1 L-W 2 L-R

REC 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

CN55 1 2 3

3 2 1 TAB No. 1 2 3

C -

REC J + +

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

J JOINT4 W/SPLICE-F (E) JOINT3

4-21

CN65

CN57 3 6

2 5

1

1

4

4

TAB No. 1 2 3 4 5 6

2 5

6 5 4

3

No. 1 2 3 4 5 6

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

6

CN58 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

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

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

1

C -

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

EZ RR SFT RLY

3

1

5

4

REC No. 1 2 3 4 5

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

2

3 5

REC

J * * CN57-3 * *

No. 1 2 3 4 5

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

J * * CN57-6 * *

OPS-LAMP RLY (Base side) 3

1

1

TAB No. 1 2

2

4

CN60 2

REC 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

REC

J * * * * CN45-32 * * *

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

3 4

4 5 6

7 8 9 10 11 12 13 14

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)

4

1 2 3

14 13 12 11 10 9 8 7

REC

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

3 2 1

2

5 1 4

REC J + -

No. C 1 G-W 2 BR

J CN50-1 CN50-2

2

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

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

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

5-1

APPENDIX Page

SST LIST ..............................................................5-2 SERVICE STANDARDS LIST..............................5-3 WIRING DIAGRAM ..............................................5-4

5

5-2

SST LIST

★ : Newly adopted SST Section

Illust.

Part number

Part name

★ 09240-23323-71

Plug-in analyzer

09610-10160-71

Oil control valve spring remover and replacer

1

3

{

{

5-3

SERVICE STANDARDS LIST OIL CONTROL VALVE Oil control valve Relief set pressure (common to lift and tilt) kPa (kgf/cm2) [psi]

Pn35 ~ 50, Cu35 ~ 55 model

Standard

18140 0 (185 0 ) [2630 0 ]

Relief set pressure (common to lift and tilt (backward)) kPa (kgf/cm2) [psi]

Pn60 ~ 80, Cu60 · 70 model

Standard

20590 0 (210 0 ) [2990 0 ]

Relief set pressure (tilt (forward)) kPa (kgf/cm2) [psi]

Pn60 ~ 80, Cu60 · 70 model

Standard

13240 0 (135 0 ) [1920 0 ]

Tightening torque

+490

+5

+70

+490

+5

+70

+490

+5

+70

Unit: N·m (kgf·cm) [ft·bf]

Outlet housing set bolt

34.3 ~ 44.1 (350 ~ 450) [25.3 ~ 32.6]

5

5-4

WIRING DIAGRAM NAME

G

D

LP

G/LP

LPS

Page

BATTERY, RELAY BOX

{

{

{

{

{

5-5

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

{

—

{

{

{

5-6

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

{

—

{

{

{

5-7

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

—

{

—

—

—

5-8

SAS AND OPS CONTROLLER

{

{

{

{

{

4-13

COMBINATION METER

{

{

{

{

{

5-9

COMBINATION METER (EZ PEDAL)

{

{

{

{

—

5-10

FUEL SYSTEM (GASOLINE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G)

{

—

—

—

—

5-11

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS)

—

—

{*1

—

{*1

5-12

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS), VSCS

—

—

{*2

—

{*2

5-13

FUEL SYSTEM (LPG CONVERTIBLE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G/LP)

—

—

—

{

—

5-14

*1: 7FGU35 ~ 45, 7FGCU35 ~ 60 *2: 7FGAU50, 7FGU60 ~ 80, 7FGCU70, 7FGU35 ~ 45 (W/ VSCS), 7FGCU35 ~ 60 (W/ VSCS)

Note: This manual shows only the wiring diagrams revised in September 2005.

As for wiring diagrams not shown herein, refer to 7FGU/7FDU35-80 and 7FGCU35-70 Repair Manuals (Pub. Nos. CU030 and CU030-1) and Parts & Service News, Ref. No. CB-4008 (issued in February 2004).

W (UL-G, LP, G/LP) B-R (UL-D)

B-Y

W

W

FL W

B-Y

UL-G UL-D UL-LP UL-G/LP

FL ALT 80A

FL AM1 40A

UL-D

FL GLOW 120A

FL HEAD 40A

W-L

ALT

B S IG L

W

W-L W-L

DISCONNECT SW

UL-LPS

BUS BAR

IGN 7.5A

RELAY BOX

B-W

ST 7.5A

B-W

L-B

FUEL 7.5A B-Y

UL-G, LP, G/LP, LPS

L

SFT 7.5A

B-R SAS WARNING LAMP RELAY

L-W

B-L (UL-G, LP, G/LP, LPS) B-O (UL-DS)

G-W

B-Y

B-R

DOUBLE

B-Y

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 G-Y

ALT-S 5A

B

L-O

W-R

W

G R-W

R-L R-B

DOUBLE HORN 7.5A

STARTER RELAY

TWC 7.5A

ECU-B 7.5A

STOP 7.5A

TAIL 7.5A

HEAD 15A

FUSE ALT-S

IG SW IG1 AM1 ST1

W-L

W-L

L-B

W

TAIL LP RLY

B-R

R

HEAD LP RLY

STARTER RELAY (COIL)

ELECTRIC SHIFT T/C LPG SOL ENGINE SHUT DOWN DEVICE (OPT) UL-G, LP, G/LP, LPS

SAS CONTROLLER

ALTERNATOR, IGNITION COIL (OPT)

TURN SIGNAL LAMP (OPT)

HOUR METER, WATER TEMP IND, FUEL IND BACK BUZZER (OPT), BACK UP LAMP (OPT) LPG WARNING IND (OPT), STROBE LIGHT (OPT) T/C OIL TEMPERATURE INDICATOR (OPT)

HORN

ALTERNATOR SENSING

STARTER

THREE WAY CATALYTIC SYSTEM

INTAKE HEATER UL-D

OPS CONTROLLER

STOP LAMP (OPT)

TAIL LAMP (OPT), CLEARANCE LAMP (OPT)

HEAD LAMP, METER ILLUMINATION

5-5

BATTERY, RELAY BOX

5

BATTERY

BUS BAR

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

IG SW

B-L

B (LP, LPS)

Rr N R

Ra

F1

F2

B N

B-W

B-R

SHIFT CONTROL SW

B-R

SLOW SOLENOID KEEP RELAY

IG1

SAFETY STARTSW (OPT)

VF

G-R

IG2

B

L

L-W

B-W

L-W

VF2 ST

R-G

B-W ST 7.5A

VR

R

B-W

L-R

Ra

RELAY BOX

R-Y

L SFT 7.5A

BZ

R-Y

B-Y

R

R-G

R-W

B-Y

R

W-B L-R

Y

T/C RR RELAY

W-B

LOCK

IG1

B-L

ST1

TWC CONTROLLER

AM1

STARTER KEEP RELAY

W-B LFC

A See pages 5-12 ,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 RELEASE

PARKING BRAKE LAMP (OPT)

AM1

EZ PEDAL

IG1

ST1

STARTER RELAY(+S)

IG SW

B-R

B

B-W RELAY BOX

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 EZ MAIN RELAY

L

SFT 7.5A

ELECTRIC SHIFT T/C, STARTING, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: 3-WAY CATALYTIC SYSTEM) 5-6

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-W

B-R

R

IG1

W-B

ST1

B

IG SW

W-B

BODY EARTH

L-W

W-B

B-Y

SAFETY STARTSW (OPT)

SOLENOID

W-B

Y

BODY EARTH SOLENOID

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)

LOCK

R-W

GAUGE 10A

R-G

W-B RELEASE

PARKING BRAKE LAMP (OPT)

ELECTRIC SHIFT T/C, STARTING, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: LESS 3-WAY CATALYTIC SYSTEM) 5-7

B-Y

W

B-R

STARTER

RELAY BOX

FL ALT 80A

FL GLOW 60A

FL HEAD 40A

FL AM1 40A

BODY EARTH

B

FL (P)

B

B W-B GLOW PLUG

G

G-R

GLOW PLUG TIMER

ALT (L)

LG-B

W-B

Y

R

IG SW (IG1)

GLOW RELAY MAIN

IGN 7.5A

B-O W-B

W-B

R

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 N R

Ra

F1

F2

B

N

B-W

B-R

IG1

SAFETY STARTSW (OPT)

IG2 VF

G-R

L

L-W

B-W

L-W

VF2 ST

R-G

B-W ST 7.5A

VR

R

B-W

L-R

B-Y

R

W-B L-R

Ra

RELAY BOX

R-Y

L

B-Y

T/C RR RELAY

IG1

ST1

SHIFT CONTROL SW

IG SW

W-B

W-B BODY EARTH

T/C FR RELAY

SOLENOID

W-B

Y

BODY EARTH SOLENOID

SFT 7.5A W-B

R

BZ

W-B

R-Y

MOTION ALARM (OPT)

LOCK

GAUGE 10A

R-G

R-W

W-B RELEASE

PARKING BRAKE LAMP (OPT)

ELECTRIC SHIFT T/C, STARTING, GLOW, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (DIESEL ENGINE) 5-8

B-Y

FL W

W

W DISCONNECT SW

W (UL-G, LP, G/LP) B-R (UL-D)

B-Y BATTERY

RELAY BOX

P-G

UL-G UL-D UL-LP UL-G/LP

W-B

P-G

SAS ECU

FL AM1 40A

SAS WARNING L-O LOCK IND

V-G

HRM1

UL-LPS

W-B

SAS WARNING LAMP RELAY OUT1

V-R

HRM2

P-L

E1 HRM3

W-L

W-B W-B

Y-B

W-B

G

V-W

Y-L

V B-Y

UL-G, D, G/LP

FUEL SENDER

IG SW IG1 AM1 ST1

OPS

V

Y-G

W-L

HOUR METER W-B

OPS-LAMP RELAY

W-B

W-B FUEL

WATER TEMP SENDER

LG

LG-B

L

GAUGE 10A

RELAY BOX

Y

Y-R

B-Y

Y

Y-R

AIR CLEANER Y-G

W-B

Y-G

RADIATOR (OPT)

R-G

W-B

W

B

COMBINATION METER

BODY EARTH

W-B WATER TEMP

BODY EARTH

CHARGE

ALTERNATOR W-B

W-B

B

VACCUM SW (AIR CLEANER) B

LG-R

LEVEL SW (OPT) (RADIATOR RESERVOIR TANK) BODY EARTH LG-R

OIL

OIL PRESSURE SW W-B UL-D

Y-B

Y-B SEDIMENTER

LEVEL SW (SEDIMENTER)

W-B

R

R-W BRAKE (OPT)

PARKING BRAKE SW (OPT) W-B Y

W-B

UL-D BODY EARTH

R

TWC ECU

TWC V-G

V-G

UL-G, LP, G/LP WATER TEMP SW (OPT)

OVER HEAT (OPT) V

W-B

R

UL-G, LP, G/LP, GOVERNOR ECU LPS (OPT) W-B W-B R UL-D

CHECK ECU (OPT) R

PRE-HEATING TIMER

GLOW

COMBINATION METER 5-9

W-B

P-G

B-Y

W (UL-G, LP, G/LP) B-R (UL-D) BATTERY

P-G SAS WARNING

L-O

SAS ECU

V-G

FL AM1 40A

OUT1

HRM1 HRM2

LOCK IND

V-R P-L W-L

E1 HRM3

Y-B

G

W-L

W-B

OPS

UL-G, D, G/LP

FUEL SENDER

V-W

Y-L

V

IG SW IG1 AM1 ST1

V

Y-G

FUEL WARNING (OPT)

W-B

RELAY BOX

W-B

SAS WARNING LAMP RELAY

W-B W-B

HOUR METER W-B

OPS-LAMP RELAY

W-B

W-B WATER TEMP SENDER

FUEL LG-B

RELAY BOX

Y-G

GAUGE 10A

RADIATOR (OPT) R-G

UL-G, D, LP, G/LP

Y-G

W-B

B-Y

L

Y

Y-R

COMBINATION METER

LG

Y

Y-R

AIR CLEANER

LG-R

LEVEL SW (OPT) (RADIATOR RESERVOIR TANK) BODY EARTH LG-R

B-Y

BODY EARTH

W-B WATER TEMP

BODY EARTH

CHARGE

ALTERNATOR W-B

W-B

B

VACCUM SW (AIR CLEANER) B

Y-B

Y-B

OIL

OIL PRESSURE SW W-B W

W-B UL-D

SEDIMENTER

LEVEL SW (SEDIMENTER)

R-G

B-R

R-W BRAKE (OPT)

R

LOCK

B-R STARTER RELAY EZ PEDAL RELAY

B

W-B

L

G-R

RELEASE

PARKING BRAKE SW W-B

W-B

UL-LP

Y

Y-B

TWC ECU

TWC

BODY EARTH

V-G

V-G

UL-G, LP, G/LP WATER TEMP SW (OPT) W-B

OVER HEAT (OPT) R

R

UL-G, LP, G/LP GOVERNOR ECU (OPT) W-B

CHECK ECU (OPT)

W-B

UL-D

R

R

PRE-HEATING TIMER

GLOW

COMBINATION METER (EZ PEDAL) 5-10

BODY EARTH

B-O

B-Y

W

FL AM1 40A

B-O

B-O

FUL

SOL

B-L

AM1

B-L L-B

IG1

ST1

STARTER SUB RELAY B-W

B-W

ST 7.5A

B-Y

B-W

B-W

B

B ST

IG SW

FUEL PUMP RELAY

W-L

B-O

G-R

B-L IG2

CLS

FL HEAD 40A

B-O

W-B

G-R

B G-B

B-Y

B-L

FUEL 7.5A

B E1

B-L

W-B

B-L

CHECKER

E0

IGN 7.5A

B-L

G-W

SH-LD

RLY

SH-LD W

IGNITION RELAY B-L

MAP SENSOR

AE

R B

GAUGE 10A

R-G

ACCEL SENSOR

B-W

RELAY BOX

STEPPING MOTOR

B

R-G

B-L

5V

R

ACCL

B-Y

GOVERNOR ECU

B

W-B

B-L

DISTRIBUTOR

V-W V-G

CHK

B-Y

REF

EST

B/P

E

MAP MEM

NIB

IB

W

NIA

CHECK ECU

G

CHG

WRN

SH-LD

IDL

IA

BUS BAR

W-B

W-B

RELAY BOX

CERAMIC CHOKE BODY EARTH

FUEL CUT SOLENOID W-B

FUEL PUMP

B-L IG1

OPEN SW BR

OPN

CLOSE SW BR BR

SHIFT CONTROL SW

DE

W

DGN

G R B

G-O

MEMORY CLEAR

B R W G

W-B

SH-LD

CHARGE B-W

TWC

TACH

B

B-O

B-O

B-W

V

R

COMBINATION METER

IGNITION COIL

SH-LD

Y

Y Y B

VACUUM SENSOR

STA

E2

W

PIM

IG-

VCC

B-W

BR

ALT

W L-W

BR

BR

BR

Y-B

Y-B

B

B

TWC 7.5A

SEL2

FCM1

E1

R-B R-W R

FCM3

L-B L-B

R-G

FCM4

CHECK CONNECTOR

L-B

B-L

E3 TE2

L-O

TWC ECU

FCM2

OX

SEL3

W-R G-W G-B

AIR BLEED CONTROL VALVE

W-B

W-B

O

O

OXYGEN SENSOR W SH-LD W-B W-B

TE1

G

VF

G-Y

IGB2

L-B

L-B

OXM IGB

V-G

W-B WATER TEMP

L-B

L-B

W-G

W-G W-G

L-O

L-B

THW

SENSOR W-G

W-G

W-B

BATT1

E02

BATT2

E01

L-O

L-O

TWC RELAY

L-O

L-O

L-O

FUEL SYSTEM (GASOLINE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G) 5-11

LPG SLOW SOLENOID

FL W

B-Y

W

DISCONNECT SW W (LPS)

W (LP)

B

FL AM1 40A

B (LPS)

FL HEAD 40A

B

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

B-O W-L

B-L

AM1

IG SW

B (LPS)

B (LPS)

B-O (LP)

FUEL PUMP RELAY FUL

B-L L-B

IG1

ST1

B-L

B-W

ST 7.5A

B-W

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

E0

W-B

DISTRIBUTOR

B-L

B B-Y

SH-LD

GOVERNOR ECU

B-Y

FUEL 7.5A

SHIFT CONTROL SW

B-Y

B-W

B-W

B

E1

REF

EST

B/P

ING 7.5A

B-L SH-LD

B-L

GAUGE 10A

B-L

R-G

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

MAP SENSOR

B-Y

CHG

R-G

B-L (LP)

CHARGE

RELAY BOX

Y

TWC

Y B

ALT

A See page 5-6

LFC

B-W

VACUUM SENSOR

COMBINATION METER

IG-

STA

E2

W

PIM

Y-B

Y-B

B

B

TWC 7.5A E1

OX

E3

L-R

RES

B-L

L-B

LPG INJECTOR

L-B

L-B

CHECK CONNECTOR

L

RESISTOR L

INJ

W-G

L-O

TE1

TWC ECU

W-R G-W

TE2

G-B

VF IGB2 OXM IGB

V-G

WATER TEMP SENSOR

BUS BAR

W

AE

B

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

Y

IGNITION COIL

SH-LD

VCC

BR

W-B O

SEL3

W-B

RELAY BOX

B

W-B

LPG MAIN SOLENOID

B-O (LP)

B-O (LP)

G-R (LP)

B-L

IG1

IG2

B

STARTER SUB RELAY

W G R B

W-B

W-B

E

R

MAP

5V

W-B B-O (LP)

B

TACH

W L-W

W-B O

OXYGEN SENSOR W SH-LD

W-B

G G-Y

W-B W-G

L-B

L-B

L-B

THW

W-G

W-G

W-G

L-O

W-B

BATT1

E02

BATT2

E01

L-O

L-O

TWC RELAY

L-O

L-O

L-O

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS) 5-12

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

B

LPG SLOW SOLENOID B

B (LPS)

B (LPS) B-O (LP)

FL W

B-Y

W

DISCONNECT SW W (LPS)

W (LP)

B (LPS) B-O (LP)

B-O (LP)

FUL

B-L

LPG RELAY

B-L

B-L

IG2

FL AM1 40A

B-O (LP)

G-R

B-L

IG1 OPN

W-L

B-L

B-W

L-B

B-W

IG SW

B

AM1

B-W

B

B

IG1

ST1

B

B

ST 7.5A

W-B

B-L

SH-LD

MAP SENSOR

B-L

IGNITION RELAY

B-L

R

B-L

SH-LD

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

G-W

RLY

W

AE

MAP

B

5V

IGN 7.5A

B-L

B-W

B

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

CHECK ECU

SH-LD

CHG

SH-LD

WRN

SAS ECU (VSCS ONLY)

VOLUME (VSCS ONLY)

R-G

RELAY BOX

SH-LD

SH-LD

ACCEL SENSOR

GAUGE 10A R-G

STEPPING MOTOR

B

W

B B-L

B-Y

SPD

BUS BAR

W R

NMR

B-Y

GOVERNOR ECU

B-L

B-Y

FUEL 7.5A

B-Y

CHECKER

E0

B-W

DISTRIBUTOR

B-L

V-W V-G

CHK

E

MEM

R W G

IDL

IA

FL HEAD 40A

G-R

G-B

SHIFT CONTROL SW E1

REF

W-B

EST

B/P

W-B G-O

NIB

IB

L

G-B

SPDF

CHARGE B-W

TWC B-W (LP) R

Y

Y B

Y

A See page 5-6

VACUUM SENSOR

LFC

B-W

ALT

VCC

COMBINATION METER

B-O (LP) B-W (LPS)

V

IGNITION COIL

SH-LD

RELAY BOX

W-B

B

LPG MAIN SOLENOID (LP)

OPEN SW BR

STARTER SUB RELAY

CLOSE SW BR

CLS ST

BR

DE

W

DGN

G R B

W-B

MEMORY CLEAR B R

ACCL

W

NIA

G

P

P-B

W-B

B-O (LP)

B

TACH

W L-W

IG-

Y-B

PIM W

BR

Y-B

E2

O

OXYGEN SENSOR

W-B

W-B

W-B

W-B

W-B

O

B

TWC 7.5A

L

INJ

L-B

CHECK CONNECTOR

TWC ECU

L

RESISTOR

B-L

TE1

L-B

LPG INJECTOR

L-B

L-B

L-B

L-B

L-O

W-B

THW

W-G

BATT2

BATT1

E01

W-G

L-O

E3

TE2

G-B

L-R

RES

SEL3

W-R G-W

IGB OXM

V-G W-G

B

STA

SEL1 E1

OX

W SH-LD W-B W-B

IGB2

G

VF

G-Y W-B WATER TEMP SENSOR W-G

W-G

L-O

L-O

L-O

TWC RELAY

L-O

L-O

E02

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS), VSCS 5-13

BODY EARTH

B-O B-Y

CERAMIC CHOKE B

W

FL AM1 40A

B B-Y

B-L

LPG

B-O

AM1

B-O

B-O

B

SOL

FUL

B-L

ST1

G-R

IG1

B-Y

B-Y

LPG RELAY B-O

IG SW

W-L

B-Y

B-Y

B-O

B-L

IG1

B-L L-B

B-L

B-W

B-W B-W

ST 7.5A

B-W

FUEL 7.5A

B-L

B-Y

B

B-Y

B

B-Y

IG2

OPN

CLS ST

B-Y

STEPPING MOTOR

B

CHG

WRN

SH-LD

ACCEL SENSOR

B-W

R-G

B-L

SH-LD

MAP SENSOR

B-L R-G

B-R

GOVERNOR ECU

W-B

B-L

B

B B-L

IGN 7.5A

B-L

IGNITION RELAY

GAUGE 10A RELAY BOX

CHECK ECU CHARGE

SH-LD

TWC B-W R Y

Y

B

ALT

IG-

Y-B

W

FCM1

SEL2

STA

E2

Y-B

B

B

R-B R-W

FCM2 SEL1

R

FCM3 E1

TWC 7.5A

AIR BLEED CONTROL VALVE

A See page 5-6

LFC

LPG

GAS

B-W

VACUUM SENSOR

COMBINATION METER

BR

BR

B-L

CHECKER

G-W SH-LD

5V

BR

BR

B-Y

B-L

B-L

W-B

B-Y

DISTRIBUTOR

V-W

DGN

V-G

CHK

E0

RLY

W

AE

E

B

MEM

NIB

R

G

IDL

B-O

W-B

W-B

BUS BAR

R-G

L-B L-B

OX

RESISTOR

L-B

L L-B LPG INJECTOR

L-B

VF

L-B

IGB

L-B

CHECK CONNECTOR

TWC ECU

L-R

RES

L

E3 TE2

INJ TE1

G

B-L

G-W G-B

IGB2 OXM

L-B

L-B

THW

SENSOR W-G W-G

L-O

W-B W-B

FL HEAD 40A

LPG SW

B

B-Y

GASOLINE

W-B

G-R

B G-B

SHIFT CONTROL SW

DE

E1

REF

EST

W-B

W-B

R

MAP

B

IB

W

NIA

IA

B-W B-O V

Y

IGNITION COIL

VCC PIM

W-B

W-B

O

SEL3

W-R

G-Y

RELAY BOX

B-L

LPG SLOW SOLENOID W-B

LPG MAIN SOLENOID BODY EARTH

FUEL CUT SOLENOID W-B

FUEL PUMP OPEN SW BR

STARTER SUB RELAY CLOSE SW BR BR

B

W G R B

B/P

G-O

MEMORY CLEAR

R

ACCL

W G

W-B B

TACH SH-LD

W L-W

W-B

FCM4

O

OXYGEN SENSOR

W SH-LD

V-G

W-B WATER TEMP

W-G

W-G

W-G

L-O

W-B L-O

BATT2

E01 E02

L-O

L-O

BATT1

TWC RELAY L-O

L-O

FUEL SYSTEM (LPG CONVERTIBLE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G/LP), VSCS 5-14

Published by

1st Printing: Oct. 2005 Pub. No. CU041 Printed in Japan

C