Page 1

MULTI-DISPLAY FUNCTIONS Page

MULTIPLE DISPLAY

3-2

GENERAL

3-2

SPECIFICATIONS

3-6

GENERAL FUNCTION AND MANAGER'S FUNCTION 3-7 DISPLAY INDICATION LIST

3-8

ABBREVIATIONS DISPLAYED ON THE SCREEN

3-10

GENERAL FUNCTIONS

3-11

.

OPERATING PROCEDURE OF FUNCTION SETTING 3-13

MANAGER'S FUNCTIONS PASSWORD FOR MANAGER'S FUNCTION

3-18

........

3-18

.

OPERATING PROCEDURE OF FUNCTION SETTING 3-19

DIAGNOSIS

3-24

DIAGNOSIS CODE

3-24

MASK FUNCTIONS

3-30

GENERAL

3-30

PASSWORD FOR MASK FUNCTION .............. 3-32 OPERATION ON MASK MENU SCREEN ........... 3-33 ANALYZER

3-34

TUNING

3-54

OPTION SET

3-64

MATCHING

3-68

CONSTANT SET

3-71


MULTIPLE DISPLAY GENERAL The multiple display indicates various types of vehicle information by switching the screen according to need.

Display and Buttons

Initial screen upon key switch on I

During traveling

Upon error occurrence

(1)

Parking brake ON indicator

(7)

(2)

Travel speed limit indicator

( 8 ) DOWN button

(3)

Diagnosis ON indicator

(9)

(4)

Overheat warning indicator

(10) Power select button

(5) Battery charge indicator (6)

Power select indicator

Multiple display area

UP button

(11) Hour meter selector button


(1) Parking brake ON indicator This indicator comes on when the parking brake is activated. If the accelerator pedal is depressed with the direction lever in the forward or reverse position, beeps sound to warn the operator. (2) Travel speed limit indicator LEVEL This indicator comes on when the level is set to 7 or less on the TRAVEL SPEED SETTING screen. (The setting in USA models can be changed only by the Manager's functions.) (3) Diagnosis ON indicator Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same time, the corresponding error code is displayed and buzzer sounds to warn the operator. Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to six error codes are displayed with alternation at intervals of 2 seconds. On a vehicle without matching performed for the SAS function, this indicator comes on to warn the service person. This indicator also comes on to warn the service person on a mini lever model vehicle without matching performed for the mini lever function. Perform matching by referring to the MATCHING section. (4) Overheat warning indicator If the temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or overheat warning At the same time, pump motor rises beyond the specified level, a buzzer sounds to warn the operator. When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks. Overheat warning indicator

Description Overheat section

Indication

Main controller DCR

Traveling AC driver

PCR

Material handling AC driver

DM

Drive motor

PM

Pump motor

Overheat section

Vehicle Operation Restriction when Overheated Overheat section

Description of control

Specification

Primary control

STD . controller STD . Traveling UL-EEspec AC driver Material handling AC driver

STD . UL-EE spec (OPT)

Secondary control

P

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

P

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

P

1. Character indication and indicator blink 2. for 5 seconds 3. Restrict material handling output

Tertiary control


Overheat section

Description of control

Mode Primary control

H

STD P

Drive motor

Secondary control

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

Character indication H

UL-EEspec P

STD

P S

2. Buzzer for 5 seconds 3. Change to S mode

and indicator blink 2. No buzzer 3. Change to half 3. Restrict drive output

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

H

Pump motor

2. Buzzer for 5 seconds 3. Change to P mode

and indicator blink 2. No buzzer

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

S

Tertiary control

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

Character indication and indicator blink 3. Restrict material


(5) Battery charge indicator This indicator indicates the remaining battery charge in 10 stages. Low remaining battery charge warning

Number of segments corresponding to the remaining battery charge.

Battery overdischarge warning

J

A: Low remaining battery charge warning The battery charge indicator blinks when the remaining battery charge drops to the set level or below. When the key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to warn the operator. B: Battery overdischarge warning (lift interrupt function) When the battery charge decreases further below the set level after the remaining battery charge warning, any attempt at traveling or material handling operation will cause all charge indicator segments to blink and the alarm to sound to warn the operator. At this time, the material handling operation is disabled in USA and Canada models. However, when the key switch is turned from.OFF to ON, the operation can be performed only once for 30 seconds. In export models, the material handling operation during traveling is disabled. Note: The level can be set using TUNING function of the mask function. (See page 3-54.)

All segments blink.

(6) Power select indicator (traveling and material handling) A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by pressing the power select button on the GENERAL screen. If all symbols are enclosed, control is performed in the original mode (level set on the POWER CONTROL LEVEL SETTING screen). (7) Multiple display area The date and time are normally displayed in this area. This area is also used for various function settings and error code displays of the diagnosis function. (8) DOWN button The DOWN button is used for setting the clock on the GENERAL DOWN button is also used for setting the level of each function on the MANAGER'S FUNCTION screen*. *: Operation can be performed by inputting the manager's password. (9) UP button The UP button is used for setting the clock on the GENERAL UP button is also used for setting the level of each function on the MANAGER'S FUNCTION screen*. *: Operation can be performed by inputting the manager's password. (11) Power select button USA models: Press the button for 2 seconds or more on the GENERAL screen to set the clock. Only when "YES" is selected on the MANAGER'S FUNCTION screen*, the S, P or H modes can be changed by this button. square indicating the selection moves to the right each time the power select button is pressed. Press the button for 2 seconds or more to set the level of each function. Export models: The button selects S, P or H mode. The selected mode can be changed each time the power select button is pressed on the GENERAL screen. Press the button for 2 seconds or more to set the level of each function. *: Operation can be performed by inputting the manager's password.


(11) Hour meter selector button This button changes displayed items of multi-hour meter function. (12) Low temperature warning indicator Warn the low temperature of the traveling and material handling AC drivers. When the material handling AC driver temperature becomes low, a buzzer sounds to warn the operator for 5 seconds. At the same time, it restricts the material handling output. The low temperature section indication blinks. Description

Indication

Low temperature section

COLD DCR

Traveling AC driver

COLD PCR

Material handling AC driver

S P H

J

Low temperature section

(13) Maintenance timer indicator This indicator blinks to notify the need of maintenance when the time set on the PLANNED MAINTENANCE HOUR SETTING screen passes. When the key switch is turned from OFF to ON in this state, the buzzer sounds for 5 seconds to warn the operator.

Maintenance timer indicator

SPECIFICATIONS LCD

Dot matrix + fixed display

Buttons

Four buttons

Back light

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

Heater

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


GENERAL FUNCTION AND MANAGER'S FUNCTION 1. General functions can generally been used or seen by the user. 2. The Manager's function is a function that the manager can use by inputting the password. 3. The functions included in the General function and the Manager's function differ in accordance with the specifications of the model as follows.

function USA model (standard model)

Functions

function

Level setting function

function

Battery charge indicator

0

0

Speedometer

0

0

Travel speed limiter indicator

0

0

Parking brake ON indicator

0

0

Power select indicator

0

0

Power select

0

Traveling power control level setting

0

Material handling power control level setting

0

Travel speed limiter level setting

0

Maintenance hour meter setting

Multi-hour meter function

Warning function

Key ON hour meter

0

0

Traveling hour meter

0

0

Material handling hour meter

0

0

Traveling or Material handling hour meter

0

0

Odometer

0

0

Lap time meter

0

0

Trip meter

0

0

Maintenance hour meter

0

0

Calendar . clock

0

0

Battery overdischarge warning

0

0

Low remaining battery charge warning

0

0

Overheat warning

0

0

Low temperature warning

0

0

Parking brake ON warning

0

0

Parking brake OFF warning

0

0

Return to neutral warning

0

0

Material handling operation lock

0*1

Overspeed alarm

0

0

Maintenance indicator

0

0

Diagnosis display

0

0

Only for models with mini lever (OPT).


DISPLAY INDICATION USA models (standard models) elected by the user Checking traveling or material handling system operation time ng to hour meter display To be set by the user Clock set Adjustment of indicated time button (3) for 2 or more.

a C

[MANAGER'S FUNCTION To be selected by the manager Switching to hour meter display Power select To be set by the manager Travel speed limiter level setting Speed alarm Power control select Clock set button (3) for 2

OPTION SET

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

Adjustment of indicated time or more.

I


Export models


3-10

ABBREVIATIONS DISPLAYED ON THE SCREEN Abbreviation

Meaning

Abbreviation

Meaning

Attachment switch 1

SSD2

Drive motor 2 rpm sensor

Attachment switch 2

SSP

Pump motor rpm sensor

Controller

STS

Steering angle sensor

DCR

Traveling AC driver

STS

Steering angle sensor 1

DM

Drive motor

STS2

Steering angle sensor 2

DSF

Forward direction switch

STSC

Steering angle sensor for straight traveling

DSR

Backward direction switch

SWAC

Accelerator switch

FAN

Cooling fan

HIM

Hour meter

K-DIFF

Deviation of steering angle knob posiTBD tion

K-POS

Steering angle knob position

TBP

Material handling AC driver control board surface temperature

KSOL

Steering synchronizer solenoid

TD

Drive motor temperature

LOAD

Material handling hydraulic pressure TEMP

L

Lift switch

THCD

Main drive circuit temperature

LSB

Brake switch

THCP

Main pump circuit temperature

LSD

Seat switch

MH

Lifting height switch

PIC

Power control

PCR

Material handling AC driver

TP

Pump motor temperature

PM

Pump motor

VB48

Battery voltage

POTA

Accelerator potentiometer

VBBD

Traveling AC driver power source voltage

POTT

Tilt angle potentiometer

VBBP

Material handling AC driver power source voltage

SPD

Main traveling speed

VBKS

Voltage after key switch

SPL

Load sensor

VBMB

Main controller input voltage

Drive motor 1 rpm sensor

VBSOL

Solenoid power source voltage

A2

Tilt knob switch Forward and backward tilt switch

T

Traveling AC driver control board surface temperature

CPU board surface temperature

Forward tilt restriction position LTL

Tilt level position Tire angle sensor voltage


3-11

GENERAL FUNCTIONS Changing Display USA models (standard models) Button

Button (2)

GENERAL screen

Hour meter display selection

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

CLOCK SET FUNCTION SELECTION screen

Press button (3)

GENERAL screen


3-12 Export models Button (1)

Button (2) Hour meter display selection

GENERAL screen

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

TRAVEL SPEED LEVEL SETTING screen J

Press button (3)

OVERSPEED ALARM SETTING screen

Press button (3)

POWER CONTROL FUNCTION SELECTION screen

Press button (3)

CLOCK SET FUNCTION SELECTION screen (To GENERAL screen)


OPERATING PROCEDURE OF FUNCTION SETTING GENERAL SCREEN 1. Hour meter display selection Press button (4) to select the hour-meter display.

Button (2)

GENERAL screen

a

a

a a a a I

Button (3)

\

I

a

Button (4)

Press button (4)

Press button (4)

H : Maintenance hour meter

A: Key ON hour meter

J

Press button (4)

Press button (4)

hour meter handling hour meter

G :Trip meter

Press button (4)

Press button (4)

or material handling hour meter

F : Lap time meter

Press button (4) The lap meter and trip meter can be reset by pressing button (1) for 2 seconds or more. Press button (3) on each screen to return to the GENERAL screen.


Description

Function A

Key ON hour meter

Indicates the total key ON time

B

Traveling hour meter

Traveling operation time

C Material handling hour meter handling hour meter

Material handling operation time Total time of traveling and material handling operation (when both operations occur at the same time, only operation time of either operation)

E

Odometer

Total distance traveled

F

Lap time meter

Lap time upon key ON

G

Trip meter

Trip distance

H

Maintenance hour meter

Accumulated time total in key on-state since last maintenance

2. Power select mode switching (S, P or H) (Export models

J

Button (3) Power select indicator

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

TRAVEL SPEED LIMITER LEVEL SETTING SCREEN (Export models only) The travel speed limiter level is set on this screen.

Button (3)

Button

Button (2)

Press button (3) on the GENERAL screen for 2 seconds or more to display the TRAVEL SPEED LIMITER LEVEL SETTING screen. 1. Press button ( I ) to decrease the travel speed limiter level. 2. Press button (2) to increase the travel speed limiter level. 3. Press button (3) to display the next screen.

OVERSPEED ALARM SETTING SCREEN (Export models The traveling speed level for the overspeed alarm is set on this screen.

Traveling speed setting for overspeed alarm

Press button (3) on the TRAVEL SPEED LIMITER LEVEL SETTING screen to display the OVERSPEED ALARM SETTING screen. 1. Press button (1) to decrease the traveling speed setting. 2. Press button (2) to increase the traveling speed setting. 3. Press button (3) to display the next screen.


Button (1)

Button (2)

\

POWER CONTROL FUNCTION SELECTION SCREEN (Export models only) The travel and material handling power control levels can be set independently using this screen. Press button (3) on the OVERSPEED ALARM SETTING screen to display the POWER CONTROL FUNCTION SELECTION screen.

Button (3) Select ''YES'' and press button (3) TRAVELING POWER CONTROL LEVEL SETTING screen

1.

on the POWER CONTROL FUNCTION Press button SELECTION screen, select "YES" and press button (3) to display the TRAVELING POWER CONTROL LEVEL SETTING screen. (1) TRAVELING POWER CONTROL LEVEL SETTING screen 1) Press button to select the lower level. button (2) to select the higher level. 3) Press button (3) to display MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen.

Press button (3)

(2) MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen to select the lower level. 1) Press button 2) Press button (1) to select the higher level. 3) Press button (3) to display the next screen.

MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen

2.

Press button (3) PLANNED MAINTENANCE HOUR SETTING screen

To display the next screen, press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select "NO" and press button (3); alternatively, press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen.


CLOCK SET FUNCTION SELECTION SCREEN The year, month, day, day of week, time and 12124-hour display can be set independently. USA models

Press button (3) on the GENERAL screen for 2 seconds or more to display the CLOCK SET FUNCTION SELECTION screen. Button

Button (2)

J

(3) Button (4) Press button (3) for 2 seconds or more.

J

Press button (3)

Press button (3) a a a a a a a a a a a a

a a

a

Each press of button (3) will shift the selection item in this order: month, day, ... and minute.

a a a

End of clock r

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


Export models Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select "NO", and press or press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING button screen to display the CLOCK SET FUNCTION SELECTION screen. Button

Button (2)

\

\

Button (3) Button (4) Select "NO" and press button (3)

Press button (3) I I

I

,

Press button (3)

Press button (3) I

I I I I I I

Each press of button (3) will shift the selection item in this order: month, day, and minute

I

End of clock setting

Press button (3) J

J

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


MANAGER'S FUNCTIONS PASSWORD FOR MANAGER'S FUNCTION Note on password input 1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button may be damaged. 2. If a mistake is made part of the way through, turn the key switch to OFF and begin again. If the MANAGER'S FUNCTION screen does not appear after several attempts, the system may be faulty. Password Input Procedure

Button (3) Button (4) 1. Press buttons (3) and (4) at the same time.

Button \

AM

2. Within 10 seconds, press button (1)

MANAGER'S FUNCTION screen

4. Within seconds, press buttons and (2) at the same time for more than 2 seconds.

3. Within 10 seconds, press button (2)

Procedure

Operation

Vehicle operation

1

Press buttons (3) and (4) at the same time.

2

Press button (1). (in 10 seconds after pressing button (3) and (4)) A short beep sounds.

3

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

4

Press buttons (1) and (2) at the same time and hold for 2 seconds End of password Short beeps sound. or more. (in 10 seconds after pressing button input)

5

The MANAGER'S FUNCTION screen appears automatically.

A short beep sounds. A short beep sounds.


OPERATING PROCEDURE OF FUNCTION SETTING Changing Display Input the password o n the GENERAL screen t o display the MANAGER'S FUNCTION screen. MANAGER'S FUNCTION screen

Button (1)

Button (2) Press button (4) Select "NO" and press button (3)

Hour meter display selection Power control selection GENERAL screen I

I

I

Button (3)

I

Button (4)

Press button (3) for 2 seconds or

I I

I I

TRAVEL SPEED LIMITER LEVEL SETTING screen

I

I I

I I I

I

I I I I I I I

Press button (3)

Press button (3) CLOCK SET FUNCTION SELECTION screen

OVER SPEED ALARM SETTING screen

Press button (3)

Press button (3) POWER CONTROL FUNCTION SELECTION screen

PLANNED MAINTENANCE HOUR SETTING screen

Press button (3). J

Select "YES" and press button (3). TRAVELING POWER CONTROL LEVEL SETTING screen

J

Press button (3) MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen


MANAGER'S FUNCTION SCREEN 1 . Hour meter display selection Press button (4) to select the hour-meter display. The displayed contents on each function screen is the same as that for the GENERAL function.

Press button (4)

Press button (4) hour meter

ON hour meter

J

Press button (4)

Press button (4)

hour meter handling hour meter

meter

RESET- lSW ---------------

Press button (4)

Press button (4) or material handling hour meter time meter

J

Press button (4)

The lap time meter and trip meter can be reset by pressing button ( I ) for 2 seconds or more.


2.

\

Button (3) Power select indicator

Power select mode switching (S, P or H) Press button (3) on the MANAGER'S FUNCTION handling power screen to change the select mode. When all of S, P and H are highlighted by squares, the control is performed in the mode set on the Power Control Level Set Menu screen. S: Standard mode P: Power mode H: High power mode *: For Export models, the mode can be set by the GENERAL FUNCTION.

TRAVEL SPEED LIMITER LEVEL SETTING SCREEN The travel speed limiter level is set on this screen.

Button (3)

Press button (3) on the MANAGER'S FUNCTION screen for 2 seconds or more to display the TRAVEL SPEED LIMITER LEVEL SETTING screen. to decrease the travel speed limiter 1. Press button level. 2. Press button (2) to increase the travel speed limiter level. 3. Press button (3) to display the next screen. *: For Export models, the mode can be set by the GENERAL FUNCTION.

OVERSPEED ALARM SETTING SCREEN Button

for overspeed alarm

Button (2)

The traveling speed level for the overspeed alarm is set on this screen. Press button (3) on the TRAVEL SPEED LIMITER LEVEL SETTING screen to display the OVERSPEED ALARM SETTING screen. 1. Press button (1) to decrease the traveling speed setting. 2. Press button (2) to increase the traveling speed setting. 3. Press button (3) to display the next screen. *: For Export models, the mode can be set by the GENERAL FUNCTION.


Button (1) Button (2) \

POWER CONTROL FUNCTION SELECTION SCREEN The travel and material handling power control levels can be set independently using this screen. Press button (3) on the OVERSPEED ALARM SETTING screen to display the POWER CONTROL FUNCTION SELECTION screen.

Button (3) Select "YES" and press button (3) TRAVELING POWER CONTROL LEVEL SETTING screen

1.

Press button ( I ) on the POWER CONTROL FUNCTION SELECTION screen, select "YES" and press button (3) to display the TRAVELING POWER CONTROL LEVEL SETTING screen. (1) TRAVELING POWER CONTROL LEVEL SETTING screen 1) Press button (1) to select the lower level. 2) Press button (2) to select the higher level. 3) Press button (3) to display MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen. (2) MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen 1) Press button ( I ) to select the lower level. 2) Press button (1) to select the higher level. 3) Press button (3) to display the next screen.

Press button (3) MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen

2.

Press button (3) PLANNED MAINTENANCE HOUR SETTING screen

To display the next screen, press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select " N O and press button (3); alternatively, press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen. *: For Export models, the mode can be set by the GENERAL FUNCTION.

PLANNED MAINTENANCE HOUR SETTING SCREEN Planned maintenance hour is set on this setting can be set 10 to 2000 hours.

Current time

Button (3)

time

Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select "NO" and press button (3); alternatively, press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen to display the PLANNED MAINTENANCE HOUR SETTING screen. 1. Press button ( I ) to decrease the setting time. 2. Press button (2) to increase the setting time. 3. Press button (4) for 2 seconds or more to reset the current time. 4. Press button (3) to display the next screen.


CLOCK SET FUNCTION SELECTION SCREEN The year, month, day, day of week, time and 12124-hour display can be set independently. (They can also be set on the GENERAL screen) Press button (3) on the PLANNED MAINTENANCE HOUR SETTING screen to display the CLOCK SET FUNCTION SELECTION screen. Button (1)

Button (2)

Button (3)

Button (4)

Press button (3)

J

Press button (3)

Press button (3) I

I I

I I

Each press of button (3) will shift the selection item in this order: month, day, ... and minute.

I I

MANAGER'S FUNCTION screen

(end of clock setting)

Press button (3)

1. Press button ( I ) on the CLOCK SET FUNCTION SELECTION screen, select "YES" and press button (3) to display the CLOCK SET screen. 2. Press button (2) on the CLOCK SET FUNCTION SELECTION screen, select "NO" and press button or press button (3) when "MINUTES" is selected on the CLOCK SET FUNCTION SELECTION FUNCTION screen. screen to display the *: As for the setting method for CLOCK SET FUNCTION SELECTION screen, refer to CLOCK SET FUNCTION SELECTION screen in GENERAL functions. (See page 3-16.)


DIAGNOSIS Wrench symbol

2.

3. Abnormality detection time (Key ON hour meter)

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

DIAGNOSIS CODE Displayed code: Code indicated on the display when an abnormality occurs in the vehicle MEMORY is in use P3-39 Diag memory code: Code indicated on the display when mask function Main controller, DCR-LH: Traveling AC driver DCR-RH: Traveling AC driver 2, PCR: Material handling AC driver Diag code

.

Faulty

Phenomenon on vehicle

code

PCR

DCR: Low temperature

Display only

PCR: Low temperature

Restricted material handling output

30-1

30-1

Low voltage

30-2

30-2

Low voltage

30-3

30-3

31-1

31-1

Low starting voltage

31-2

31-2

Low starting voltage

31-3

31-3

Material handling and power steering stop Traveling disabled Material handling and power steering stop

PCR: Low starting voltage EEPROM abnormality

32-2

32-2

EEPROM abnormality

32-3

32-3

Operate under the default

PCR: EEPROM abnormality

PCR

Communication abnormality from DCR-LH

to

33-2

Communication abnormality from DCR-RH

to

33-3

Communication abnormality from PCR

to

33-1

61-1

61-1

Load sensor: Open

61-2

61-2

Load sensor: Short circuit

PCR

Traveling disabled

PCR: Low voltage

32-1

Detection controller

DCR-LH Traveling disabled DCR-RH Material handling and power steering stop NL control and forward tilt restriction automatic leveling

PCR


Diag Faulty

Phenomenon on vehicle

code

62-1

62-1

Tilt angle sensor: Open

62-2

62-2

Tilt angle sensor: Short circuit

63-1

63-1

Forward and backward tilt simultaneously on

63-2

Forward tilt SW: Short circuit for more than minutes

63-3

Backward tilt SW: Short circuit for more than 2 minutes

64-1

64-1

Lift solenoid: Open

64-2

64-2

Lift solenoid: Short circuit

64-3

64-3

Lift solenoid: Drive circuit abnormality

65-1

65-1

Tilt solenoid: Open

65-2

65-2

Tilt solenoid: Short circuit

65-3

65-3

Tilt solenoid: Drive circuit abnormality

66-1

66-1

Tilt matching abnormality

forward tilt restriction (Forward tilt disabled)

Interruption of tilt solenoid output forward tilt restriction automatic leveling

67-1

71-1

71-1

Tire angle sensor: Open

71-2

71-2

Tire angle sensor: Short circuit

72-1

72-1

Steering angle sensor:

72-2

72-2

sensor: STS2 abnormality

72-3

72-3

Steering angle sensor: STSC abnormality

72-4

72-4

Steering angle sensor: Open

73-1

Steering knob synchronizer solenoid: Open

73-2

forward tilt restriction automatic leveling

lnterruption of lift solenoid output

67-1

73-2

Detection controller

height switch abnormality

low lift restriction and forward tilt restriction automatic leveling Traveling stop, no steering knob synchronizer

abnormality

Steering knob synchronizer solenoid: Short Steering knob synchronizer solenoid output stop Steering knob synchronizer solenoid: Drive circuit abnormality

74-1

74-1

Tire angle sensor matching abnormality

Traveling restriction, no steering synchronizer

AO-1

DCR main drive circuit overheat

Restricted traveling output

AO-2

PCR main drive circuit overheat

Restricted material handling output

DCR

PCR

High voltage

.Traveling disabled Material handling and power steering disabled (solenoid

PCR


Diag Faulty

Phenomenon on vehicle

code A1-2

A1-2

A1-3 A1-4

High voltage High voltage

A1-4 A2-1

Detection controller

Traveling disabled Material handling and power steering disabled

PCR: High voltage board overheat

Restricted traveling output

A2-2

DCR-LH or DCR-RH board overheat

Restricted traveling output

A2-3

PCR board overheat

Restricted material handling output

DCR LH

DCR

PCR

PCR

A3

A3

Incorrect battery connection

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

A4

A4

Accelerator switch abnormality

Traveling disabled

A6-1

A6-1

Lift switch abnormality

A6-3

A6-3

Tilt switch abnormality

A6-5

A6-5

Attachment switch

AA-1

AA-1

CPU board thermo-sensor abnormality

AA-2

AA-2

board thermo-sensor abnormality

AA-3

AA-3

board thermo-sensor abnormality

AA-4

AA-4

AC

AC

Material handling disabled

abnormality

PCR board thermo-sensor abnormality

Semiconductor switch abnormality

AD-1

Communication abnormality from DCR-L to (1)

AD-2

Communication abnormality from DCR-L (2) to

AD-3

Communication abnormality from DCR-R to

Restricted traveling output Restricted material han-

dling .Traveling disabled .Material handling and power steering disabled not turned on

Traveling disabled (when AD-4 and AD-6 occur at the same time, MB not turned on)

AD-4

Communication abnormality from DCR-R to CIR (2)

Traveling disabled (when AD-2 and AD-6 occur at the same time, MB not turned on)

AD-5

Communication abnormality from PCR to CIR (1)

Material handling and power steering disabled

PCR


Diag Phenomenon on vehicle

Faulty code

Material handling and power steering disabled

Communication abnormality from PCR to (2)

AD-6

AF-1

AF-1

CPU abnormality

AF-2

AF-2

CPU abnormality (2)

AF-3

AF-3

CPU abnormality (3)

AF-4

AF-4

CPU abnormality (4)

Detection controller

occur at the same time, MB not turned on) ,Traveling disabled .Material handling disabled steering disabled

current sensor offset abnormality

DCR-LH

C1-2

C1-2

Overcurrent

C1-3

C1-3

current sensor offset abnormality

C1-4

C1-4

Overcurrent

Traveling disabled DCR-RH DCR-LH DCR-RH

Drive motor overheat DM

C2-2

Drive motor 1 thermo-sensor abnormality

C2-3

Drive motor 2 thermo-sensor abnormality

C3-1

DCR-LH main drive circuit thermo-sensor abnormality DCR-RH main drive circuit thermo-sensor abnormality

C3-2

Restricted traveling output

DCR-RH DCR-LH .

Restricted traveling output DCR-RH

C4-1

C4-1

Accelerator potentiometer abnormality (1)

C4-2

C4-2

Accelerator potentiometer abnormality (2)

C4-3

C4-3

Accelerator potentiometer abnormality (3)

C4-4

C4-4

Accelerator potentiometer abnormality (4)

Display only

C7

C7

Direction switch abnormality

Traveling disabled

C8-1

C8-1

Drive motor 1 rpm sensor abnormality

C8-2

C8-2

Drive motor 2 rpm sensor abnormality

Traveling disabled

Restricted traveling output

CB-1

CB-1

MB contactor abnormality

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

CB-2

CB-2

MB contactor fused

Display only abnormality

El-2

PCR: Overcurrent

power steering disabled

E2-1

Pump motor overheat

Restricted material handling output

E2-2

Pump motor thermo-sensor abnormality

-2

PM

E2-2

DCR-LH

PCR

PCR


Diag Faulty

Phenomenon on vehicle

code E3 E8

E8

PCR main drive circuit thermo-sensor abnormality

Restricted material handling output

Pump motor rpm sensor abnormality

Material handling disabled PCR

EE-1

Communication abnormality from Display (I) to

EE-2

Communication abnormality from Display (2) to

EE-3

Communication abnormality from Display to (3)

Operate under the default

EF-1

EEPROM abnormality

Operate under the default

EF-2

EF-2

EEPROM abnormality (2)

Operate under the default

EF-3

EF-3

CPU abnormality

Display only

EF-4

EF-1

EEPROM abnormality (3)

Operate under the default

FF

FF

Communication abnormality from Display

to

Communication abnormality from Display (2)

to

overcurrent

-1

Lift potentiometer abnormality (1)

H1-2

-2

Lift potentiometer abnormality (2)

-3

-3

Lift potentiometer abnormality (3)

HI-4

HI-4

Lift potentiometer neutral abnormality

HI-5

HI-5

Lift potentiometer matching abnormality

H2-1

H2-1

Tilt potentiometer abnormality (1)

H2-2

H2-2

Tilt potentiometer abnormality (2)

H2-3

H2-3

Tilt potentiometer abnormality (3)

H2-4

H2-4

Tilt potentiometer neutral abnormality

H2-5

H2-5

Tilt potentiometer matching abnormality

H3-1

H3-1

H3-2

H3-2

H3-3

H3-3

H3-4

H3-4

H3-5

H3-5

H4-1

H4-1

Display only

Display off

Lift operation stop

Tilt operation stop

Attachment 1 potentiometer abnormality Attachment 1 potentiometer abnormality Attachment 1 potentiometer abnormality

Attachment 1 operation stop

Attachment 1 potentiometer neutral abnormality Attachment 1 potentiometer matching

Attachment 2 potentiometer abnormality

PCR

Display only

EF-1

F1-2

Detection controller

Attachment 2 operation stop

Display


Diag Faulty

Phenomenon on vehicle

code H4-2

H4-2

H4-3

H4-3

H4-4

H4-4

H4-5

H4-5

H5-1

H5-1

H5-2

Attachment 2 potentiometer abnormality Attachment 2 potentiometer abnormality Attachment 2 operation stop

Attachment 2 potentiometer neutral Attachment 2 potentiometer matching Lift b l (UP) solenoid abnormality

Lift operation stop

Lift b l (UP) solenoid abnormality (2)

Material handling disabled

H5-3

H5-3

Lift

(DOWN) solenoid abnormality (1)

Lift operation stop

H5-4

H5-4

Lift

(DOWN) solenoid abnormality (2)

Material handling disabled

H5-5

H5-5

Lift solenoid drive circuit abnormality

Material handling disabled

H6-1

H6-1

Tilt a2 (FRONT) solenoid abnormality (1)

Tilt operation stop

H6-2

H6-2

Tilt a2 (FRONT) solenoid abnormality (2)

Material handling disabled

H6-3

H6-3

Tilt b2 (REAR) solenoid abnormality (1)

Tilt operation stop

H6-4

H6-4

Tilt b2 (REAR) solenoid abnormality (2)

Material handling disabled

H6-5

H6-5

Tilt solenoid drive circuit abnormality

Material handling disabled

H7-1

H7-1

Attachment 1 a3 solenoid abnormality

H7-2

H7-2

Attachment 1 a3 solenoid abnormality (2)

H7-3

H7-3

Attachment 1 b3 solenoid abnormality

H7-4

H7-4

Attachment 1 b3 solenoid abnormality (2)

H7-5

H7-5

H8-1

H8-1

Attachment 2 a4 solenoid abnormality (1)

H8-2

H8-2

Attachment 2 a4 solenoid abnormality (2)

H8-3

H8-3

Attachment 2 b4 solenoid abnormality (1)

H8-4

H8-4

Attachment 2 b4 solenoid abnormality (2)

H8-5

H8-5

H9-2 H9-3

Attachment 1 solenoid drive circuit

Attachment 2 solenoid drive circuit

H9-1

Unload valve solenoid open

H9-2

Unload valve solenoid short

H9-3

Attachment 1 operation Material handling disabled Attachment 1 operation Material handling disabled Material handling disabled Attachment 2 operation Material handling disabled Attachment 2 operation Material handling disabled Material handling disabled

Material handling disabled

Unload valve solenoid drive circuit

: Only on the vehicle with the steering knob synchronizer (OPT). *2: Only on the vehicle with the mini lever (OPT).

Detection controller


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

When used Board

Function

Description

Analyzer

Displays the vehicle's electrical system operating status and reads the error information detected by controllers.

Tuning

Makes fine adjustment of traveling and material handling functions.

0

Sets each vehicle option and other specifications.

0

Enables or disables each control function.

0

vehicle delivery

Others

ment

Specification setting

Option set

function disable

Hour meter start Starts the hour meter count. Demo mode

Matching

Tire constant set

Enables or disables the demo mode. (Material handling prohibition during traveling for vehicle delivery) Updates voltage values of sensor signals under the standard vehicle condition. Makes the speedometer reading appropriate.

Upon vehicle abnormality detection As requested by customer

.

. 0

0 Upon new vehicle demonstration

-

0 0

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


Preparation for the MASK MENU screen Caution: When going to the MASK MENU screen from the general screen, always jack up the vehicle until the drive wheels (front tires) leave the ground, and support the vehicle with wooden blocks under the front frames. Be sure to fully lower the fork. 1.

2.

Check that the battery plug is connected securely and turn the key switch to ON. Operate mask functions according to Password Input Procedure. (See page 3-32.)


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

Button (2)

AM

MASK MENU screen

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

Button (1)

J

5. The VERSION screen is displayed for about 3 seconds.

2. Within 10 seconds, press button (1)

Button (2)

3. Within

Procedure

4. Within seconds, press buttons (2) and (3) at the same time for more than 2 seconds.

seconds, press button (2)

Operation

Vehicle operation A short beep sounds.

1

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

2

Press button (1). (in 10 seconds after pressing button (1) and (2)) A short beep sounds.

3

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

4

Press buttons (2) and (3) at the same time and hold for 2 seconds or more. (in 10 seconds after pressing button End of Short beeps sound. password input)

5

The version screen is displayed automatically.

6

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

A short beep sounds.


VERSION screen

OPERATION ON MASK MENU SCREEN Caution: Unlike the analyzer function selection on of previous models, display of test screen does not prohibit the vehicle's ordinary operation.

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

Press button or (2) to switch screen.

Press button or (2) to switch screen.

Press button or (2) to switch screen.

Press button or (2) to switch screen.

Press button (3) GENERAL screen

Input the password on the general screen (see page 3-32) to display the MASK MENU screen. Press button (1) or (2) to select the desired menu item, and press button (3) (enter) to display the menu or setting screen for each function. (1) ANALYZER screen This screen displays the vehicle's electrical system operating status and the error code detected by the controller. (2) TUNING screen Performs fine adjustment of traveling and material handling control. (3) OPTION SET screen Matches the controller or display control according to the set option or control. (4) MATCHING screen This screen is for updating the sensor output voltage stored in the controller (output voltage values from the SAS function sensors in the standard vehicle condition). (5) WHEEL screen Updates the tire information in the controller to correct the speed and trip meter display. (6) END screen GENERAL screen can displayed from this screen. Press button (3) on this screen to display the GENERAL screen. As an alternative method, turn the key switch to OFF when any screen is displayed to display the general screen.


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


3-35 ANALYZER MENU SCREEN * Values shown i n the 2nd column are display examples and not the standard values. ANALYZER MENU screen 1.

MEMORY

Display Ist column

DIAG-1 to

Error codes and detection time

1-1

Main drive circuit 1 temperature (heat sink): Main drive circuit 2 temperature (heat sink):

1-2

Main pump circuit temperature (heat sink):

1-3

Drive motor 1 temperature: Drive motor 2 temperature:

TD:

1-4

Pump motor temperature:

1-5

Traveling AC driver 1 board temperature: Traveling AC driver 2 board temperature:

2. (voltage, temperature)

TBP:+25

CPU board temperature:

1-8

Battery voltage: V

1-9

Key start voltage: V

1-10

Solenoid voltage: V

1-11

Main battery input voltage: V

1-12

Traveling AC driver 1 DC-BUS voltage: V Traveling AC driver 2 DC-BUS voltage: V

1-13

Material handling AC driver SWAC:0

LSB:1 LSD:1

MONITOR2 (traveling system)

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

2-4

Drove motor 1 rpm: rpm [Main controller instruction rpm: rpm]

2-5

Drove motor 2 rpm: rpm [Main controller instruction rpm: rpm]

2-6 MONITOR3 (material handling system and mast control)

Accelerator potentiometer voltage: V Acceleration switch: (OFF), 1 (ON) Forward switch: (OFF), 1 (ON) Reverse switch: (OFF), 1 (ON)

2-2

4.

Material handling AC driver board temperature:

1-7

2-1

3.

Meaning

2nd column

SPD:10.0

Main traveling speed: Lift switch:

3-1

*1 3.50 10

(OFF), 1 (ON)

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

voltage: V


ANALYZER MENU screen

Display Ist column

L (SOL):-.3-2

T-.-

10

3-3 T0.90 3.50 10 T (SOL):-.3-4

Forward tilt switch: (OFF), 1 (ON) Backward tilt switch: (OFF), 1 (ON) Tilt lever angle 1 sensor voltage: V Tilt lever angle 2 sensor voltage: V Forward tilt switch: (OFF), 1 (ON) Backward tilt switch: (OFF), 1 (ON) Unused Tilt proportional valve current: A

T Al:

-.-- 1- Attachment 1 switch: (OFF), 1 (ON)

3-5 A1 MONITOR3 (material handling system and mast control)

Unused Lift proportional valve current: A

L

4.

Meaning

2nd column

3.50 01 (SOL):-.-

3-6

Attachment 1 lever angle 1 sensor voltage: V Attachment 1 lever angle 2 sensor voltage: V Attachment 1 raise switch: (OFF), 1 (ON) Attachment 1 lower switch: (OFF), 1 (ON) Unused Attachment 1 proportional valve current: A

A2:-.--

Unused

3-7 3.50 01 A2 (SOL):-.3-8

Attachment 2 lever angle 1 sensor voltage: V Attachment 2 lever angle 2 sensor voltage: V Attachment 2 raise switch: (OFF), 1 (ON) Attachment 2 lower switch: (OFF), 1 (ON) Unused Attachment 2 proportional valve current: A

A2 3-9

Tilt knob switch:

3-10

Pump motor rpm: rpm [Main controller instruction rpm: rpm]

3-11

Lifting height switch:

3-12

Tilt angle sensor voltage: V

3-13

(1.7)

(OFF), 1 (ON)

(OFF), 1 (ON)

Load sensor voltage: V

display)


ANALYZER MENU screen

Display column

Meaning

2nd column Unused

4-1

Steering angle sensor pulse: (-)

4-2 5.

MONITOR4 (steering control)

K-POS:159 (150)

(OFF), 1 (ON)

Unused Steering angle knob position: Actual (target) Unused

4-3

Deviation of steering angle knob position Steering knob synchronizer solenoid: (OFF), 1 (ON)

K-DIFF:100

Tire angle sensor voltage: V

4-4 ACT-1

FAN: ONIOFF

Fan output Fan voltage: V Unused

6. ACTIVE TEST (operation test)

ACT-2

Steering knob synchronizer solenoid output Steering knob synchronizer solenoid check signal: o (normal), I (error)

KSOL:

(-)

ACT-3

PSOL: ONIOFF

: Mini lever models (OPT) *2: 3-way and 4-way mini lever models (OPT) *3: 4-way mini lever models (OPT) *4: Steering knob synchronizer models (OPT)

Unused Unload valve output Unload valve check signal:

(normal), 1 (error)


Operating Procedure 1. Input the password on the general screen (see page 3-32) to display the MASK MENU screen. 2. Check that ANALYZER is selected on the MASK MENU screen and press button (3) (enter) to display the ANALYZER MENU screen. 3. Select the menu item using buttons and (2) and then press button (3) (enter) to display the set screen. Button (1): To the previous menu item screen Button (2): To the next menu item screen Button (3): Enter (to the selected menu item screen) the MASK MENU screen If you select "7. END" on the MENU screen of the analyzer and press button is displayed.

..-.- button (3) 7. END screen

I . DIAG Press button (1) or (2) to switch screen.

,

or Press button (I) (2) to switch screen.

6. ACTIVE TEST screen

or Press button (2) to switch screen.

2.

screen

5.

or Press button (2) to switch screen. MONITOR4 screen

4.

Press button or (2) to switch screen. MONITOR3 screen

Press button ( I ) or (2) to switch screen.

3.

MONITOR2 screen

Press button ( I ) or (2) to switch screen.

J


Diagnosis Memory Function (DIAG MEMORY) of the most recent errors. The DlAG MEMORY screen displays these The controller stores up to diagnosis error codes together with their detection time (as key ON hour meter reading). The most recent diagnosis error code is displayed as followed by DIAG-2, DIAG-3 and so on to DIAG-10.

Operating Procedure

Button

Press button (3)

J

Key ON hour meter Press button (3)

Display the ANALYZER MENU screen. DlAG MEMORY" is displayed and press 2. Check that button (3) (enter). Past diagnosis codes are displayed sequentially starting with the newest one. 3. Functions of buttons on the DlAG MEMORY screen are as follows: Button (1): Unused Button (2): Unused Button (3): Displays past diagnosis codes *. Press button (3) on the screen to display the ANALYZER MENU screen. When no error codes are displayed on the screen and the hour meter time is it indicates that no error codes are stored in the memory. Other screen cannot be displayed from DlAG MEMORY screen. Display ANALYZER MENU screen to display other screen. *: For the details of diagnosis error codes, see DIAGNOSIS CODE on P3-24.

Press button (3)

No error occurrence is indicated

Press button (3)

Press button (3) ANALYZER MENU screen


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

Warning method

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

Indication Parking brake ON warning indicator blinks Beep Short beeps

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

Beep Short beeps

Overdischarge warning (lift interrupt): Warns if the battery discharge exceeds the level set by the tuning function. (see page 3-54.) When the warning is activated, material handling operation is disabled on USA models (Including Canadian models). However, when the key switch is turned from OFF to ON, the operation can be performed only once for 30 seconds. As for export models, the material handling operation during traveling is disabled.

Displayed code

No display

lndication i ndica

,

,

tor Beep

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

Beep Short beeps

No display

Material handling lock (OPT): When the operator leaves the seat while operating the mini lever and then sits down 5 again, a buzzer sounds to warn the operator and the material handling operation will be disabled.

Beep Short beeps

No display

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

Indication Wrench symbol


MONITOR Activated function No

Detected error code at present

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

Description of activated function

MONlTORl This function displays the temperature of each electrical functional part and the voltage at the respective terminal. Button (1) Button (2) ANALYZER MENU screen

\

Operating Procedure 1. 2. 3.

4. \

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

1-1 screen

Display the ANALYZER MENU screen. Press button (2). Check that "2. is displayed and press monitor function (1) is activated button (3) (enter). 1-1 to 1-13 are displayed sequential every and time button (3) is pressed. Functions of buttons on the MONlTORl screen are as follows: Button (1): Unused Button (2): Unused 1-1 to 1-13 screens Button (3): Displays sequentially

*: Press button (3) on the 1-13 screen to display the ANALYZER MENU screen. MONlTORl Other screen cannot be displayed from screen. Display ANALYZER MENU screen to display other screen. Press button (3) (2)

(1)

screen THCD: Main drive circuit (1) (2) temperature Temperatures of the main drive circuit element (1) (2) are displayed Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed.

(2)

1-2 screen THCP: Main pump circuit temperature Temperature of the main pump circuit element is displayed. Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed.

1-2 screen

Press button (3) 1-3 screen


screen

(3)

1-3 screen TD: Drive motor (2) temperature Temperatures of the drive motor (1) (2) is displayed. Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed.

(4)

screen TP: Pump motor temperature Temperature of the pump motor is displayed. Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed.

Button (2) (3)

(4)

1-3 screen

1-4 screen

(3) Press button (3)

(5)

(5)

1-5 screen

Traveling AC driver board surface temperature Surface temperatures of the traveling AC driver board are displayed. Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed.

Press button (3)

(6)

1-6 screen

(7)

1-7 screen

1-8 screen

1-5 screen

Press button (3)

1-6 screen TBP: Material handling AC driver board surface temperature

Surface temperature of the material handling AC driver board is displayed. Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed. Press button (3)

(7)

screen TEMP: CPU board temperature The surface temperature of the main controller CPU board is displayed. Checks if the temperature measurement function is functioning properly. The temperatures at the time of measurement are displayed.

Press button (3)

(8)

screen Battery voltage (V) The battery voltage is displayed. Standard: 36 V (36V models) 48 V (48V models)

J

Press button (3) 1-9 screen


1-8 screen

(9)

1-9 screen VBKS: Key start voltage (V) Power source voltage of traveling and material handling AC drivers are displayed. Standard: 36 V (36V models) 48 V (48V models)

(10)

1-10 screen VBSOL: Solenoid power source voltage (V) Solenoid power source voltage is displayed. Standard: 36 V (36V models) 48 V (48V models)

(11)

1-11 screen VBMB: Main battery voltage input (V) Main controller input voltage after the MB contactor is displayed. Standard: 36 V (36V models) 48 V (48V models)

(12)

1-12 screen VBBD: main drive circuit voltage (V) Traveling AC driver main drive circuit Voltages of the traveling AC driver are displayed. Standard: 36 V (36V models) 48 V (48V models)

(13)

1-13 screen VBBP: Material handling AC driver main drive circuit voltage (V) Voltage of the material handling AC driver main drive circuit is displayed. Standard: 36 V (36V models) 48 V (48V models)

Button (2) (9)

1-9 screen

\

J

Button (3) Press button (3) (10)

1-10 screen

Press button (3) (11)

1-11 screen

Press button (3) (12)

1-12 screen

J

Press button (3) (13) 110 1-13 screen

Press button (3) ANALYZER MENU screen


Displays each switch ONIOFF state and analog input voltages from sensors for traveling and swing control. Button (1) Button (2) ANALYZER MENU screen

Operating Procedure 1. 2. 3.

4. I

(1)

J

2-1 screen

Display the ANALYZER MENU screen. Press button (2) twice. is displayed and press Check that "3. button (3) (enter). monitor function (2) is activated 2-1 to 2-6 are displayed sequential every and time button (3) is pressed. MONITOR2 screen are Functions of buttons on the as follows: Button (1): Unused Button (2): Unused 2-1 to 2-6 screens Button (3): Displays sequentially

*: Press button (3) on the 2-6 screen to display the ANALYZER MENU screen. MONITOR2 Other screen cannot be displayed from screen. Display ANALYZER MENU screen to display other screen

7

Press button (3) 2-2 screen

(1)

2-1 screen POTA: Accelerator potentiometer voltage (V) A: When the accelerator pedal is released (SWAC: OFF) Standard: 0.3 to 2.4 V B: Standard voltage when the accelerator pedal is depressed to its stroke end Standard: 1.7 to 4.7 V B- A= SWAC: Accelerator switch When the accelerator pedal is released SWAC: 0 = OFF Standard voltage when the accelerator pedal is depressed to its stroke end SWAC: 1 = ON Operate the accelerator pedal to judge switch ONIOFF quality.


screen

(2)

2-2 screen

Button (1)

Button (2)

(2) 110 2-2 screen Direction switch inspection DSF: Forward traveling switch DSR: Reverse traveling switch

\ DSF

DSR

Forward traveling

1 (=ON)

0 (=OFF)

Neutral

0 (=OFF)

0 (=OFF)

(=OFF)

1 (=ON)

Reverse traveling

(3)

Operate the direction lever to judge switch ONIOFF quality.

2-3 screen

Press button (3) (4)

2-4 screen

Press button (3)

(5)

2-5 screen

(3) 110 2-3 screen LSB: Brake switch inspection When the brake pedal is released LSB: I = ON When the brake pedal is depressed LSB: OFF Operate the brake pedal to judge switch ONIOFF quality. LSD: seat check When the seat is occupied LSD: 1 ON When the seat is not occupied LSD: = OFF Take or leave a seat to judge switch quality. (4) 110 2-4 screen : Drive motor 1 rprn [target rpm] lnspect the rprn sensor while the vehicle is traveling. The rprn of the drive motor increases according to the speed increase.

(5)

Press button (3) (6)

2-6 screen

P

Press button (3) ANALYZER MENU screen

2-5 screen Drive motor 2 rprn [target rpm] lnspect the rprn sensor while the vehicle is traveling. The rprn of the drive motor increases according to the speed increase.

(6) 110 2-6 screen SPD: Traveling speed (mph or Check the traveling speed while the vehicle is jacked up. Gradually depress the accelerator pedal. Check that the traveling speed increase is almost at the same rate of the depression of the accelerator pedal to judge the quality.


This function displays the ONIOFF status of material handling and mast control switches and analog input from sensors. Button (1) Button (2) ANALYZER MENU screen

Operating Procedure 1. 2. 3.

MENU'

4. Button (3) Press button (3)

(I) 3-1 screen Standard models

Display the ANALYZER MENU screen. Press button (2) three times. is displayed and press Check that "4. button (3) (enter). monitor function (3) is activated 3-1 to 3-13 are displayed sequential every and time button (3) is pressed. Functions of buttons on the MONITOR3 screen are as follows: Button (1): Unused Button (2): Unused Button (3): Displays 3-1 to 3-13 screens sequentially

*: Press button (3) on the 3-13 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from screen. Display ANALYZER MENU screen to display other screen Mini lever models

(1)

Press button (3)

(2) . . ,

,

3-2 screen Standard models

Mini lever models (OPT)

Lift lever angle 1 Lift lever angle 2 sensor voltage sensor voltage

.

Press button (3) 3-3 screen

3-1 screen Standard models L: Lift switch inspection When the lift lever is in the UP position L: -.1- = ON When the lift lever is in the neutral or DOWN position . . . 0- =OFF Operate the lift lever to judge quality. Mini lever models (OPT) L: Lift lever angle 1 sensor voltage (V) Lift lever angle 2 sensor voltage (V) 1=ON) Lift raise switch Lift lower switch Judge the raise and lower input quality by lift lever operation.

Raising

1.1 to 2.3 V

2.2 to 3.5 V

Lowering

0.4 to 1.6 V

2.9 to 4.2 V

(2) 110 3-2 screen Standard models L (SOL): Unused Mini lever models (OPT) L (SOL): Lift proportional valve solenoid current (A) Judge the output quality to lift proportional valve solenoid by lift lever operation. Standard: 0.3 to 0.85 A (Lever operated)


(3)

3-2 screen

3-3 screen Standard models Forward and backward

switch inspection Forward Backward switch tilt switch

Operation 10

1 (=ON)

(=OFF)

00

(=OFF)

(=OFF)

-.- 01

(=OFF)

1 (=ON)

Forward tilt Backward

T:

quality. Operate the lever to judge Mini lever models (OPT) Tilt angle 1 sensor voltage (V) Tilt lever angle 2 sensor voltage (V) 1=ON) Forward tilt switch 1=ON) Backward tilt switch Judge the forward and backward tilt input quality by lever operation.

lever models (OPT) Button (3)

Press button (3) (4)

3-4 screen Standard models

(4)

screen Standard models T (SOL): Unused Mini lever models (OPT) T (SOL): Tilt proportional valve current (A) Judge the output quality to the by tilt lever operation. Standard: 0.3 to 0.85 A (Lever operated)

(5)

3-5 screen Standard models : Attachment 1 lever inspection When the attachment 1 lever is ON : -.1- = ON When the attachment 1 lever is in the neutral position -.- -.- 0- OFF Operate the attachment 1 lever to judge ONIOFF quality. 3-way and 4-way mini lever models (OPT) A l : Attachment 1 lever angle 1 sensor voltage (V) Attachment 1 lever angle 2 sensor voltage (V) 1=ON) Attachment 1 raise switch Attachment 1 lower switch 1=ON) Judge the input quality by attachment 1 lever operation.

lever models (OPT)

Press button (3) (5)

3-5 screen Standard models

3-way and 4-way

lever models (OPT)

Attachment 1 lever Attachment lever angle 2 sensor angle 1 sensor voltage voltage

J

Press button (3) 3-6 screen

Raising Lowering

1.1 to

2.2 to 3.5 V

0.4 to 1.6 V

2.9 to 4.2 V


(6)

3-5 screen (6)

3-6 screen Standard models

Button (2)

J

Button (3) lever models (OPT)

.

3-way and 4-way

(7)

Press button (3) 3-7 screen Standard models 2-way and 3-way mini lever models (OPT)

3-6 screen Standard models (SOL): Unused 3-way and 4-way mini lever models (OPT) (SOL): Attachment 1 proportional valve solenoid current (A) proportional Judge the output quality to attachment valve solenoid by attachment 1 lever operation. Standard: 0.3 to 0.85 A (Lever operated)

1 0 3-7 screen (7) 1 Standard models, 2-way and 3-way mini lever models (OPT) Unused 4-way mini lever models (OPT) Attachment 2 lever angle 1 sensor voltage Attachment 2 lever angle 2 sensor voltage I=ON) Attachment 2 raise switch 1=ON) Attachment 2 lower switch Judge the forward and backward tilt input quality by tilt lever operation.

Attachment 2 lever Attachment 2 lever angle 2 sensor angle 2 sensor voltage voltage Raising Lowering

4-way

(8)

lever models (OPT)

button (3) 3-8 screen Standard models 2-way and 3-way mini lever models (OPT)

4-way

lever models (OPT)

Press button (3) 3-9 screen

(8)

1.1 to

2.2 to 3.5 V

0.4 to 1.6 V

2.9 to 4.2 V

3-8 screen Standard models, 2-way and 3-way mini lever models (OPT) A2 (SOL): Unused 4-way mini lever models (OPT) A2 (SOL): Attachment 2 proportional valve solenoid current (A) Judge the output quality to attachment 2 proportional valve solenoid by attachment 2 lever operation. Standard: 0.3 to 0.85 A (Lever operated)


3-8 screen

(9)

3-9 screen Automatic fork leveling cancel switch inspection 0 = OFF 1 =ON Operate the tilt knob switch to judge ONIOFF quality.

(10)

3-10 screen SSP: Pump motor rpm [target rpm] Inspect the rpm sensor during the actual material handling operation. Check that the pump motor rpm increases according to the material handling speed increase.

(11)

3-11 screen MH: Lifting height switch inspection Combination of lifting height switch ONIOFF

Button (3) Press button (3) (10)

3-10 screen

switch

Press button (3) (11)

3-11 screen

Change the lifting height to judge ONIOFF quality.

(12)

3-12 screen POTT Tilt angle sensor voltage (V) Check the input voltage of tilt angle sensor controller Standard when the mast is in the vertical position: Approx. 1.3 V When operating the mast forward from the vertical position: lnput voltage decrease When operating the mast backward from the vertical position: lnput voltage increase

(13)

3-13 screen display) SPL: Load sensor voltage (V), Check the input voltage of load sensor controller. Standard without load: Approx. 0.8 V lnput voltage increases according to the load increase

J

Press button (3) (12)

3-12 screen

Press button (3) (13)

3-13 screen

J

Press button (3)

ANALYZER MENU screen

MH2-1 switch


state of knob steering synchronizer and other switches and the analog input value from each sensor are indicated. Button (1)

Operating Procedure 1. 2. 3.

4. Button (3) Press button (3) (1)

4-1 screen

Display the ANALYZER MENU screen. Press button (2) four times. is displayed and press Check that "5. monitor function (4) is activated button (3) (enter). 4-1 to 4-4 are displayed sequential every and time button (3) is pressed. Functions of buttons on the MONITOR4 screen are as follows: Button (1): Unused Button (2): Unused 4-1 to 4-4 screens Button (3): Displays sequentially.

*: Press button (3) on the 4-4 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from MONITOR4 screen. Display ANALYZER MENU screen to display other screen. Press button (3) 4-2 screen

(1) .

4-1 screen Standard models STS: Unused Steering knob synchronizer model (OPT) STS: Steering angle sensor inspection 0 = OFF 1 =ON

STSl STS2 STSC Turning the steering wheel one round will turn STSl and ON, OFF and then ON. STSC turns on only when the steering wheel is in the standard position. STSC sensor turns on when the actual value is 80 on 4-2 screen. the


(2)

4-1 screen

Button (3) Press button (3)

4-2 screen Standard models K-POS: Unused Steering knob synchronizer models (OPT) K-POS: Actual value of knob position (target) Actual value: Knob position computed by the controller from the steering angle sensor signal. Target value: Knob position computed by the controller from the tire angle sensor signal,

4-3 screen

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

4-2 screen

(3)

4-3 screen Standard models K-DIFF: Unused SOL: Unused Steering knob synchronizer models (OPT) K-DIFF: Deviation of steering angle knob position 4-2. Difference between target and actual values at SOL: Steering synchronizer solenoid 0 = OFF 1 =ON Operate the steering wheel to check that the steering synchronizer solenoid turns on when there is deviation of steering angle knob position.

(4)

4-4 screen TIRE: Tire angle sensor voltage (V) Operate the steering wheel to check the variation in voltage. Standard at tire straight travel position: Approx. 2.40 V

Button (2)

F F

1 0 0

Button (3) Press button (3) (4)

4-4 screen

Press button (3) ANALYZER MENU screen


ACTIVE TEST This function outputs signals to each switch related to the electrical system and compares controller input signals with those signals. Button (1) ANALYZER MENU screen

Button (2)

Operating Procedure 1. 2. 3.

4.

Button (3) Press button (3) (1) ACT-1 screen

Display the ANALYZER MENU screen. Press button (2) five times. Check that "6. ACTIVE TEST is displayed and press button (3) (enter). ACTIVE TEST function is activated and ACT-1 to ACT-3 are displayed sequential every time button (3) is pressed. Functions of buttons on the ACTIVE TEST screen are as follows: Button (1): Forced ON Button (2): Forced OFF Button (3): Displays ACT-1 and ACT-3 sequentially Press button (3) on ACT-3 screen to display the ANALYZER MENU screen. Other screen cannot be displayed from ACTIVE TEST screen. Display ANALYZER MENU screen to display other screen.

Press button (3) (2) ACT-2 screen

Press button (3) ACT-3 screen

(1) ACT-1 screen FAN: Fan (fan voltage (V)) Forcibly output the signal to check the fan operation and display visually. Press button ( I ) to select ON. rotates and fan voltage is displayed. Press button (2) to select OFF. stops rotating and fan voltage is displayed. Note: Be sure to open the battery hood and remove the side cover to check the fan operation.

(2) ACT-2 screen Standard models KSOL: Unused Steering knob synchronizer models (OPT) KSOL: Steering knob synchronizer solenoid I: Signal check line ON (error) Signal check line OFF (normal) Turn the steering wheel slowly to check the deviation in the rear tire movement. ON (bypass open) selected: Tires rarely move OFF (bypass close) selected: Tires normally move


ACT-2 screen

Mini lever models (OPT)

Button (3)

Press button (3) ANALYZER MENU screen

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


TUNING General This function performs fine adjustment of traveling and material handling controls. When the use requests to limit the maximum speed or weaken the regenerative braking force, each setting can be performed on the TUNING screen in the procedures same as power control level setting. 59 tuning items are prepared including spares. Tuning

List

decreasing rate of battery charge

Tilt power control: Changes the pump motor output for when

: 4-way mini lever models (OPT)


Tuning No. 20

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

22

Lift lowering adjustment (4): Adjusts acceleration during lift lowering operation.

: Initial setting position) 3 4 5 6 7 8 1

I I

Small

I I

Large

4 I

Lift lowering adjustment (2): Adjusts inching speed during lift lowering operation. Lift lowering adjustment (3): Adjusts the maximum solenoid output current during lift lowering operation.

Level 1 2

I I

I I

I

I I

I

I

Fast

I

Small

a

I I I

I

I I

I

a

Weak

Strong

I

I

I

I

Lift lowering adjustment (5): Adjusts deceleration during lift lowering operation. 25

Lift raising adjustment (1): Adjusts solenoid output current at the beginning of lift raising operation. Lift raising adjustment (2): Adjusts inching speed during

27

Lift raising adjustment (5): Adjusts deceleration during lift raising operation.

32

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

I

I

I

I I I I

Large

I

I

I

I I

I

Fast

I

Large I

I I

I

Weak

Strong I I

I

I I

I I

I I I

I

Weak

Strong I I I

Small

,

Forward tilt adjustment (3): Adjusts the maximum solenoid output current during forward tilt operation.

Small

Backward tilt adjustment (1): Adjusts solenoid output current at the beginning of backward tilt operation.

a

I

I

Slow

Forward tilt adjustment (5): Adjusts deceleration during forward tilt operation. 35

I I

Small

Forward tilt adjustment (2): Adjusts inching speed during forward tilt operation.

Forward tilt adjustment (4): Adjusts acceleration during forward tilt operation.

Strong

I

Small

raising operation.

Lift raising adjustment (4): Adjusts acceleration during lift raising operation.

30

A

I I I

Lift raising adjustment (3): Adjusts the maximum solenoid output current during lift raising operation.

I

I

Weak

I

I I

I

I I

I I

I

I

I I I I

I

I

Fast

Large I I

I I

I

Strong

Weak I I

I

I I

a

Weak

I

I

I

I

I I

I

Small

Strong

Large I I

I I


42

Attachment 1 lowering adjustment (3): Adjusts the maximum solenoid output current during lowering operation of attachment 1.

43

Attachment 1 lowering adjustment (4): Adjusts acceleration during lowering operation of attachment 1.

I

I

45

Attachment 1 raising adjustment (1): Adjusts solenoid output current at the beginning of raising operation of attachment 1.

Small

46

Attachment 1 raising adjustment (2): Adjusts inching speed during raising operation of attachment 1.

Slow

47

48

49

50

51

I

I I

I I

I

I I

Strong I

I

Large I I I

Small

Attachment 1 raising adjustment (4): Adjusts acceleration during raising operation of attachment 1.

Weak

I

I

I

I

I I

I I

I I

I I

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

Small

Fast

Large

I I

Weak

I I I I

I

Attachment 1 raising adjustment (5): Adjusts deceleration during raising operation of attachment 1.

Strong

I I

I I

Attachment 1 raising adjustment (3): Adjusts the maximum solenoid output current during raising operation of attachment 1.

Attachment 2 lowering adjustment (2): Adjusts inching speed during lowering operation of attachment 2.

a

Weak

Weak

I

I I I

I I

Attachment 1 lowering adjustment (5): Adjusts deceleration during lowering operation of attachment 1.

44

I

a

Small

a

I

Strong I I

I

I

I

I

I I I I

I I I

Strong

I

Large I

I I

I

I I

I

Slow

Fast


Level

Tuning No.

I

52

Attachment 2 lowering adjustment (3): Adjusts the maximum solenoid output current during lowering operation of attachment 2.

53

Attachment 2 lowering adjustment (4): Adjusts acceleration during lowering operation of attachment 2.

Weak

54

Attachment 2 lowering adjustment (5): Adjusts deceleration during lowering operation of attachment 2.

Weak

55

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

56

57

58

59

: Initial setting position)

I I

I I

Large I I

a

I

I

a

Strong

Large I I

I

I I

I I

a

I

Fast I I

I

a

I

Large

I

II I

I

II

I

I

I I

I

I

Weak

I

a

Small

Small

Strong

I

I I

Attachment 2 raising adjustment (3): Adjusts the maximum solenoid output current during raising operation of attachment 2.

I I

I I I

I I

Slow

Attachment 2 raising adjustment (5): Adjusts deceleration during raising operation of attachment 2.

I I

Small

Attachment 2 raising adjustment (2): Adjusts inching speed during raising operation of attachment 2.

Attachment 2 raising adjustment (4): Adjusts acceleration during raising operation of attachment 2.

I I

I

Weak I

I

I

I I

I

Strong


TUNING Screen Operating Procedure 1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen. 2. Press button (2) to display "2. TUNING" and press button (3) (enter) to display the TUNING MENU screen. 3. Press button (1) or (2) to display the tuning item desired to be set. Press button (3) (enter) to display the TUNING screen of the selected item. Button (1): Display the previous tuning item Button (2): Display the next tuning item Button (3): Enter (display the selected tuning item) *: Press button (3) on the TUNING MENU screen, select "6. END" and press (3) to display MASK MENU screen. LIFTV" to (tuning to 59) are not used on the standard models. They are only used on the mini lever models (OPT). MASK MENU screen

Button (2)

a I

a a

I

a a

a

Button (3) Press button (3)

Press button (3)

Press button or (2) to switch screen Press button

or Press button (2) to switch screen

*: Mini lever models only

or

(2) to switch screen *: Mini lever models only

Press button or (2) to switch screen *: Mini lever models only

Press button ( I ) or (2) to switch screen *: Mini lever models only

,

Press button or (2) to switch screen


Button

Button (2)

TUNING 1 This function sets the tuning level of the standard functions.

OPERATING PROCEDURE

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

3.

4.

Press button (3)

Display the TUNING MENU screen. is displayed and press button Check that (3) (enter) to display TUNING level setting screen. Press button (3) to display the tuning item desired to be set. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen)

*: Press button (3) on the TUNING setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING1. Display TUNING MENU screen to display other screen.

Press button (3) TUNING MENU screen

Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels (TUNING *: The default is level 7.


Button TUNING MENU screen

Button (2)

TUNING 2 LIFTV This function changes the tuning level of the lift lever. OPERATING PROCEDURE 1.

Display the TUNING MENU screen. or (2) to display LIFTV" and press button (3) (enter) to display TUNING level setting screen. Press button (3) to display the tuning item desired to be set. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen)

2. Press button (3) Press button (3)

3. 4.

Press button (3)

Press button (3)

Press button (3) TUNING MENU screen

*: Press button (3) on the TUNING No.29 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING2 LIFTV. Display TUNING MENU screen to display other screen.


Button TUNING MENU screen

Button (2)

TUNING 3 TILTV This function changes the tuning level of the tilt lever. OPERATING PROCEDURE

1. 2.

MENU=

\

J

(3) Press button (3)

3. 4.

Press button (3)

Press button (3)

J

Press button (3) TUNING MENU screen

Display the TUNING MENU screen. Press button (1) or (2) to display TILTV and press button (3) (enter) to display TUNING level setting screen. Press button (3) to display the tuning item desired to be set. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen)

*: Press button (3) on the TUNING No.39 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING3 TILTV. Display TUNING MENU screen to display other screen.


Button

Button (2)

TUNING 4 This function changes the tuning level of the attachment 1 lever. OPERATING PROCEDURE

1. 2.

3. 4.

Press button (3)

Press button (3)

Press button (3) TUNING MENU screen

Display the TUNING MENU screen. ATTIV Press button (1) or (2) to display and press button (3) (enter) to display TUNING level setting screen. Press button (3) to display the tuning item desired to be set. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen)

*: Press button (3) on the TUNING No.49 setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting screen of TUNING4 ATTIV. Display TUNING MENU screen to display other screen.


Button TUNING MENU screen

Button (2)

TUNING 5 This function changes the tuning level of the attachment 2 lever. OPERATING PROCEDURE 1. 2.

(3) Press button (3)

3. 4.

Press button (3)

Press button (3)

Press button (3) TUNING MENU screen

Display the TUNING MENU screen. Press button (1) or (2) to display and press button (3) (enter) to display TUNING level setting screen. Press button (3) to display the tuning item desired to be set. Functions of buttons on the TUNING level setting screen are as follows: Button (1): Tuning level down Button (2): Tuning level up Button (3): Enter (to the next item screen)

*: Press button (3) on the TUNING setting screen to display the TUNING MENU screen. Other screen cannot be displayed from each level setting Display TUNING MENU screen of TUNING5 screen to display other screen.


3-64

OPTION SET OPTION SET Menu List Indication

No.

Description

Selection IndiIndiMeaning Meaning cation cation

OPT-1 DEMO MODE

Enables simultaneous operation of traveling and material handling before starting the hour meter.

Y

Enable

N

disable

OPT-2 HIM START

Starts hour meter count.

Y

Counting

N

No counting

OPT-3 PIC LOCK

Disables level setting of handling power control, 2-speed travel speed and overspeed alarm (OPT).

Y

Lock

N

Unlock

OPT-4 DESTI *

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

J

Japan

I

Other than Japan

OPT-5

-

OPT-6 MPH *

Not used. Changes the traveling speed unit to mph.

Settingto

Set to

A

Feature A

Feature B

Y

Enable

N

disable

Y

Enable

N

disable

Y

Enable

N

disable

Y

Enable

N

disable

2

TYPE2 48V

Y

OPT-7 OPT-8 OPT-9 OPT-10 OPT-11 OPT-12

Not used Adjust the charge indicator calculation BATTERY * constant. Not used operation of the auto power-off function in relation to the seat SEAT P-OFF switch. parking brake OFF PARKING ERR warning. the active mast front tilt CONT

OPT-13 KNOB CONT

OPT-15 B-TYPE * OPT-16 36V * OPT-17 2-WAY VALVE *

OPT-18 4-WAY VALVE * OPT-19 USA* OPT-20 OPT-21 OPT-22 -

Enablesldisables the steering knob synchronizer. the mast forward tilt speed limit control. Battery type Switches the battery voltage between 36V and Sets specification of 2-way mini lever

Sets specification of 4-way mini lever Sets specification of USA models Not used Not used Not used

1 Y

36V

N

Y

2-way

N

Y

4-way

N

Y

USA

N

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

Other than 2-way Other than 4-way Others


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

I Indication when disable

Operating Procedure for OPTION SET Screen 1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen. OPTION S E T and press button (3) (enter) to display the OPTION 2. Press button (2) twice to display SET MENU screen. 3. Press button (3) to display the desired option item to be set on the screen. 4. Functions of buttons on the OPTION SET screen are as follows: Button (1): N+Y Button (2): Y+N Button (3): Enter (to the next item screen) *: Press button (3) on OPT-22 OPTION SET screen to display the MASK MENU screen. OPT-4 screen MASK MENU screen

Button (1) Button (2)

Press button (3)

\

Button (3) Press button (3)

Press button (3)

Press button (3) START) hour meter starting method: OPT-2 pressed Press button (2) while keeping button (I) for 2 seconds or more.


OPT-3 screen

OPT-16 screen Button (2)

.

Not used

Press button (3)

Press button (3)

Press button (3)

4 ' F - L I M

J

Not used

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Not used

Press button (3)


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

Button (3) Press button (3)

Press button (3)

Press button (3)

Press button (3) Not used

v

MASK MENU screen Press button (3)

Press button (3)

Not used

Not used

Press button (3)


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

Description

No. Indication 1

Tilt angle sensor output in the fork level position is stored in the controller.

3 LOAD

Tilt angle sensor output of forward tilt control in the mast vertical position is stored in the controller. Load sensor output in the no load state is stored in the controller.

Steering knob synchronizer Matching

No. Indication

No. Indication

. . . .

.

.

and Condition (OPT)

Description Tire angle sensor output in the straight travel position is stored in the controller.

Mini lever Matching

Condition . *3.

Condition

and Conditions (OPT)

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

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

Condition .

. ,

.


Before Matching Vehicle should be in the "Standard state" for matching. "Standard state" means the vehicle satisfies the following conditions: 1.

2.

mast

3.

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

4.

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

Operating Procedure for MATCHING screen 1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen. 2. Press button (2) three times to display "4. MATCHING" and press button (3) (enter) to display the MATCHING setting screen. 3. Press button (3) to display the desired matching item. 4. Functions of buttons on the MATCHING setting screen are as follows: Button (1): Unused Button (2): Starts matching for the selected item Button (3): Display the next item


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

a

a a a a

!

(3) Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

,

Press button (3)


CONSTANT SET General In order to optimize the speed meter, tire constant that matches the tire outside diameter needs to be input in the controller. Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire size is changed or the tires are worn excessively to a degree affecting the speedometer function. Operating Procedure for Tire Constant Setting Button MASK MENU screen

\

Button (2)

1. 2.

3. \

J

Button (3) Press button (3)

4.

Input the password on the general screen (see page 3-32) to display the MASK MENU screen. Press button (2) four times to display "5. WHEEL D I A and press button (3) (enter) to display the tire constant setting screen. Press button (1) or (2) to set the desired tire constant and press button (3) (enter) to display the MASK MENU screen. Functions of buttons on the tire constant setting screen are as follows: Button (1): Decrease the tire constant Button (2): Increase the tire constant Button (3): Enter and display MASK MENU screen

I Tire constant

Tire Constant List Tire size

Tire type

Applicable model

Tire constant

Smooth Cushion 18 x 7 x 12.118 Cushion Non-Mark . Pneumatic

All models

25

Smooth

J lug

18 x 7-8-16

20

J lug

18 x 7-8

24


TROUBLESHOOTING Page

BEFORE TROUBLESHOOTING

4-2

TROUBLESHOOTING METHOD SST SETTING METHOD DIAGNOSIS CODE

4-11

WHEN AN ERROR CODE IS DISPLAYED

4-15

CPU BOARD

4-15 HANDLING AC DRIVER

....

4-105

SAS SYSTEM

4-137

MULTI-DISPLAY

4-143

WHEN NO ERROR CODE IS DISPLAYED

4-144

Toyota forklift  

user manual

Toyota forklift  

user manual

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