7FBEU15-20 OPS Repair Manual CU341 - Toyota Material …dealerapplications.tmhna.com/TechInfo/TechnicalDocs//service... · FOREWORD This manual describes the explanation and service

FOREWORD

This manual describes the explanation and service procedures concerning themodified portions of the Toyota Battery Forklifts 7FBEU15, 18, 20. For the portionsnot described herein, please refer to the New Model Features and Repair Manualsshown below.

This repair manual contains the information on the vehicles manufactured as ofOctober 2005. Please understand that the description herein may not be applicableto the vehicles produced thereafter. Any change or modifications thereafter will beinformed by Toyota Industrial Vehicles’ Parts & Service News.

The performance values described herein are for standard vehicles under ourspecified test conditions. Since the conditions (weather, road surface, maintenanceand operation) are different in actual use, the values will vary accordingly.

<Reference>New Model Features and Repair Manuals related to this manual are as follows:

NEW MODEL FEATURES7FBEU15, 18, 20 (Pub. No. PU315)

REPAIR MANUAL7FBEU15, 18, 20 (Pub. No. CU330) Vol. 17FBEU15, 18, 20 (Pub. No. CU331) Vol. 2

Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32

Service Information Bulletin1 SIB MA06-001 - 7FBCU Option Menu Changes2 SIB CC06-001 - A5 Error Code Additional Information3 SIB RA06-002 - Tie Rod Change4 SIB FA06-003 - Front Axle Hub Change5 SIB FA06-002 - Changes to Reamer Bolt Torque6 SIB RA04-001 - New Tie Rod End Design7 SIB MA05-009 7FBEU Option Set Menu Changes8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload Specification)9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust12 SIB DU05-004 - Reduction Gear Change13 SIB ST99-001R - Recommended Special Service Tools14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32)17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55)18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32)19 SIB FA05-001 - Gear Case Change (7FBCU35-55)20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20)21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~2022 SIB CE05-001 Key Switch Change (All Models)23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20)24 SIB CE05-008 7FBEU Voltage Conversion25 SIB CC05-011 Low Battery Voltage / Performance Reduction26 SIB CC05-007 MB Contactor Cover (7FBEU15-20)27 SIB ST06-001 - Recommended Special Service Tools28 SIB CE05-006 Pump Motor Cooling Fan29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit30 SIB MA07-005 - Maintenance Indicator Changes31 SIB RA07-001 Rear Axle Flange Change32 SIB HS07-001 Addition of Back-Tilt Lock Valve33 SIB CE06-005R - Display Battery Replacement34 SIB CE06-005R Display Battery Replacement35 SIB FA07-001R Front Axle Shaft Change36 SIB CC07-004 - Tuning No. 14 Information37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section38 SIB CC08-003R Inching While Braking Option (Tuning Level 13)39 SIB DU08-001R 7BNCU Drive Unit Repair Correction40 SIB ST08-001 Recommended Special Service Tools41 SIB CE08-002R Battery Connector Bracket42 SIB HS08-002 Addition of OPSS Back-tilt Lock Valve


43 SIB CC08-010 7FB10-J35 Programming Changes44 SIB Option Setting and Tuning Modes (7FB Models)45 SIB BR09-001 7FB Repair Manual Corrections 46 CC09-001 7FB Revision of Repair Manual 47 CC09-003 Error Codes 31-1, 31-2 and 31-348 DU09-003 Gear Case Bolt Torque Change49 CC09-004 5F and 5G codes 50 DM09-001 Drive, Pump and Steer Motor through Bolt Torque51 DM09-002 Pump Motor Cable Clearance52 CC10-001 Flashware v4.2 53 HS10-001 7FBEU Steering Circuit Hydraulic Schematics 54 SIB CE10-004 8FBC(H)U Voltage Conversion55 SIB ST10-001 Measuring Parking Brake Force on 8FBC(H)U Trucks56 SIB BR10-001 Stainless Steel Deadman Switch Mounting Screws57 SIB CC10-005 v3.1 Software Update for Auxiliary Functions58 SIB MA10-002 8FBCU Tuning Modes Explained59 SIB CE10-006 7FBEU Motor Sensor Bearing Change60 SIB CE10-007 8FBCU Height Selector Information61 SIB CE10-008 8FBCU Shock Sensor Information62 SIB MA10-003 8FBCU Auto Speed Control Information63 SIB MA10-004 8FBCU Touch Pad Information64 SIB MA10-006 AC Motor Controller Change65 SIB CE11-001 Clamp Release Interlock (Mini Lever Units)66 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin67 SIB FA11-001 7FBEU Front Axle Repair Kits68 SIB CC11-004 8FBCU Tuning No.1 Explained69 SIB CE11-002 8FBCU Horn Wires Breaking70 SIB CE11-003 Clamp Release Interlock (Standard Lever Units)71 SIB DM11-002 7BNCU New Auxiliary Motor and Pump

Technical News Brief1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal

Option, Over Heating Diagnosis, and 7FBCU Voltage Specs2 TNB - 2004-07 - Hydraulic oil change3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump5 TNB - 2006-05 - Plate to Prevent Chain Rollback6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage


9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display10 TNB - 2006-09 - 7-Series Electric ROM Write11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention12 TNB-2006-03 - 7FBEU Counterweight Squeaking13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure14 TNB-2008-10 7BNCU Steer Sensor Alignment Tool15 TNB-2008-16 Dual Contactor (Units with Pump Chopper)16 TNB-2009-04 7FBEU Static Strap Update

Hotline Tech Tips1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels

7FBCU2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU

gradeability; 7FBCU CB1 and CB23 HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on

7FBEU and 7FBCU4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential

Oil Level5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU

Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction Mode and Lift Interrupt Settings

7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 29 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon11

HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures;

7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse Replacement13

HTT-2006-01 - 7 Series Electric Lift Truck Erratic Display; 7FBE Drive Unit Part Numbers14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-316 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption19 HTT-2006-07 - 7FBEU Slow Motor Speed20 HTT-2006-08 - 7FBEU E2-1 Error Code21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes23 HTT-2006-11 - 7FBCU Drive Transistors


24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU28 HTT-2007-04 - Class 1 gear case oil29 HTT-2007-05 - 7FBCU Gear Case Sealing30 HTT-2007-06 - Steer Cylinder change31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting33 HTT-2007-09 - Repair Manual 32234 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors35 HTT-2007-11 - CU322 Repair manual clarification, 7FBEU 31-1, 31-2, 31-336

HTT-2007-12 - Class 1 Alarm with OPSS37 HTT-2008-01 - Class I Gear Noise38 HTT-2008-02 - Drive Unit Part Numbers, EF-1 & EF-2 Error Codes, Flashware Cable for 39 HTT-2008-03 - 7FBE Error Codes 64-2 & H9-2, 7FBCU15-55 A8, A1 & C3 Error Codes, 40 HTT-2008-04 - No Display with EZ Pedal, (30)7FBCU15-32 Complaint of Low Top Speed 41 HTT-2008-05 - 7FBCU20-32 Battery Slide out Field Installation Kit, (30)7FBCU15-55 Drive 42 HTT-2008-06 - 7FBE Front Hub Induction Hardening and Drive Axle Clattering43 HTT-2008-07 - 7FBCU15-25 Inspecting the EHPS Transistor44 HTT-2008-08 - 7FBE Internal Gear Hardened45 HTT-2008-09 - (30)7FBCU15-32 Error Code C0-(1-6)46 HTT-2008-10 - 7FBE Drive Axle Connector Rod Adjustment47 HTT-2008-11 - Using The SST Tools In Diagnosing Board Issues and UL Ratings48 HTT-2008-12 - Diagnostic Tips49 HTT-2009-01 - Slow Lowering or Incorrect Staging During Lowering50 HTT-2009-02 - C2-2 or C2-3 Error Codes and Trouble Shooting Error Codes H9-1,2,3 Or 64-

1,2,351 HTT-2009-03 - Static Strap Mounting and Lift Interrupt Settings52

HTT-2009-04 - Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters53 HTT-2009-05 - Error Codes After Card Replacement54 HTT-2009-06 - Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On55 HTT-2009-07 - Slow Travel Speed56 HTT-2009-08 - Occurrence of Error Code AO-457 HTT-2009-09 - Jerky Travel at Slow Speeds58 HTT-2009-10 - Gear Case Bolt Torque Increase59 HTT-2009-11 - A5 Error Code On 7FBE and 7FBC Forklifts With OPSS, 5F and 5G Codes

for the 7BNCU Model Forklifts60 HTT-2009-12 - 7FBCU Transistor Test Procedure & Speed Sensor Check61 HTT-2010-01 - FE-4, E2-2, E2-4 Error Codes62 HTT-2010-02 - Switch Adjust, RF Interference on AC Trucks


63 HTT-2010-03 - Documenting 7FBCU Brake Inspection and Adjustment During PDI, Flashware v4.2

64 HTT-2010-04 - Class I Brush Warning Option 14, 7BNCU Diode Replace Instructions65 HTT-2010-05 - Class I 7FBEU Front Axle Repair Kits66 HTT-2010-06 - Class I AC Drive Motor Over Current Limit Checks, SAS Manual Lowering

Valve67 HTT-2010-07 - 8FBCU Slow Travel or Surging Hydraulics, Setting Time/Date68 HTT-2010-08 - 8FBCU Display, Main CPU and Changing Voltage69 HTT-2010-09 - 8FBCU Measuring Parking Brake Force, 7BNCU Software v3.170 HTT-2010-10 - 8FBCU Service Information Bulletins71 HTT-2010-11 - 8FBCU Slow Attachment Speeds, Seat Switch Failures 72 HTT-2010-12 - 8FBCU Travel Alarm in Both Forward and Reverse73 HTT-2011-01 - Speed Limit Adjustment on 8FBCU74 HTT-2011-02 - Class I-VI Common Electrical Acronyms, 7FBEU Error Codes 72-1, 72-2 or

Missing Manager's Functions75 HTT-2011-03 - Class I 8FBCU Slow Lowering w/Standard Levers76 HTT-2011-04 - Class I 8FBCU H Power Mode, 7FBEU RPM Sensor Bearing Damage77 HTT-2011-05 - Class I Adding Electrical Devices, 78 HTT-2011-06 - Class I Battery Option/Type79 HTT-2011-07 - Class I 7FBCU35-55 Using SST3 On CN11280 HTT-2011-08 - Class I 8FBCU Tuning No. 1, Back to Basics Troubleshooting81 HTT-2011-09 - Class I Important SIBs82 HTT-2011-10 - Class I 8FBC(H)U Controller Software Change83 HTT-2011-11 - Class I Adding Forward Travel Alarm84 HTT-2011-12 - Class I C1-2 Error Codes, Hyd Oil Maint and Diagnosing Intermittent

Complaints85 HTT-2012-01 - Class I 8FBCU Relief Valve Structure, Using DVOM to Check Voltage Drop

NAME SECTION

SECTION INDEX

GENERAL 0OPS & IMPROVEMENTS 1BODY 2APPENDIX 3

0123456789101112131415161718

0-1

GENERALPage

PERIODIC MAINTENANCE............................... 0-2OPS SYSTEM .................................................... 0-2

GENERAL ................................................................... 0-2CHANGES FOR INSTALLATION OF

OPS FUNCTION ...................................................... 0-3SYSTEM CONFIGURATION AND

OPERATION PRINCIPLE ........................................ 0-3DISPLAY ............................................................ 0-5

GENERAL ................................................................... 0-5

0-2

PERIODIC MAINTENANCEComparison with Former Edition: Repair Manual, Pub. No. CU330, Page 0-22

Change:

INSPECTION METHODI : Inspection. Repair or Replacement if required.M : Measurement. Repair or Adjustment if required.T : Retightening C : Cleaning L : Lubrication

OPS SYSTEM

GENERALThe OPS (Operator Presence Sensing) System is equipped as the standard feature on all models. The switch installed on the seat detects the operator, and when the operator is not seated in the normal operatingposition (operator’s seat), the OPS system interrupts the traveling power and restricts load handling operation.When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding thebuzzer (pi-)* for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turningoff the seat switch. When the controller detects malfunction, the display indicate the diagnosis error code.

*: The buzzer sounds only export model.

Every 6 weeks

Every 3 months

Every 6 months

Every 12 months

Every 250 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

SAFETY DEVICES, ETC.

SEAT

Loosening and damage of mounting I ← ← ←

Seat belt damage and function I ← ← ←

Seat switch function I ← ← ←

OPS Function I ← ← ←

Inspection timing

Item

S P H

0-3

0123456789101112131415161718

CHANGES FOR INSTALLATION OF OPS FUNCTION1. Change in return-to-neutral function

When the key switch or seat switch is turned ON with the direction lever in the forward or reverse position or theaccelerator pedal depressed, traveling is disabled unless the direction lever and accelerator pedal are returnedto the neutral positions.

SYSTEM CONFIGURATION AND OPERATION PRINCIPLENote:When OPS operates, the power assistance of the steering wheel is lost because the pump motor is stopped.(except for Mini-Lever Opt.)

Item Operation explanation

Travel OPSWhen the controller detects the seat switch turned off for two seconds, the drive motor control is stopped. Travel OPS is released by returning the direction lever and accelerator pedal to the neutral position and turning on the seat switch.

Material handling OPS

Standard:When the controller detects the seat switch turned off for two seconds, the movement of lift down and tilt forward is stopped by controlling the lift lock valve, tilt controlling valve. The movement of tilt backward, lift up and attachment is stopped by stopping the pump motor. Material handling OPS is released by passing one second after turning on the seat switch.

Main controller

Seatswitch

DisplayKey switch

Battery

N1

Acceleratorpedal switch

Directionswitch

Oilcontrolvalve

Liftcylinder

TiltcylinderOil

tank

Oilpump

Pumpmotor

Drivemotor

Motor driver

Motor driver

0-4

(*) The buzzer sounds only export model.

SEATSTD equipped seat is the same one equipped on previous model. It has been equipped with non-suspension seatwith seat belt manufactured by Michigan seat.Compared to previous model, variety of optional seat is increased. Optional seats are shown below. (Equipped seatsvary with the specification of option.)All seats equip switches for operator presence sensing system.When replacing seat, always use a genuine TOYOTA seat.Otherwise, the OPS may fail to operate.

Item Operation explanation

Material handling OPS

Note:• Tilt backward

When the tilt lever is operated in the state of OPS operation, the mast might move by the self-weight in the state of backward tilting.

• AttachmentWhen the attachment lever is operated in the state of OPS operation, the attachment mightmove by the self-weight.

Mini lever (OPT):When the controller detects the seat switch turned off for two seconds, the movement of lift, tilt and attachment is stopped by stopping the pump motor control and controlling the proportional solenoid valve. Load handling material handling OPS is released by returning the all hydraulic control levers to the neutral position and turning on the seat switch.(In case of mini lever, it is additional to the condition of releasing material handling OPS to return the all hydraulic control levers to the neutral position. Because the mini lever is small and physical operation force is light, it is considered that the luggage etc. put on the armrest move the mini lever by mistake.)

OPS operation information

(*)

When the controller detects the seat switch turned off, it informs OPS operation to the operator by sounding the buzzer (pi-) for about 0.5 seconds and the display indication. Moreover, the display indication keeps while turning off the seat switch.

Return to neutral warning

When the accelerator pedal is operated with turning on the seat switch without returning the direction lever to the neutral position, it informs the operator that the travel OPS is not released by sounding the buzzer (pipipipi).

Abnormality warning When the controller detects malfunction, the display indicates the diagnosis error code.

0-5

0123456789101112131415161718

DISPLAY

GENERALThe multiple display is provided in two types: standard easy model and optional all-round model.

Function list (only added or modified items):Provided — :Not provided

1. Return-to-neutral warning

(1) When the operator turns the key switch on while depressing the accelerator pedal or turning the directionswitch on to start the vehicle.

(2) After sat up, the operator depresses the accelerator pedal while turning the direction switch on and sittingdown.

2. OPS indicatorOPS indicator is displayed and the buzzer sounds for half seconds when the operator leaves the seat.

Note:The buzzer sounds only export model.

Function Easy model (standard) All-round model (optional)

Status display function 1 OPS indicator

S P H

0123456789101112131415161718

1-1

OPS & IMPROVEMENTSPage

GENERAL .......................................................... 1-2MULTI-DISPLAY FUNCTIONS .......................... 1-3

MULTI-SCREEN DISPLAY......................................... 1-3DIAGNOSIS ................................................................ 1-5MASK FUNCTIONS .................................................... 1-5

TROUBLESHOOTING ....................................... 1-9

1-2

GENERAL

Main controller

Seatswitch

DisplayKey switch

Battery

N1

Acceleratorpedal switch

Directionswitch

Oilcontrolvalve

Liftcylinder

TiltcylinderOil

tank

Oilpump

Pumpmotor

Drivemotor

Motor driver

Motor driver

1-3

0123456789101112131415161718

MULTI-DISPLAY FUNCTIONS

MULTI-SCREEN DISPLAY

GENERAL

Display and ButtonsComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-2.

Change:

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

(2) 2-speed travel speed set indicator (8) DOWN button

(3) Diagnosis ON indicator (9) UP button

(4) Overheat warning indicator (10) Power select button

(5) Battery charge indicator (11) Hour meter selector button

(6) Power select indicator

S P H

S E P / 3 0 A M 11 : 0 0S P H

S P H

01 11 : 0 0m p h

S P H

During traveling

S P HS P H

A 1 1 A 1 2 A 1 3

hO.1 2 3 4 5

Upon error occurrence

When OPS is operated

(7) (6) (10) (11)(5)

(1) (2) (3) (4) (8) (9)

Initial screen upon key switch on

A S E Q DU I P P ES

S P H

OT Y O T A

S P H S P H

1-4

GENERAL FUNCTIONSComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-7.

Change:: General function : Manager’s function

DISPLAY INDICATION LISTComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-8, 9.

Add:

USA model (standard model) Export model

Status display function OPS indicator

ModelFunction

GENERAL Screen

MASK FUNCTION Screen

OPTION SET SEAT BUZZER The buzzer sound before OPS operation.*

To be set by dealer or serviceman

En

ter

pa

ssw

ord

*: The buzzer sound only export model.

1-5

0123456789101112131415161718

DIAGNOSIS

DIAGNOSIS CODE LISTComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-26.

Add:

MASK FUNCTIONS

ANALYZER

Vehicle Abnormalities Not Stored in Diag MemoryComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-40.

Change:

OPTION SET

OPTION SET Menu ListComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-64.

Add:

Display code Diag memorycode Faulty Phenomenon on vehicle Detection controller

A5 A5 Seat switch Seat switch abnormality C/R

Warning indicators Warning method Displayed code

4

Return to neutral warning:Warning buzzer sounds when starting is attempted by turning the key switch or seat switch ON with the direction switch ON or the accelerator pedal depressed.

• BeepShort beeps No display

No. Indication DescriptionSelection

Indication Meaning indication Meaning

OPT-23 SEAT BUZZEREnable/disableThe buzzer sound only export model.

Y Enable N Disable

1-6

Operation Procedure for OPTION SET ScreenComparison with Former Edition: Repair Manual, Pub. No. CU331, Page 3-65, 66, 67.

New:

1. Input the password on the GENERAL screen (see page 3-32) to display the MASK MENU screen.

2. Press button (2) twice to display “3. OPTION SET” and press button (3) (enter) to display the OPTION SETscreen.

3. Press button (3) to display the desired option item to be set on the screen.

4. Functions of buttons on the OPTION SET screen are as follows:• Button (1): N → Y• Button (2): Y → N• Button (3): Enter (to the next item screen)

*: Press button (3) on OPT-23 OPTION SET screen to display the MASK MENU screen.

S P H

=

3 O P T I O N S E T.

=M E N U

MASK MENU screen

Press button (3)

Press

button (3)

Press button (3)

OPT-4 screen

Press button (3)

OPT-2 (H/M START) hour meter starting method:

Press button (2) while keeping button (1) pressed

for 2 seconds or more.

Button (3)

Button (1)

Button (2)

S P H

S P H

< >OD E M O M O D E

P T 1

Y / N

S P HS P H

< >OH / M S T A R T

P T 2

Y / N

S P H

S P H

< >OP / C L O C K

P T 3

Y / N

S P H

1-7

S P H

< >OD E S T I

P T 4

J / I

OPT-3 screen

S P H

< >OB L E V E L

P T 5

Y / N

S P H

< >OM P H

P T 6

Y / N

S P H

< >OC / C N T R E S

P T 7

Y / N

S P H

< >OS H O U O K UT

P T 9

Y / N

S P H

< >OB T Y P E

P T 51

1 / 2

OPT-16 screen

S P H

< >OT I L T F L I M

P T 41

Y / N

S P H

< >OK N O B C O N T

P T 31

Y / N

S P H

< >OT I L T C O N T

P T 21

Y / N

S P H

< >OP A R K I GN E RR

P T 11

Y / N

S P H

< >OS E A T O F FP

P T 01

Y / N

P H

< >OB A T T E YR

P T 8

A / B

S

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)

Press button (3)

Press button (3)

Press button (3)

Not used

Not used

Not used

Button (3)

Button (1) Button (2)

S P H

S P H

S P H

S P H

S P H

S P H S P H

S P H

S P H

S P H

S P H

S P H

1-8

OPT-15 screen

Not used

Not used

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Press button (3)

Not used

ADD:

Press

button (3)

Press button (3)

Button (3)

Button (1)

Button (2)

S P H

< >O3 6 V

P T 61

Y / N

S P H

S P H

< >O2 WA Y V L V EA

P T 71

Y / N

S P H

S P H

< >O4 W A Y V A L V E

P T 81

Y / N

S P H

S P H

< >OU S A

P T 91

Y / N

S P H

S P H

< >OW H E E L I N D

P T 02

Y / N

S P H

S P H

< >OS A S

P T 2 1

Y / N

S P HS P H

< >OF I S H E M A NR

P T 22

Y / N

S P H

MASK MENU screen

Press button (3)

S P HS P H

MENU

< >OS E A T U Z Z E RB

P T 32

Y / N

1-9

TROUBLESHOOTINGDIAGNOSIS CODE LIST

OPS relation

WHEN AN ERROR CODE IS DISPLAYED

Display code Diag memory code Error mode Page

A5 A5 Seat switch abnormality 1-10

WHEN NO ERROR CODE IS DISPLAYED

Display code Vehicle condition Page

Traveling and material handling fail with OPS operation display even after sitting on the seat. 1-12

Harness change relation


Display code Diag memory code Error mode Page

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

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

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

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

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

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

A4 A4 Acceleration switch abnormality 1-22

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

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

C7 C7 Direction switch abnormality 1-27

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

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

FF FF D15 overcurrent 1-30

H5-1, 2, 3, 4, 5 H5-1, 2, 3, 4, 5 Lift solenoid abnormality 1-31

H6-1, 2, 3, 4, 5 H6-1, 2, 3, 4, 5 Tilt solenoid abnormality 1-34

H7-1, 2, 3, 4, 5 H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality 1-37

H8-1, 2, 3, 4, 5 H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality 1-40

H9-1, 2, 3 H9-1, 2, 3 Unload valve solenoid abnormality 1-43


Display code Vehicle condition Page

— No display on multi-display 1-52

— Only traveling disabled (no motor revolution) 1-53

— Constant automatic fork leveling 1-55

1-10

OPS Relation


A5 Seat switch abnormality (STD)

Output when the seat switch is kept ON.

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

Seat switch

1

2

5

12

CN22

Condition for Error Detection

Has the operator been sitting on the seat before key switch ON? NormalYES

Disconnect the seat SW harness CN22 and check the LSD.ANL.: I/O MONITOR 2 I/O 2-3LSD ON/OFF check

Seat switch abnormalityLSD: 0

NO

LSD: 1

• CPU-CN22 harness abnormality (potential 67 grounded) or• CPU board abnormality

1-11

A5 Seat switch abnormality (Mini Lever)

Output when the seat switch is kept ON.

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

Seat switch

1

2

5

12

CN43CN42

7

8


Has the operator been sitting on the seat before key switch ON? NormalYES

Disconnect the seat SW harness CN43 and check the LSD.ANL.: I/O MONITOR 2 I/O 2-3LSD ON/OFF check


NO

LSD: 1

• CPU-CN43 harness abnormality (potential 67 grounded) or• CPU board abnormality

1-12


Traveling and material handling fail with OPS operation display even after sitting on the seat. (STD)

Seat switch OFF or discontinuity.

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

Seat switch

1

2

5

12

CN22


Disconnect CN22, connect SST2 to CN22 and check the LSD.ANL.: I/O MONITOR 2 I/O 2-3LSD ON/OFF check


LSD: 0

• CPU-CN22 harness abnormality (potential 67 line discontinuity) or• CPU board abnormality

1-13

Traveling and material handling fail with OPS operation display even after sitting on the seat. (Mini Lever)

Output when seat switch OFF or discontinuity.

Related Portion

CPU board

CN101-5 (67, LSD)

CN101-16 (51, LS–)

CN161

Seat switch

1

2

5

12

CN43CN42

7

8


Disconnect CN43, connect SST2 to CN43 and check the LSD.ANL.: I/O MONITOR 2 I/O 2-3LSD ON/OFF check


LSD: 0

• CPU-CN43 harness abnormality (potential 67 line discontinuity) or• CPU board abnormality

1-14


CPU Board

63-1, 2, 3 Tilt switch abnormality

Output when open or short circuit of the tilt switch line from the CPU board to the tilt switch is detected.63-1 Forward and backward tilt switch abnormality63-2 Forward tilt switch abnormality63-3 Backward tilt switch abnormality

Related Portion

CPUboard

CN101-23 (61, LSTF+)

CN101-16 (51, LS–)

CN161Tilt switch

17

13

CN122

11

10

CN102-8 (61, LSTF)

CN101-17 (62, LSTR+)

CN102-9 (62, LSTR)

J21

12 1 J2

CN87

1

3

4

2


A6-3 error is indicated

No error

The forward and backward tilt switches were turned ON at the same time in the past.(Check adjustment of each switch installation)

Disconnect battery plug.Connect battery plug again and turn key switch ON.

Check if an error is detected when the tilt lever is operated in either direction.

No error

63-1 error is indicated

Perform troubleshooting for A6-3.

• Tilt switch installation defect• Tilt switch abnormality

1 is displayed on either switch.

0 is displayed on either switch after operating the tilt lever several times.

Memory 63-1

Memory 63-2, 63-3

ANL : I/O MONITOR 3 I/O3-3Operate the tilt lever in either direction and check the switch input valve when the tilt lever is neutral position.

Check the diagnosis memory The tilt lever has been turned ON for two minutes or more in the past.

1-15

• 72-1

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

Output when open or short circuit of the sensor line from the CPU board to the steering angle sensor is detected.72-1 Steering angle sensor STS1 abnormality72-2 Steering angle sensor STS2 abnormality72-3 Steering angle sensor STSC abnormality72-4 Steering angle sensor open

Related Portion

CPUboard

CN103-10 (16, D15V)

CN101-16 (51, LS–)

CN162

Steering angle sensor

13

CN101-24 (312, STS1)

CN101-30 (313, STS2)

CN101-21 (314, STSC)

J21

CN161

9

11

8

12

CN124

1

CN120

10

11

12

1 J1

J4

CN19

1

3

4

5

2


72-1 error is not indicated


Connect battery plug and turn the key switch ON.Turn the steering wheel.

Connector connection check.

ANL : I/O MONITOR 4 I/O4-1Check the STS1 input value turning the steering wheel.

Remain 1

Remain 0

A

B

1-16

Remain 0

Change to 1

CPU board defect

No continuity

Continuity

Main harness defect

Steering angle sensor defect

Remain 1

No continuity

CPU board defect

Continuity

Change to 0

Main harness defect


A B

Disconnect battery plug.Disconnect CN32.Short between CN19-3 and CN19-2 of main harness side with SST2.Connect battery plug and turn the key switch ON.

ANL : I/O MONITOR 4 I/O4-1Check the STS1 input value

Disconnect battery plug.Disconnect CN101.(SST2 is connection state.)CN101-24 (312) b Continuity checkCN101-16 (51)

Disconnect battery plug.Disconnect CN19.Connect battery plug and turn the key switch ON.


Disconnect battery plug.Disconnect CN19, CN101.CN101-24 (312) b Continuity checkCN101-16 (51)

1-17

• 72-2


Remain 0

Remain 1

Connector connection check


Remain 0

Change to 1

CPU board defect

No continuity

Continuity

Main harness defect


Remain 1

No continuity

CPU board defect

Continuity

Change to 0

Main harness defect






ANL : I/O MONITOR 4 I/O4-1Check the STS2 input value turning the steering wheel.



Disconnect battery plug.Disconnect CN19, CN101.CN101-30 (313) b Continuity checkCN101-16 (51)

1-18

• 72-3


Remain 0

Remain 1

Connector connection check


Remain 0

Change to 1

CPU board defect

No continuity

Continuity

Main harness defect


Remain 1

No continuity

CPU board defect

Continuity

Change to 0

Main harness defect


ANL : I/O MONITOR 4 I/O4-1Check the STSC input value


Disconnect battery plug.Disconnect CN101.(SST2 is connection state.)CN101-21 (314) b Continuity measurementCN101-16 (51)

ANL : I/O MONITOR 4 I/O4-1Check the STSC input value turning the steering wheel.


ANL : I/O MONITOR 4 I/O4-1Check the STSC input value

Disconnect battery plug.Disconnect CN19, CN101.CN101-21 (314) b Continuity measurementCN101-16 (51)

Connect battery plug and turn the key switch ON.Turn the steering wheel to left or right for one round or more.

1-19

• 72-4

Main harness defect

Approx. 0 V

Approx. 15 V

72-4 error is not indicatedConnector connection check


Perform troubleshooting for 72-1 (STS1), 72-2 (STS2)

CPU board defect

Approx. 15 V

Approx. 0 V


Disconnect battery plug.Disconnect CN19.Connect battery plug.

Check voltage of power supply for steering angle sensor.CN19-1 (16) b Voltage measurementCN19-2 (51)

Disconnect battery plug.Connect CN19.Connect battery plug and turn the key switch ON.

Disconnect battery plug.Disconnect CN101, CN103.Connect battery plug.Check voltage of power supply for steering angle sensor (at controller side connector).CN103-10 (16) b Continuity checkCN101-16 (51)

1-20

• 73-1

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

Output when open or short circuit of the solenoid line from the CPU board to the steering knob synchronizersolenoid is detected.73-1 Steering knob synchronizer solenoid open73-2 Steering knob synchronizer solenoid short73-3 Drive circuit MOS of steering knob synchronizer solenoid short

Related Portion

CPUboard

CN104-21 (329, SOLST+)CN161

Steering knob synchronizer solenoid

18

CN104-28 (330, SOLST–)20

CN122

4

3

CN98

1

2


ACTIVE TEST : ACT-2 KSOLTurn the steering knob synchronizer solenoid ON.

73-1 error is indicated.

73-1 error is not indicated.Connector connection check

Other than 9.9 ± 1 Ω (at 25°C)

CPU board defect

Main harness defect

9.9 ± 1 Ω (at 25°C)

Other than 9.9 ± 1 Ω (at 25°C)

9.9 ± 1 Ω (at 25°C)

Steering knob synchronizer solenoid defect

Disconnect battery plug.Disconnect CN98.

Disconnect battery plug.Disconnect CN104.CN104-21 (329) b Resistance measurementCN104-28 (330)

Disconnect CN98.CN98-1 (329) b Resistance measurementCN98-2 (330)

1-21

• 73-2

• 73-3

Disconnect battery plug.Disconnect CN98.Connect battery plug.




No continuity

Harness defectContinuity

CPU board defect

Disconnect battery plug.Disconnect CN104.CN104-21 (329) b Continuity checkCN104-28 (330)



73-1 error is indicated.Steering knob synchronizer solenoid defect




No continuity

Harness defectContinuity

CPU board defect

Disconnect battery plug.Disconnect CN152 and turn the key switch ON.Check continuityCN104-21 (329) to P1CN104-21 (329) to P2CN104-28 (330) to P1CN104-28 (330) to P2

1-22

A4 Acceleration switch abnormality

Output when the acceleration ON signal is detected upon battery plug ON.

Related Portion

CPUboard

CN102-1 (64, SWAC)CN162

Acceleratorpotentiometer

1

CN102-22 (51, POT–)8

CN121

10

4

CN262

1J22 J3


NO

YESNormal

YES

Adjust acceleration switch

Harness defect

NO

No continuity

Continuity (Less than 20 Ω)

CPU board defect

Was the accelerator pedal operated upon battery plug connection?

Disconnect battery plug and disconnect CN102.CN102-1 (64) b Continuity checkCN102-22 (51)

Disconnect CN26.

Reconnect battery plug.

Is A4 error displayed?

1-23

A6-1, 3, 5 Material handling switch abnormality

Output when the material handling switch ON signal is detected upon battery plug ON.A6-1 Lift switch abnormalityA6-3 Forward and backward tilt switch abnormalityA6-5 Attachment No. 1 switch abnormality

Related Portion

CPUboard

CN101-32 (60, LSL+)

CN161Lift switch

12

CN101-16 (51, LS–)

CN122

CN11

J21

CN102-6 (60, LSL)

CN101-11 (66, LSAT1+)

CN102-10 (63, LSAT1)

CN101-23 (61, LSTF+)

CN102-8 (61, LSTF)

CN101-17 (62, LSTR+)

CN102-9 (62, LSTR)

7

17

13

12

12

9

11

10

1 J2

1

2

CN21

1

2

CN87

1

2

3

4

AttachmentNo.1 switch

Forwardtilt switch

Backwardtilt switch


NO

YESNormal

YES

Adjust limit switch or switch abnormality.NO

Was the material handling lever operated upon battery plug connection?

Is A6 error displayed?

Disconnect CN11 (A6-1), CN87 (A6-3) or CN21 (A6-5), and connect battery plug.

A

1-24

OK (short circuit)

NG (open circuit)Harness defect

OK (open circuit)

Harness defectNG (short circuit)

A

Disconnect battery plug.Disconnect CN101, CN102.Continuity check• A6-1

CN101-32 (60) to CN102-6 (60)• A6-3

CN101-23 (61) to CN102-8 (61)CN101-17 (62) to CN102-9 (62)

• A6-5CN101-11 (63) to CN102-10 (63)

Continuity check• A6-1

CN102-6 (60) to CN101-16 (51)• A6-3

CN102-8 (61) to CN101-16 (51)CN102-9 (62) to CN101-16 (51)

• A6-5CN102-10 (63) to CN101-16 (51)

CPU board defect

1-25

• C4-1

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

C4-1 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is on.C4-2 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is on.C4-3 Accelerator line (POTA) voltage exceeds the specified level when the acceleration switch is off.C4-4 Accelerator line (POTA) voltage is below the specified level when the acceleration switch is being

operated.

Related Portion

CPUboard

CN102-1 (64, SWAC)CN162

1

CN102-2 (52, POTA)

CN102-14 (53, POTA+)Acceleratorpotentiometer

CN102-22 (51, POT–)J22

2

5

8

CN121

10

1

7

4 J3

CN26

2

3

4

1


Less than 0.3V

0.3 V or moreCPU board defect

The POTA value does not change.

Potentiometer adjustment defect

The POTA value changes.

CN102-2 (52) b Voltage measurementN1

ANL : I/O MONITOR 2 I/O 2-1Check the POTA value when the accelerator switch SWAC is turned from 0 to 1.

ANL : I/O MONITOR 2 I/O 2-1Check the POTA value as the accelerator is depressed further.

Disconnect CN26, and short between POTA and POTA+ with SST8.

Error is indicated

Potentiometer defect

Error is not indicated

4.8 V or more Less than 4.8 V

CPU board defect Main harness defect

1-26

• C4-2

• C4-3

• C4-4If C4-2, 3 occurs at the same time, perform troubleshooting for C4-2, 3 first.

NO

YESAccelerator potentiometer check

Less than 4.5 V

Main harness defectCN102-2 (52) b Voltage measurementN1

Does C4-2 go out after disconnecting CN26?

CPU board defect

4.5 V or more

Less than 2.5 V

Changes to 1.

0 remainsAccelerator switch defect

2.5 V or more

CN102-2 (52) b Voltage measurementN1

ANL : I/O MONITOR 2 I/O2-1Check if the SWAC value changes from 0 to 1 as the accelerator pedal is depressed.

ANL : I/O MONITOR 2 I/O2-1Check maximum POTA value when SWAC is 0.

Does C4-3 go out after disconnecting CN26?

NO

Accelerator potentiometer checkYES

NO

CPU board defect

Main harness defect

Less than 2.5 VIs C4-3 error displayed?

CPU board defect

YES

2.5 V or more

Less than 1.4 V

1.4 V or morePotentiometer adjustment defect

ANL : I/O MONITOR 2 I/O2-1Check the POTA value when the SWAC display is turned from 0 to 1 or from 1 to 0.

CPU board defect

1-27

C7 Direction switch abnormality (STD)

Output when both forward and reverse direction switches are ON.

Related Portion

CPUboard

CN101-1 (45, DSF)CN161

1

CN101-2 (46, DSR)

CN101-16 (51, LS–)

Directionswitch2

12

CN120

2

3

1J21 J1

CN9

5

4

6


Becomes 0.

DSF or DSR display will be 1.

Direction switch inspection

OK (Approx. 5 V)

CPU board defect

NG (Other than OK)

Disconnect battery plug and disconnect CN9.

ANL : I/O MONITOR 2 I/O2-2Check the value of DSF, DSR.

CN101-1 (45)CN101-2 (46) b Voltage measurementN1

Harness short circuit

1-28

C7 Direction switch abnormality (EZ Pedal)

Output when both forward and reverse direction switches are ON.

Related Portion

CPUboard

CN101-1 (45, DSF)CN161

1

CN101-2 (46, DSR)

CN101-16 (51, LS–)

Directionswitch2

12

CN120

2

3

1J21 J1

CN9

5

4

1


Becomes 0.

DSF or DSR display will be 1.

Direction switch inspection

OK (Approx. 5 V)

CPU board defect

NG (Other than OK)


ANL : I/O MONITOR 2 I/O2-2Check the value of DSF, DSR.

CN101-1 (45)CN101-2 (46) b Voltage measurementN1

Harness short circuit

1-29

• EE-1

• EE-3• Reset the tuning value.• If EE-3 is displayed frequently, either the CPU board or the display may be defective.

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

Output upon detection of communication data abnormality from display.

Related Portion

CPUboard

CN103-13 (144, SMTDK)CN162

17

Display

CN103-14 (143, SDTMK)

CN103-15 (142, SDTMA)

CN103-16 (141, SMTDA)

CN103-10 (16, D15V)

CN103-12 (14, GNDD)

18

14

15

16

13

CN124

2

3

9

8

7

1

CN1

7

4

8

3

1

2

CN70-23

CN70-24

CN70-21

CN70-22

CN-14

CN-30


Disconnect CN1CN103-10 (16) b Voltage measurementCN103-12 (14)

NO

YESSee F1 error

OK (Approx. 0 Ω)

Connect the display

NG (Other than 0 Ω)

Was the battery plug connected when the display is removed?

YES

• Display defect• CPU board defect

14 V or more Less than 14 V

• Sub harness defect• Display defect

• CPU board defect• Harness defect

Is F1 error displayed?

YES

NO

Does the display turn on upon key switch ON?

NO

Disconnect battery plug and disconnect CN103 and CN70.Check the continuity.CN103-15 (142) to CN70-21 (142)CN103-14 (143) to CN70-24 (143)

• Connector connection defect• Harness defect

• EE-2

1-30

FF D15 overcurrent

Output when overcurrent of D15V power source is detected.

Related Portion

CPUboard

CN103-10 (16, D15V)CN162

13CN103-12 (14, GNDD)

Multi-display board16

J4

CN124

1

7

CN1

2

1


Approx. 1 kΩ or more

Display defect

Approx. 1 kΩ or less

Disconnect CN70, connect battery plug, and turn key switch ON.

CPU board defect

No error

FF error is indicated.

Disconnect battery plug, disconnect CN103, and measure the resistance between 10 pin and 12 pin of harness side.CN103-10 pin (Tester probe ) b Resistance measurementCN103-12 pin (Tester probe )

Harness defect

1-31

• H5-1

H5-1, 2, 3, 4, 5 Lift solenoid abnormality

Output when open or short circuit is detected in the lift solenoid line from CPU board to the lift solenoid (raise and/or lower).

• Error indication (reference)H5-1 Lift b1 (UP) solenoid open-circuit abnormalityH5-2 Lift b1 (UP) solenoid load short-circuit abnormalityH5-1 Lift a1 (DOWN) solenoid open-circuit abnormalityH5-2 Lift a1 (DOWN) solenoid load short-circuit abnormalityH5-5 Lift solenoid drive circuit MOS short-circuit

Related Portion

CPUboard

CN104-3 (3, SOL1+)CN163

4Lift a1 (DOWN)solenoid

CN104-5 (5, SOLa1)

CN104-4 (4, SOLb1)

CN164

10

CN163

5

CN122

12

11

CN121

5

CN75

4

8

CN74

4

8

J45

Lift b1 (UP)solenoid


Connect battery plug and turn key switch ON.Lift raising operation. (note that lift on the vehicle is lowered.)

H5-1 error is indicated.

0.1 A or more

Check connector connection

CPU board defect

H5-1 error is not indicated.


Connect battery plug.Turn key switch ON.Lift raising operation.

ANL : I/O MONITOR3 I/O3-2Check lift solenoid current (during lift raising operation).

0.1 A or less

Disconnect battery plug.Replace CN74 with CN75.(Use SST 20)

Harness defect

Lift b1 (UP) solenoid defect


1-32

• H5-2

• H5-3





Continuity




CPU board defect

Harness defect

No continuity



Lift b1 (UP) solenoid defect

Connect battery plug and turn key switch ON.Lift lowering operation. (note that lift on the vehicle is raised.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Lift lowering operation.

ANL : I/O MONITOR3 I/O3-2Check lift solenoid current (during lift lowering operation).

0.1 A or less


Harness defect

Lift a1 (DOWN) solenoid defect


1-33

• H5-4

• H5-5





Continuity




CPU board defect

Harness defect

No continuity



Lift a1 (DOWN) solenoid defect




10 V or more

Connect battery plug.Turn key switch ON.Lift raising/lowering operation.

CPU board defect

10 V or less

Disconnect battery plug.Disconnect CN104.Connect battery plug and turn key switch ON.Lift lever at neutral position.Check the voltage betweenCN104-3 (3) and CN104-23 (N2), CN104-5 (5) and CN104-23 (N2), CN104-4 (4) and CN104-23 (N2).

Harness defect

1-34

• H6-1

H6-1, 2, 3, 4, 5 Tilt solenoid abnormality

Output when open or short circuit is detected in the tilt solenoid line from CPU board to the tilt solenoid (forwardand/or backward).

• Error indication (reference)H6-1 Tilt a2 (FRONT) solenoid open-circuit abnormalityH6-2 Tilt a2 (FRONT) solenoid load short-circuit abnormalityH6-3 Tilt b2 (REAR) solenoid open-circuit abnormalityH6-4 Tilt b2 (REAR) solenoid load short-circuit abnormalityH6-5 Tilt solenoid drive circuit MOS short-circuit

Related Portion

CPUboard

CN104-6 (6, SOL2+)

Tilt a2 (FRONT)solenoidCN104-7 (7, SOLa2)

CN104-8 (8, SOLb2)11

CN163

6

7

CN75

3

7

CN74

3

7

J46

Tilt b2 (REAR)solenoid

6

CN122

10

9


Connect battery plug and turn key switch ON.Forward tilt operation. (note that mast is tilted backward on the vehicle.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Forward tilt operation.

ANL : I/O MONITOR3 I/O3-4Check tilt solenoid current (during forward tilt operation).

0.1 A or less


Harness defect

Tilt a2 (FRONT) solenoid defect


1-35

• H6-2

• H6-3





Continuity




CPU board defect

Harness defect

No continuity



Tilt a2 (FRONT) solenoid defect

Connect battery plug and turn key switch ON.Backward tilt operation. (note that mast is tilted forward on the vehicle.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Backward tilt operation.

ANL : I/O MONITOR3 I/O3-4Check tilt solenoid current (during backward tilt operation).

0.1 A or less


Harness defect

Tilt b2 (REAR) solenoid defect


1-36

• H6-4

• H6-5





Continuity

Connect battery plug.Turn key switch ON.Backward tilt operation.



CPU board defect

Harness defect

No continuity



Tilt b2 (REAR) solenoid defect




10 V or more

Connect battery plug.Turn key switch ON.Forward/backward tilt operation.

CPU board defect

10 V or less

Disconnect battery plug.Disconnect CN104.Connect battery plug and turn key switch ON.Tilt lever at neutral position.Check the voltage betweenCN104-6 (6) and CN104-23 (N2), CN104-7 (7) and CN104-23 (N2), CN104-8 (8) and CN104-23 (N2).

Harness defect

1-37

• H7-1

H7-1, 2, 3, 4, 5 Attachment 1 solenoid abnormality

Output when open or short circuit is detected in the attachment 1 solenoid line from the CPU board to theattachment 1 solenoid (raise and/or lower).

• Error indication (reference)H7-1 Attachment 1 a3 solenoid open-circuit abnormalityH7-2 Attachment 1 a3 solenoid load short-circuit abnormalityH7-3 Attachment 1 b3 solenoid open-circuit abnormalityH7-4 Attachment 1 b3 solenoid load short-circuit abnormalityH7-5 Attachment 1 solenoid drive circuit MOS short-circuit

Related Portion

CPUboard

CN104-11 (9, SOL3+)

Attachment 1b3 solenoidCN104-13 (11, SOLb3)

CN104-12 (10, SOLa3)13

CN164

12

14

CN74

2

6

CN75

2

6

J47

Attachment 1a3 solenoid

7

CN122

8

11

CN121

CN122


Connect battery plug and turn key switch ON.Attachment 1 raising operation.(note that the attachment 1 is lowered on the vehicle.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Attachment 1 raising operation.

0.1 A or less


Harness defect

Attachment 1 a3 solenoid defect


ANL : I/O MONITOR3 I/O3-6Check attachment 1 solenoid current (during attachment 1 raising operation).

1-38

• H7-2

• H7-3





Continuity




CPU board defect

Harness defect

No continuity




Connect battery plug and turn key switch ON.Attachment 1 lowering operation.(note that the attachment 1 is raised on the vehicle.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Attachment 1 lowering operation.

0.1 A or less


Harness defect

Attachment 1 b3 solenoid defect


ANL : I/O MONITOR3 I/O3-6Check attachment 1 solenoid current (during attachment 1 lowering operation).

1-39

• H7-4

• H7-5





Continuity




CPU board defect

Harness defect

No continuity







10 V or more

Connect battery plug.Turn key switch ON.Attachment 1 raising/lowering operation.

CPU board defect

10 V or less

Disconnect battery plug.Disconnect CN104.Connect battery plug and turn key switch ON.Attachment 1 lever at neutral position.Check the voltage betweenCN104-11 (9) and CN104-23 (N2), CN104-12 (10) and CN104-23 (N2), CN104-13 (11) and CN104-23 (N2).

Harness defect

1-40

• H8-1

H8-1, 2, 3, 4, 5 Attachment 2 solenoid abnormality

Output when open or short circuit is detected in the attachment 2 solenoid line from the CPU board to theattachment 2 solenoid (forward and/or backward).

• Error indication (reference)H8-1 Attachment 2 a4 solenoid open-circuit abnormalityH8-2 Attachment 2 a4 solenoid load short-circuit abnormalityH8-3 Attachment 2 b4 solenoid open-circuit abnormalityH8-4 Attachment 2 b4 solenoid load short-circuit abnormalityH8-5 Attachment 2 solenoid drive circuit MOS short-circuit

Related Portion

CPUboard

CN104-16 (34, SOL4+)

Attachment 2a4 solenoidCN104-17 (35, SOLa4)

CN104-18 (36, SOLb4)17

CN164

15

16

CN75

1

5

CN74

1

5

J48

Attachment 2b4 solenoid

12

CN122

6

5

CN121


Connect battery plug and turn key switch ON.Attachment 2 forward tilt operation. (note that the attachment 2 is tilted backward on the vehicle.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Attachment 2 forward tilt operation.

0.1 A or less


Harness defect



ANL : I/O MONITOR3 I/O3-8Check attachment 2 solenoid current (during attachment 2 forward tilt operation).

1-41

• H8-2

• H8-3





Continuity




CPU board defect

Harness defect

No continuity




Connect battery plug and turn key switch ON.Attachment 2 backward tilt operation. (note that the attachment 2 is tilted forward on the vehicle.)


0.1 A or more


CPU board defect



Connect battery plug.Turn key switch ON.Attachment 2 backward tilt operation.

0.1 A or less


Harness defect



ANL : I/O MONITOR3 I/O3-8Check attachment 2 solenoid current (during attachment 2 backward tilt operation).

1-42

• H8-4

• H8-5





Continuity




CPU board defect

Harness defect

No continuity




Connect battery plug.Turn key switch ON.Attachment 2 forward/backward operation.




10 V or more

CPU board defect

10 V or less

Disconnect battery plug.Disconnect CN104.Connect battery plug and turn key switch ON.Attachment 2 lever at neutral position.Check the voltage betweenCN104-16 (34) and CN104-23 (N2), CN104-17 (35) and CN104-23 (N2), CN104-18 (36) and CN104-23 (N2).

Harness defect

1-43

• H9-1

H9-1, 2, 3 Unload valve solenoid abnormality

Output when open or short circuit is detected in the unload valve solenoid line from the CPU board to the unloadvalve solenoid.

• Error indication (reference)H9-1 Unload valve solenoid open-circuit abnormalityH9-2 Unload valve solenoid load short-circuit abnormalityH9-3 Unload valve solenoid drive circuit MOS short-circuit

Related Portion

CPUboard

CN104-26 (12, SOLP+)CN164

Unload valve solenoid

18

CN104-27 (13, SOLP–)19

CN122

2

1

CN76

1

2



9.9 ± 1Ω (at 25°C)


CPU board defect


Other than 9.9 ± 1Ω(at 25°C)

Unload valve solenoid defect

Harness defect

ACTIVE TEST : ACT-3 PSOL Set the unload valve solenoid to ON in the ACTIVE TEST.(Connect battery plug and turn key switch ON.)

Disconnect battery plug.Disconnect CN104.CN104-26 (12) b Harness continuity checkCN104-27 (13)

Disconnect CN76.CN76-1 (12) b Solenoid resistance checkCN76-2 (13)

9.9 ± 1Ω (at 25°C)

Other than 9.9 ± 1Ω(at 25°C)

1-44

• H9-2

• H9-3



Unload valve solenoid defect


CPU board defect

Harness defect


Disconnect battery plug.Disconnect CN104.CN104-26 (12) b Harness continuity checkCN104-27 (13)

Continuity exists

No continuity








CPU board defect

Harness defect


10 V or more

10 V or less

Disconnect battery plug.Disconnect CN104.Connect battery plug and turn key switch ON.Voltage check (short circuit in the harness) betweenCN104-26 (12) and CN104-23 (N2), CN104-27 (13) and CN104-23 (N2).

1-45

• 61-1

61-1, 2 Load sensor abnormality

Output when the voltage of the load sensor is outside the specified range (open or short).61-1 Load sensor open61-2 Load sensor short

Related Portion

CPUboard

CN102-17 (58, SPL+)CN162

Load sensor

7

CN102-5 (59, SPL)

J22CN102-22 (51, POT–)

4

8

CN121

9

3

4 J3

CN90

4

3

8

CN91

1

2

3


Disconnect battery plug.Disconnect CN102. (SST2 is connection state.)CN102-17 (58) b Continuity checkCN102-5 (59)

61-2 error is not indicated.

No continuity

• Load sensor defect• Sub harness defect

Main harness defect

Continuity

Main harness defect

CPU board defectNo continuity

Continuity


CN102-5 (59) b Continuity checkCN102-22 (51)


1-46

• 61-2

61-2 error remains.

No continuity

Continuity

• Main harness defect

CPU board defect

Continuity

Disconnect battery plug, disconnect CN90, connect battery plug, and turn the key switch ON.


Disconnect battery plug.Disconnect CN102.Short between CN90-3 and CN90-8 of main harness side with SST2.CN102-5 (59) b Continuity checkCN102-22 (51)

No continuity

• Load sensor defect• Sub harness defect

Main harness defect

Change to 61-1 error.

1-47

• 62-1

62-1, 2 Tilt angle sensor abnormality

Output when the voltage of the tilt angle sensor is outside the specified range (open or short).62-1 Tilt angle sensor open62-2 Tilt angle sensor short

Related Portion

CPUboard

CN102-16 (57, POTTA+)CN162

Tilt anglesensor

6

CN102-4 (56, POTTA)

J22CN102-22 (51, POT–)

3

8

CN121

8

2

9 J3

CN8

1

2

3


(SST2 is connection state.)CN102-4 (56) b Continuity checkCN102-22 (51)


62-2 error is not indicated.

No continuity

Tilt angle sensor defect

Main harness defect

Continuity

Main harness defect


Continuity

Disconnect battery plug.Disconnect CN86.Short between CN86-1 and CN86-2 of main harness side with SST2.Connect battery plug and turn key switch ON.


1-48

• 62-2

62-2 error remains.

No continuity

Continuity

Main harness defect

CPU board defect

Continuity

Disconnect battery plug, disconnect CN86, connect battery plug, and turn the key switch ON.


Disconnect battery plug.Disconnect CN102.Short between CN86-2 and CN86-3 of main harness side with SST2.CN102-4 (56) b Continuity checkCN102-22 (51)

No continuity

Tilt angle sensor defect Main harness defect

Change to 62-1 error.

1-49

67-1 Lifting height switch abnormality

Output when open or short circuit of the lifting height switch line from the CPU board to the lifting height switch isdetected.

Related Portion

CPUboard

CN101-20 (91, MH2-1)CN161

Lifting height switch

16

CN101-19 (90, MH1)

J21CN101-16 (51, LS–)

15

12

CN120

6

7

1 J1

CN92

3

2

1

CN90

1

6

2


Other than MH: 00–

MH: 00–• Sub harness defect• Lifting height switch defect

Other than MH: 00–

Main harness defect


Continuity

ANL : I/O MONITOR 3-11Check the lifting height switch input value.

MH: 00–A


ANL : I/O MONITOR 3-11Check the lifting height switch input value. (with battery plug connected)

Disconnect battery plug and disconnect CN101, and check the continuity.CN101-20 (91) to CN101-16 (51)CN101-19 (90) to CN101-16 (51)CN101-20 (91) to CN101-19 (90)

1-50

NG• Sub harness defect• Lifting height switch defect

Less than H2000

CPU board defect

Main harness defectNo continuity

Continuity

H2000 or more

A

Check the lifting height upon error indicating.

Disconnect battery plug and CN90, and check continuity.CN90-6 (90) to CN90-2 (51)

[OK] Continuity, [NG] No continuityCN90-1 (91) to CN90-2 (51)

[OK] No continuity, [NG] Continuity

OK

Disconnect battery plug and CN90, and check continuity.CN90-6 (90) to CN90-2 (51)

[OK] No continuity, [NG] ContinuityCN90-1 (91) to CN90-2 (51)

[OK] Continuity, [NG] No continuity

NG

Disconnect battery plug, disconnect CN101 and CN103, and check the continuity.• Short between CN90-6 and CN90-2

of main harness side with SST2.CN101-19 (90) b Continuity checkCN101-16 (51)

• Short between CN90-1 and CN90-2 of main harness side with SST2.CN101-20 (91) b Continuity checkCN101-16 (51)

OK

1-51

Note:Other error codes, if any, are not indicated because of no communication from the CPU board when F1-1occurs. F1-1 is kept indicated on the multi-display screen regardless of key switch ON or OFF.

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

Output upon detection of communication data abnormality from CPU board.

Related Portion

CPUboard

CN103-16 (141, SMTDA)CN162

Multi-display15

CN103-13 (144, SMTDK)17

CN124

8

2

CN1

3

7

CN70-22 (141, SMTDA)

CN70-23 (144, SMTDK)


OK

No continuity

Harness defect (Between CN103 and CN70)

Correct the defect

Continuity

NGCN103, CN124, CN70 and CN1 connection condition check

Disconnect battery plug, disconnect CN103 and CN70.CN103-16 (141) b Continuity checkCN70-22 (141)CN103-13 (144) b Continuity checkCN70-23 (144)

• CPU board defect• Multi-display defect

1-52


No display on multi-display

• No power supply to multi-display• Multi-display defect

Related Portion

CPUboard

CN103-10 (16, D15V)CN162

Muli-display13

CN103-12 (14, GNDD)16

CN124

1

7

CN1

2

1

CN70-14 (16, D15V)

CN70-30 (14, GNDD)


OK

CPU board defect

See page 4-145. (Vehicle does not move.)

NG (1. ∞ Ω2. Approx. 0 Ω)

NG

Disconnect battery plug, disconnect CN1 and CN103.1. CN1-2 (16)

b Continuity checkCN103-10 (16)CN1-1 (14) b Continuity checkCN103-12 (14)

2. CN1-2 (16) b Short-circuit checkCN1-1 (14)

Harness defect(Between CN1 and CN103)

It is possible to perform traveling and material handling operation.

Disconnect battery plug, disconnect CN1, and connect battery plug.CN1-2 (16) b Voltage measurementCN1-1 (14)

NG (0 V)

OK (Approx. 15 V)Disconnect battery plug, connect CN1, disconnect CN70, and connect battery plug.CN70-14 (16) b Voltage measurementCN70-30 (14)

OK (Approx. 15 V)

Multi-display defect Harness defect (Between CN1 and CN70)

NG (0 V)

OK ( 1. Approx. 0 Ω2. ∞ Ω)

1-53

Only traveling disabled (no motor revolution)

Related Portion

CPUboard

CN101-1 (45, DSF)CN161

Direction switch

1

CN101-2 (46, DSR)

J1CN101-16 (51, LS–)

CN102-1 (64, SWAC)

CN102-2 (52, POTA)

CN102-14 (53, POTA+)

CN102-22 (51, POT–)

2

12

CN120

2

3

1

CN9

5

4

6

Acceleratorportentiometer

CN162

1

2

5

8

CN121

16

1

7

4 J3

CN262

3

4

1

NO

Accelerator OFF, direction switch OFF, and parking OFF (It returns.)

YES

Changes

Both have no change.

Has beep sound been output?

ANL : I/O MONITOR 2 I/O2-1SWAC and POTA value check with accelerator pedal depressing.

Both change.

ANL : I/O MONITOR 2 I/O2-2DSF and DSR value check with direction switch operation.

Voltage measures with direction switch ON and accelerator ON.P7 , P8 , P9 b Voltage measurementN1 P71 , P81 , P91 b Voltage measurementN1

OK (All approx. 24 V)

A

No change

Other than OK

Accelerator check

Direction switch check

Traveling AC driver defect

1-54

YES

Motor cable and motor checkNO

Rotates

Is there sound from the motor?

Perform troubleshooting for C8

A

Does not rotate

Brake check

Disconnect battery plug.Does front wheels rotate when jack up the vehicle to cause the front wheels to float?

1-55

Constant automatic fork leveling

Related Portion

CPUboard

CN101-18 (70, SWTK) CN161

Knob switch4

CN101-16 (51, LS–)12

CN122

2

1

CN841

2

OFF (display 0)

Tilt cylinder check

Leaned forward from leveling position

ON (display 1)

Perform matching No.1, No.2Lift down the fork and operate the tilt lever to the forward position.

Automatic fork leveling is remained ON

OFF (display 0)

ON (display 1)

Operate normally

Does not stop

ANL : I/O MONITOR 3 I/O3-9Check the valve of automatic fork leveling switch.

Tilt knob switch OFF.

ANL : I/O MONITOR 3 I/O3-9Check the valve of automatic fork leveling switch.

Use it as it is.

CN101-18 b Voltage measurementCN101-16

Approx. 5 V

• Harness defect• Switch defect

Approx. 0 V

CPU board defect

Not leaned forward from leveling position

Does pump motor stop without a turning steering wheel when direction switch is neutral position and the fork is at leveling position?

StopCPU board defect

0123456789101112131415161718

2-1

BODYPage

SEAT SWITCH ................................................... 2-2

2-2

SEAT SWITCHInspection:

Push the seat cushion to check seat switch continuity.

Measuring position : between seat switch CN22-1 and CN22-2

Standard : When not pushed : ∞ ΩWhen pushed : 0 Ω

Note:If the standard is not satisfied, replace the cushion ASSY.

CN43

0123456789101112131415161718

3-1

APPENDIXPage

SST LIST ............................................................ 3-2CONNECTOR DRAWING .................................. 3-3CONNECTING DIAGRAM................................ 3-13ELECTRIC WIRING DIAGRAM ....................... 3-14

3-2

SST LIST

Illust. Part number Part nameSection

1 2

09230-13130-71 AC controller diagnosis kit

3-3

0123456789101112131415161718

CONNECTOR DRAWING

( ):OPT( ):OPT

(41) - (AM) (41) (GR) (CN29-1)

2

1 1

2

NO

1

2

TABP C J NO

1

2

RECP C J

CN3 HORN SW.

12 1 2

J1

RECTAB

2

1

2

1

JCPNOJCPNO

BR

R

65

51 B51

CN120-4Y65

CN6

BLS

BLS

BRAKE SW.

12 1 2

NO

1

TABP C J NO

RECP C J

1

2 2 CN123-1STLS

STLS

111 R

101 Y

111 SL

101 R J9

CN5 STOP LAMP SW.

CN4

CN29-1(-)- AM(-) 41(-) GR(-)

JCP

REC

2

1

NOJCP

TAB

2

1

NO

4

41(-)

1

4

1

KEY SW.

3

8 6

4

7

1

5

2

5 6

1

7

42

8

3

CN1

8 8

6 6

5

4

7

3

5

4

2

1

2

1

JCP

REC

7

3

NOJCP

TABNO

DISPLAY

14 W14 W CN124-7CN70-30

16 R J4

141 V CN124-8

143 SL CN124-3

144 O CN124-2

142 B CN124-9

16 R CN70-14

141 V CN70-22

143 SL CN70-24

144 O CN70-23

142 B CN70-21

48 P HORN48 - HO+

41 GR J641 - HO-

33

4 43 Y CN29-2434 - IG

2

3

2

3

14

13

12

11

10

9

8

7

14 11 10

6 5

13

4

12 9

3

8

2 1

7 7

1 2

8

3

9 12

4

13

5 6

10 11 14

CN8

5

4

3

2

RECJCP

TAB

1

NO

TURN & LIGHT SW.

6

115 - LH

116 - LT

N2 - EL

108 - TR

109 - TL

110 - TB CN12-1GR110

J13G109

J14SL108

J8LN2

CN46-3LG116

CN45-3P115

6

NO

1

P C J

2

3

4

5

7

8

9

10

11

12

13

14

LIFT SW.CN11

NO P C J NO P C J

1

2

1

2

TAB REC

212 1

123456789

18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18

987654321

TAB REC

CN9

CN9

DIRECTIONAL SW.

14

13

12

11

10

9

8

7

5

4

3

2

JCP

1

NO

6 51 B J1

43 Y J5VBKY-43

LS--516

NO

1

P C J

2

3

4

5

7

8

9

10

11

12

13

14

15 15

16 16

17 17

18 18

103 P CN123-6DSBU-103

120 Y CN123-5DSFO-120

46 G CN120-3DSR-46

45 W CN120-2DSF-45

43 - VBKY 43 Y J5

60 R CN122-12

51 LG J2

60 R

51 BR

LS L

LS L

6 6

55

44

NO

3

TABP C J NO

3

RECP C J

1

2

1

2

DIRECTIONAL PEDAL

1 2 3

4 5 6

123

456

<OPT>

51 - LS-

120 - DSFO

103 - DSBU

46 - DSR

45 - DSF

43 - VBKY

51 B J1

120 Y CN123-5

103 P CN123-6

46 G CN120-3

45 W CN120-2

43 Y J5

3-4

N2 L CN14-2 J8LN2

12 1 2

NO

1

TABP C J NO

RECP C J

1

2 2

CN20 HEAD LAMP LH

44

33

JCP

2

1

NOJCP

2

1

NO

FR COMBI LHCN18

RECTAB

1 2

3 4

12

34

LF-L

LF-L

LC-L

LC-L104

N2

N2

109 -

-

-

-

FR COMBI LHCN17

2

1

2

1

JCP

REC

3

NOJCP

TAB

3

NO

5 43 2 1 1 2 3

4 5

4 4

5 5

66

66

-

-

-

-108

N2

N2

104 LC-R

LC-R

LF-R

LF-R

4 3

2 1

43

21

TAB REC

CN14 FR COMBI RH

NO

1

2

P C J NO

1

2

P C J

3 3

4 4

HEAD LAMP RHCN16

22

1

JCP

RECNOJCP

TAB

1

NO

212 1

1

2 2

1

CN12

110

43

-

-

FRY

FRY

110

43

GR

Y

CN8-14

J522

1

JCP

RECNOJCP

TAB

1

NO

FLASHER RILAY

6 5 4 3

2 1

6543

21

CN19

55

44

2

1

2

1

JCP

REC

6

3

NOJCP

TAB

6

3

NO

STEERING SENSOR

NO

2

1

TABP C J NO

2

1

RECP C J

PBLS

PB

2 1 21

CN15

-

-

LS

PARKING SW.

6 6

6 6

55

44

54321123

45

NO

3

TABP C J NO

3

RECP C J

1

2

1

2

CN13 FR COMBI RH

N2 L J8

104 O J10

102 G J11

108 SL J14

101 Y J9

N2 W J51

104 G CN14-4

102 Y CN16-1

108 G-Y CN14-1

101 R CN96-7

108 G-Y CN13-4

N2 L CN13-5

N2 W J51

104 G CN13-2

51

66

51 B J1

66 R CN120-8

LH-R102 -

LH-RN2 -

CN13-3102 Y

J51N2 W

N2 L J8

J10O104

102 G J11

J13

J8L

G109

N2

N2 J51W

CN18-4G104

102 Y CN20-1

CN18-1G-Y109

N2 L CN18-2

109 G-Y CN17-4

N2 CN17-5

N2 J51

104 G CN17-2

W

L

16 R J4

51 B J1

312 Y CN120-10

313 V CN120-11

314 L CN120-12

16 - IG

51 - ESS

312 - SS1

313 - SS2

314 - SSC

102 - LH-L

N2 - LH-L

102 Y CN17-3

N2 W J51

SMART ALARM

-N2

-103

BZ

BZ

CN23-2

WN2

O103 J56

J5422

2

1

2

1

1

JCP

RECNOJCP

TAB

1

NO

SEAT SW.CN22

NO P C J NO P C J

1

2

1

2

TAB REC

212 1

ATT SW.CN21

NO P C J NO P C J

1

2

1

2

TAB REC

212 1

NO

1

TABP C J NO

RECP C J

1

1

2

1

2

2 2

198

N2

CN23

CHI

CHI

198

N2

BACK CHIME

63 R

BR51

63 V CN122-9

J2LG51

ATT

ATTLS

LS

DLS-67

51 - DLS

67 L CN161-5

51 B J21

-

-

GR J12

L J31

3-5

0123456789101112131415161718

123456 654

321

TAB

CN29 KEY SW.

REC

2 1 21

NO P C J NO P C J

2 2

1 1

GND

OUT

W

Y317

51-

-317

51

CN32

NO

1

2

TABP C J NO

1

2

RECP C J

1 2 3123

3 316 - VCC 3 316 SL

TIRE ANGLE SENSOR

3 3

NO

3

6

TABP C J NO

3

6

RECP C J

1

2

1

2

4 4

5 5

CN34

J56

R

R

R

R

R

103

108

103

111

104

N2

TRN108 BR CN38-5

O

SL J53

G J55

B/U

STP

TL

103

111

104

EN2 W J54

1 2

4

5 656

12

4

RR COMBI RH

3 34

2 1

4

21

104

111

109

TL

STP

TRN

N2 E

109

104

111

N2

L

L

L

L

CN31

44

2

1

2

1

JCP

REC

3

NOJCP

TAB

3

NO

RR COMBI LH

NO

3

4

TABP C J NO

3

4

RECP C J

1

2

1

2

1 2 3 41234

VC

VTA

IDL

E2

52

64

51

53-

-

-

-

52

64

51

53

CN26 ACCEL

FORWARD CHIMECN24

N2

120

22

2

1

2

1

1

JCP

RECNOJCP

TAB

1

NO

W J3

SL CN121-10

GR CN121-1

O CN121-7

41 GR CN4-1

43 Y CN4-2

41 GR J6

43 Y J5

F6-4 44 J30BR444

3 3

F4,F5,F6 FUSE

P2

NO

1

2

TABP C J NO

1

2

RECP C J

PP2F6- CN136-6

CN27

J29- F5 41 GR

6

5

6

5 41

L

Y CN123-5

J31

P1 W CN136-4- F5P1

P1 B CN136-3- F4P1

101 Y CN123-4101 - F4

J55G

J53SL

CN38-6G-Y

J54W

J22

CN163-13

CN163-14

LW

LW-

-N2

107 CN38-7V107

J54WN2

12 1 2

NO

1

TABP C J NO

RECP C J

1

2 2

CN36 RR WORKING LAMP

11

8 8 N2N2

7 7 107107

6 6 109109

5 5 108108

8 7 6 5 4

3 2

87654

32

NO

3

4

TABP C J NO

3

4

RECP C J

1

2

1

2

CN38

104

198

111

104

198

111

RR UPR

4343 L FB

SL J53

O J56

G J55

BR CN34-5

G-Y CN31-3

V CN36-1

W J54

Y J39

R CN123-1

GR CN165-5

O CN123-3

SL CN123-7

G CN123-8

B CN123-2

L J31

20

21

28

22

23

29

24

25

30

5151

30

25

24

29

23

22

28

21

20

MINI LEVER

51010

5

10 10

9 9

CN41

NO P C J NO P C J

1

2

1

2

TAB REC

876321

8 7 63 2 14

949

3

4

5

6

7

8

3

4

5

6

7

8

R CN161-19

B CN164-2

G CN164-6

O CN161-17

LG CN161-13

Y CN164-7

V CN161-7

L CN164-3

GR CN164-8

W CN164-1

<OPT>

R

B

G

O

LG

Y

V

L

GR

W J49

CN79-1

CN79-3

CN79-2

CN78-1

CN78-3

CN78-2

CN77-1

CN77-3

CN77-2

3-6

12 1 2

51

67

70

31

27

26

MINI LEVER

26

27

31

70

67

518

7

6

5

4

3

8

7

6

5

4

3

84

84 123

5671 2 35 6 7

RECTAB

2

1

2

1

JCPNOJCPNO

CN42

V CN164-4

SL CN164-5

LG CN164-9

BR CN161-14

L CN161-5

B J21

<OPT>

<OPT>

B CN42-8

L CN42-7

SEAT SW

NO

1

2

TABP C J NO

1

2

RECP C J

CN43

67

51 -

- 67

51SOL P

SOL P

V CN80-2

SL CN80-3

LG CN80-1

BR CN85-2

L CN43-1

B CN43-2

CN46

RECTAB

4

1

4

1

TAIL LAMP RELAY

2

3

2

3

-4 4

-3 3

3

2

3

2

HEAD LAMP RELAY

1

4

1

-

4

NO

1

2

TABP C J NO

1

2

RECP C J

-

CN45

CN110-12

J27

CN110-11

CN110-9

SL

P

BR

O

77

78

76

75

77

78

76

75

DM SPEED LH

4 L SSD12 4

3 B SSD1- 3

SSD1+

SSD11

R

W

NO

1

2

TABP C J NO

1

2

RECP C

CN59

J

43

211 2

3 4

CN110-13

J27

W

P

87

78

87

78

DM TEMP LH

NO

1

2

TABP C J NO

1

2

RECP C J

2 1 21

TD1-

TD1+

B

R

CN58

CN111-12

J26

CN111-11

CN111-9

R

P

W

LG83

84

86

85SSP2

SSP-

SSP1

SSP+

85

86

84

83

PM SPEED

4 L 4

3 B 3

R

W

NO

1

2

TABP C J NO

1

2

RECP C

CN56

J

43

211 2

3 4

CN109-12

J28

CN109-11

CN109-9

SL

P

BR

O

43

21 1 2

3 4

J

CN53

81

82

CP

REC

2

1

NOJCP

TAB

2

1

NO

W

R

81

82

SSD21

SSD2+

80

3SSD2-B

80

3

79

4SSD22L

79

4

DM SPEED RH

CN111-13

J26

BR

P

CN55

89

86

JCP

REC

2

1

NOJCP

TAB

2

1

NO

89

86

1 212

B

R

TP-

TP+

PM TEMP

101 Y J9

101 Y J9

115 P CN8-8

102 G J11

101

101

115

102

COIL+

SW+

COIL-

SW-

SW-

COIL-

SW+

COIL+

104

116

101

101

J10O104

CN8-9LG116

J9Y101

J9Y101-

JCP

2

1

NOJCP

2

1

NO

-

33 -

44 -

CN109-13

J28

CN52

88

82

R

B

88

82

TD2+

TD2-

1 212

JCP

REC

2

1

NOJCP

TAB

2

1

NO

DM TEMP RH

R

P

12 21

FAN(EX)

B

BR

J23

J30

39

44

FAN EX (-)B39

R44 FAN EX (+)

CN50

22

1

JCP

RECNOJCP

TAB

1

NO

3-7

SOL P

SOL P 13

12-

-13

12

CN76

JCP

REC

2

1

NOJCP

TAB

2

1

NO

12 21

C/V PRESSURE SOL.

W

G

B

R

CN41-3

CN41-2

CN41-1

J49

28

21

20

51

VC

VTA2

VTA1

E2

28

21

20

51

LIFT LEVER

NO

3

4

TABP C J NO

3

4

RECP C J

1

2

1

2

1 2 3 41234

-

-

-

-

CN77

CN122-2BR

CN122-1LG

<OPT>

<OPT>

W

LG

SL

V

ATT2 LEVER

31

27

26

51 E2

VTA1

VTA2

VC 31

27

51

26

CN42-3

CN42-2

CN42-1

J49

CN80

-

-

-

-

4 3 2 1 4321

2

1

2

1

JCP

REC

4

3

NOJCP

TAB

4

3

NO

W

V

L

GR

J49

30

25

24

51

ATT1 LEVER

51

24

25

30 VC

VTA2

VTA1

E2

CN41-9

CN41-8

CN41-7

NO

3

4

TABP C J NO

3

4

RECP C J

1

2

1

2

1 2 3 41234

-

-

-

-

CN79

Y

LG

O

W

TILT LEVER

51

22

23

29 VC

VTA2

VTA1

E2 51

22

23

29 CN41-6

CN41-5

CN41-4

J49

CN78

-

-

-

-

4 3 2 1 4321

2

1

2

1

JCP

REC

4

3

NOJCP

TAB

4

3

NO

<OPT>

<OPT>

<OPT>

16 16

17 17

18 18

6 6

22

33

6

161718

23

181716

632

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

127

126

9 125

8 124

180

138

137

7

4

5

18212

13 181

16

N2

139

140

142

141

144

143

123

122

121

183

184

11

10

14

15

19

20

21

22

23

24

25

26

27

28

29

30 14

1 43 -

2829

13 12 7

30 27 26 25 24 23 22 21 20 19 15

14 11 10 9 8 5 4 1

TAB

REC

30

29

28

27

26

25

24

23

22

21

20

19

15

14

10

11

GNDD 14 W CN1-1

AVD4

AVD3

CHG SW1

CHG SW2

CHG SW3

SL143 CN1-4SDTMK

144SMTDK CN1-7O

SMTDA 141 V CN1-3

SDTMA 142 B CN1-8

SLL

STT

N1

D15V CN1-2R16

AVD1 13

12AVD2

1 4 5 8 9 10 11 14

15 19 20 21 22 23 24 25 26 27 30

7 12 13

2928

NO

TABP C J NO

5

RECP C J

1

4

7

CN70

SL/L+

48V

SL/L-

AVD(+)

8CHG LED1

9CHG LED2

CHG LED3

CHG LED4

DISPLAY

-

-

-

-

-

-

-

-

C/V SOL.(UPR)

4

8

11

36

3

6

9

4

8

11

36

3

6

9

34 34

SOL Lb1 (-)

SOL Tb2 (-)

SOL ATb3 (-)

SOL ATb4 (-)

SOL Lb1 (+)

SOL Ta2 (+)

SOL ATa3 (+)

SOL ATa4 (+)

CN74

NO P C J NO P C J

1

2

1

2

TAB REC

765321

7 6 53 2 14

848

3

4

5

6

7

8

3

4

5

6

7

8

-

-

-

-

-

-

-

-

C/V SOL.(LWR)

3

5

7

10

35

6

9

34

5

7

10

35

3

6

9

34

SOL La1 (-)

SOL Ta2 (-)

SOL ATa3 (-)

SOL ATa4 (-)

SOL Lb1 (+)

SOL Ta2 (+)

SOL ATa3 (+)

SOL ATa4 (+)

CN75

NO P C J NO P C J

1

2

1

2

TAB REC

765321

7 6 53 2 14

848

3

4

5

6

7

8

3

4

5

6

7

8

G J48

L J47

LG J46

R J45

W CN121-12

GR CN121-11

P CN121-6

B CN121-5

G J48

L J47

LG J46

R J45

P CN122-5

BR CN122-7

V CN122-9

O CN122-11

<OPT>

<OPT>

SOLD(-)

SOLD(+) BR701-701

22

JCPNOJCPNO

-51 B51

1 212

REC

TILT KNOB SW.CN84

TAB

CN122-2

J1

BR

W

TILT KNOB SW.

CN42-5

J49

70

51

-

- SWTK(-)51

SWTK(+)70

TAB RECJCP

2

1

NOJCP

2

1

NO

CN85

1 22 1

<OPT>

3-8

1-1

22

JCPNOJCPNO

-

REC

TILT SOL.CN89

TAB

TAB

CN88 LIFT SOL.

REC

2 1 21

-

NO P C J NO P C J

2 2

1 - 1

TILT SW.CN87

4

3

4

2

1

2

1

JCP

REC

3

NOJCP

TABNO

2

43

112

34JCP

REC

2

1

NOJCP

TAB

2

1

NO

CN98

SOL ST-

- SOL ST

1 212

STEERING SOL.

3 2 1 321

SWMH1-902CN90-6O902

JCP

REC

3

1

NOJCP

TAB

3

1

NO

SWMH1CN90-2

CN90-1

-

-91

51R

B91

51

CN92

SWMH1

HEIGHT SW.

CN91-1BR

8 8 51CN91-351 R

7 7

6 6 90CN92-290 O

5 5

NO

3

4

P C J NO

3

4

P C J

1

2

1

2

58

59

51

58

CN91-259 Y

CN92-151 R

91CN92-3B91

8 7 6 54 3 2 1

8765

4321

CN90

RECTAB

MAST HARNESS

321123

CN86

57

51 -

- 57

51VRAT

VRAT

NO

1

3

TABP C J NO

1

3

RECP C J

2 56 - VRAT 2 56

TILT SENSOR

CN90-3Y592SPL-592

JCP

REC

3

1

NOJCP

TAB

3

1

NO

CN90-4SPL

SPL

BR

R51

58-

-51

58

CN91

CN90-8

PRESSURE SENSOR

61 - LSTF 61 O CN122-11

51 LG J2

62 LG CN122-10

51 LG J2

51 - LS-

62 - LSTR

51 - LS-

CN121-9

J3W

CN120-7

CN121-3Y

J1B

CN120-6GR

BR

O

329 B CN122-4

330 GR CN122-3

329

330

L CN121-8

G CN121-2

W J3

1 212

SOL L +

SOL L -

SOL T +

SOL T -

3 P CN163-4

4 LG CN163-5

6 G CN163-6

7 B CN163-7

3

4

6

7

1

32

23

1

<OPT>

7

1 1

7

CMP LAMP SWCN96

LCMP

JCP

RECTAB

JCPNO NO

STPOT--117 SL117

2

1

2

1

3 3

4 4

5 5

6 6

7 101 - SPL 7 101 R CN13-6

8 8

DRIVE CONT.RH

RECTAB

1 2 4 5 67 8 9 10 11 12 13

1245678910111213

3 3

CN109

CN110

33

-

-

-

-

-

-

-

-

-

-

-

-

-

13

13 12 11 10 9 8 76 5 4 2 1

1312111098765421

TABP C J

3

7

REC

1

2

4

5

6

9

8

12

11

10

NO

145

146

147

42

75

78

76

77

87 TD1+

SSD12

SSD11

SSD1-,TD1-

SSD1+

CUDON

KEYSTART

CANGND

CANTRD

CANL

CANH

CUDID1

CUDID0

DRIVE CONT.LH

J66

J65

J64

W

SL

BR

P

O

G

L

V

B

CN58-2

CN59-4

CN59-2

J27

CN59-1

J25

87

77

76

78

75

42

147

146

145

12

11

10

8

9

6

5

4

7

3

2

1

JCPNO

13

13

NO P C J

1

2

3

7

4

5

6

9

8

10

11

12

145

146

147

42

79

82

80

81

88

J25

CN53-1

J28

CN53-2

CN53-4

CN52-2

B

V

L

G

O

P

BR

SL

R

J64

J65

J66

82 CUDID0

CUDID1

CANH

CANL

CANTRD

CANGND

KEYSTART

CUDON

SSD2+

SSD2-,TD2-

SSD21

SSD22

TD2+88

81

80

82

79

42

147

146

145

NO

10

11

12

8

9

6

5

4

2

1

7

3

JCP

13

-

-

-

-

-

-

-

-

-

-

-

-

-

82 P J28

3-9

NO

10

11

12

CN111

8

9

6

5

4

2

1

REC

7

3

JCP

TAB

1 2 4 5 67 8 9 10 11 12 13

1245678910111213

13

-

-

-

-

-

-

-

-

-

-

-

-

-

3 3

KEYSTART

SSP+

SSP-,TP-

SSP1

SSP2

TP+

CANTRD

CANL

CANH

CUPID1

CUPID0

CANGND

CUPON

86

145

146

147

42

83

86

84

85

89

PUMP CONT.

BR

R

W

P

LG

G

L

V

B

P

CN55-2

CN56-4

CN56-2

J26

CN56-1

J26

J66

J65

J64

J25

89

85

84

86

83

42

147

146

145

86

13

NO P C J

1

2

3

7

4

5

6

9

8

10

11

12

85 6 7

4321

11109 12

CN122

12 91011

1234

7 6 58

1212

1111

NO P C J NO

3

7

P C J

1

2

1

2

4

5

3

7

4

5

66

9 9

88

10 10

J21(CN164-19)51(13) LG J2(CN76-2)

70(12) BR CN84-1(CN76-1)

330 GR CN98-2

329 B CN98-1

(35) (P) (CN75-5)

(34) (G) (J48)

(10) (BR) (CN75-6)

(9)

63(7) V CN21-1(CN75-7)

62(6) LG CN87-3(J46)

61(5) O CN87-1(CN75-8)

60(3) R CN11-1(J45)

CN161-14(CN164-18)

CN161-20

CN161-18

(CN164-16)

(CN164-15)

(CN164-13)

(CN164-12)

CN161-7(CN163-7)

CN161-13(CN163-6)

CN161-17(CN164-10)

CN161-19(CN163-4)

51(13) LG

70(12) BR

330 GR

329 B

(35) (P)

(34) (G)

(10) (BR)

(9) (L)

63(7) V

62(6) LG

61(5) O

60(3) R

(L) (J47)

JOINT

TAB REC ( ):OPT( ):OPT

O

W

Y

71

REC

1098 112 3 4 5 6

JC

G CN86-2

CN90-3

J3

CN26-4

GR CN26-3

L CN86-1

BR CN90-4

SL CN26-2CN162-1

CN162-7

CN162-6

CN162-2

CN162-5

J22

CN162-4

CN162-3

J

10

8

9

6

5

4

7

3

2

1

PNO

11

12

JOINT

56

59

51

53

52

57

58

64

TAB

10

8

9

6

5

4

2

1

7

3

CPNO

11

12

56 G

59 Y

51 W

53 O

52 GR

57 L

58 BR

64 SL

CN121

112

23456711 8910

(4) (B) (CN163-5)

(8) (P) (CN164-11)

(4) (B) (CN74-8)

(8) (P) (CN74-7)

(11) (GR) (CN74-6)

(36) (W) (CN74-5)

(11) (GR) (CN164-14)

(36) (W) (CN164-17)

( ):OPT ( ):OPT

12

JOINT

RECTAB

12 91011

8 567

4 3 2 1

CN120

129 10 11

1 2 3 4

765 8

CN19-5L314

CN19-4V313

CN19-3Y312

CN15-2R66

CN90-6O90

CN90-1GR91

CN6-2Y65

CN9-4G46

CN9-5W45

J1B51

10

8

9

6

5

4

2

1

7

3

JCPNO

11

12L314

V313

Y312

R66

O90

GR91

Y65

G46

W45

B51

CN161-8

CN161-11

CN161-9

CN161-4

CN161-15

CN161-16

CN161-3

CN161-2

CN161-1

J21

10

8

9

6

5

4

7

3

2

1

JCPNO

11

12

W55 CPR

CN126

L5522

1

JCP

RECNOJCP

TAB

1

NO

23 2 3

RESISTOR

CN163-8

NO

1

TABP C J NO

RECP C J

1

2 2

CN113

FAN EX (+)44 R

39 B FAN EX (-)

44

39

J30

J23

BR

B

FAN(EX)

1 22 1

B

BR

J23

J30

39

44

FAN EX (-)B39

R44 FAN EX (+)

CN114

22

1

JCP

RECNOJCP

TAB

1

NO

FAN(EX)

2112

3 2 1 1 2 3

NO

1

TABP C J NO

RECP C J

1

2 2

145

146

CN112

145 -

146 -

147 33

R

R

RESISTOR

J66

J65

J64B

V

G

CN136-5GP23P2WP23

11

3-10

6

CN124

75432

118 91

106 5 4 3 2

121

10 9 811 7

J5

CN1-8

CN1-3

J4

CN1-1

J8

J6

CN1-4

CN1-7

Y43

B142

V141

R16

W14

LN2

GR41

SL143

O144

J39Y43

CN162-14B142

CN162-15V141

CN162-13R16

CN162-16W14

J31LN2

J29GR41

CN162-18SL143

CN162-17O144

JOINT

1212

1111

NO P C J NO

3

7

P C J

1

2

1

2

4

5

3

7

4

5

66

9 9

88

10 10

TAB REC

12

CN24-1Y120

J32P103

CN38-5SL108

CN38-6G109

CN38-2R111

CN38-7B107

CN38-4O104

101 Y CN27-6

104 O J10

107 B SWR

111 R CN5-2

109 G J13

108 SL J14

103 P CN9-2(CN9-3)

120 Y CN9-3(CN9-2)

J9Y101

( ):OPT RECTAB

JOINT

NO P C J

1

2

3

7

4

5

6

88

6

5

4

7

3

2

1

JCPNO

1

5 76

432

8

CN123

4

8 7

123

56

6 6

55

44

NO

3

TABP C J NO

3

RECP C J

1

2

1

2

CN136 CONTACTOR

1 2 34 5 66 5 4

3 2 1

2 R CN163-11

1 V CN163-10

P1 B CN27-3

P1 W CN27-2

P2 G CN126-3

P2 P CN27-1

2 -

-1

P1 -

-P1

P2 -

P2 -

MB-

MB+

P1 TERM

P1 TERM

P2 TERM

P2 TERM

CN165-6BR19911OPT0-199

( ):OPT

( ):OPT

( ):OPT

( ):OPT

MAIN CONT.

MAIN CONT.

MAIN CONT.

MAIN CONT.

CN121-12W36

CN122-6G34

CN122-7

CN121-11

18 18

CN122-5

17 17

16 16

15 15

14 14

13 13

12 12 CN122-8

11 11 CN121-6

CN41-9

CN41-3

CN42-1

CN41-6

CN42-2

CN41-8POTAT12

1010

8 8

99

6 6

5

4

7

3

5

4

2

1

2

1

JCP

REC

7

3

NOJCP

TABNO

19 19 CN122-1

20 20

POTL2

POT-

POTAT22

POTAT2+

POTAT21

POTL+

POTT+

POTAT1+

SOLa1

SOLb2

SOL3+

SOLa3

SOLb3

SOL4+

SOLa4

SOLP-

SOLb4

51

21

25

26

27

28

29

30

31

8

5

9

10

11

35

13

-

-

-

-

-

-

-

-

-

-

CN41-2

CN41-10

CN122-11

CN42-3

-

-

-

-

-

-

-

-

-

-

-

-

-

W

B

L

V

SL

G

Y

GR

LG

O

P

L

BR

GR

P

LG

12 BR CN122-2SOLP+-

36

34

51

21

25

26

27

28

29

30

31

8

5

9

10

11

35

13

12

CN32-3SL316 - POTH+ 316

329

330

60(20)

91

70

62(23)

51

42

313

312

314

63(24)

39

67

66

65

46

45

90

61(22)

- SOLST+ CN122-4B329

SDTMK 143

144

14

141

142

16

147

146

145

51

58

57

53

59

56

52

64

SL

O

W

V

B

R

G

V

B

W

BR

L

O

Y

G

GR

SL

-143 CN124-3

CN124-2

CN124-8

51 2 3 4 6 7 89 10 11 12 13 14 15 16 17 18

CN124-1

CN124-9

16

142

141

18

14

18

CN124-7

17 17

16 16

15 15

14 14

13 13

12 12

11 11 J66147

51 J22

CN121-8

18 17 16 15 14 13 12 11 10 98 7 6 4 3 2 1

53

CN121-3

CN121-9

CN121-7

CN121-2

CN162

POTTA

1010

8 8

99

58

6 6

5

4

7

3

5

4

2

1

2

1

JCP

REC

7

3

NOJCP

TABNO

57

59

56

5

POTA

SWAC

POTA+

CANH

SPL

POTTA+

SPL+

POT-

CANL

CANGND

D15V

SDTMA

SMTDA

GNDD

52

64

146

145

144 SMTDK

-

-

-

-

-

-

CN121-1

CN121-10

J65

J64

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

317

N2

2

1

44

55

7

6

4

3

18

41

43

14

13

N2 TERMWN2N2

14

13 317 POTH Y CN32-2

CN88-1(CN122-12)P(R)SOLL+(SOL1+)3

CN89-1(CN122-10)G(LG)SOLT+(SOL2+)6

CN89-2(CN122-9)B(V)SOLT-(SOLa2)7

J30BRVBMB44

CN88-2(CN121-5)LG(B)SOLL-(SOLb1)4

J39YVBKY43

614 13

5124

11 1039 8

271 651

12 12

11 2 MB- 11 R CN136-1

55 CPR L CN126-2

J29

J29

CN163

B48V

VBBT

1010

8 8

99

6 6

5

4

7

3

5

4

2

1

2

1

JCP

REC

7

3

NOJCP

TABNO

O

GR

18

41

2 3 413 147 8 9 10 11 12

CN136-2VMB+1

GR

R

GR

BR

LG

B

V

L

Y

L

V

B

L

R

Y

G

W

-

-

-

-

-

-

-

-

-

-

-

-

-

-

CN120-10

J25

CN120-2

CN120-3

-

-

-

-

-

-

-

-

-

-

330

60(20)

91

70

62(23)

51

42

313

312

314

63(24)

39

67

66

65

46

45

LSTF(POTT1)

SOLST-

LSL(POTL1)

MH2-1

MH1

SWTK

LSTR(POTT2)

LS-(POT-)

STS2

KEYSTART

STSC

LSAT1(POTAT11)

FAN-

LSPB

STS1

LSD

DSF

DSR

CN122-32020

CN122-12(CN41-1)1919

NO

TABP C J NO

3

7

RECP C J

1

2

1

2

4

5

3

7

4

5

66

9 9

88

10 10

LSB CN120-4

CN22-1(CN42-7)

CN122-9(CN41-7)

CN120-8

J23

CN120-12

CN120-111111

J211212

1313

1414

1515

1616

1717

CN120-6

1818

CN122-2(CN42-5)

CN122-10(CN41-5)

90 O CN120-7

61(22) O CN122-11(CN41-4)

181716151413121198764321 5

20191019205 12346789

101112131415161718

CN161<OPT>CN164

18 17 16 15 14 13 12 11 109 8 7 6 4 3 2 15

20 19 10 19 2051 2 3 4 6 7 8 9

11 12 13 14 15 16 17 18

3-11

BACK RELAY

NO

3

6

TABP C J NO

3

6

RECP C J

1

2

1

2

4 4

5 5

CN165

J19

G

103

N1

16

199

43

654321

6 5 43 2 1

O CN9-3

Y

L J11

R J70

CN165-4103

BR CN161-10

103 G CN165-5

198 GR CN38-3

CN38-3GR198OUT-W198

CN161-10BR199 IN-

16

N1

43

IN+

GND

OUT+

J70R

J11L

Y

CN9-3O

123456

1 2 34 5 6

43

199

16

N1

103

W

B

R

W

J19

CN165

55

44

2

1

2

1

JCP

REC

6

3

NOJCP

TAB

6

3

NO

BACK RELAY

EXCEPTEZ PEDAL

EZ PEDAL

3-12

CN165-5

J70

(198,GR)

CN23-1

CN38-3

J66

CN162-11

CN112-3

(147,G)

CN109-6

CN110-6

CN111-6

J65

CN162-10

CN112-2

(146,V)

CN109-4

CN110-4

CN111-4

J64

CN162-9

CN112-1

(145,B)

CN109-3

CN110-3

CN111-3

JOINT

J1

(51,B)

CN90-2

CN120-1

CN6-1

CN9-6(CN9-1)

CN15-1

CN84-2

CN19-2

CN124-1

CN1-2

(16,R)

J4 CN19-1

CN124-12

CN12-2

CN29-2

CN9-8

CN9-7(CN9-6)

(43,Y)

J5

CN29-1J6

(41,GR)

CN3-2

CN124-5

CN13-6

CN45-1

CN46-2CN46-1

SWR

CN5-1

CN123-4

CN45-2

(101,Y)

J9

J8

(N2,L)

CN8-10

CN17-1

CN13-5

CN13-1

CN124-6H

CN17-5

CN123-8

CN8-13

(109,G)

J13 CN17-4

CN13-4

CN123-7

CN8-12

(108,SL)

J14

CN165-2 CN45-4J11

(102,G)

CN13-3

CN17-3

CN122-1

CN21-2

CN87-4

(51,LG)

J2

CN11-2

CN87-2

CN17-2

J10

(104,O)

CN123-3

CN46-4

CN13-2

CN14-3,CN18-3

CN13-1,CN17-1

CN16-2,CN20-2

(N2,W)

J51

J3

(51,W)

CN121-4

CN26-1

CN86-3

CN90-8

J32

(103,P)

CN23-1

CN38-3

CN123-6

CN165-3 CN38-1

CN124-12

CN163-1

(43,Y)

J39

CN50-1 CN113-1

CN163-9

CN27-4

(44,BR)

J30

CN114-1

CN24-2 CN38-8

N2 TERMINAL

CN124-6

CN23-2

(N2,L)

J31

CN38-2

J53

(111,SL)

CN31-2

CN34-2

CN31-1

CN34-1

CN38-4

(104,G)

J55

CN23-2-2

J54

(N2,W)

CN31-4

CN34-6

CN38-8

CN36-2

FB

J22

(51,W)

CN121-4

CN32-1

CN162-8

J27

(78,P)

CN58-1

CN110-10

CN59-3

CN111-2

J26

(86,P)

CN55-1

CN111-10

CN56-3

CN109-1

J28

(82,P)

CN52-1

CN109-10

CN53-3

CN50-2

J23

(39,B)

CN161-6

CN113-2

CN114-2

CN161-12

CN120-1

CN22-2(CN42-8)

(51,B)

J21

CN122-1

CN161-10

CN111-7

J25

(42,L)

CN110-7

CN109-7

J29

(41,GR)

CN27-5

CN124-5

CN163-2

CN163-3

( ):OPT

CN74-2

(9,L)

CN122-8

CN75-2

J47

CN74-3

(6,LG)

CN75-3

J46

CN122-10

(3,R)

J45

CN75-4

CN122-12

CN74-4

(34,G)

J48

CN75-1

CN122-6

CN74-1

(51,W)

CN79-4

CN41-10

CN77-4

J49

CN78-4

CN80-4

CN85-1

3-13

TABREC

TABREC

TABREC

SWK

TABREC

TABREC

FRY

H COM

NO

NC

COM

NO

NC

LSTF

LSTR

SOLLSOLT

TA

BR

EC

TA

BR

EC

TABREC

LF-L

LC-L

LH-L

TABREC

TABREC

TABREC

LSD

TABREC

TABREC

RECTAB

TABREC

RECTAB

TABREC TAB

REC

TABREC

TA

BR

EC

TA

BR

EC

TA

BR

EC

RE

CT

AB

RECTAB

RECTAB

RECTAB

TABREC

TABREC

RE

CT

AB

RE

CT

AB

TA

BR

EC

TA

BR

EC

TA

BR

EC

TABREC

TABREC

TABREC

BATT

AMPRE

CT

AB

RE

CT

AB

TABREC

TABREC

RE

CT

AB

RE

CT

AB

RE

CT

AB

RE

CT

AB

TA

BR

EC

TABREC

TABREC

LBU-RLT-RLST-R

LF-RR LF-LLLT-LLST-L

TABREC

TABREC

TABREC

TABREC

TABREC

TABREC

TABREC

TABREC

TABREC

TABREC

TABREC

SWR

TABREC

TA

BR

EC

COM

NO

NC

RECTAB

TRY

TABRECTAB

REC

TABREC

TABREC

TABREC

TABREC

TABREC

HRY

TABREC

LSD

TABREC

TA

BR

EC

RE

CT

AB

RE

CT

AB

RE

CT

AB

RE

CT

AB

SWL

SWD

SWH

LSPB

DISPLAY

BACKRELAY

TABREC

TABREC

TABREC

FANEX

TA

BR

EC

CN50

CN120CN121

ONLY EZ PEDALCN165

<STD>(EXCEPT MINI -LEVER OPT)

<LEVER CONT. UNIT>

REC

<MINI-LEVER OPT>

SST

CN3

CN19

CN9

CN8

SWL

SWH

SWD

CN164

(101,Y)J9

(107,B)CN123-2

CN43

N2 TERMINAL

<MINI-LEVER OPT>

CN4

<COMPARTMENT LAMP OPT>

(117,SL)

(N1,L)CN96

RECTAB

SWCMP

LCMP

CN27

F6 F4F5

CN45

CN21

CN46

CN124 CN123 CN122

CN98

<KEY-LESS-KEY OPT>

<MINI-LEVER OPT>

CN41CN42

CN85 CN80(4)

CN79(3)

CN78(2)

CN77(1)

LIFT LEVER

TILT LEVER

ATT1 LEVER

ATT2 LEVER

SWTK

CN32

VRAH

CHI

CN24 (F)

CN23(R)

CN31CN34

WL R B

CN36CN23-2

BZ LWFB

CN38

CN22

AMD

RH

AMD

LH

SSD

STMD

W

V

U

CN52

CN53

SSD

STMD

W

V

U

CN58

CN59

W

V

U

+

-

CN110

DRIVE CONTROLUNIT LH

DRIVE CONTROLUNIT RH

CN109

-

+

U

V

W

SSP

STMP

CN55

CN56

U

V

W

-+

P3P1

CN136

CONTACTOR PANEL

+

W

V

U

-

CN111

PUMP CONTROLUNIT

CN163

CN162

CN126

CN161

CN112

R

FANEX

CN114

CN113

FANEX

MAIN CONTROL PANEL

CN9

<DIRECTIONAL CONTROL PEDAL OPT>

SOLST

SPL

SWMH1

CN90

CN91

CN92

CN74

CN75

SOL AT2L

SOL AT1L

SOL TR

SOL LU

SOL AT2U

SOL AT1U

SOL TF

SOL LD

CN76

SOL

CN86

VRAT

TILT

LF-R

LC-R

LH-R

SWK

CN20

CN16

CN12

CN29BR

R

LSATT

LSL

BR

NC

NO

COM

NC

NO

COM

R

(N2,L)J8

(48,P)CN3-1

R

SL

R

BR

CN70

CN15

CN89

CN88

CN87CN11

CN84

CN1

CN26

LSB

LSST

CN6

CN5

CN18

CN17

CN13

CN14

CN4

ACCEL

VRAD

SWTK

CO

NN

ECTI

NG

DIA

GR

AM

3-14

ELEC

TRIC

WIR

ING

DIA

GR

AM

Published by

1st Printing: Dec. 2005

Pub. No. CU341

Printed in Japan

C

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7FBEU15-20 OPS Repair Manual CU341 - Toyota Material …dealerapplications.tmhna.com/TechInfo/TechnicalDocs//service... · FOREWORD This manual describes the explanation and service