7FDF OPS S

Tillägg för OPS (fr.o.
m 2006)
SECTION INDEX
NAME SECTION
GENERAL 0
OPS 1
BODY 2
MATERIAL HANDLING SYSTEM 3
OIL CONTROL VALVE 4
MINI LEVER 5
SAS 6
APPENDIX 7
<Tillbaka till Index

0-1
GENERAL
Page 0
PERIODIC MAINTENANCE .................................0-2
OPS SYSTEM.......................................................0-3
SAS.......................................................................0-8
MINI LEVER .......................................................0-11
0-2
PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or Replacement if required.

M : Measurement. Repair or Adjustment if required.
T : Retightening C : Cleaning L : Lubrication
* : For new vehicle *1 : Flaw detector
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
SAFETY DEVICES, ETC.
Loosening and damage of mounting I ← ← ←
Seat Seatbelt damage and function I ← ← ←
Seat switch function I ← ← ←
OPS Functions I ← ← ←
0-3
OPS SYSTEM
General
The OPS (Operator Presence Sensing) system is added as standard.
The switch mounted underneath the seat detects the operator on the seat. When there is no operator, the OPS
system cuts off the driving power and restricts material handling operations. (Refer to page 0-6.) 0
The OPS system operates (to disable traveling and material handling) upon lapse of 2 seconds after the operator
leaves the seat.
When the OPS controller detects the seat switch going off, it sounds the OPS buzzer (bleeping) for about one
second and turns the OPS lamp on before OPS activation. Furthermore, the OPS lamp keeps lighting while the seat
switch stays off.
If the seat switch is turned on without returning the forward/reverse lever to the neutral position after drive OPS
activation, the newly added return to neutral warning function sounds the buzzer at short intervals (pip-pip) to warn
the operator of the unreleased state of the drive OPS.
When the OPS controller detects any system malfunction, the OPS lamp blinks to warn the abnormality.
Control block diagram

*: Parts added or changed for OPS
* Seat switch
* OPS lamp relay
* Plug in
* OPS lamp analyzer
* OPS buzzer
* OPS
SAS
Key switch Forward tilt switch Controller Controller
Bakward tilt switch
Foward reverse * Lower limit switch Tilt
Battery switch
cylinder
F
N
R Lift
* Tilt * Lift
cylinder
* Unload control lock
valve valve valve
* Forward * Reverse
interrupt relay interrupt relay
Forward drive
Reverse drive * Oil control
valve valve
valve
Oil
T/C pump
Engine
Oil tank
Note:
On the mini-lever specification (OPT) vehicle, the oil control valve is substituted by a proportional
solenoid valve and the mini-lever controller is added. Moreover, the forward/backward tilt switch, lower
switch, tilt control valve and lift lock valve are not provided.
0-4
Name of each part　

　
(14)
(13) (2)
(7) (8) (9)

(3) (4)
(10) (11) (12)
(15)
(5) (6) (1)

(16)
(1) OPS controller (9) Backward tilt switch
(2) Seat switch (10) Unload valve
(3) Forward switch (11) Lift lock valve
(4) Reverse switch (12) Tilt control valve
(5) Forward interrupt relay (13) OPS lamp
(6) Reverse interrupt relay (14) OPS lamp relay
(7) Lower switch (15) OPS buzzer
(8) Forward tilt switch (16) Plug-in analyzer

0-5
Function of each part

Input to controller
Name Function
(2) Seat switch

This switch mounted underneath the seat detects the operator sitting on
the seat. 0
This switch inputs the voltage branched from the forward drive valve
(3) Forward switch power supply line to the OPS controller that detects the forward drive
operation.
This switch inputs the voltage branched from the reverse drive valve
(4) Reverse switch power supply line to the OPS controller that detects the reverse drive
operation.
This limit switch installed at the lift spool of the oil control valve detects
(7) Lower switch
the lowering operation by the lift lever.
This limit switch installed at the tilt spool of the oil control valve detects
(8) Forward tilt switch
the forward operation of the tilt lever.
This limit switch installed at the tilt spool of the oil control valve detects
(9) Backward tilt switch
the backward operation of the tilt lever.
Output from controller
Name Function
This relay cuts off the voltage supply to the forward drive valve in the
(5) Forward interrupt relay
torque converter according to the instruction from the OPS controller.
This relay cuts off the voltage supply to the reverse drive valve in the
(6) Reverse interrupt relay
torque converter according to the instruction from the OPS controller.
Provides a bypath to the tank circuit for the hydraulic oil supplied from
(10) Unload valve
the oil pump to the oil control valve.
This valve cuts off the oil flow from the lift cylinder to the oil tank
(11) Lift lock valve according to the instruction from the OPS controller to disable fork
lowering.
This valve changes the oil path to the tilt cylinder according to the
(12) Tilt control valve instruction from the OPS controller to disable forward tilting and to slow
down the backward tilting speed.
This lamp lights while the seat switch is off to indicate the OPS
(13) OPS lamp operation. Furthermore, it blinks when the OPS controller detects any
abnormality.
The OPS lamp electric circuit is opened or closed according to the
(14) OPS lamp relay instruction from the OPS controller. The lamp is kept on when there is
no instruction from the OPS controller.
This buzzer sounds in the predetermined pattern when the seat switch
(15) OPS buzzer is turned off or when the forward/reverse shift lever needs returning to
the neutral position (return to neutral warning).
This new plug-in analyzer is added with the OPS analyzer functions to
the service functions of the conventional SAS analyzer. It is connected
to the same service connector.
OPS analyzer functions
(16) Plug-in analyzer • Diagnostic display (More detailed display than OPS lamp blinking
frequency)
• I/O monitor display (Shortening the time required for troubleshooting)
• Output test (Shortening the troubleshooting time by setting each
output on and off according to the instruction from the OPS controller)
0-6
Control specifications
1. Drive OPS
When the OPS controller detects seat switch off state for 2 seconds, the forward/reverse interrupt relay is
operated to disconnect the driving power supply to the forward/reverse drive relay in the transmission.
This drive OPS operation is released when the seat switch is turned on and the forward/reverse shift relay is
returned to the neutral position.
2. Material handling OPS
(1) Standard lever vehicle
When the OPS controller detects seat switch OFF for 2 seconds, the lift lock valve and tilt control valve
are controlled to stop fork lowering and forward tilting. Other material handling operations such as
backward tilting, fork lifting and attachment operations are stopped by interrupting the hydraulic oil
supply by means of the unload valve. The disabled material handling operations are released upon lapse
of 1 second after seat switch ON.
Caution:
• Backward tilting: If the material handling lever is operated while the OPS is functioning, the
mast may be tilted backward because of the weight of the tilted mast or the back pressure at the
unload valve.
• Attachment: If the material handling lever is operated while the OPS is functioning, the
attachment may move because of the own weight of the attachment or the back pressure at the
unload valve.
(2) Mini-lever vehicle (OPT: Remains unchanged from the present vehicle)
When the mini-lever controller detects seat switch off state for two seconds through the OPS controller,
the proportional solenoid valve is activated to disable lift, tilt and attachment operations.
When the seat witch is turned on with all levers returned to their neutral positions, this material handling
OPS activated state is released. (In the case of mini-lever option, returning the levers to their neutral
positions is added as the OPS release condition because small levers are easy to be operated, possibly
causing erroneous lever operation by movement of a luggage placed on the armrest.)
1. OPS operation notice
When the OPS controller detects the seat switch off state, it sounds the OPS buzzer (bleep) for about one
second, and turns the OPS lamp on to warn the operator of the OPS operation.
2. Return-to-neutral warning
The OPS controller warns the driver of the failure in releasing the drive OPS by sounding the buzzer at short
intervals (pip-pip) when the seat switch is turned on without returning the forward/reverse shift lever to its
neutral position.
3. Malfunction alarm
When the OPS controller detects any malfunction, it blinks the OPS lamp to warm the malfunction. The lamp
blinking frequency identifies the defective part.
Seat
Every seat has the seat switch for operator detection.
When replacing seat, install a genuine TOYOTA seat designed specifically for this lift truck. (The OPS does not
function unless the correct seat is installed.)
Combination Meter
OPS lamp
This lamp indicates OPS operation and warns an OPS error.
0-7
Oil Control Valve

1. A new oil control valve is adopted for use with the added OPS system.
2. An electronic hydraulic control mechanism is incorporated in the tilt control circuit for controlling the mast tilting
operation.
3. The additional check valve in each of the lift and tilt circuit greatly reduces natural drop and natural forward tilt.
4. The unload valve provided in the supply circuit.
Unloading solenoid valve

Manual downlifting valve
Open this valve to

forcibly lower the
fork with the engine
key turned OFF.
Lift lock solenoid valve Tilt control solenoid valve
Specifications
1-ton series 2-ton series 3-ton series J3.5-ton series
Relief pressure setting Lift 17800 (182) 18700 (191) ← ←

kPa (kgf/cm2) Tilt 11800 (120) 14700 (150) ← 15700 (160)
Flow divider flow rate L/min 13.0 ← 15.2 ←

0-8
SAS
Hydraulic circuit diagram
The integral control valve has integrated the unload valve (unload SOL), lift lock valve (lift lock SOL) and the tilt
control valve (tilt control SOL) with the oil control valve in the previous model. Each solenoid valve (SOL) is normally
closed.
T2 R
(4)
P
(1)
OUT
(1) Unloading valve

(Unloading SOL)
(2) Lift lock valve
(Lift lock SOL)
(3) Tilt control valve
(Tilt control SOL)
(4) Gage port
(2)
C1
(3)
C2
C3
C4
C5
T1
0-9
Hydraulic circuit control

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

Semi-open circuit Forward tilt circuit Tilt stop circuit
backward tilting
• High lifting height,
• Tilt lever at neutral
backward tilting speed
• Stop with forward tilting
restriction • Low lifting height,
• Forward tilting angle restriction
• Low lifting-height, backward tilting
• Automatic leveling stop
backward tilting speed
with forward tilting
restriction*
*Backward tilting operation with the tilt lever knob switch depressed.
1. Tilt stop circuit

Tilt Cylinder The tilt stop circuit refers to the state where the tilting
operation is disabled as upon tilt lever setting at the neutral
Tilt Control position or upon stopping with forward tilting angle restriction
Valve or fork automatic leveling. The tilt cylinder operation is
stopped because the tilt control valve in the control valve is
Pilot closed.
Line
Tilt
Lever SOL OFF
2. Tilt semi-open circuit

Tilt Cylinder The tilt semi-open circuit refers to the state where the tilting
operation speed is restricted (slowed down).
Tilt Control The tilting speed is slowed down because the orifice in the tilt
Valve control valve is connected to reduce the oil flow to the tilt
(Orifice) cylinder.
Pilot
Line
Tilt
Lever SOL ON
0-10
Tilt Cylinder 3. Tilt full open circuit

The tilt full open circuit refers to the state where the tilting
Tilt Control speed is not restricted. The forward/backward tilting speed at
Valve the low lifting height becomes the normal tilting speed.
The fully opened circuit in the tilting control valve results in
normal tilting speed with no restriction.
Pilot
Line
Tilt
Lever RR Tilt : SOL OFF
FR Tilt : SOL ON
Key-off lift lock

1. The integral control valve is designed for addition of the OPS system and the lift hydraulic circuit is modified
accordingly.
2. When the engine key is turned off, the fork cannot be lowered when the lift lever is set to the down position.
3. Since the check valve was closed during no hydraulic pressure generation in the past, lowering operation was
disabled. After the change, the lift lock solenoid valve is adopted to enable lowering when the engine is
stopped so loan as the key switch is at the ON position.
0-11
MINI LEVER
General
1. The fork automatic leveling is effective when the lever is operated toward the forward tilting side while pushing
the button beside the knob.
2. The lever position is adjustable in the front-back direction. Loosen the lever box fixing lever by raising it, set
the box at the position desired by the operator, and fix the lever by pushing it.
On the cabin model, push the fixing lever for loosening and pull it up for fixing.
Note:
• Since automatic fork leveling function is disabled with a load on the fork at a high lifting height (2 m (78.7
in) or above), forward tilting fails while the automatic leveling switch is kept on.
• Forward tilting is fully disabled at the maximum fork height regardless of whether loaded or unloaded
(only when the automatic leveling switch is ON).
Load handling operation is prohibited when operator leave the

seat.
Att lever Arm pad
Tilt lever
Lift lever
Fork automatic leveling switch
Lever for fixing rotation of lever box

0-12
Armrest structure
1. The armrest is fixed on the seat to slide with the seat.
2. The armrest height is adjustable. Loosen the armrest fixing knob, set the armrest in the position desired by the
operator, and tighten the knob for fixation.
Adjustable
Adjustable
Lever for fixing lever box

Knob for fixing the armrest
Engine hood opening procedure

Other than the cabin model
1. Move the seat to the frontmost position.
2. Pull the lever box fixing lever.
Move the mini-lever box to the rearmost position.
Pull the lever box rotation lock lever, and flip up the armrest.
3. Pull the unlock lever. Tilt the steering post forward.
4. Open the engine hood.
0-13
Cabin model
1. Move the seat to the frontmost position.
2. Pull the lever box fixing lever.
Move the mini-lever box to the frontmost position.
Push the lever box rotation lock lever.
Tilt the armrest forward.
3. Pull the unlock lever.
Tilt the steering post forward.
1-1
OPS
Page
GENERAL ............................................................1-2
1
COMPONENTS ....................................................1-4
OPS CONTROLLER ............................................1-5
REMOVAL · INSTALLATION ..................................1-5
OPS PLUG-IN ANALYZER ..................................1-6
SCREEN CONFIGURATION ...................................1-6
BASIC OPERATION ..............................................1-7
ANALYZER ..........................................................1-9
TROUBLESHOOTING .........................................1-14
OPS TROUBLESHOOTING...............................1-16
DIAGNOSIS........................................................1-16
DIAGNOSIS ERROR CODE LIST ..........................1-17
TROUBLESHOOTING BY ERROR CODE ..............1-20
TROUBLESHOOTING BY PHENOMENON ............1-35
Note:
See Section 6 (SAS) for the connector layout, controller sequence and
connector diagram.
1-2
GENERAL
*: Parts added or changed for OPS
* Seat switch
* OPS lamp relay
* Plug in
* OPS lamp analyzer
* OPS buzzer
* OPS
SAS
Key switch Forward tilt switch Controller Controller
Bakward tilt switch
Foward reverse Tilt
* Lower limit switch
Battery switch
cylinder
F
N
R Lift
* Tilt * Lift
cylinder
* Unload control lock
valve valve valve
* Forward * Reverse
Forward drive
Reverse drive * Oil control
valve valve
valve
Oil
T/C pump
Engine
Oil tank
Note:
On the mini-lever specification (OPT) vehicle, the oil control valve is substituted by a proportional
solenoid valve and the mini-lever controller is added. Moreover, the forward/backward tilt switch, lower
switch, tilt control valve and lift lock valve are not provided.
1-3
(14)
1
(13) (2)
(7) (8) (9)

(3) (4)
(10) (11) (12)
(15)
(5) (6) (1)

(16)
(1) OPS controller (9) Backward tilt switch
(2) Seat switch (10) Unload valve
(3) Forward switch (11) Lift lock valve
(4) Reverse switch (12) Tilt control valve
(5) Forward interrupt relay (13) OPS lamp
(6) Reverse interrupt relay (14) OPS lamp relay
(7) Lower switch (15) OPS buzzer
(8) Forward tilt switch (16) Plug-in analyzer

1-4
COMPONENTS
1910
5701
1-5
OPS CONTROLLER
REMOVAL · INSTALLATION
Removal Procedure
1 Open the engine compartment lid.
2 Remove the toe board.
3 Remove the step LH.
4 Remove the OPS controller set bolts.
5 Disconnect the connector and remove the OPS controller.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
1-6
OPS PLUG-IN ANALYZER

For the maintenance and service of OPS functions, a separate type plug-in analyzer is introduced as an SST
(Special Tool for Service).
The plug-in analyzer is designed to read the operating state of sensors and actuators used for the OPS functions
and the error information detected by the controller. It serves to check on the operating state of OPS functions and
shortens the repair time for a problem. Moreover, it is installed with save function to file data displayed on the screen
in the SST.
SST 09240-23323-71
Menu name Content of function Reference page
DIAG MEMORY Indication of ten error codes and sub-codes in past. 1-9
OPS controller on the vehicle side
Communication function with the
Monitoring input voltage value from the sensors and the

IN/OUT MONITOR 1-10
output signal, etc. to the solenoid, etc.
OPS
ACTIVE TEST Forced operation of solenoids and warning lamps. 1-12
Indication of OPS controller abbreviation number and

CONTROLLER DATA 1-13
version
SCREEN CONFIGURATION
1-7
BASIC OPERATION
Name of Sections and the Switch Functions
Position of
Name of section Mark Function Switch
indication
Main unit
• Move the cursor to the above item.
• Move to the preceding page.
Selector
A • Move the cursor to right or left. switch c
<Blank> <No function>
Connector
• Select the item below.
A Switch • Move to the following page.
Screen title Selector
B
switch d
<Blank> <No function>
Determine an item for selection.

Menu
C
switch e
B C
Switch mark indicator <Blank> • Move to MENU screen.
Caution on using:
• Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections.
• Operate the switch with finger tip.
• Donít give it strong impact from dropping or collision.
• Donít leave it under the direct rays of the sun for long time.
Connection and Operation of SST
1. Turn the key switch OFF.
2. Open the diagnosis connector cover of the vehicle and properly
connect the connector on the SST side.
SST
SST 09240-23323-71
Note:
Diagnosis connector Since the connector has no locking device, securely connect
it to prevent contact defect upon closing the engine hood
with the connector in connected state.
3. Turn the key switch ON or start engine.
4. Display of the initialization screen
After about 15 seconds of display, "LANGUAGE SET" or "MAIN
MENU" screen appears. The screen may be changed during
PLUG IN this period by pressing the menu switch e.
ANALYZER
SYSTEM PROG
VER 4.00
1-8
5. "LANGUAGE SET" screen

Since this screen appears only when the language is
undefined, determine a language to use for display.
(1) Select a display language by pressing selector switch c
and d.
• Japanese
• English
(2) Press MENU switch e to determine the language setting.
Note:
Once the display language is defined, "LANGUAGE SET"
screen will not be displayed from the next time onward. To
change language, go to "TESTER SET" of "MAIN MENU".
6. "MAIN MENU" screen

(1) Select the menu using selector switch c and d and
determine by pressing menu switch e.
• SAS: Moves to SAS MENU screen.
• OPS: Moves to OPS ANALYZER MENU screen.
• TESTER SET: Moves to TESTER SET screen.
Removal of SST
1. Check that the screen title is for one of the MENU screens.
2. Turn the key switch OFF.
3. Disconnect the connector.
Note:
To disconnect, hold the body of the connector.
4. Close the diagnosis connector cover.
1-9
ANALYZER
ANALYZER MENU Display contents and function Page
1. DIAG MEMORY Indication of error codes for 10 most recent errors 1-9
2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 1-10
3. ACTIVE TEST Forced operation signal output to the selected item 1-12
4. CONTROLLER DATA Indication of the OPS controller part number and version 1-13
Operation Procedure
1. Select and enter "2OPS" on the main menu screen to display
the OPS ANALYZER MENU screen.
2. ANALYZER MENU screen

(1) Move the cursor to the desired menu by operating selector
switch c or d, and enter by operating MENU switch e.
(2) Select and enter "END" to return to the MAIN MENU
screen.
"1 DIAG MEMORY"

This screen displays ten error codes from the most recent one.
[Explanation on display contents]
(1) Order of error occurrence
(2) Error codes
[Clear memory]
(1) (2) Press selector switch c continuously for 2 seconds.
[End]
Press MENU switch e to return to the ANALYZER MENU screen.
Note:
• Only "-" appears at the end of the item involving no error
occurrence.
• If reception has not been completed, only the number
appears without "-" indication.
1-10
"2 IN/OUT MONITOR" (Excluding the mini-lever

vehicle)
(1)
(2)
(1) SEAT: Seat switch input signal
(3)
(2) DIR: Direction switch input signal
(4) FWD: Forward direction switch input signal
REV: Reverse direction switch input signal
(3) RLY: Output signal to forward/reverse interrupt relay
FWD: Output signal to forward interrupt relay
REV: Output signal to reverse interrupt relay
(1)
(5) (4) VOLTAGE: OPS controller power supply voltage
(6)
(7) (5) LIFT LOWER: Lift lowering switch input signal
(8)
(6) UNLOAD SOL: Output signal to unload solenoid
(4)
(7) LWR SOL: Output signal to lowering lock solenoid
(8) TILT SOL: Output signal to tilt solenoid
(9) TILT: Tilt lever switch input signal
FWD: Forward tilt switch input signal
(1)
(9) BWD: Backward tilt switch input signal
CONT: SAS tilt control command input signal
(8)
(10) (10) LSOPT: Reserved.
(4)
[End]
1-11
"2 IN/OUT MONITOR" (Mini-lever vehicle)

(1) (1) SEAT: Seat switch input signal
(2)
(2) DIR: Direction switch input signal
(3)
FWD: Forward direction switch input signal
(4)
REV: Reverse direction switch input signal
(3) RLY: Output signal to forward/reverse interrupt relay
FWD: Output signal to forward interrupt relay
REV: Output signal to reverse interrupt relay
(4) VOLTAGE: OPS controller power supply voltage
(1)
(5)
(5) LIFT LOWER: Lift lowering switch input signal
(6) TILT: Tilt lever switch input signal
(4) FWD: Forward tilt switch input signal

BWD: Backward tilt switch input signal
CONT: SAS tilt control command input signal
(7) LSOPT: Reserved.
[End]
(1)
(6)
(7)
(4)
1-12
"3 ACTIVE TEST" (Excluding the mini-lever vehicle)
Note:
(1) ON indication on the screen shows the controller output
(2)
(3)
state. The operation, therefore, should be checked visually,
(4) by operating sound, etc.
(5)
(6) 1. Select the item by selector switch d, and set OFF/ON by
(7)
selector switch c.
(1) RLY FWD
Set to ON for forced output of forward interrupt relay
activating signal. (Forward traveling disabled state)
(2) RLY REV
Set to ON for forced output of reverse interrupt relay
activating signal. (Reverse traveling disabled state)
(3) UNLOAD SOL
Set to ON for forced output of unload solenoid activating
signal. (Material handling disabled state)
(4) LWR SOL
Set to ON for forced output of lowering lock solenoid
activating signal. (Lowering enabled state)
(5) TILT SOL
Set to ON for forced output of tilt solenoid activating signal.
(Forward tilting enabled state with backward tilting speed
restriction)
(6) LAMP
Set to ON for forced output of OPS lamp lighting signal.
(OPS lamp lighting state)
(7) BUZZER (Export model)
Set to ON for forced output of OPS buzzer sounding signal.
(Continuous OPS buzzer sounding)
2. After resetting all items to OFF, press MENU switch e to return

to the ANALYZER MENU screen.
1-13
"3 ACTIVE TEST" (Mini-lever vehicle)
Note:
(1) ON indication on the screen shows the controller output
(2)
state. The operation, therefore, should be checked visually,
by operating sound, etc.
(3) 1. Select the item by selector switch d, and set OFF/ON by

(4)
selector switch c.
(1) RLY FWD
Set to ON for forced output of forward interrupt relay
activating signal. (Forward traveling disabled state)
(2) RLY REV
Set to ON for forced output of reverse interrupt relay
activating signal. (Reverse traveling disabled state)
(3) LAMP
Set to ON for forced output of OPS lamp lighting signal.
(OPS lamp lighting state)
(4) BUZZER
Set to ON for forced output of OPS buzzer sounding signal.
(Continuous OPS buzzer sounding)
2. After resetting all items to OFF, press MENU switch e to return

to the ANALYZER MENU screen.
"4 CONTROLLER DATA"
The OPS controller abbreviation No. and version No. can be
displayed on this screen.
(1)
(1) DATA
(2) Controller abbreviation No.
(2) VER
Version No.
[End]
1-14
TROUBLESHOOTING
z No display on the screen.
Related Portion
ECU-IG CN6-3
REC
TAB
To IG SW
CN44-12
(IG, Power supply) 1
OPS controller
CN46-3
REC
REC
TAB
CN44-1
TAB
REC
TAB
REC
TAB
J2 Analyzer
CN45-1
CN44-3 13
Analyzer CN
(E2, Main GND)
Estimated Causes:
c Connector contact defect
d Analyzer harness (power supply) defect
e Plug-in analyzer defect
NG
Check CN44 and analyzer connector for any disconnection. Screen check after correction.
OK NG
Inspection 1: NG
Harness defect on vehicle side
Measure the voltage between CN44-12 and CN44-3.
OK
Inspection 2: NG
Analyzer harness defect
Measure the voltage between analyzer CN-1 and analyzer CN-13.
OK
Plug-in analyzer defect
Inspection 1:
Measure the voltage between CN44-12 and CN44-3. 1 2 3 4 5 6 18
Key switch ON (engine in stopped state)
19
7 8 9 10 11 20
12 13 14 15 16 17 21 22 23
CN44 (REC)
Standard:
CN44-12 (+) ~ CN44-3 (-) 8 to 16 V
Inspection 2:
Measure the voltage between analyzer CN-1 and analyzer CN-13.
Standard: Analyzer CN (REC)
Analyzer CN-1(+) ~ analyzer CN-13 (-) 8 to 16 V

1-15
z No data display on data (DIAG MEMORY, voltage value, etc) display screen
Related Portion
ECU-IG CN6-3
REC
TAB
To IG SW
CN44-12
(IG, Power supply) 1
OPS controller
CN46-3
REC
REC
TAB
CN44-1
TAB
REC
TAB
REC
TAB
J2 Analyzer
CN45-1
CN44-3 13
Analyzer CN
(E2, Main GND)
Estimated Causes:
c Connector contact defective e Plug-in analyzer defect
d Analyzer harness (communication) defect f OPS controller defect
NG
Check CN44 and analyzer connector for any disconnection. Data display check after correction.
OK NG
Inspection 1: NG
Harness defect on vehicle side
Check continuity between CN44-1 and CN45-1.
OK
Inspection 2: NG
Analyzer harness defect
Check continuity between analyzer CN-6 and CN44-1.
OK
NG
Check data display by connecting the analyzer to another vehicle. Plug-in analyzer defect
OK
OPS controller defect
Inspection 1:
Key switch OFF, disconnection between CN44 and CN45.
1 2 3 4 5 6 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19
7 8 9 10 11 20
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
12 13 14 15 16 17 21 22 23
Standard: CN45 (REC) CN44 (REC)
CN44-1 ~ CN45-1 Continuity
Inspection 2:
Check continuity between analyzer CN-6 and CN44-1.
Key switch OFF, disconnection between analyzer CN and
CN44.
Analyzer CN (REC) CN44 (TAB)
Standard:
Analyzer CN-6 ~ CN44-1 Continuity
1-16
OPS TROUBLESHOOTING
DIAGNOSIS
The diagnosis function informs the operator of a trouble occurrence and the trouble position by blinking the OPS
lamp on the combination meter when the OPS controller detects an abnormality. The trouble position is indicated by
the lamp blinking count.
Note:
• The OPS lamp is lit for 1 second upon key switch ON for broken lamp check.
• The OPS lamp comes on when the operator leaves the seat.
• If multiple errors occur at a time, only the lowest error code appears. Upon correction of that error, the
next lowest error code appears.
Example:
Display example of error code 3
Break point indication Code indication

ON
OFF
2 sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.
0.5 sec. 0.5 sec. 0.5 sec.
Abnormality detection
(Code 3)
DIAGNOSIS ERROR CODE LIST
Error Phenomenon on vehicle

Lamp Vehicle spec. Error description Major cause
code Standard model Mini lever model
ON — — Dead lamp check — — —
Blinking (one
Sticking
short ON 1-1 All specifications Seat switch abnormality No OPS functioning No OPS functioning
GND fault
pulse)
Blinking (two No special change from normal
Other than mini Lift lowering switch Sticking
short ON 2-1 state —
lever model abnormality GND fault
cycles) (Excessive leak during lowering)
Forward traveling is possible while Forward traveling is possible while
Discontinuity
OPS is operating. OPS is operating.
Forward interrupt relay
3-1 GND fault ↑ ↑
(RYF) abnormality
Forward traveling is always Forward traveling is always
Blinking (three +B shorting
disabled. disabled.
short ON All specifications
Reverse traveling is possible while Reverse traveling is possible while
cycles) Discontinuity
OPS is operating. OPS is operating.
Reverse interrupt relay
3-2 GND fault ↑ ↑
(RYR) abnormality
Reverse traveling is always Reverse traveling is always
+B shorting
disabled. disabled.
Lift lowering and backward tilting
are disabled but other material
Discontinuity —
handling operations are possible
while OPS is operating
Blinking (four GND fault ↑ —
Unload solenoid (SOL1)
short ON 4-1 All material handling operations are
abnormality
cycles) disabled while OPS is operating.
While OPS is not operating, only lift
+B shorting —
lowering is possible but other
material handling operations are
Other than mini disabled.
lever model
While OPS is operating, all material
handling operations are disabled. While
Discontinuity OPS is not operating, only forward —
tilting is disabled and all other material
Blinking (four handling operations are possible.
Lowering lock solenoid
short ON 4-2
(SOL2) abnormality GND fault ↑ —
cycles)
While OPS is operating, only lift
lowering is possible and all other
+B shorting —
material handling operations are
1-17
disabled.
1
1-18
Error Phenomenon on vehicle
Lamp Vehicle spec. Error description Major cause
code Standard model Mini lever model
While OPS is operating, all material
handling operations are disabled.
While OPS is not operating, only
Blinking (four Discontinuity —
Other than mini Tilt solenoid (SOL3) forward tilting is disabled and all
short ON 4-3 other material handling operations
lever model abnormality
cycles) are possible.
GND fault ↑ —
+B shorting Automatic leveling stop is disabled. —
Blinking (five When OPS is operating, releasing When OPS is operating, releasing
short ON 5-1 All specifications Shift lever abnormality +B shorting is disabled (locked state by return is disabled (locked state by return
cycles) to neutral function). to neutral function).
7-1 CPU abnormality Drive OPS does not function,
7-2 CPU abnormality lowering is always disabled, and
ON Drive OPS does not function.
material handling OPS does not
7-3 CPU abnormality function.
Blinking
Controller
(seven short 7-4 All specifications CPU abnormality None in particular None in particular
abnormality
ON cycles)
7-5 EEPROM abnormality Drive OPS does not function,
lowering is always disabled, and
ON Drive OPS does not function.
7-6 EEPROM abnormality material handling OPS does not
function.
Low battery Ordinary control (Failure in control Ordinary control (Failure in control
ON — All specifications Low voltage alarm
voltage may arise.) may arise.)
ON — — OPS operation Departure from seat — —
1-19
List of Reference Pages for Error Codes and Sub Error Codes
Without analyzer (SST) With analyzer (SST)
Error code Error description Page Error code Error description Page
1 Seat switch abnormality 1-20 1-1 Seat switch abnormality 1-21

2 Lowering switch abnormality 1-23 2-1 Lowering switch abnormality 1-25
Forward interrupt relay (RYF) Forward interrupt relay (RYF)

3-1 1-27
abnormality abnormality
3 1-27
Reverse interrupt relay (RYR) Reverse interrupt relay (RYR)
abnormality 3-2 1-27
abnormality
Unload solenoid (SOL1)
4-1 1-29
abnormality
4 Solenoid (SOL) abnormality 1-29 Lowering lock solenoid (SOL2)
4-2 1-29
abnormality
4-3 Tilt solenoid (SOL3) abnormality 1-29
5 T/C shift lever abnormality 1-31 5-1 T/C shift lever abnormality 1-33
7-1 CPU abnormality —
7 OPS controller abnormality —
7-5 EEPROM abnormality —
7-6 EEPROM abnormality —
List of Pages to be Referenced by Phenomenon

Pages to be referenced
Description
Without analyzer With analyzer
The OPS buzzer does not sound or keeps sounding. 1-35 1-35
The OPS lamp dos not come on. 1-39 1-39
The OPS lamp keeps lighting (including the state where traveling and material
1-41 1-44
handling are both disabled).
The fork cannot be lowered (excluding the mini-lever vehicle). 1-47 1-50
The material handling OPS does not function (including the state where fork
1-52 1-52
lowering and forward tilting are both disabled).
The material handling OPS does not function (mini-lever vehicle). 1-53 1-53
Material handling fails (including the case where only fork lowering is possible). 1-55 1-55
Material handling fails (mini-lever vehicle). 1-56 1-56
The mast backward tilting speed is always slow or unrestricted (excluding the mini-
1-58 1-58
lever vehicle).
Mast forward tilting fails (excluding the mini-lever vehicle). 1-62 1-62
The drive OPS does not function. 1-66 1-66
Traveling fails (including forward the cases of traveling only, reverse traveling only
1-69 1-69
and occasional failures).
Note:
The illustration for the STD lever vehicle is shown as the analyzer screen in the troubleshooting for both
the STD lever and mini-lever vehicles.
1-20
TROUBLESHOOTING BY ERROR CODE

z Error Code 1 · 1-1 (Seat switch abnormality)
Related Portion
CN4 CN50 CN60

OPS controller
CN45-23 (DMI, Seat SW) 3 1 1

REC
REC
REC
REC
TAB
TAB
TAB
TAB
Seat switch
J1
CN45-17 (E03, Switch GND) 2 2 2
Estimated Causes:
c Connector contact defect e Harness defect
d Seat switch defect f Controller defect
Error code 1
Check CN45, CN50, CN60 and CN4 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG
Inspection 1: NG
Seat switch defect
Check the seat switch individually for continuity.
OK
Inspection 2: NG
Harness defect
Check continuity between CN45-23 and CN45-17
OK
Controller defect
*: After correction, check the OPS lamp indication.

After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFF
again.
After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display error
code 1 with blinking.
1-21
Inspection 1:
Check the individual seat switch for continuity.
Key switch OFF, CN 60 disconnection. 2 1
Standard: CN60 (TAB)
Seated Unseated
CN60-1 ~ CN60-2 Continuity No continuity
Inspection 2:
Key switch OFF, CN45 disconnection. (CN4, CN50 and CN60 must be connected.) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Standard: CN45 (REC)
Seated Unseated
Error code 1-1
Check CN45, CN50, CN60 and CN4 connectors for any NG After correction, check the OPS lamp
OK NG
Inspection 1: OK
Seat switch defect
With CN60 disconnected, check the input signal to the controller.
NG
Inspection 2: NG
Harness defect
Check continuity between CN45-23 and CN45-17
OK
Controller defect
*: After correction check the OPS lamp indication.

After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFF again.
After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display error code
1 with blinking.
1-22
Inspection 1:
With CN60 disconnected, check the input signal to the controller.
CN60 connector disconnection, key switch OFF ⇒ ON
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR
Standard:
Seated Unseated
SEAT OFF OFF
Inspection 2:
Key switch OFF, CN45 disconnection. (CN4, CN50 and CN60 must be connected.) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Seated Unseated
1-23
z Error Code 2
z Error Code 2-1 (Lowering switch abnormality)
Related Portion
CN45-26 (DOWN, Lowering switch) CN49-1

OPS controller
Lowering
REC
TAB
REC
TAB
switch
CN45-17 (E03, SW-GND) CN49-2

J1
Estimated Causes:
c Connector contact defect f Controller defect
d Lowering switch defect g Lowering switch installation defect
e Harness defect
Error code 2
Check the CN45 and CN49 connectors for any disconnection or NG After correction check the OPS lamp
internal wetting. indication.*
OK NG
Inspection 1: OK
Controller defect
Check the lift lowering switch wiring for continuity.
NG
Inspection 2: OK
Harness defect
Check the lift lowering switch for continuity.
NG
Inspection 3: NG
Switch defect
Check the lift lowering lever switch for continuity.
OK
Lever switch installation defect
*: After correction check the OPS lamp indication.

After key switch ON, keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.
The OPS lamp must not indicate error code 2 with blinking.
1-24
Inspection 1:
Check the lift lower lever switch wiring for continuity.
Key switch OFF, CN45 disconnection. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Lever at neutral position Lever at up position Lever at down position

CN45-26 ~ CN45-17 No continuity No continuity Continuity
Inspection 2:
Check the lift lower lever switch individually (as installed on the vehicle) for continuity.
Key switch OFF, CN49 disconnection. 2 1

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

1-25
Error code 2-1
Check CN45 and CN49 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG
Inspection 1: Inspection 4:
NG
Disconnect CN49, and check the switch output upon lowering Check continuity between CN45 and
operation. CN49.
OK NG OK
Inspection 2: OK Harness Controller defect

Check lift lower lever switch individually (as installed on the vehicle) defect (Error occurrence upon
for continuity. continuing lowering
NG
operation for 2 minutes or
more, however, is normal.)
Inspection 3: NG
Lower switch defect
Check the lift lower lever switch individually (as removed from the
vehicle) for continuity.
OK
Lever switch installation defect

After key switch ON, keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.
Inspection 1:
Disconnect CN49 and check the switch output upon lowering operation.
Standard:
Lift lower switch
LIFT LOWER OFF OFF OFF
Inspection 2:
Check the lift lower lever switch individually (as installed on the vehicle) for continuity.

Lift lower switch
1-26
Inspection 3:
Check the lift lower lever switch individually (as removed from the vehicle) for continuity.
Switch free Switch pressed

Inspection 4:
Check continuity between CN45 and CN49.
Key switch OFF, CN45 and CN49 disconnection. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Standard: CN45 (REC) CN49 (REC)
CN45-26 ~ CN45-17 No continuity

1-27
z Error Code 3
z Error Code 3-1 (Forward interrupt relay (RYF) abnormality)
z Error Code 3-2 (Reverse interrupt relay (RYR) abnormality)
Related Portion
T/C relay block

CN45-10 (RYF, Forward interrupt relay) 2
Forward
OPS controller
interrupt
1 relay
REC
TAB
CN45-11 (RYR, Reverse interrupt relay) 2

Reverse
interrupt
REC
TAB
1 relay
CN45-17, (E03, SW-GND) CN46-6
Estimated Causes:
c Connector contact defect f Harness defect
d Forward interrupt relay defect g Controller defect
e Reverse interrupt relay defect
Error Codes 3, 3-1, 3-2
Check the CN45 and CN46 connectors for disconnection or internal NG After correction, check the OPS lamp
wetting and the relays for insertion. indication.*
OK NG
Inspection 1: NG
Interrupt relay defect
Check the forward/reverse interrupt relay individually (on the coil
side) for the resistance value.
OK
Inspection 2: NG
Check the wiring between CN45 and the T/C relay block for Harness defect
continuity.
OK
Controller defect

After key switch ON, place the shift lever in the forward or reverse position and leave the seat to check if the OPS
lamp blinks.
The OPS lamp must not display error code 3 with blinking.
Note:
When the analyzer is provided, check the related portion after checking the error memory for the current
error code. See p1-9 "1 DIAG MEMORY" for the error memory check method.
1-28
Inspection 1:
Check the forward/reverse interrupt relay (on coil side) individually.
Measure the resistance between terminals of each of the forward and reverse interrupt relays. 1 4 2
(5)
Key switch OFF, relay disconnection from T/C relay block. 3
RLY
Standard:
Resistance
Forward interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)
Reverse interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)
Inspection 2:
Check continuity of the wiring between CN45 and T/C relay block.
Key switch OFF, CN45 disconnection, relay removal from the T/C relay block. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

• Discontinuity check
3 3
CN45-10 ~ Forward interrupt relay terminal 2 Continuity 5

1 4 2
5
1 4 2
CN45-11 ~ Reverse interrupt relay terminal 2 Continuity T/C FR RLY T/C RR RLY
CN45-17 ~ Forward interrupt relay terminal 1 Continuity

CN45-17 ~ Reverse interrupt relay terminal 1 Continuity
• GND fault check

• +B shorting check
• IG line shorting check

CN45-10 ~ CN45-15,-16 No continuity
1-29
z Error Code 4
z Error Code 4-1 (Unload solenoid (SOL1) abnormality)
z Error Code 4-2 (Lowering lock solenoid (SOL2) abnormality)
z Error Code 4-3 (Tilt solenoid (SOL3) abnormality)
Related Portion
CN45-14 (SOL1, Unload SOL) CN47-1
REC
TAB
Unload SOL1
W/SPLICE-Z
OPS controller
CN47-2
CN45-13 (SOL2, Lowering lock SOL) CN48-1
REC
Lowering lock
TAB
REC
TAB
CN45-12 (SOL3, Tilt SOL) SOL2

CN48-2
CN12-1
REC
TAB
CN45-30 (E3, SOL-GND) CN46-8 Tilt SOL3
REC
TAB
CN12-2
CN45-29 (E3, SOL-GND) CN46-9
(E3, Body GND)
Estimated Causes:
c Connector contact defect f Tilt solenoid defect
d Unload solenoid defect g Controller defect
e Lowering lock solenoid defect h Harness defect
Error Codes 4, 4-1, 4-2, 4-3
Check the CN45, CN46, CN47, CN48 and CN12 connectors for any NG After correction, check the OPS lamp
OK NG
Inspection 1: NG
Solenoid defect
Check the solenoids (SOL1 - SOL3) individually for the resistance
value.
OK
Inspection 2: NG
Harness defect
Check the wiring between CN45 and each solenoid (SOL1 - SOL3)
for continuity.
OK
Controller defect

After starting the engine, operate lift up/down, forward/backward tilt in each of OPS activation and deactivation to
check if the OPS lamp blinks.
Note:
When the analyzer is provided, check the related portion after checking the error memory for the current
error code. See p1-9 "1 DIAG MEMORY" for the error memory check method.
1-30
Inspection 1:
Check the resistance of each solenoid (SOL1 to SOL 3).
Key switch OFF, CN47, CN48 and CN12 disconnection. 2 1
2 1
2 1
Standard: CN47 (TAB) CN48 (TAB) CN12 (TAB)
Resistance
SOL1 CN47-1 ~ CN47-2 Approx. 9 Ω (20°C)
Inspection 2:
Check continuity of the wiring between CN45 and each of solenoids SOL1 to SOL3.
Key switch OFF, CN45, CN47, CN48 and CN12 disconnection.
Standard:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CN45-29 ~ CN47-2 Continuity 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
CN47-2 ~ Frame Continuity

1 2 1 2 1 2
CN47 (REC) CN48 (REC) CN12 (REC)

• GND fault check


1-31
z Error Code 5 · 5-1 (T/C shift lever abnormality)
Related Portion
SFT CN6-8 CN53-6
REC
TAB
To IG SW
T/C relay block
Shift lever
OPS controller
REC
Forward Reverse
REC
TAB
CN45-3 (DRF, Forward drive switch)

CN46-1 CN53-5 (CN57-3)
REC
TAB
CN46-11 CN53-1 (CN57-6)
CN45-4 (DRR, Reverse drive switch)
Estimated causes:
d Shift lever switch defect g Fuse defect
e Harness defect
Error Code 5
NG After correction, check the OPS lamp

Check if the fuse (SFT) is blown.
indication.*
OK NG
Check connectors CN45, CN46, CN53 and CN6 for any NG After correction, check the OPS lamp
OK NG
Inspection 1: NG
Shift lever defect
Check the shift lever individually for continuity.
OK
Inspection 2: NG
Harness defect
Check the continuity of wiring between CN45 and IG SW.
OK
Controller defect

After key switch ON, operate the shift lever to forward or reverse position and check if the OPS lamp blinks.
1-32
Inspection 1:
Check the T/C shift lever individually for continuity.
Key switch OFF, CN53 disconnection. 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Standard: DIRECTION SWITCH
Lever at neutral Lever at forward Lever at reverse

position traveling position traveling position
Between pins 5 and 6 on lever side No continuity Continuity No continuity
Between pins 6 and 1 on lever side No continuity No continuity Continuity
Inspection 2:
Check the wiring between CN45 and IG SW for continuity.
Key switch OFF, CN45 and IG SW connectors disconnection. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(CN6, CN46 and CN53 must be connected.)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
Standard:
• Lever at neutral 2
3 4
CN45-3 ~ IG SW-4 No continuity IG SW
CN45-4 ~ IG SW-4 No continuity

1-33
Error code 5-1
NG After correction, check the OPS lamp

indication.*
OK NG
Check CN45, CN46 and CN53 connectors for any disconnection or NG After correction, check the OPS lamp
internal wetting. indication.*
OK NG
Inspection 1: OK
Shift lever defect
Disconnect CN53, and check the input signal to the controller.
NG
Inspection 2: NG
Harness defect
OK
Controller defect

After key switch ON, operate the shift lever to the forward or reverse position and check if the OPS lamp blinks.
Inspection 1:
Disconnect CN53, and check the input signal to the controller.
CN53 disconnection, and key switch ON (engine in stopped state)
Standard:
Lever at forward Lever at reverse
Lever at neutral position
traveling position traveling position
DIR FWD OFF OFF OFF
DIR REV OFF OFF OFF
1-34
Inspection 2:
Key switch OFF, CN45 and IG SW connectors disconnection. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(CN6, CN46 and CN53 must be connected.)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
Standard:
• Lever at neutral 2
3 4
CN45-3 ~ IG SW-4 No continuity IG SW
CN45-4 ~ IG SW-4 No continuity

1-35
TROUBLESHOOTING BY PHENOMENON
z The OPS buzzer does not sound.
z The OPS buzzer keeps sounding.
Related Portion
ECU-IG
To IG SW
OPS controller
CN51-1
REC
TAB
CN45-9 (BZO, OPS buzzer)
REC
OPS buzzer
TAB
CN51-2
Estimated Causes:
d OPS buzzer defect g Fuse defect
e Harness defect
The OPS buzzer does not sound.
NG After correction, check the OPS

Check for blown fuse (ECU-IG).
buzzer sound.*
OK NG

Check the CN45 and CN51 for any disconnection or internal wetting.
buzzer sound.*
OK NG
Inspection 1: NG
Harness defect
Check the continuity between the IG SW and CN51, and between
CN45 and CN51.
OK
Inspection 2: OK
OPS buzzer defect
Check the continuity between CN51-2 and the frame.
NG
Controller defect
*: After correction, check the OPS buzzer sound.

After connecting all connectors, turn the key switch ON, and leave the seat to check if the buzzer sounds.
1-36
Inspection 1:
Check the continuity between the IG SW and CN51, and between CN45 and CN51.
Key switch OFF, CN45, CN51, IG SW connector disconnection. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
IG SW-4 ~ CN51-1 Continuity

1 2
CN51 (REC)
Inspection 2: 2
3 4
IG SW
• Without analyzer
Disconnect CN51 and turn the key switch to ON (engine in stopped state).
Standard:
Buzzer ON Buzzer OFF 1 2
Between CN51-2 and the frame Continuity No continuity CN51 (REC)
* Normally, the buzzer sounds for 1 second upon lapse of 0.5 seconds after the operator leaves the seat.
• With analyzer
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST
Standard:
Forcibly turn the OPS buzzer ON and OFF, and check the continuity
between CN51-1 and CN51-2.
Buzzer ON Buzzer OFF
1 2
Between CN51-2 and the frame Continuity No continuity
CN51 (REC)
1-37
The OPS buzzer keeps sounding.

Check CN45 and CN51 for any disconnection or internal wetting.
buzzer sound.*
OK NG
Inspection 1: NG
Harness defect
Check the continuity between IG SW and CN51, between CN45 and
CN51, and between CN45 and the frame.
OK
Inspection 2: OK
OPS buzzer defect
NG
Controller defect
*: After correction, check the OPS buzzer sound.

After connecting all connectors, turn the key switch to ON and leave the seat to check if the buzzer sounds.
Inspection 1:
Check the continuity between the IG SW and CN51, and between CN45 and CN51.
Key switch OFF, CN45, CN51, IG SW connector disconnection.
Standard:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
IG SW-4 ~ CN51-1 Continuity 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45-9 ~ CN51-2 Continuity CN45 (REC)
Between CN45-9 and the frame No continuity

1 2
CN51 (REC)
2
3 4
IG SW
1-38
Inspection 2:
Disconnect CN51 and turn the key switch to ON (engine in stopped state). 1 2
CN51 (REC)
Standard:
Between CN51-2 and frame Continuity No continuity
* Normally, buzzer sounds for 1 second upon lapse of 0.5 sec after the operator leaves the seat.
• With analyzer
Standard:
Forcibly turn the OPS buzzer ON and OFF, and check the continuity
between CN51-1 and CN51-2.
Between CN51-2 and frame Continuity No continuity
1 2
CN51 (REC)
1-39
z The OPS lamp does not come on.
Related Portion
GAUGE
To IG SW
Combination
ECU-IG
CN41-12 meter
W/SPLICE 4
2
OPS controller
1 OPS lamp
relay
CN45-8 (RYLP, OPS lamp relay) CN6-9
REC
REC
TAB
TAB
SAS lamp
relay
Estimated Causes:
c Connector contact defect f Harness defect
d OPS lamp defect g Controller defect
e OPS lamp relay defect h Fuse defect
NG After bulb replacement, check that the

Check if the OPS lamp is burnt out.
OPS lamp comes on.
OK NG
NG After correction, check that the OPS

Check for blown fuse (GAUGE).
lamp comes on.*
OK NG
Check CN45, CN41 and CN6 for any disconnection or internal NG After correction, check that the OPS
wetting, and check any relay disconnection. lamp comes on.*
OK NG
Inspection 1: NG
Harness defect
Check the continuity between fuse (ECU-IG), CN45, CN41, frame,
and OPS lamp relay.
OK
Inspection 2: NG
OPS lamp relay defect
Check the OPS lamp relay.
OK
Controller defect
*: After correction, check OPS lamp lighting.

After connecting all connectors, turn the key switch to ON (engine in stopped state) and leave the seat to see that
the OPS lamp comes on.
1-40
Inspection 1:
Check the continuity between fuse (ECU-IG), CN45, CN41, frame, and OPS lamp relay.
Turn the key switch OFF, disconnect CN45 and CN41, and remove the OPS lamp relay.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Standard: 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
Between fuse (ECU-IG) and relay pin 2 Continuity
Between CN45-8 and relay pin 1 Continuity
1 2 3 4 5 6 7 8 9 10 11 12 13
Between frame and replay pin 3 Continuity
Between CN41-12 and relay pin 4 Continuity CN41 (REC)
Between frame and relay pin 1 No continuity

3
5
Inspection 2: 1 4 2
OPS LAMP RLY

(1) Turn the key switch OFF, remove the OPS lamp relay from the relay block, and then turn the key switch to ON (engine
in stopped state). Check the continuity between OPS lamp relay pin 1 and the frame with no one on the seat.
Standard:
3
Lamp ON Lamp OFF 5
1 4 2
Between relay pin 1 and frame No continuity Continuity OPS LAMP RLY
(2) Turn the key switch to OFF, reinstall the OPS lamp relay, and then turn the key switch to ON (engine in
stopped state). Measure the voltage between OPS lamp relay pins 3 and 4.
Standard:
Lamp ON Lamp OFF
Between relay pins 3 and 4 0V Approx. 12 V
• With analyzer
(1) Turn the key switch to OFF, remove the OPS lamp relay from the relay
block, and then turn the key switch to ON (engine in stopped state).
Check the continuity between OPS lamp relay pin 1 and the frame with
no one on the seat.
Standard:
Forcibly turn the OPS lamp ON and OFF, and check the continuity.
3
5
Lamp ON signal Lamp OFF signal 1 4 2
Standard:
Lamp ON Lamp OFF
1-41
z The OPS lamp keeps lighting. (Including when traveling and material handling are both
disabled)
Related Portion
GAUGE
To IG SW
Combination
ECU-IG
CN41-12 meter
ECU-B
4
To battery W/SPLICE
2
CN45-32 (BATT, +B) 1 OPS lamp
CN45-15 (IG, IG line) CN46-5 relay
REC
REC
CN6-9
TAB
TAB
CN45-16 (IG2, IG line) CN46-4
3
4
OPS controller
CN45-8 (RYLP, OPS lamp relay)

SAS lamp
REC
TAB
relay
CN4 CN50 CN60
CN45-23 (DMI, Seat switch) REC
3 1 1
REC
REC
TAB
TAB
TAB
Seat switch
2 2 2
J1
CN45-17
(E03, Switch GND)
Estimated Causes:
c Contactor contact defect g Controller defect
d OPS lamp defect h Fuse defect
e OPS lamp relay defect i Low battery voltage
f Harness defect j Seat switch discontinuity
1-42
Without Analyzer

Check for blown fuse (ECU-B).
lamp goes off.*
OK NG
Check CN45, CN46, CN4, CN6, CN50 and CN60 for any NG After correction, check that the OPS
disconnection or internal wetting, and check the OPS lamp relay for lamp goes off.*
connection. NG
OK
Inspection 1: NG
Harness defect
Check and measure the continuity and voltage between IG SW and
CN45, between battery and CN45, between IG SW and OPS lamp
relay, between OPS lamp relay and CN45, and between CN60 and
CN45.
OK
Inspection 2: NG
Battery defect (low battery voltage)
Check the input voltage from the IG line to the controller.
OK
Inspection 3: NG
OK
Inspection 4: NG
Seat switch defect
Check the seat switch.
OK
Controller defect
*: After correction, check that the OPS lamp goes off.

After connecting all connectors, turn the key switch to ON while staying on the seat (engine in stopped state).
Check that the OPS lamp goes off in 1 second.
1-43
Inspection 1:
Check and measure the continuity and voltage between IG SW and CN45, between the battery and CN45,
between IG SW and OPS lamp relay, between OPS lamp relay and CN45, and between CN60 and CN45.
Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamp
relay.
Standard:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
IG SW-4 ~ CN45-15 Continuity CN45 (REC)
Between IG SW-4 and relay pin 2 Continuity

Between CN45-8 and relay pin 1 Continuity 1 2

2
CN45-15 ~ CN45-31 No continuity 3 4
CN45-16 ~ CN45-31 No continuity IG SW

3
CN45-32 ~ CN45-31 Approx. 12 V 5
1 4 2
OPS LAMP RLY
Inspection 2:
Disconnect CN45 and turn the key switch to ON. (Connectors other than CN45 must be connected).
Standard:
CN45-15 ~ CN45-31 11 V or more
CN45-16 ~ CN45-31 11 V or more
Inspection 3:
(1) Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch to
ON (engine in stopped state). Check the continuity between OPS lamp relay pin 1 and frame with no one on
the seat.
Standard:
3
Lamp ON Lamp OFF 5
1 4 2
Standard:
Lamp ON Lamp OFF
1-44
Inspection 4:
Check the individual seat switch for continuity.
Turn the key switch to OFF, and disconnect CN60.
2 1
Standard:
CN60 (TAB)
Seated Unseated
With Analyzer

Check for blown fuse (ECU-B).
lamp goes off.*
OK NG
Check CN45, CN46, CN4, CN6, CN50, CN58 and CN60 for any NG After correction, check that the OPS
disconnection or internal wetting, and the OPS lamp relay for lamp goes off.*
connection. NG
OK
Inspection 1: NG
Harness defect
Check and measure the continuity and voltage between the IG SW
and CN45, between the battery and CN45, between the IG SW and
the OPS lamp relay, and between the OPS lamp relay and CN45, and
between CN60 and CN45.
OK
Inspection 2: NG
Battery defect (low battery voltage)
OK
Inspection 3: NG
OK
Inspection 4: OK
Seat switch defect
Check the seat switch.
NG
Controller defect
*: After correction, check that the OPS lamp goes off.

After connecting all connectors, turn the key switch to ON with no one on the seat (engine in stopped state).
Check that the OPS lamp goes off in 1 second.
1-45
Inspection 1:
Check and measure the continuity and voltage between the IG SW and CN45, between the battery and CN45,
between the IG SW and the OPS lamp relay, between the OPS lamp relay and CN45, and between CN60 and CN45.
Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamp relay.
Standard:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
IG SW-4 ~ CN45-15 Continuity CN45 (REC)
Between IG SW-4 and relay pin 2 Continuity

Between CN45-8 and relay pin 1 Continuity 1 2

CN45-15 ~ CN45-31 No continuity 2
3 4
CN45-16 ~ CN45-31 No continuity IG SW
CN45-32 ~ CN45-31 Approx. 12 V 3
5
1 4 2
OPS LAMP RLY

Inspection 2:
After connecting all connectors, turn the key switch to ON (engine in stopped state).
Standard:
Key ON
VOLTAGE 11 V or more
Inspection 3:
(1) Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch to
ON (engine in stopped state). Check the continuity between OPS lamp relay pin 1 and the frame with no one
on the seat.
Standard:
Forcibly turn the OPS lamp to on and off, and check the continuity.
Lamp ON signal Lamp OFF signal
Between relay pin 1 and frame No continuity Continuity
Standard:
3
Lamp ON Lamp OFF 5
1 4 2
Between relay pins 3 and 4 0V Approx. 12 V OPS LAMP RLY

1-46
Inspection 4:
Check the seat switch individually.
Turn the key switch to OFF and disconnect CN60. 2 1
Seated Unseated
1-47
z Cannot lower the fork. (Excluding mini-lever vehicle)
Related Portion
CN45-26 (DOWN, Lowering switch) CN49-1
REC
Lowering
TAB
OPS controller
CN45-17 (E03, SW-GND) CN49-2 switch

J1
REC
TAB
CN45-13 (SOL2, Lowering lock solenoid) CN48-1
REC
Lowering lock
TAB
CN48-2
solenoid
CN45-30 (E3, SOL-GND) CN46-8
REC
TAB
W/SPLICE-Z
CN45-29 (E3, SOL-GND) CN46-9
(E3, Body GND)
Estimated Causes:
c Connector contact defect f Lowering lever switch installation defect
d Lowering switch defect g Controller defect
e Control valve lowering lock valve sticking defect h Harness defect
1-48
Without Analyzer
Is the OPS lamp blinking to indicate an Yes Perform troubleshooting

error. according to the error code.
No
No Perform troubleshooting for "The

Does the OPS lamp go off when seated.
OPS Lamp keeps lighting".
Yes
Check CN45, CN46, CN48 and CN49 for NG After correction, get on the seat
any disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG
Inspection 1: NG Inspection 2: NG
Harness defect
Check the lift lowering lever switch wiring Check the continuity between
for continuity. CN45 and CN49.
OK OK
Inspection 3: NG Lowering switch

Check the lift lowering lever defect
switch (as removed from the
OK
Lowering lever switch

installation defect
Put a hand on the lowering lock solenoid NG

Controller defect
(at the rear lower left-hand portion of the
control valve) and operate for lowering the
fork while seating to check the solenoid
open/close sound (with the engine in
stopped state and the fork in the fully
lowered position).*
OK
Lowering lock valve sticking
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
Inspection 1:
Check the lift lowering lever switch wiring for continuity.
Turn the key switch to OFF and disconnect CN45. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Lever at neutral position Lever at up position Lever at lowering position

1-49
Inspection 2:
Check the continuity between CN45 and CN49.
Turn the key switch OFF, and disconnect CN45 and CN49.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2
Standard: 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC) CN49 (REC)

Inspection 3:
Check the lift lowering lever switch individually (as removed from the vehicle) for
continuity. 2 1
Turn the key switch OFF, and disconnect CN49.

CN49 (TAB)
Standard:
Free Pressed
1-50
With Analyzer
Is the OPS lamp blinking to indicate an Yes Perform troubleshooting

error? according to the error code.
No
Does the OPS lamp go off when seated. No Perform troubleshooting for "The
OPS Lamp keeps lighting."
Yes
Check CN45, CN46, CN48 and CN49 for NG After correction, get on the seat
any disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG
Inspection 1: NG Inspection 2: NG
Harness defect
Check the switch output when operated for Check the continuity between
fork lowering. CN45 and CN49.
OK OK
Inspection 3: NG Lowering switch

Check the lowering lever switch defect
individually (as removed from
the vehicle) for continuity.
OK
Lowering lever switch

installation defect
Put a hand on the lowering lock solenoid NG

Controller defect
(at lower rear left-hand portion of the
control valve) and operate for fork lowering
on the seat to check the solenoid open/
close sound (with the engine stopped and
the fork in the fully lowered position).*
OK
Lowering lock valve sticking
Caution:
Inspection 1:
Check the switch output when operated for lowering.
Turn the key switch to ON (engine in stopped state).
Standard:
Lever at neutral position Lever at up position Lever at lowering position
LIFT LOWER OFF OFF ON
1-51
Inspection 2:
Turn the key switch to OFF, and disconnect CN45 and CN49.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2
Standard: 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC) CN49 (REC)

Inspection 3:
Check the lift lowering lever switch individually (as removal from the vehicle) for continuity.
Turn the key switch to OFF, and disconnect CN49. 2 1
Free Pressed
1-52
z The material handling OPS does not function (Including when lowering and forward
tilting are disabled).
Related Portion
REC
TAB
Unload SOL
OPS controller
W/SPLICE CN47-2
REC
TAB
CN45-13 (SOL2, Lowering lock SOL) CN48-1
REC
Lowering lock
TAB
SOL
CN45-30 (E3, SOL-GND) CN46-8 CN48-2
REC
TAB
CN45-29 (E3, SOL-GND) CN46-9 (E3, Body GND)
Estimated Causes:
c Controller defect
d Control valve unload valve or lowering lock valve defect
Yes Perform troubleshooting according to

Is the OPS lamp blinking?*1
the error code.
No
NG
Check the operating sound of the control valve solenoid.*2 Controller defect
OK
Sticking unload valve on control valve or lowering lock valve
*1: Check if the OPS lamp is blinking.

Turn the key switch to OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle as it
is for 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.
*2: Check the control valve solenoid operating sound.
• Turn the key switch to ON (engine in stopped state) and put a hand on the unload solenoid of the control valve
to check the solenoid open/close sound is heard in 2 seconds after leaving the seat or upon getting on the
seat.
• Put a hand on the lowering lock solenoid of the control valve while seating to confirm the solenoid open/close
sound is heard upon fork lowering operation.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.
1-53
z Material handling OPS does not function. (Mini-lever vehicle)
Related Portion
OPS controller
REC REC
CN45-19 (DMO, Seat switch output) CN101-16
Mini lever
controller
REC
TAB
TAB
CN45-18 (DGND, Seat switch output GND)
REC
CN102-12
TAB
CN46-10 CN102-25
(E5, Body GND)
Estimated Causes:
c Connector contact defect e OPS controller defect
d Harness defect f Mini-lever controller defect

Isn't the OPS lamp blinking?
the error code
No
Inspect connectors CN45, CN46, CN101 and CN102 for no NG After correction, check if all material
disconnection or internal wetting. handling operations are possible
OK when the operator is on the seat.
NG
Inspection 1: NG
Harness defect
Check continuity of the wiring between CN45 and CN101/CN102.
OK
Inspection 2: NG
Check the OPS controller seat switch output. OPS controller defect
OK
Mini-lever controller defect
*: Make sure that the OPS lamp does not blink.

Set the key switch OFF → ON (2 sec or more) → OFF with no one on the seat. After waiting for 15 minutes
without any operation, turn the key switch ON again and make sure that the OPS lamp does not blink.
1-54
Inspection 1:
Check continuity between CN45 and CN101/CN102.
Key switch OFF, and CN45, CN101, CN102 disconnection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45-18 ~ CN102-12 Continuity 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CN45-19 - Frame No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
CN102 (REC)
Inspection 2:
Inspect the OPS controller seat switch output.
CN101 and CN102 disconnection, key switch ON (engine in stopped state) 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Tester Seated Unseated

Digital CN101-16 (+) ~ CN102-12 (-) Continuity No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Analog CN101-16 (-) ~ CN102-12 (+) Continuity No continuity CN102 (REC)
1-55
z Material handling fails (Including when fork lowering is disabled)
Related Portion
OPS controller
REC
Unload
TAB
REC SOL
TAB
CN47-2
CN45-30 (E3, SOL-GND) CN46-8
REC
TAB
W/SPLICE-Z
CN45-29 (E3, SOL-GND) CN46-9
(E3, Body GND)
Estimated Causes:
c Sticking unload valve on control valve
d Controller defect

Is the OPS lamp blinking to indicate an error?
the error code.
No
No Perform troubleshooting for "The OPS

Check if OPS lamp turns OFF while sitting on the seat.
lamp keeps lighting".
Yes
NG
Check the unload solenoid operating sound.* Controller defect
OK
Sticking unload valve on control valve
*: Check the control valve solenoid operating sound.

Turn the key switch to ON (engine in stopped state) and put a hand on the unload solenoid of the control valve to
check if the solenoid open/close sound is heard in 2 seconds after leaving the seat or upon getting on the seat.
Caution:
1-56
z Material handling fails. (mini-lever vehicle)
Related Portion
OPS controller
REC REC
CN45-19 (DMO, Seat switch output) CN101-16
Mini lever
controller
REC
TAB
TAB
CN45-18 (DGND, Seat switch output GND)
REC
CN102-12
TAB
CN46-10 CN102-25
(E5, Body GND)
Estimated Causes:
c Connector contact defect e OPS controller defect
d Harness defect f Mini-lever controller defect
No Perform troubleshooting for "OPS

Does the OPS lamp go off when the operator is on the seat?
lamp keeps blinking".
Yes
Does not
Turn the key switch to OFF and to ON with all levers at neutral and go off
Perform mini-lever troubleshooting.
the operator on the seat to check if the mini-lever lamp goes off.
Goes off
Check connectors CN45, CN46, CN101 and CN102 for any NG After correction, check if all material
disconnection or internal wetting. handling operations are possible
OK when the operator is on the seat.
NG
Inspection 1: NG
Harness defect
Check continuity of the wiring between CN45 and CN101/CN102.
OK
Inspection 2: NG
Inspect the OPS controller seat switch output.
OK
Mini-lever controller defect

1-57
Inspection 1:
Check continuity between CN45 and CN101/CN102.
Key switch OFF, CN45, CN101 and CN102 disconnection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CN45-18 ~ CN102-12 Continuity 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Inspection 2: 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Check the OPS controller seat switch output. CN102 (REC)
CN101 and CN102 disconnection, key switch ON (engine in stopped state)
Standard: 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Tester Seated Unseated
CN101 (REC)
Digital CN101-16 (+) ~ CN102-12 (-) Continuity No continuity
Analog CN101-16 (-) ~ CN102-12 (+) Continuity No continuity
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
CN102 (REC)
1-58
z The mast backward tilting speed is always slow or unrestricted. (Excluding the mini-
lever vehicle)
Related Portion
CN34
CN45-25 (TFI, Forward tilt switch) 1
Forward tilt
2
lever switch
REC
TAB
CN45-24 (TRI, Backward tilt switch) 3
Backward tilt
CN46 4
lever switch
OPS controller
CN45-17 (E03, SW-GND)

J1
REC
TAB
6
REC
CN45-20
TAB
(TGND, Forward/Backward tilt GND) CN1-22
SAS controller
10 CN1-23
W/SPLICE-A
REC
TAB
CN45-22 (TFO, Forward tilt output) CN1-10
CN45-21 (TRO, Backward tilt output) CN1-9
CN45-5 (TCON, Tilt control) CN1-13
Estimated Causes:
c Connector contact defect g Sticking tilt control valve
d Harness defect h OPS controller defect
e Tilt lever switch defect i SAS controller defect
f Tilt lever switch installation defect
Perform SAS troubleshooting (check the auto level switch and lift
height switch). (See page 6-10)
OK

Is the OPS lamp blinking?*1
the error code.
No
Check CN1, CN34, CN45 and CN46 for any disconnection or internal NG After correction, check the backward
wetting. tilting speed while staying on the
seat.*2
NG
To be continued
1-59
Continued
Inspection 1: Inspection 2: Harness defect

NG OK
Check the tilt lever switch signal to the OPS Check the tilt lever switch (between CN34 and
controller. individually (as installed on the CN45)
OK
NG
Inspection 3: NG Tilt lever switch

Check the tilt lever switch defect
individually (as removed from
the vehicle) for continuity.
OK
Tilt lever switch installation

defect

NG NG
Check tilt lever switch signal to SAS Check the continuity between (between CN45 and
controller. CN45 and CN1. CN1)
OK OK
OK Sticking tilt control

Check the tilt solenoid operating sound.*3
valve
NG
Inspection 6: NG
Check tilting control by the OPS controller.
OK
SAS controller defect
*1: Check if the OPS lamp is blinking.

Turn the key switch to OFF → ON (2 seconds or more) → ON with no one on the seat. Leave the vehicle as it is
for 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.
*2: After correction, check the backward tilting speed while staying on the seat.
After turning the key switch to ON while staying on the seat, check the mast backward tilting speed.
*3: Check the tilt solenoid operating sound.
Turn the key switch to ON (engine in stopped state) and put a hand on the tilt solenoid of the control valve to
check the solenoid open/close sound upon forward tilting operation with the unloaded fork at a height of 500 mm
(20 inches).
Caution:
Inspection 1:
Check the tilt lever switch signal to the OPS controller.
Turn the key switch to OFF and disconnect CN45. (CN34 and CN46 must be 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
connected.) 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
Standard
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
CN45-25 ~ CN45-17 No continuity Continuity No continuity
1-60
Inspection 2:
Check the tilt lever switch individually (as installed on the vehicle) for continuity.
Turn the key switch to OFF and disconnect CN34.
2 1
Standard: 4 3
CN34 (TAB)
Lever at Lever at forward Lever at backward
neutral position tilt position tilt position
Inspection 3:
Check the tilt lever switch individually (as removed from the vehicle) for continuity.
Turn the key switch to OFF and disconnect CN34.
2 1
Standard: 4 3
• Forward tilting switch (upper switch as installed on the vehicle) CN34 (TAB)
Free Pressed
• Backward tilting switch (lower switch as Installed on the vehicle)

Free Pressed
Inspection 4:
Check the tilt lever switch signal to the SAS controller. 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Disconnect CN1 and turn the key switch to ON (engine in stopped state). CN1 (REC)
Standard:
Lever at neutral Lever at forward Lever at backward
Circuit tester
position tilt position tilt position
CN1-10 (+) ~ CN1-23 (-) No continuity Continuity No continuity
Digital type
CN1-9 (+) ~ CN1-23 (-) No continuity No continuity Continuity
CN1-10 (-) ~ CN1-23 (+) No continuity Continuity No continuity
Analog type
CN1-9 (-) ~ CN1-23 (+) No continuity No continuity Continuity
Note:
As the key switch is turned to ON with the connector disconnected for this inspection, the SAS lamp comes
on and the error code (F1) appears.
1-61
Inspection 5:
Turn the key switch to OFF, and disconnect CN1 and CN45. (CN46 must be 1 2 3 4 5 6 7 8 9 10 11 12 13
connected.) 14 15 16 17 18 19 20 21 22 23 24 25 26
CN1 (REC)
Standard:
CN45-22 ~ CN1-10 Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
Between CN45-22 and frame No continuity
Between CN45-21 and frame No continuity
Inspection 6:
Check the tilt control by the OPS controller.
Disconnect CN1 and turn the key switch to ON. (CN34 and CN46 must be connected).
Operate the tilt lever to check the mast movement.
Standard:
Lever at neutral position Mast does not move.
Lever at forward tilt position Mast tilts forward.
Lever at backward tilt position Mast tilts backward at the normal speed.
Note:
1-62
z Mast forward tilting fails. (Excluding the mini-lever vehicle)
Related Portion
CN34 1
CN45-25 (TFI, Forward tilt switch)
REC
Forward tilt
TAB
CN46
CN45-17 (E03, SW-GND) 6 lever switch
OPS controller
J1
REC
TAB
2
REC
CN45-20 (TGND, Forward/reverse tilt GND) CN1-22

TAB
SAS controller
10 CN1-23
REC
TAB
W/SPLICE-A
CN45-22 (TFO, Forward tilt output) CN1-10
CN45-5 (TCON, Tilt control) CN1-13
Estimated Causes:
c Connector contact defect g Sticking tilt control valve
d Harness defect h OPS controller defect
e Forward tilt lever switch defect i SAS controller defect
f Forward tilt lever switch installation defect

Check if the OPS/SAS lamp blinks to indicate an error.
the error code.
No
No Perform troubleshooting for Disabled

Get on the seat and check if the fork can be lifted. Material handling error.
Yes
Check CN1, CN34, CN45 and CN46 for any disconnection or internal NG After repair, get on the seat and check
wetting. forward tilting operation.*1
OK NG
To be continued
1-63
Continued

NG OK
Check the forward tilt lever switch signal to Check the forward tilt lever switch (as (between CN34
the OPS controller. installed on the vehicle) for continuity. and CN45)
OK NG
Inspection 3: NG Forward tilt lever

Check the forward tilt lever switch (as switch defect
removed from the vehicle) for continuity.
OK
Forward tilt lever switch installation defect
Inspection 4: NG Inspection 5: NG Harness defect

Check the forward tilt lever switch signal to Check continuity between CN45 and CN1. (between CN45
the SAS controller. OK and CN1)
OK
OK
Check the tilt solenoid operating sound.*2 Sticking tilt control valve
NG
Inspection 6: NG
Check tilt control by the OPS controller.
OK
*1: Get on the seat and check forward tilting operation:

Stay on the seat and turn the key switch to ON. Operate the tilt lever with the unloaded fork at a height of 500
mm (20 inches) to check if the mast can be tilted forward.
*2: Check for tilt solenoid operating sound:
Stay on the seat and turn the key switch to ON (with the engine in stopped state). Put a hand on the tilt solenoid
of the control valve with the unloaded fork at a height of 500 mm (20 inches) to check for the solenoid operating
sound when the tilt lever is operated toward the forward tilting side.
Caution:
Inspection 1:
Check the forward tilt lever switch signal to the OPS controller.
Key switch OFF, CN45 disconnection. (CN34 and CN46 must be connected.) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Lever at neutral position Lever at forward position Lever at backward position

1-64
Inspection 2:
Check the forward tilt lever switch (as installed on the vehicle) for continuity.
4 3

Inspection 3:
Check the forward tilt lever switch (as removed from the vehicle) for continuity.
Key switch OFF, CN34 disconnection 2 1
4 3

Tilt forward switch (upper switch when installed on the vehicle)
Free Pressed
Inspection 4:
Check the forward tilt lever switch signal to the SAS controller.
CN1 disconnection, key switch ON (with the engine in stopped state) 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard: CN1 (REC)

Circuit tester
Digital type CN1-10(+) ~ CN1-23(-) No continuity Continuity No continuity
Analog type CN1-10(-) ~ CN1-23(+) No continuity Continuity No continuity
Note:
Inspection 5:
Key switch OFF, CN1 and CN45 disconnection. 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard: CN1 (REC)
CN45-22 ~ CN1-10 Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
1-65
Inspection 6:
Check tilt control by the OPS controller.
CN1 disconnection, key switch ON. (CN34 and CN46 must be connected.)
Operate the tilt lever and check the mast movement.
Standard:
Lever at neutral position Mast does not move.
Lever at forward tilt position Mast tilts forward.
Lever at backward tilt position Mast tilts backward at the normal speed.
Note:
1-66
z The drive OPS does not function.
Related portion
SFT
REC
CN6-8 CN53-6
TAB
To IG SW
REC
CN53-5
Shift lever
T/C relay block

CN45-10 (RYF, Forward interrupt relay) CN53-1
2 4
1 3
REC
CN46-6
TAB
CN45-17 (E03, SW-GND) Forward interrupt relay
OPS controller
1 4
REC
TAB
CN45-11 (RYR, Reverse interrupt relay) 2 3

Reverse interrupt relay 5 7
CN45-3 (DRF, Forward drive switch) CN46-1 REC
REC
CN52
TAB
TAB
CN45-4 (DRR, Reverse drive switch) CN46-11
1 2
CN54 REC
Shift SOL
Estimated Causes:
c Connector interrupt defect f Harness defect
d Forward interrupt relay defect g Controller defect
e Reverse interrupt relay defect
1-67

Check if the OPS lamp blinks to indicate an error.*1
the error code.
No
Check CN45, CN46, CN54, CN6, CN52 and CN53 for any NG After correction, check if the OPS
disconnection or internal wetting, and any relay disconnection. functions normally.*2
OK NG
Inspection 1: NG
Harness defect
Check continuity of the wiring between CN53 and T/C relay block,
and the wiring between CN54 and T/C relay block.
OK
Inspection 2: NG
Check the forward/reverse interrupt relay.
OK
Controller defect
*1: Check if the OPS lamp blinks to indicate an error.

Without getting on the seat, turn the key switch to OFF → ON (2 seconds or more) → OFF. Leave the vehicle as
it is for at least 15 minutes. Then turn the key switch to ON again and make sure that the OPS lamp does not
blink.
*2: After correction, check if the drive OPS functions normally.
Turn the key switch ON, set the shift lever to either forward or reverse and leave the seat. Check if the drive OPS
is activated.
Inspection 1:
Check continuity of the wiring between CN53 and T/C relay block, and the wiring between
CN54 and T/C relay block. 1 2 3 4 5 6 7 8 9
10 11 12 14 14 15 16 17 18
Turn the key switch OFF, disconnect CN53 and CN54, and remove the relays from the T/C
relay block. CN53 (REC)
Standard: 1 2
Between CN53-5 and pin 4 of forward interrupt relay Continuity CN54 (REC)
Between CN53-1 and pin 4 of reverse interrupt relay Continuity 2

Between CN54-1 and pin 3 of forward interrupt relay Continuity 3 4
IG SW
Between CN54-2 and pin 3 of reverse interrupt relay Continuity
CN53-6 ~ IG SW-4 Continuity
3 3
5 5
1 4 2 1 4 2
T/C FR RLY T/C RR RLY

1-68
Inspection 2:
Check the forward/reverse interrupt relay individually.
(1) Turn the key switch to OFF and disconnect the relays from the T/C relay block. Measure the
resistances between the specified pins of the forward/reverse interrupt relay. 1 4 2
(5)
3
Standard: RLY
Resistance
Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
(2) Install the relay and disconnect CN53 and CN54. Leave the seat unseated, and turn the key
switch to ON (with the engine in stopped state). 1 2 3 4 5 6 7 8 9
10 11 12 14 14 15 16 17 18
• Without analyzer CN53 (REC)
Standard: 1 2
Unseated Seated CN54 (REC)
CN53-5 ~ CN54-1 No continuity Continuity

• With analyzer
Forcibly set forward and reverse interrupt relays to ON and OFF and check continuity in each state.
Standard:
• Forward interrupt relay (RLY FWD)
Relay ON Relay OFF
• Reverse interrupt relay (RLY REV)

Relay ON Relay OFF
1-69
z Traveling fails (Including forward cases of traveling only, reverse traveling only, and
occasional failures)
Related Portion
SFT
REC
CN6-8 CN53-6
TAB
To IG SW
REC
CN53-5
Shift lever
T/C relay block

CN45-10 (RYF, Forward interrupt relay) CN53-1
2 4
1 3
REC
CN46-6
TAB
CN45-17 (E03, SW-GND) Forward interrupt relay
OPS controller
1 4
REC
TAB
CN45-11 (RYR, Reverse interrupt relay) 2 3

Reverse interrupt relay 5 7
CN45-3 (DRF, Forward drive switch) CN46-1 REC
REC
TAB CN52
TAB
CN45-4 (DRR, Reverse drive switch) CN46-11
1 2
CN54 REC
Shift SOL
Estimated Causes:
c Connector contact defect g Controller defect
d Forward interrupt relay defect h Shift lever switch defect
e Reverse interrupt relay defect i Fuse defect
f Harness defect

Check if the OPS lamp blinks to indicate an error.
the error code.
No
No Perform troubleshooting for "OPS

Stay on the seat and check if the OPS lamp goes off.
lamp keeps lighting".
Yes
NG After correction, check if the OPS

functions normally.*
OK
Check CN6, CN45, CN46, CN52, CN53 and CN54 for any NG After correction, check if the OPS
disconnection or internal wetting. functions normally.*
OK NG
To be continued
1-70
Continued
Inspection 1: NG
Shift lever defect
Check the shift lever unit individually for continuity.
OK
Inspection 2: NG
Harness defect
Check the wirings between CN53/CN54 and the T/C relay block, and
between CN45 and CN53 for continuity.
OK
Inspection 3: NG
Check the forward/reverse interrupt relay.
OK
Controller defect
* After correction, check if the OPS functions normally.

When the operator leaves the seat with key switch ON to activate the OPS, sets the shift lever to the forward
position then sits on the seat again, check that forward traveling is disabled with the buzzer sounding at short
intervals.
Next, check that forward traveling is enabled if the shift lever is set to neutral once and then to forward again.
Inspection 1:
Check the T/C shift lever unit individually for continuity.
Key switch OFF, CN53 disconnection. 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
Standard: DIRECTION SWITCH
Lever at neutral Lever at forward Lever at reverse

Between pins 6 and 5 on lever side No continuity Continuity No continuity
Between pins 6 and 1 on lever side No continuity No continuity Continuity
Inspection 2:
Check the wiring between CN53/CN54 and T/C relay block and between CN45 and CN53 for continuity.
Turn the key switch to OFF, disconnect CN53, CN54 and CN45, and disconnect relays from the T/C relay block.
Standard:
1 2 3 4 5 6 7 8 9
Between CN53-5 and pin 4 of forward interrupt relay Continuity 10 11 12 14 14 15 16 17 18
Between CN53-1 and pin 4 of reverse interrupt relay Continuity CN53 (REC)
Between CN54-1 and pin 3 of forward interrupt relay Continuity

1 2
Between CN54-2 and pin 3 of reverse interrupt relay Continuity
CN53-6 ~ IG SW-4 Continuity CN54 (REC)
CN45-3 ~ CN53-5 Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CN45-4 ~ CN53-1 Continuity 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN45 (REC)
1-71
Inspection 3:
Check the forward/reverse interrupt relay individually.
(1) Turn the key switch OFF and remove the relays from the T/C relay block. Measure the resistance
between pins of each of forward and reverse interrupt relays. 1 4 2
(5)
3
Standard: RLY
Resistance
Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
(2) Install the relays and disconnect CN53 and CN54. Turn the key switch to ON (with the engine in stopped
state) after leaving the seat.
1 2 3 4 5 6 7 8 9
10 11 12 14 14 15 16 17 18
Standard:
CN53 (REC)
Unseated Seated
CN53-5 ~ CN54-1 No continuity Continuity 1 2

CN54 (REC)
• With analyzer
Forcibly turn each of the forward and reverse interrupt relays ON and OFF, and check the continuity in each state.
Standard:
• RLY FWD
Relay ON Relay OFF
• RLY REV
Relay ON Relay OFF
2-1
BODY
Page
COMPONENTS ....................................................2-2
RELAY BLOCK ....................................................2-3
RELAY INSPECTION ............................................2-4 2
PORTIONS PROTECTED BY FUSES ......................2-5
PROCEDURE FOR ENGINE HOOD OPENING ..2-6
SEAT SWITCH .....................................................2-7
INSPECTION ........................................................2-7
2-2
COMPONENTS
5701
2-3
RELAY BLOCK
Layout Front
Front
OPS lamp relay block Torque converter relay block
OPS T/C
LAMP FR
T/C
RR
2-4
RELAY INSPECTION
Individual Relay Continuity Inspection
Head/tail relay
Measurement
Measurement state Standard
positions
Head/tail relay
1-2 Continuity
Glow/ST relay Normal state
3-5 No continuity
When the battery voltage is
3-5 Continuity
applied to terminals 1 and 2:
Glow/ST relay
SAS-Lamp relay, OPS Lamp relay, T/C FR relay,
1-2 No continuity
T/C RR relay Normal state
3-4 Continuity
1-2 Continuity
SAS-LAMP relay, OPS Lamp relay, T/C FR relay, T/C RR relay
Normal state 1-2, 3-4 Continuity
3-4 No continuity
2-5
PORTIONS PROTECTED BY FUSES

NO Name Capacity Main protected portions
ECU-B 7.5A Mini lever controller, OPS controller
DPF2 7.5A DPF ECU activation
ST (Starting motor) 7.5A Starting motor relay (IG) and glow plug timer (IG)
SFT (Shift) 7.5A Electric shift T/C
ECU-IG 7.5A
SAS controller, steering angle sensor, and SAS error lamp relay,
OPS controller, and OPS lamp relay 2
Alternator, glow plug timer, ignition coil, emission control, ABCV,
IGN (Ignition) 7.5A injection, LPG main solenoid, LPG slow solenoid, fuel cut and
emission controller
TURN (Turn) 7.5A Turn signal lamp and flasher relay
Hour meter, water temperature gauge, fuel gauge, warning lamps

(charge, engine oil pressure, air cleaner, lock indicator,
sedimenter, glow indicator, fuel, brake, cooling water and battery),
GAUGE (Meter) 10A
back-up buzzer, T/C oil thermometer, speed meter, strobo, speed
alarm, wiper relay (coil side), heater relay (coil side), back-up lamp
and SAS buzzer
HTR (Heater) 10A Heater
WIPER (Wiper) 15A Front wiper, rear wiper, room lamp and washer motor
HORN (Horn) 7.5A Horn
ALT-S (Alternator sending) 5A Alternator sending
HEAD (Headlamp) 15A Headlamp
DPF1 15A DPF system drive circuit
TAIL (Tail) 7.5A Tail lamp, clearance lamp and meter illumination
WORK-LP (Work lamp) 10A Rear work lamp
STOP (Stop lamp) 7.5A Stop lamp
Including options
Fusible links
NO. Name Capacity Type
HTR 30A
FL
GOV 30A
Cartridge type
FL AM1 40A
FL HEAD 40A
2Z engine
120A
FL GLOW
1DZ-II engine Screw-fastened type
60A
FL ALT 80A
2-6
PROCEDURE FOR ENGINE HOOD OPENING

Excluding the Cabin
1. Move the seat to the most forward position.
2. Pull the lever for fixing lever box.
Move the mini lever box to the most backward position.
Pull the lever for fixing rotation of lever box.
Flip-up the armrest.
3. Pull the lock release lever.
Incline the steering post forward.
At Cabin
1. Move the seat to the most forward position.
2. Pull the lever for fixing lever box.
Move the mini lever box to the most forward position.
Push the lever for fixing rotation of lever box.
Incline the armrest forward.
3. Pull the lock release lever.
Incline the steering post forward.
2-7
SEAT SWITCH
INSPECTION
Push on the seat cushion and check continuity of the seat switch.
Measurement position:
Between seat switch connectors CN50-1 and CN50-2 in LH side of
engine room
Standard:
Not pushed: OFF (∞ Ω)
When pushed: ON (0 Ω)
3-1
MATERIAL HANDLING SYSTEM

Page
COMPONENTS ....................................................3-2
OIL LEAK TEST ...................................................3-3
LIFT CYLINDER ....................................................3-3
TILT CYLINDER ....................................................3-3 3
3-2
COMPONENTS
6801
3-3
OIL LEAK TEST

LIFT CYLINDER
1. Set the mast in the vertical position with the standard load on
the fork. Lift the fork by 1 to 1.5 m (40 to 59 in).
2. Slowly tilt the mast fully forward, and stop the engine. After 5
minutes, disconnect the oil control valve to oil tank hose.
Place a measuring cylinder under the elbow and measure
the amount of oil leaking in one minute.
3
Standard (at lift port): 8 cm3 (0.49 in3) or less
Note:
If the natural drop is great even though the oil leak
amount is within the standard, the lift cylinder packing is
defective.
TILT CYLINDER
1. Set the mast in the vertical position with standard load on the
fork. Lift the fork by about 50 cm (19.7 in) and stop the
engine.
2. After waiting for 5 minutes, disconnect the oil control valve to
oil tank hose. Place a measuring cylinder under the elbow
and measure the amount of oil leaking in one minute.
Standard (total for lift and tilt): 16 cm3 (0.98 in3) or less
3. The leak amount at the tilt port is the total leak amount less
the leak amount from the lift port.
Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard, either the tilt lock valve or
the tilt cylinder packing is defective.
4-1
OIL CONTROL VALVE

Page
GENERAL ............................................................4-2
SPECIFICATIONS................................................4-7
COMPONENTS ....................................................4-7
OIL CONTROL VALVE ASSY .............................4-8
DISASSEMBLY · INSPECTION · ASSEMBLY...........4-9
4
RELIEF PRESSURE ADJUSTMENT.................4-14
LIFT LOCK RELEASE BOLT ............................4-16
4-2
GENERAL
X1
T2
X2 X3 X4
OUT C2
C4
R P
X1
C5
X4
C1
C3
X2 X3
T1
4-3
X1-X1
Flow divider valve
Relief valve
Unloading SOL
X2-X2
Lift lock SOL
Manual down valve
Lift spool
Lower limit switch

4-4
X3-X3
Tilt control SOL
Tilt spool
Backward tilt limit switch Forward tilt limit switch
X4-X4
Attachment spool
4-5
SOLENOID CONNECTOR DIAGRAM
Lift limit switch connector
Lift lock solenoid connector
Unload solenoid connector
Tilt control solenoid connector
Tilt limit switch connector

4-6
HYDRAULIC CIRCUIT DIAGRAM
T2 R
(1) P
OUT
(2)
C1
(3)
C2
C3
C4
C5
T1
(1) Unloading SOL

(2) Lift lock SOL
(3) Tilt control SOL
R: Gauge port
4-7
SPECIFICATIONS
Vehicle model
1 ton series 2 ton series 3 ton series J3.5 ton series
Item
Type Add-on type

17.8 (182) 18.7 (191)
Relief set pressure Lift ← ←
[2590] [2720]
11.8 (120) 14.7 (150) 15.7 (160)
MPa (kgf/cm2) [psi] Tilt ←
[1710] [2130] [2280]
Flow divider frow rate
13.0 (3.43) ← 15.2 (4.01) ←
l/min (US gal/min)
COMPONENTS
6705
4-8
OIL CONTROL VALVE ASSY

T=N·m (kgf·cm) [ft·lbf]
T=61 (620) [449]
7
6
Removal Procedure
1 Remove the toe board.
2 Remove the lower panel.
3 Remove the instrument panel RH.
4 Disconnect the lever rod.
5 Disconnect the connector.
6 Disconnect the piping.
7 Remove the oil control valve W/bracket.
(Carefully operate so as not to damage the limit switch underneath the oil control valve.)
8 Remove the oil control valve.
9 Remove the fitting.
Remarque
• Apply grease (chassis grease) on the oil control valve lever links.
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
4-9
DISASSEMBLY · INSPECTION · ASSEMBLY

Note:
• Select a clean location for operation.
• Since each part is finished with high precision, carefully operate so as not to damage it.
T=N·m (kgf·cm) [ft·lbf]
3
9
7
6
1
10
2
4
4
5 11
5
10 11
T=39.2 (400) [28.9]
Disassembly Procedure
1 Remove the lift solenoid. [Point 1]
2 Remove the lift limit switch and spring cover. [Point 2]
3 Remove the lift spool. [Point 3]
4 Remove the tilt solenoid. [Point 4]
5 Remove the tilt limit switch and spring cover. [Point 5]
6 Remove the tilt spool. [Point 6]
7 Remove the unload solenoid. [Point 7]
8 Remove the flow divider valve. [Point 8]
9 Remove the relief valve. [Point 9]
10 Remove the attachment valve.
11 Remove the rod bolt and the housing.
Assembly Procedure
The assembly procedure is the reverse of the disassembly procedure.
Note:
Thoroughly wash each part, remove dirt by blowing compressed air, and apply hydraulic oil before
assembly.
4-10
Point Operations
[Point 1]
Disassembly:
Provide a match marks on each solenoid to ensure installation
in the correct position.
Inspection:
Inspect continuity of the lift solenoid.
Inspection:
Inspect and wash the filter to eliminate clogging.
Inspection:
Inspect and wash orifice to eliminate clogging.
Assembly:
Assemble while checking match marks.
Carefully prevent incorrect installation of each solenoid spool.
[Point 2]
Inspection:
Inspect continuity of the lift limit switch.
4-11
[Point 3]
Washer Disassembly·assembly:
Remove the compression spring from the lift spool.
SST 09610-10161-71
Use the SST with a washer.
SST
[Point 4]
Inspection:
Inspect continuity of the tilt solenoid.
Inspection:
Inspection:
Assembly:
Carefully prevent incorrect installation of each solenoid spool.
[Point 5]
Inspection:
Inspect continuity of the tilt limit switch.
Forward tilting side (between terminals 1 and 2):
No continuity when the switch is pressed.
Backward tilting side (between terminals 3 and 4):
No continuity when the switch is pressed.
Assembly:
Carefully prevent confusion between forward and backward tilt
limit switches.
4-12
[Point 6]
Washer Disassembly·assembly:
Remove the compression spring from the tilt spool.
SST 09610-19161-71
Use the SST with a washer.
SST
[Point 7]
Inspection:
Inspect continuity of the unload solenoid.
Inspection:
[Point 8]
Inspection:
[Point 9]
Inspection:
4-13
Assembly:
When the relief valve is disassembled, temporarily install it after
setting the nuts as illustrated.
a a = 27.0 mm (0.62 in)
4-14
RELIEF PRESSURE ADJUSTMENT

Note:
• Since the relief valve is structured in two stages, always adjust the relief pressure in the correct order: the
lift (high pressure) side first and the tilt (low pressure) side later. (If the lift side is normal and the tilt side
is abnormal as the result of relief pressure inspection, it is allowed to adjust only the tilt side pressure.)
• Always adjust the relief pressure as described below. Thoughtless adjustment may give rise to a high
pressure, possible damaging the hydraulic equipment such as the oil pump.
• Make sure that the no-load maximum speed is as specified before the adjustment operation.
1. Install an oil pressure gauge.
Remove the oil pressure detection port plug installed on the left
side of the oil control valve, and install the oil pressure gauge.
Plug size: 9/16-18UNF
Fitting size: 9/16-18UNF ² PF1/4
9/16-18 Fitting: 90407-13469-71
UNF
Fitting
2. Set adjusting screw A and adjusting sleeve B of the relief

Adjusting screw A valve as follows:
Lock nut 1 (1) Loosen lock nut 1 and fully tighten adjusting screw A.
Adjusting sleeve B
Then loosen it by one to two turns.
(2) Loosen lock nut 2, and position adjusting sleeve B to
a
Lock nut 2 satisfy the following dimension:

a = 27 mm (0.62 in)
3. Start the engine and check for any oil leak or abnormal noise.
4. Adjust the lift side relief pressure.
(1) Turn the seat switch to ON. (Operate by two persons with
one on the operator's seat)
(2) Operate the lift lever to raise the fork to the uppermost
position.
(3) With the engine running at the maximum speed, operate
the lift lever to the lift side. Gradually tighten adjusting
sleeve B to adjust the oil pressure in the relief state to
satisfy the standard below for adjustment, and fix it by
turning lock nut 2.
5. Adjust the tilt side relief pressure.
(1) Turn the seat switch to ON. (Operate by two persons with
one on the operator's seat.)
(2) Operate the tilt lever to tilt the mast fully backward.
(3) With the engine running at the maximum speed, operate
the tilt lever for backward tilting. Gradually tighten adjusting
screw A until the oil pressure in the relief state satisfies the
standard below. Then fix the position by turning lock nut 1.
6. Turn the key switch to OFF.
7. Remove the oil pressure gauge and tighten the plug.
4-15
Standards
Unit: MPa (kgf/cm2) [psi]
Vehicle model 1 ton series 2 · 3 ton series J3.5 ton series

Lift side relief pressure 17.8 +1.7 +17 +240
0 (182 0 )[2590 0 ] 18.7 +1.7 +17 +240
0 (191 0 )[2720 0 ]
←
Tilt side relief pressure 11.8 +1.7 +17 +240

0 (120 0 )[1710 0 ] 14.7 +1.7 +17 +240
0 (150 0 )[2130 0 ] 15.7 +1.7 +17 +240
0 (160 0 )[2280 0 ]
4-16
LIFT LOCK RELEASE BOLT T=N·m (kgf·cm) [ft·lbf]

Lift lock
unlocking bolt
T = 28.8 ~ 35.2 (294 ~ 359) [21.3 ~ 26.0]
When the forks do not descend, due to a malfunction or other cause, loosen the lift lock unlocking bolt to lower the
forks in emergencies.
After making repairs, tighten it appropriately.
5-1
MINI LEVER
Page
GENERAL ............................................................5-2
COMPONENTS ....................................................5-4
MINI-LEVER BOX ................................................5-5
DISASSEBLY · INSPECTION · ASSEMBLY .............5-7
MINI LEVER MATCHING .....................................5-8
MINI LEVER TROUBLESHOOTING....................5-9 5
CONTROLLER SEQUENCE..............................5-12
CONNECTOR LAYOUT .....................................5-13
CONNECTOR DIAGRAMS ................................5-14
5-2
GENERAL
Arm pad
Attachment lever
Tilt lever Lift lever
Lever for fixing rotation of lever box
Lift Lever-Attachment Lever
Neutral
2 3.
5° 5°
23.
5V
1
PS1
2
GND
3
PS2
4
5-3
Tilt Lever
Neutral
23.
5° 5°
23.
5V
1
PS1
2
GND
3
PS2
4
5
Connector pin arrangement
(1) Power line : Red
(2) GND line : Black
(3) Signal line : Green
Direction Switch
8 7 6 5 4 3 2 1
P T N IG1 IG2 VF ST VR Ra
F1
R
Rr
Ra
5-4
COMPONENTS
6712
6712
5-5
MINI-LEVER BOX
1
4
5
5
Removal Procedure
1 Remove the cover from the rotation lock lever and disconnect the connector.
2 Remove the bolt and remove the armrest with stand ASSY.
3 Remove the rotation lock lever. [Point 1]
4 Remove the armrest fixing knob, and remove the stand lower.
5 Remove the lever box fixing knob, and remove the stand upper. [Point 2]
6 Remove the lever box from the armrest.
Note:
Apply MP grease on the sliding contact portion before assembly.
Point Operations
[Point 1]
Reassembly :
Adjust the position of the serrated portion to satisfy the
B illustrated dimension. (Visual check allowable)
One serration notch moves the B portion by 6 mm (0.24 in).
6 ± 3 mm (0.24 ± 0.12 in)
5-6
[Point 1]
Reassembly :
Match the clamp bracket hole with the protrusion in the lever
Clamp bracket shaft, and turn the bracket as illustrated.
Reassembly :
Arm pad Tighten the flange nut to adjust the grip operating force.
Confirm no movement by manually pushing and pulling the arm
Nut A pad. If it moves, tighten the flange nut further.
Tighten nut A to the specified torque.
Grip
T = 14 N · m (143 kgf · cm) [10.3 ft · lbf]
Flange nut
5-7
DISASSEBLY · INSPECTION · ASSEMBLY
Disassembly Procedure
1 Remove the lever cover.
2 Disconnect the connector and remove each lever switch. [Point 1]
3 Remove the direction switch.
Assembly Procedure
The assembly procedure is the reverse of the disassembly procedure.
Note:
When the lift lever potentiometer, tilt lever potentiometer or attachment potentiometer is disassembled or
replaced, perform mini lever matching (see page 5-8).
[Point 1]
Disassembly :
Put tags showing connector numbers to the connectors.
Reassembly :
Connect the connectors by matching the numbers.
5-8
MINI LEVER MATCHING

Note:
Before starting matching, be sure that the vehicle conditions are as follows:
1. All levers are in neutral positions.

2. The mini lever matching connector is connected.
Mini lever lamp Mini Lever Matching Procedure

1. Turn the key switch to ON.
Note:
In case of initial matching, the mini lever lamp comes on for
two seconds and then blinks at intervals of one second. If
matching has been performed earlier, the lamp goes off after
lighting for two seconds.
2. Disconnect the mini liver matching connector.

The mini lever lamp blinks at intervals of 0.5 second.:
Mini lever matching connector (black, one pole)
3. Turn the fork automatic leveling switch ON.

The mini lever lamp goes off after lighting for two seconds.
(Matching is completed.)
Note:
Check neutral setting of all levers again, and turn the fork
automatic leveling switch ON.
4. Connect the mini lever matching connector and turn the key
switch to OFF.
5-9
MINI LEVER TROUBLESHOOTING

Note:
Troubleshooting is the same except for the following:
• Delete the following item from the items for "No error code display".
Delete: All material handling operations (all levers) disabled
For troubleshooting for this phenomenon, see the troubleshooting in the OPS section.
• Troubleshooting for the following phenomenon is changed.
Fork automatic leveling, backward tilting speed restriction and forward tilting angle restriction are invalid.
5-10
Fork automatic leveling, backward tilting speed restriction and forward tilting angle restriction are invalid.
Related portion
CN101 CN21
TAB REC REC TAB
Main harness
9 9 8 8
ECU
SAS
11 11 13 13
ECU
Body ground 23 23
CN101
TABCN101
REC CN106 CN122 CN125
TAB REC REC TAB REC TAB REC TAB
13 13
CN106 CN122 CN125
13 13 2 REC2 TAB 2 REC2 TAB 1 REC 1TAB
Fork automatic
ECU CN102 Relay 15 15 15 15 3 3 leveling switch
ECU TAB REC 3 3 1 1 2 2 Fork
Body ground automatic
13 13 3 3 4 4 2 2
leveling
switch
12 12 Body ground 2 2 5 5 1 1
Condition for error detection
•The automatic leveling switch simulation signal is not output (harness open circuit)
•The automatic leveling switch is open-circuited (harness open circuit)
•The SAS tilt control command is not output (SAS ECU defect)
Operate for forward tilting immediately after relief at the

maximum lifting height without load, and check if the Refer to SAS troubleshooting (automatic
NG
operation is stopped upon forward lifting by about 1°. leveling disabled).
(Slowly operate with the fork automatic leveling switch Check the tilt angle sensor operation.
turned to OFF.)
OK
Key switch: OFF

Disconnect CN101 and check continuity between
CN101(REC)-9 and CN21(REC)-8, between NG
Main harness defect
CN101(REC)-11 and CN21(REC)-13, and between
CN21(REC)-23 and body ground with a circuit tester.
[OK] Continuity, [NG] No continuity
OK
Key switch: ON
Check continuity between CN101(REC)-13 and body
ground with a circuit tester.
When the automatic leveling switch is ON:
[OK] Continuity, [NG] No continuity
When the automatic leveling switch is OFF:
[OK] No continuity, [NG] Continuity
OK NG
(A) (B)
5-11
(A) (B)
Key switch: ON Key switch: OFF

Perform forward tilting, connect all connectors, and Disconnect CN100, CN101, CN102 and CN 125, and
measure the voltage between CN101-1 and CN101-2 with check continuity with a tester.
a circuit tester. (REC) ~ (REC) OK NG
[OK] 4 V or more during forward tilting
[NG] Less than 4 V during forward tilting CN125-3 ~ CN101-13 Continuity No continuity
Perform backward tilting, connect all connectors, and CN125-1 ~ CN102-13 ↑ ↑
measure the voltage between CN101-1 and CN101-10
with a circuit tester. CN125-2 ~ CN102-12 ↑ ↑
[OK] 4 V or more during backward tilting CN125-1 ~ CN125-2 No continuity Continuity
[NG] Less than 4 V during backward tilting
CN125-2 ~ CN125-3 ↑ ↑
CN125-3 ~ CN125-1 ↑ ↑
OK NG OK NG
SAS ECU defect Mini lever ECU defect Fork automatic leveling Harness defect
switch defect
40A
FL AM1
RELAY BOX
CIRCUIT
AM1
IG SW
IG1
ST1
CONNECTOR
DETECTION
MATCHING
MINI LEVER
W-B
W-B
CONNECTOR
O
V-R
P-B
R-G
W-B
BOX
LG-R
LG
RELAY
RE-SETTING CONNECTOR
(CN101-7)
LG-B
COMMUNICATION DETECTION
IGN 10A
DETECTION
GAUGE
10A
W-B
RELAY
RE-SETTING CONNECTOR RE-SETTING CONNECTOR
ECU-B
TXD
RXD
GND
W-B W-G 7.5A
+12V
E2
(CN102-13)
(CN101-8)
(CN101-6)
(CN101-4)
(CN101-3)
DGND
SEAT-SW
(CN101-12)
MATCHING
MINI LEVER
G-W G-R W-G
CONNECTOR
+12V
DMI
DMO
(CN102-26)
DETECTION SW
SEAT SW W-G
OPS ECU
(CN101-16)
BR-W GND
E03
(CN102-12)
BR SAIMULADED SIGNAL COMMON W-B
GND
(CN101-1) (CN102-25)
FORK AUTOMATIC LEVELING SW
L SAS TILT CONTROL FORK AUTOMATIC
LEVELING SW OUT GND
E02
(CN101-11) G-B
TILT1
SW1
(CN101-13)
P-G FORK AUTOMATIC VCC
ATT SELECTOR SW
MN
LEVELING SW
(CN101-9) (CN101-5) MINI LEVER LAMP
Y
LG
SAS ECU
TILT FORWARD SW
E1
MF
MINI LEVER LAMP
(CN101-2) (CN102-2)
Y-B
MR
TILT BACKWARD SW W
STOP SW +
(CN101-10)
(CN102-11)
R-B
C/V
RAISE LIFT SOL +
STOP SW -
(CN100-9)
Y-B (CN102-4)
RAISE LIFT SOL -
V
RAISE LIFT
(CN100-20) POT POWER 1
V-W (CN102-4)
C/V
LOWER LIFT SOL + L-R
(CN100-8) LIFT POT 1
G-B (CN102-8)
LIFT POT1
LIFT POT2
LOWER LIFT SOL - B
LOWER LIFT
(CN100-19) POT GND1
B-O (CN102-10)
TILT BACKWARD SOL +
C/V
G-R
TILT
(CN100-6) LIFT POT 2
L-O (CN102-21)
TILT CACKWARD SOL -
Y
(CN100-17) POT POWER 2
G-O (CN102-17)
TILT FORWARD SOL +
MINI LEVER ECU
C/V
TILT
(CN100-7) L-Y
TILT POT 1
W-L
(CN102-7)
TILT POT1
TILT FORWARD SOL -

TILT POT2
BACKWARD FORWARD
(CN100-18) B-Y
POT GND 2
Y (CN102-23)
ATT1-1SOL +
C/V
(CN100-5 ) G-Y
TILT POT 2
BR-W
ATT1-1
ATT1-1 SOL - (CN102-20)

(CN101-16) R-W
Y-R POT POWER 3
ATT1-2 SOL + (CN102-3)
(CN100-4)
C/V
P
LG-B ATT1POT1
ATT1-2
ATT1-2 SOL - (CN102-6)

(CN100-15)
ATT1 POT1
ATT1 POT2
B-W
Y-G POT GND3
ATT2-1 SOL + (CN102-9)
(CN100-3)
C/V
G-W
L-B ATT1POT2
ATT2-1
ATT2-1 SOL - (CN102-19)

(CN100-14)
V POT POWER 4 Y-G
ATT2-2 SOL +
(CN100-2) (CN102-16)
C/V
GR L
ATT2-2
ATT2-2 SOL - ATT2POT1

(CN100-13) (CN102-5)
ATT2 POT1
ATT2 POT2
V-G BR
ON-OFF SOL + POT GND4
C/V
(CN100-1) (CN102-22)
B ATT2POT2 G
ON-OFF SOL -
ON-OFF
(CN100-12) (CN102-18)
CONTROLLER SEQUENCE
5-12
5-13
CONNECTOR LAYOUT
OPS ECU
CN45
CN53
SHIFT SW
CN60
Note:
Connector Nos. are only the mini lever, and they do not agree with the SAS and OPS connector Nos.
5-14
CONNECTOR DIAGRAMS
5-15
CN110 CN60, CN113
1 1 2 1 1 2
TAB REC TAB REC
CN125
CN126, CN127, CN128, CN129
1 2 3 4 4 3 2 1
TAB REC
CN45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
TAB REC
CN106, CN122
6 5 4 3 2 1 1 2 3 4 5 6
15 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14 15
TAB REC
CN12
13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13
TAB REC
6-1
SAS
Page
RE-SETTING ........................................................6-2
RE-SETTING PROCEDURE (VEHICLE WITH MINI
LEVER) .............................................................6-2
CUSTOMIZE.........................................................6-4
CUSTOMIZE PROCEDURE (VEHICLE WITH MINI
LEVER) .............................................................6-4
TROUBLESHOOTING .........................................6-5
TROUBLESHOOTING BY ERROR CODE ................6-6
TROUBLESHOOTING BY PHENOMENON ............6-10 6
CONNECTOR LAYOUT (SAS, OPS).................6-15
CONTROLLER SEQUENCE (SAS, OPS) .........6-16
CONNECTOR DIAGRAMS (SAS, OPS)............6-17
6-2
RE-SETTING
Re-setting of the mini-lever specification vehicle is possible either by the hour meter and the lift lever or by the plug-
in analyzer.
For the method by the plug-in analyzer, refer to page 15-40 in repair manual No. CE026.
This manual describes the method by the hour meter and the lift lever.
Refer to page 15-21 in repair manual No. CE026 for the standard vehicle conditions for the re-setting operation.
SAS Re-setting connector RE-SETTING PROCEDURE (VEHICLE WITH

(White, 2-pole)
MINI LEVER)
Note:
Turning the key switch ON (or starting engine) after
disconnecting the re-setting connector causes an error (error
code 41) to be displayed and stored to the controller, for
which care must be taken.
1. Turn the key switch ON (or start the engine).
2. Disconnect the re-setting connector (white color).
(1) The hour meter display reads "SET" and the SAS lamp
Raise Lift side turns ON.
Note:
Upward lift operation is disabled after re-setting connector
disconnection until the end of re-setting. (Downward lift
operation is possible).
3. Operate the lift lever for 2 seconds or more in the up
direction until the re-setting mode (SET1) is displayed.
4. Display the set number subject to the re-setting.
(1) Set number display changes sequentially each time the lift
lever is operated (for less than 2 seconds) in the up
direction.
Lift lever
Note:
Be careful since re-setting starts if you operate the lift lever in
the up direction for two seconds or more.
Set No. Object of re-setting
SET1 Fork stop position with automatic leveling
SET2 Forward tilting limit position and no-load standard load
SET3 Tires in straight traveling position
SET4 *1 –
*1: Indication may be made but actually it is not used.
5. Set the sensor of the display set number to the standard

state (or check if it is in the standard state). (See page 15-21
in the Repair Manual (No. CE026))
6-3
6. Execute re-setting by operating the lift lever for 2 seconds or

more in the up direction.
O indication
O indication: Re-setting is completed. (SAS lamp starts to
blink)
H indication: Check for the sensor abnormality,
H indication disconnection of the harness and the short-
circuit since the signal voltage value is outside
the re-setting rang. (Read the troubleshooting
section.)
Note:
• For re-re-setting, repeat Step 6.
• To make a separate re-setting, repeat Steps 4 to 6.
7. Connect the re-setting connector and turn the key switch
OFF.
6
6-4
CUSTOMIZE
Customize operation of the mini-lever vehicle is possible either by the hour meter and the lift lever or by the plug-in
analyzer.
Refer to page 15-42 in repair manual No. CE026 for the method by the plug-in analyzer.
This manual describes the method by the hour meter and the lift lever.
Caution:
When the customize is changed, maintain the caution label of "CAUTION FOR OPERATION."
SAS Re-setting connector CUSTOMIZE PROCEDURE (VEHICLE WITH

(White, 2-pole)
MINI LEVER)
Note:
Turning the key switch ON (or starting engine) after
disconnecting the re-setting connector causes an error (error
code 41) to be displayed and stored to the controller, for
which care must be taken.
1. Turn the key switch ON (or start the engine).
2. Disconnect the re-setting connector. (white color)
(1) The hour meter display reads "SET" and the SAS lamp
Tilt lever turns ON.
Note:
Upward lifting is disabled after re-setting connector
disconnection until the end of customize operation.
(Downward lift operation is possible).
3. With the tilt lever kept operated for 5 seconds or more in the
backward tilt direction, operate the lift lever in the up
direction until the option set mode (OPT1) is displayed, and
then return both levers.
Lift lever 4. Display the option number to change the option set.
(1) The displayed set No. changes each time the lift lever is
operated (for less than 2 seconds) in the up direction.
Option No. Control name
OPT1 Mast forward tilt angle control
OPT2* –
*: Displayed but not in use.
5. When the lift lever is operated for 2 seconds or more in the

up direction until the SAS lamp blinks, the display changes
from y to n (y→n) or from n to y (n→y).
y: Control valid
n: Control invalid
Note:
When invalid Upward lifting is disabled after re-setting connector
disconnection until the end of customize operation.
(Downward lift operation is possible).
6. Connect the re-setting connector and turn the key switch

When valid OFF.
7. Perform the maintenance of caution label.
If the control is invalidated:
Remove the pertinent validation indication to replace with
invalid indication.
If the control is validated:
Replace the caution label to indicate valid control.
6-5
TROUBLESHOOTING
Troubleshooting is described only for the portion changed by adoption of the OPS.
List of Reference Pages for Error Codes and Sub Error Codes
Without analyzer (SST) With analyzer (SST)
Error code Error description Page Error code Error description Page
63-1 Tilt lever switch simultaneous ON 6-6

Forward tilt switch short circuit for 2
63-2 6-6
63 Tilt lever switch abnormality 6-6 minutes
Backward tilt switch short circuit for 2
63-3 6-6
minutes
64 Tilt solenoid abnormality 6-8 64-1 Tilt solenoid abnormality 6-8
List of Pages to Be Referenced by Phenomenon
Description
Page to be referenced
6
Without analyzer With analyzer
The active mast rear tilt speed control is not regulated, or the
6-10 6-13
Active mast
controller
backward tilting speed is always slow.

function
See "Mast forward tilting fails." section in OPS

The mast does not perform front tilt.
Troubleshooting.
6-6
TROUBLESHOOTING BY ERROR CODE

z Error code 63 (Tilt lever switch abnormality)
z Error code 63-1 (Both tilt lever switches ON at the same time)
z Error code 63-2 (Forward tilt switch 2-minute short circuit)
z Error code 63-3 (Backward tilt switch 2-minute short circuit)
Related Portion
CN1-10 (MF, Forward tilt switch) CN45-22

SAS controller
CN45-21
OPS controller
CN1-9 (MR, Backward tilt switch) CN46-10 CN45-20
REC
REC
TAB
TAB
REC
TAB
CN1-23 (E02, SW-GND) CN45-17
J1
CN45-24
CN45-25
CN34-1
Forward tilt
CN34-2
switch
REC
TAB
CN34-3
Backward tilt
switch
CN34-4
Estimated Causes:
c Connector contact defect f Backward tilt switch defect
d Harness defect g Tilt switch installation defect
e Forward tilt switch defect h Controller defect
Error code 63
Check CN1, CN45 and CN46 for any disconnection or internal NG After correction, check the indication
wetting. by the SAS lamp. *
OK NG
Inspection 1: OK
Check the wiring between the tilt lever switch and the OPS controller
for continuity.
NG
Inspection 2: NG
Harness defect
OK
Perform troubleshooting for error code 2 for the OPS controller. For
this defect, the SAS lamp blinks instead of the OPS lamp.
* After the ignition switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward. Make
sure that the 2-minute waiting SAS lamp blinks when the tilt lever is on the neutral position.
6-7
Inspection 1:
Check continuity through the tilt lever switch wiring.
Turn the key switch OFF and disconnect CN1.
Standard: CN1 (REC)

Circuit tester
CN1-10 (+) ~ CN1-23 (-) No continuity Continuity No continuity
Digital type
CN1-9 (+) ~ CN1-23 (-) No continuity No continuity Continuity
CN1-10 (-) ~ CN1-23 (+) No continuity Continuity No continuity
Analog type
CN1-9 (-) ~ CN1-23 (+) No continuity No continuity Continuity
Inspection 2:
Turn the key switch OFF and disconnect CN1 and CN45.
CN1 (REC)
Standard:
CN1-10 ~ CN1-9 : No continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CN1-10 ~ CN1-23 : No continuity

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN1-9 ~ CN1-23 : No continuity CN45 (REC)

Between CN1-10 and frame : No continuity
Between CN1-9 and frame : No continuity
6-8
z Error Code 64 · 64-1 (Tilt solenoid abnormality)
Related Portion
CN1-13 (TILT, Tilt solenoid) CN45-5
OPS controller
REC
SAS controller
TAB
CN45-29
REC
TAB
CN45-30
CN45-12
CN1-24 CN12-1
REC
TAB
(E1, main GND) CN46-8 Tilt solenoid
REC
TAB
CN12-2
CN46-9
(E3, body ground)
Estimated Causes:
c Connector contact defect e SAS controller defect
d Harness defect f OPS controller defect
Check CN1, CN45 and CN46 for any disconnection or internal NG After correction, check the indication
wetting, and disconnected the body ground. by the SAS lamp.*
OK NG
Inspection 1: NG
Harness defect
OK
Inspection 2: NG
Measure the resistance between input pins of OPS controller.
OK
* After correction, check the indication by the SAS lamp.

Start the engine and operate for forward and backward tilting to check if the SAS lamp blinks.
The SAS lamp must not blink.
6-9
Inspection 1:
Turn the key switch OFF, and disconnect CN1 and CN45.
Standard:
CN1-13 ~ CN45-5: Continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CN1-24 ~ CN45-29: Continuity 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
CN1-24 ~ CN45-30: Continuity CN45 (REC)
• GND fault check

CN1-13 ~ CN1-24: No continuity
• +B shorting check 1 2 3 4 5 6 7 8 9 10 11 12 13
CN45-5 ~ CN45-32: No continuity 14 15 16 17 18 19 20 21 22 23 24 25 26
CN1 (REC)
• Ignition line shorting check
CN1-13 ~ CN1-11: No continuity
Inspection 2:
Measure the resistance between input pins of the OPS controller.
Turn the ignition switch OFF, and disconnect CN45. 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard: CN1 (REC)

CN45-4 ~ CN45-31: Approx. 800Ω (at 20°C)
6-10
TROUBLESHOOTING BY PHENOMENON
z The active mast rear tilt speed is not regulated, or the backward tilting speed is always
slow.
Related Portion
Active fork leveling switch

(MN Tilt knob SW)
Controller
(E02 SW-GND)
Lifting height switch
(E02, SW-GND)
Lifting height switch

(MH1, Lifting
Controller
height sensor 1)
(MH21, Lifting
height sensor 21)
6-11
Without
analyzer
Stopping with automatic
leveling occurs when tilted
forward (without pressing
the automatic leveling
switch) when the fork is
raised to approx. 500 mm
(19.6 in) without a load.
NO YES
Stopping with automatic Check connectors CN1 and Check if the backward
NG NG
leveling occurs upon CN33 for disconnection or tilting speed is normal after
automatic leveling switch internal wetting. the repair.
operation when the fork OK NG
is raised to approx.
500 mm (19.6 in) without
Inspection1 OK
a load. Controller defect.
Check the automatic
OK leveling switch wiring for
continuity.
NG
Inspection 2 NG Automatic leveling switch

Check continuity of the defect.
automatic leveling switch
alone.
OK
Inspection 3 NG
Harness defect.
Check continuity between
CN1 and CN33.
OK
CN33 connector defect.
Inspection 4 Perform troubleshooting

OK
Check continuity of the fork for "The mast backward
height switch alone. tilting speed is always slow
NG or unrestricted". (P. 1-58).
Fork height switch

abnormality.
6-12
Inspection 1:
Check continuity of the active fork leveling switch wiring.
Key switch OFF, CN1 disconnection.
Standard: CN1 (REC)

Active fork leveling switch free
depressed
Inspection 2:
Check continuity of the active fork leveling switch only.
Standard:
CN33 (TAB)
Active fork leveling switch Active fork leveling switch
free depressed
Inspection 3:
Turn the key switch OFF and disconnect CN1 and CN33.
Standard: CN1 (REC)

CN1-8 ~ CN33-1: Continuity
CN33 (REC)
Inspection 4:
Check continuity of the lifting height switch only.
CN31 (REC)
Standard:
Low lifting height High lifting height
6-13
With analyzer
OK Inspection 1
Check the output signal of the
active fork leveling switch.
NG
Check for slip off of the CN1 NG After correction, check the
and CN33 connectors. backward tilting speed.
OK NG
Inspection 2 OK CN1 connector or

Check continuity of the active controller defect
fork leveling switch wiring.
NG
Inspection 3 NG Active fork leveling switch

Check continuity of the individual defect
active fork leveling switch.
OK
Inspection 4 NG
Harness defect
Check continuity between
CN1 and CN33.
OK
CN33 connector defect.
Inspection 5 OK
Perform troubleshooting
Check the output signal of for "The mast backward
the lifting height switch. tilting speed is always slow
or unrestricted". (P. 1-58).
NG
Inspection 6 NG
Lifting height switch defect
Check continuity of the
individual lifting height switch.
OK
Controller defect.
Inspection 1
Check the output signal of the active fork leveling switch.
Turn the key switch ON (with the engine in stopped state).
Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA
Standard:
Active fork leveling Active fork leveling
switch free switch depressed
KNOB OFF ON
6-14
Inspection 2:
Check continuity of the active fork leveling switch wiring.
Standard:
free depressed
CN1 (REC)
Inspection 3:
Check continuity of the active fork leveling switch only.
Standard:
free depressed
CN33 (TAB)
Inspection 4:
Key switch OFF, CN1 and CN33 disconnection.
Standard:
CN1-8 ~ CN33-1: Continuity CN1 (REC)
Inspection 5:
CN33 (REC)
Check the output signal of the lifting height switch.
Turn the key switch ON (start the engine).
Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA
Standard:
When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows:
SW1: ON
SW21:OFF
SW22:OFF
Inspection 6:
Check continuity of the lifting height switch only.
Standard:
Low lifting height High lifting height
CN31-1 ~ CN31-3 No continuity Continuity CN31 (REC)
6-15
CONNECTOR LAYOUT (SAS, OPS)
COMB MET
HOUR MET
SAS LP MAST SW1
SWN LOCK LP
OPS LP SHIFT SW
PRES SSR CN53
SPD SSR REC
CN22 CN31 TAB
TAB
REC CN26
OPS LAMP
OPS BZR
RLY(OPS LAMP R/B)
TAB SAS BZR NTRL TILT SW

REC
STRG SSR
TAB REC FPC

CN51 CN3 TAB TAB
REC TAB TAB
REC
CN33
REC
REC TAB
CN43 CN21 SAS ECU REC
CN41 CN42
TAB TAB
REC REC CN2 CN27
CN1
CN37
REC
TAB
TAB
REC
HOUR CN12 CN34 TILT AGL

T/C RLY SHIFT SOL REC
MET CNN REC SSR
(T/C R/B) TAB
TAB
CN46
TAB TAB
OPS J/C REC REC CN54
REC
CN52 TAB CN47
REC
TAB
TAB CN35 TILT TILT SW1

DIAG SW REC
SOL TILT SW2
(CHKR) SAS RE-SETTING
FR W/H
OPS ECU REC

CN48 UNLOAD
REC REC
TAB
TAB TAB
CN49 SOL
TAB
CN44
CN4 FR W/H
REC CN45
REC TAB TAB DIODE A
TAB CN5 REC REC CN55
E/G W/H CN6
SIDE W/H
REC
DOWN LIFT
TAB
CN50
REC LOCK SW
TAB CN14 STRG SEAT SW SOL
SOL
SAS-LAMP RLY TAB CN60

(R/B) REC
SIDE FR LWR
W/H W/H
REC
TAB
CN7
REC REC
TAB CN11 TAB CN23
SWN TIRE AGL

SOL SSR
6-16
CONTROLLER SEQUENCE (SAS, OPS)

SFT(7.5A)
8 EF1
W/SPLICE
FL AM1
T/C SYSTEM
IG1 ECU-IG(7.5A)
6 EF1
(40A)
10 EF1
SHIFT LEVER
BUS BAR
GAUGE(10A)
3 EF1
Table 1
ECU-B(7.5A)
9 EF2
A
(MH1) (E02) (MH1)
T/C FR T/C RR (E02)
TILT SWITCH RB
TILT SWITCH FB
(MH21) (MH21)
RELAY RELAY
SEAT SWITCH
LIFT SWITCH
(MH22) (MH22)
5 FT1 7 FT1 *1 SAS spec. *1 SAS less spec.

JOINT1
2 SY1
2 FS2
JOINT4 JOINT3
SOLENOID
SOLENOID
*1 : "SAS less spec." has not been applied to your destination.
RB
FB
D2 PEDAL DIODE A
FT1 1 SY1
11
DIRECTION DIRECTION 8 FF1
1 FF1 6 FF1 3 FS2
SWITCH FR SWITCH RR
SAS SYSTEM
FT1 4
FF1 5
DRF
SPI1
SPI2
DGND
RYF
TRI
DRR
DMI
DOWN
DMO
E03
RYR
TFI
TIRE ANGLE
TILT ANGLE
SHIFT SOL SHIFT SOL IG
SAS RE-SETTING
RELAY(FR) RELAY(RR)
SENSOR
SENSOR
BATT
4 FF1
BCON IG
CONNECTOR
CONNECTOR
TILT SWITCH
W/SPLICE
See Table1.
MATCHING
OPS CONTROLLER
NEUTRAL
STARTER PRESS
BCIN SENSOR - + - +
RELAY N/O RELAY
TCON
TGND
- +
RYLP
SOL1
SOL2
SOL3
NO.1
3 FF1
W/SPLICE
TRO
BZO
SIL
TFO
E3
E3
E2
FT1 2
6
3 FT2 6 FT2
10
9 FF1 5 FS2
MAST SWITCH
FF1
2 FF1 - + 1
PARKING 8 FF1 STEERING
FS2
SWITCH W/SPLICE SENSOR
MF1
T/C FR T/C RR 2 YAW RATE
RELAY RELAY MF1 SENSOR
- +
4
OPS BUZZER 7 MF1
TO
MF1
UNLOAD
SOLENOID
DOWN LOCK
SOLENOID
TILT
SOLENOID
E03
5 FT1 7 FT1
MF
SS2
5SA
SW1
SW2
MH21
MH22
MR
5MA
MN
SS1
SSC
SA
5PRS
5T
PRES
MH1
E01
MA
T
E02
IG
JOINT4 JOINT3
SOLENOID RB
SOLENOID FB
JOINT2
SAS CONTROLLER
SHIFT
SHIFT
HRM1
HRM2
HRM3
STRG
OUT1
SPDF
SPD+
SPD-
SWN
TRG
SPD
SIL
TILT
YB1
RLY
E1
DIODE A
8 FT1
11
1 FF1 FF1 7
CHKR FS2
SPEED
RYF
DRF
RYR
DRR
ANALYZER TRG SENSOR

STEERING SWING
PLUG-IN
SIL SAS-LAMP
OPS CONTROLLER RELAY SOLENOID SOLENOID
11
EF2
IG
10
EF2
E0 COMBINATION METER
L L L
OPS-LAMP OPS SAS LOCK

RELAY LAMP WARNING INDICATOR
3 EF3
LAMP
6-17
CONNECTOR DIAGRAMS (SAS, OPS)
CN1
13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13
26 25 24 23 22 21 20 19 18 17 16 15 14 14 15 16 17 18 19 20 21 22 23 24 25 26
TAB REC
No. C J No. C J
1 5PRS 1 G- CN3-1
2 SIL 2 V CN46-3
3 MH1 3 L- CN3-7
4 MH21 4 L-B CN3-4
5 MH22 5 - -
6 SW2 6 LG-B CN44-23
7 SW1 7 LG CN35-1
8 MN 8 P-G CN33-1
9 MR 9 Y-B CN45-21
10 MF 10 Y CN45-22
11 IG 11 B-R W/SPLICE-Y(IG)
12 TLT2 12 - -
13 TLT1 13 L- CN45-5
14 5MA 14 G-R CN27-1
15 5T 15 P-B CN4-6
16 YR 16 - -
17 MA 17 Y-G CN27-2
18 PRES 18 G-Y CN3-2
19 - 19 - -
20 T 20 G-W CN4-5
21 SA 21 - -
22 E01 22 BR- W/SPLICE-A
23 E02 23 BR- W/SPLICE-A
24 E1 24 W-B BODY EARTH05
25 SWN 25 L-B CN4-7
26 STRG 26 L-W CN6-11
CN2
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16
TAB REC
No. C J No. C J
1 RLY 1 L-W CN5-11
2 - 2 - -
3 HRM1 3 V-G CN41-4
4 SPD+ 4 G-B CN22-1
5 SPD- 5 G-R CN22-2
6 SS1 6 Y-R CN21-3
7 SS2 7 V-W CN21-4
8 5SA 8 - -
9 OUT1 9 L-O CN42-9
10 SPDF 10 P-B CN6-5
11 HRM3 11 P-L CN42-12
12 HRM2 12 V-R CN41-3
13 SPD 13 P- CN6-7
14 SSC 14 LG-B CN21-5
15 YB1 15 - -
16 TRG 16 L-B CN44-14
6-18
CN3 (MF1) CN4 (FS2)
4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8 8 7 6 5 5 6 7 8
TAB REC TAB REC

No. C J No. C J No. C J No. C J
1 G CN1-1 1 G CN26-3 1 Y-B * 1 Y-B *
2 G-Y CN1-18 2 G-Y CN26-2 2 BR CN50-2 2 BR-W JOINT 1
3 BR W/SPLICE-A(E) 3 BR-W CN31-1 3 G-W CN50-1 3 G-W CN45-23
4 L-B CN1-4 4 L-B CN31-3 4 BR CN7-3 4 BR CN1-22
5 BR W/SPLICE-A(E) 5 BR CN26-1 5 G-W CN7-2 5 G-W CN1-20
6 - - 6 - - 6 P-B CN7-1 6 P-B CN1-15
7 L CN1-3 7 L CN31-2 7 L-B CN7-4 7 L-B CN1-25
8 - - 8 - - 8 - - 8 - -
Note:
*: Terminal not related to SAS and OPS.
Parenthesized connectors are used
also for other functions than SAS.
For function other than SAS, see the
electrical wiring diagram in Section 7.
CN5 (EF2)
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9 9 10 11 12
TAB REC
No. C J No. C J
1 R-L * 1 R-L *
2 R-B * 2 R-B *
3 R-W * 3 R-W *
4 G-Y * 4 G-Y *
5 R-Y * 5 R-Y *
6 W * 6 W *
7 LG-B * 7 LG *
8 W-B BODY EARTH 05 8 W-B STARTER RLY(-S)
9 W-R CN45-32 9 W-R F=ECU-B
10 P-G CN41-1 10 P-G SAS-LAMP RLY(B)
11 L-W CN2-1 11 L-W SAS-LAMP RLY(+S)
12 W-B BODY EARTH 02 12 W-B CN14-2,*
6-19
CN6 (EF1) CN12
2 1 1 2
3 2 1 1 2 3
5 4 4 5
6 6 TAB REC
8 7 7 8 No. C J No. C J
1 R Phorting: (+) 1 GR-R CN45-12
11 10 9 9 10 11 2 B Phorting: (-) 2 W-B W/ SPLICE-Z (E)
TAB REC
No. C J No. C J
1 B- * 1 B- * CN14
2 B-W * 2 B-W *
3 B-R W/SPLICE-Y (IG) F=ECU-IG (L)
3 B-R 2 1
4 B-W * SAS-LAMP RLY (-S) 1 2
5 P-B CN2-10 4 B-W *
6 B-Y * 5 - -
TAB REC
7 P- CN2-13 6 B-Y *
8 L CN53-6 7 - - No. C J No. C J
9 W-B OPS-LAMP RLY (L) 8 L F=SFT 1 L-W CN6-11 1 Phorting: (+)
10 W-L * 9 W-B SAS-LAMP RLY (L) 2 W-B CN5-17 2 Phorting: (-)
11 L-W CN1-26 10 W-L *
11 L-W CN14-1
CN21
CN7 (LS1) 2 1 1 2
6 5 4 3 3 4 5 6
2 1 2 1 TAB REC
5 4 3 3 No. C J No. C J
4 5
7 6 1 - 1G(12V) 1 B-R W/ SPLICE-Y (IG)
6 7 2 - GND 2 BR- W/ SPLICE-A (E)
3 - SS1 3 Y-R CN2-6
4 - SS2 4 V-W CN2-7
TAB REC
5 - SSC 5 LG-B CN2-14
No. C J No. C J 6 - * 6 - *
1 P-B CN4-6 1 P- CN23-1
2 G-W CN4-5 2 G-W CN23-2
3 BR- CN4-4 3 W-B CN23-3,CN24-1
4 L-B CN4-7 4 L-B CN11-1
5 W-B BODY EARTH03 5 W-B CN11-2 CN22
6 - - 6 - -
7 - - 7 - -
2 1 1 2
TAB REC
CN11 No. C J No. C J
1 +S 1 G-B CN2-4
2 -S 2 G-R CN2-5
2 1 1 2
TAB REC
No. C J No. C J
1 - Phorting: (+) 1 L-B CN7-4
2 - Phorting: (-) 2 W-B CN7-5
6-20
CN23
CN33
3 2 1 2 1
1 2 3 1 2
TAB REC TAB REC

1 - Sensor power supply 1 P- CN7-1 1 BR 5V or GND 1 P-G CN1-8
2 - Sensor output 2 G-W CN7-2 2 BR GND or 5V 2 BR W/SPLICE-A
3 - Sensor GND 3 W-B CN7-3
CN34
CN26
2 1 1 2
3 2 1 1 2 3
4 3 3 4
TAB REC
TAB REC
No. C J No. C J
No. C J No. C J
1 - GND (Ground) 1 BR CN3-5
1 R Forward tilt side (+) 1 P-G CN45-25
2 - Vout (output) 2 G-Y CN3-2
2 BR Forward tilt side (-) 2 BR-W JOINT 1
3 - Vcc power supply 3 G CN3-1
3 R Backward tilt side (+) 3 P-L CN45-24
4 B Backward tilt side (-) 4 BR-W JOINT 1
CN27
CN35
3 2 1 1 2 3
1 1
TAB REC TAB REC

1 - Power supply 1 G CN1-14 1 BR- 1 LG- CN1-7
2 - Sensor output 2 Y-G CN1-17
3 - GND 3 BR W/SPLICE-A
CN31
3 2 1
1 2 3
TAB REC
No. C J No. C J
1 BR-W CN3-3 1 BR COM
2 L CN3-7 2 W NC
3 L-B CN3-4 3 R NO
6-21
CN37 CN43
2 1 1 2 2 1
1 2
TAB REC
No. C J No. C J TAB REC
1 P-G CN5-10 1 L-W CN43-1 No. C J No. C J
2 W-B BODY EARTH02 2 Y-B CN41-6 1 B GND 1 L-W SAS relay
2 R Power supply 2 R-G Fuse
CN41
CN44
1 2 3 4 5 6 7 8 9 10 11 12 13
1 2 3 4 5 6 18
REC 19
7 8 9 10 11 20
No. C J
1 P-G CN5-10 12 13 14 15 16 17 21 22 23
2 Y-R * REC
3 V-R CN12-2 No. C J
4 V-G CN2-3 1 V JOINT 2
5 - * 2 - *
6 Y-B CN37-2 3 BR-W BODY EARTH02
7 W-B BODY EARTH02 :
8 V- * :
9 - - :
10 LG-R * :
11 - - :
12 G OPS-LAMP RLY (B) 12 B-R W/ SPLICE-Y (IG)
13 Y- * 13 *
14 L-B CN2-16
:
:
CN42 22 BR W/ SPLICE-A (E)
23 LG-B CN1-6
1 2 3 4 5 6 7 8 9 10 11 12 13
REC
No. C J SAS Lamp relay (Base side)
1 - -
2 LG-B *
3(B)
3 W-B BODY EARTH02
4 R-W * 5
5 - -
6 R-G * 1 4 2
(+S) (L) (-S)
7 Y-B *
8 R- *
9 L-O CN2-9 No. C J
10 - - 1 L-W CN5-11
11 G- * 2 B-R CN6-3,F=ECU-IG
12 P-L CN2-11 3 P-G CN5-10
13 W-B BODY EARTH02 4 W-B STARTER RLY(-S),CN6-9
5 - -
6-22
CN45
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
TAB REC
No. C J No. C J
1 SIL 1 V CN46-3
2 - 2 - -
3 DRF 3 G-R CN46-1
4 DRR 4 R CN46-11
5 TCON 5 L CN1-13
6 - 6 - -
7 - 7 - -
8 RYLP 8 O OPS-LAMP RLY (-S)
9 BZO 9 W-G CN51-2
10 RYF 10 G T/C FR RLY (+S)
11 RYR 11 Y-R T/C RR RLY (+S)
12 SOL3 12 GR-R CN12-1
13 SOL2 13 GR-L CN48-1
14 SOL1 14 GR-G CN47-1
15 IG 15 B-R CN46-5
16 IG2 16 B-R CN46-4
17 E03 17 BR-W CN46-6
18 - 18 - -
19 - 19 - -
20 TGND 20 BR CN46-10
21 TRO 21 Y-B CN1-9
22 TFO 22 Y CN1-10
23 DMI 23 G-W CN4-3
24 TRI 24 P-L CN34-3
25 TFI 25 P-G CN34-1
26 DOWN 26 P-B CN49-1
27 - 27 - -
28 - 28 - -
29 E3 29 W-B CN46-9
30 E3 30 W-B CN46-8
31 E2 31 W-B CN46-2
32 BATT 32 W-R CN5-9
CN46
5 4 3 2 1 1 2 3 4 5
11 10 9 8 7 6 6 7 8 9 10 11
TAB REC
No. C J No. C J
1 G-R CN45-3 1 G-R T/C FR RLY (B)
2 W-B CN45-31 2 W-B BODY EARTH10
3 V CN45-1 3 V CN1-2
4 B-R CN45-16 4 B-R W/SPLICE-Y (IG)
5 B-R CN45-15 5 B-R W/SPLICE-Y (IG)
6 BR-W CN45-17 6 BR-W T/C RR RLY (-S)
7 - - 7 - -
8 W-B CN45-30 8 W-B W/SPLICE-Z (E)
9 W-B CN45-29 9 W-B W/SPLICE-Z (E)
10 BR CN45-20 10 BR W/SPLICE-A (E)
11 R CN45-4 11 R T/C RR RLY (B)
6-23
CN47 CN52 (FT1)
4 3 2 1 1 2 3 4
2 1 1 2
8 7 6 5 5 6 7 8
TAB REC
TAB REC
No. C J No. C J
1 W - 1 GR-G CN45-14 No. C J No. C J
2 W - 2 W-B W/ SPLICE-Z (E) 1 Y-R * 1 Y-R *
2 G * 2 G *
3 L-B * 3 R-Y *
4 L * 4 G-W *
5 L-W CN54-1 5 L-W T/C FR RLY (L)
CN48 6 - - 6 - -
7 L-R CN54-2 7 L-R T/C RR RLY (L)
8 W-B W/SPLICE-F (E) 8 W-B BODY EARTH02
2 1
1 2
TAB REC CN53

No. C J No. C J
1 W - 1 GR-L CN45-13 (LH SHIFT LEVER)
2 W - 2 W-B W/ SPLICE-Z (E)
(MINI LEVER)
1 2 3 4 5 6 7 8 9
CN49 10 11 12 13 14 15 16 17 18
2 1 (RH SHIFT LEVER)

1 2
9 8 7 6 5 4 3 2 1
TAB REC 18 17 16 15 14 13 12 11 10
No. C J No. C J
1 R - 1 P-B CN45-26
2 B - 2 BR-W JOINT1 REC
No. C J
1 R T/C RR RLY (B)
2 R-Y *
3 B/B-Y *
CN50 (SY1) 4 - -
5 G-R T/C FR RLY (B)
6 L CN6-8
2 1 1 2
7 B-W *
8 R-G *
9 - -
TAB REC 10 - -
No. C J No. C J 11 - -
1 G-W CN60-1 1 G-W CN4-3 12 - -
2 BR CN60-2 2 BR CN4-2 13 - -
14 - -
15 - -
16 - -
17 - -
CN51 18 - -
2 1 1 2
CN54
TAB REC
No. C J No. C J
1 - - 1 B-R W/SPLICE-Y (IG) 2 1 1 2
2 - - 2 W-G CN45-9
TAB REC
No. C J No. C J
1 - FB 1 L-W CN52-5
2 - RB 2 L-R CN52-7
6-24
CN55 T/C FR RLY

(Base side, in T/C R/B)
3 2 1 1 2 3
3
TAB REC 5
No. C J No. C J
1 - + 1 L-W JOINT4 1 4 2
2 - - 2 W-B BODY EARTH02
3 - + 3 L-R JOINT3
REC
No. C J
1 BR-W T/C RR RLY (-S)
2 G CN45-10
CN57 (FT2) 3 L-W CN52-5
CN46-1,
4 G-R
CN53-5 or CN57-3
3 2 1 1 2 3 5 - -
6 5 4 4 5 6
TAB REC T/C RR RLY

No. C J No. C J
1 R-W * 1 R-W * (Base side, in T/C R/B)
2 B * 2 B *
3 G-R SFT SOL RLY (FR) (NO) 3 G-R T/C FR RLY (B) 3
4 R-G * 4 R-G *
5 B-W * 5 B-W * 5
6 R SFT SOL RLY (RR) (NO) 6 R T/C RR RLY (B)
1 4 2
REC
No. C J
CN60 1 BR-W T/C FR RLY (-S),CN46-6
2 Y-R CN45-11
3 L-R CN52-7
2 1 1 2 CN46-11,
4 R
CN53-1 or CN57-6
5 - -
TAB REC
No. C J No. C J
1 - + 1 G-W CN50-1
2 - - 2 BR CN50-2
OPS-LAMP RLY
(Base side, in OPS R/B)
SFT SOL RLY (FR) SFT SOL RLY (RR) 3
5
1 2 3 1 2 3
1 4 2
4 5 4 5
REC REC REC
No. C J No. C J No. C J
1 W-L * 1 W-G * 1 O CN45-8
2 L-B * 2 L-B * 2 B-R W/SPLICE-Y (IG)
3 G-R CN57-3 3 R CN57-6 3 W-B CN6-9
4 W-B * 4 W-B * 4 G CN41-12
5 G-W * 5 G-W * 5 - -
7-1
APPENDIX
Page
SST LIST ..............................................................7-2
SERVICE STANDARDS LIST..............................7-3
WIRING DIAGRAM (2005.8 ~) .............................7-5
7
7-2
SST LIST
★ : Newly adopted SST
Section
Illust. Part number Part name
1 4
★
09240-23323-71
Plug-in analyzer {
Oil control valve spring remover and

09610-10161-71
replacer
{
7-3
SERVICE STANDARDS LIST

MATERIAL HANDLING SYSTEM
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard 8 (0.49) or less
Tilt cylinder oil leak amount
(total for lift and tilt) cm3 (in3) Standard 16 (0.98) or less
OIL CONTROL VALVE

OIL COMNTROL VALVE
+1.7
1 ton series Standard 17.8 0 (182
+17
0 ) [2590
+240
0 ]
Lift 2·3 ton series Standard 18.7
+1.7
0 (191
+17
0 ) [2720
+240
0 ]
Relief set pressure J 3.5 ton series Standard ↑
MPa (kgf/cm2) [psi] 1 ton series Standard 11.8
+1.7
0 (120
+17
0 ) [1710
+240
0 ]
+1.7 +17 +240
Tilt 2·3 ton series Standard 14.7 0 (150 0 ) [2130 0 ]
+1.7 +17 +240
J 3.5 ton series Standard 15.7 0 (160 0 ) [2280 0 ]
7
7-4
7-5
WIRING DIAGRAM (2005.8 ~)

Page
WIRE TO WIRE LIST (ROUTE) ...........................7-6
WIRE TO WIRE LIST (CONNECTOR).................7-7
POWER FUSES (R/B)..........................................7-9
ELECTRICAL SHIFT
TORQUE CONVERTER ..................................7-10
ELECTRICAL SHIFT
TORQUE CONVERTER (4Y-ECS) ..................7-11
ELECTRICAL SHIFT
TORQUE CONVERTER (D2 PEDAL) .............7-12
FUEL (2Z) ...........................................................7-13
COMBINATION METER.....................................7-14
7
Note:
This manual shows only the wiring diagrams changed in August 2005. For
wiring diagrams not shown in this manual, refer to the Parts & Service News Ref.
No. CB-4009 (published in May 2005).
7-6
WIRE TO WIRE LIST (ROUTE)
FR STAY W/H
FR STAY W/H
FA1
FA2
FI1
INSTRUMENT
PANEL W/H
IJ1
MAST W/H
FR W/H MF1
FN1
JE1
T/C HEAT GAUGE SUB
FT2
E/G W/H (DPF)

T/M W/H (T/C)
FT1
FS2
FS1
EF3
EF2
EF1
(MINI LEVER)
FS3
BOX W/H
LPG E/G
W/TWC
FY1
SE1
SIDE W/H
FY2
E/G W/H (T/C)

SY1
YZ1
YZ2
HOOD W/H
RR LWR W/H HOOD W/H (MINI LEVER)
LPG PRESS SW W/H
(France spec.)
LS1
SX1
US1
RR UPR W/H
W/H: Wire harness

WIRE TO WIRE LIST (CONNECTOR)
E/G FR FR T/M MAST FR
Portion Symbol
1 2 3 4 4 3 2 1 1 2 3 4 4 3 2 1
E/G E 1 2 3 3 1
2
5 6 7 8 8 7 6 5 5 6 7 8 8 7 6 5
FR F 4 5 5 4
6 6
T/M T 7 8 8 7
9 10 11 11 10 9
FT1 (GR) MF1 (GR) (CN3)
Side S
RR LWR L
T/C HEAT SIDE FR
EF1 (DG) (CN6) FR GAUGE SUB
RR UPR U
4 3 2 1 1 2 3 4
1 1
Instrument panel I 8 7 6 5 5 6 7 8
FR E/G
FR STAY A 12 11 10 9 9 10 11 12
FN1
Mast M 4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8 FS1
HOOD Y
12 11 10 9 9 10 11 12 FR SIDE
1 2 3 4 4 3 2 1 SIDE FR
OPT EF2 (CN5) 5 6 7 8 8 7 6 5
Portion Symbol 2 1 1 2
DPF display J
FR E/G FS2 (GR) (CN4)
T/C heat gauge N FS3
5 4 3 2 1 1 2 3 4 5
DPF FL P
11 10 9 8 7 6 6 7 8 9 10 11
LPG PRESS SW X SIDE FR
(France spec.)
EF3 1 2 2 1
Mini lever Box Z
INSTRUMENT PANEL FR
SE1
4 3 2 1 1 2 3 4
11 10 9 8 7 6 5 5 6 7 8 9 10 11
FI1
7-7
7-8
RR LWR SIDE SIDE RR UPR SIDE LPG PRS
1 1
1 2 3 4 4 3 2 1
2 1 2 2
1 2
5 6 7 8 8 7 6 5
3 4 5 5 4 3
6 7 7 6
SX1
US1 (GR)
LS1 (GR) (CN7) FR FR STAY

SIDE HOOD
2 1 1 2
INSTRUMENT PANEL DPF SUB 6 5 4 3 3 4 5 6
1 2 2 1
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 13 14 15 15 14 13 12 11 10 9 8 7 FA1
SY1 (B) (CN50)
IJ1 FR FR STAY
FR T/M
DPF SUB E/G 2 1 1 2
6 5 4 3 3 4 5 6
1 2 3 4 5 6 6 5 4 3 2 1 1 2 3 3 2 1
7 8 9 10 11 12 13 14 15 15 14 13 12 11 10 9 8 7 4 5 6 6 5 4
FA2 (B)
JE1
FT2 (CN57)
HOOD FR
BOX HOOD
6 5 4 3 2 1 1 2 3 4 5 6
15 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14 15 6 5 4 3 2 1 1 2 3 4 5 6
15 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14 15
FY1 (NA) (CN61)

YZ1 (NA) (CN63)
FR HOOD
BOX HOOD
7 6 5 4 3 2 1 1 2 3 4 5 6 7
16 15 14 13 12 11 10 9 8 8 9 10 11 12 13 14 15 16 7 6 5 4 3 2 1 1 2 3 4 5 6 7
16 15 14 13 12 11 10 9 8 8 9 10 11 12 13 14 15 16
FY 2 (NA) (CN62)
YZ2 (NA) (CN64)
POWER FUSES (R/B)
FL HEAD
HEAD LP RLY
40A R HEAD 15A R-L HEAD LAMP
R-B
TAIL LP RLY
W TAIL 7.5A G TAIL LAMP, CLEARANCE LAMP, METER ILLUMINATION
R-W
W (4Y,1DZ-II)
STOP 7.5A W STOP LAMP

BUS BAR
B-W (2Z)
WORK-LP 10A R-Y REAR WORKING LAMP

FL GLOW B-R (2Z)
60A (1DZ-II)
120A (2Z)
B (1DZ-II) B-R
GLW PLG RLY ECU-B 7.5A W-R OPS ECU, MINI LEVER ECU
FL AM1 W/SPLICE
40A W-L W-L B
W-L ST RLY ALT-S 5A W-L ALTERNATOR SENSING

FL HTR
30A L-B HTR 10A EMISSION CONTROL ECU (4Y-ECS)
SPOOL
SPOOL
TWO-
WIPER 15A 4Y-ECS ECU, ELECTRONIC THROTTLE
TWO-
FL ALT
80A DPF SYSTEM
R DPF1 15A R
R DPF2 7.5A R DPF ECU

HORN 7.5A G-Y HORN
IG SW
HOUR METER, WATER TEMPERATURE GAUGE, FUEL METER, WARNING LAMP, BACKUP
IG1 B-Y B-Y GAUGE 10A R-G BUZZER, T/C OIL TEMPERATURE GAUGE, STROBE, SAS BUZZER
SPOOL
ST1
TWO-
AM1 TURN 7.5A G-W TURN SIGNAL LAMP, FLASHER RELAY

ALTERNATOR, GLOW PLUG TIMER, IGNITION COIL, EMISSION
FUSE ALT-S CONTROL ECU
B-Y IGN 7.5A B-O EMISSION CONTROL ABCV, INJECTION, LPG MAIN SOLENOID, LPG SLOW SOLENOID
FUSE IGN
W/SPLICE
SPOOL
FUEL CUT SOLENOID, VEHICLE SPEED CONTROL ECU

TWO-
ECU-IG 7.5A B-R SAS ECU, STEERING ANGLE SENSOR, OPS ECU, OPS LAMP RELAY
B-R L-W SAS ECU
B S IG SAS-LAMP
ALT B-Y SFT 7.5A L ELECTRONICALLY SHIFTING T/C
B-W ST 7.5A B-W STARTING MOTOR RELAY (COIL SIDE), GLOW PLUG TIMER
E/B (ENGINE ROOM)
7-9
ELECTRICAL SHIFT TORQUE CONVERTER
7-10
4 6
FL AM1 IG B-Y B-Y
10 2 G EF1
40A W-L W-L AM ST B-W 2 1 2 3 5 6 7 8
EF1 G G 3 4 3
3
IGNITION SW. EF1 2 6
G
A
D
7.5A 7.5A 10A
ST SFT GAUGE
1
1 2
B-W
R-G
H
L
1 2
4 EF1 EF1 8 EF3 3 B
R-G F
B-W
OPS ECU
7 A 6 A 8 A
1 2 3
J 17 J 10 J 11 J 4 J 3 N IG1 IG2 VF1 VF2 ST VR R.
F1 C
F1
N
BR-W
G-R
Y-R
G
R
R 3 4 10 11
RA 17
5 A 3 A 1 A 2 A
W-L
R-Y
G-R
R
9 2
T/C RR
T/C FR
RELAY
RELAY
R-Y
FS1 US1 FT1 3
R-Y
R-Y
L-W
BR-W
L-R
1 5 FT1
F 1
B FT1 7 D 3
BUZZER
EF1
BACK
B
L-W
RH
L-W L-R D 6
F 2
STARTER
W-B
W-B
RELAY 1C 1 B C 3 B 2
SOLENOID
1 SOLENOID
W-B
B
H
EF2 12 2 C C 2
STARTER US1 1 FT1 8
W-B
W-B
W-B
8 FT1 8 FT1
ELECTRICAL SHIFT TORQUE CONVERTER (4Y-ECS)
4 6
FL AM1 IG B-Y B-Y
10 2 G EF1
40A W-L W-L AM ST B-W VSV
EF1 G G RELAY 1 2 3 5 6 7 8
3
IGNITION SW. EF1 2
B-L
2 I I 1 A
7.5A 7.5A 10A
ST SFT GAUGE SFT
RELAY
L-R
1 2
R-G
3 I I 4
B-W
L
W-B
B
4 EF1 EF1 8 EF3 3
B-W
R-G
OPS ECU 1 2 3
7 A 6 A 8 A 4 1 2 3
J 17 J 10 J 11 J 4 J 3 N IG1 IG2 VF1 VF2 ST VR R.

I C
F1
F1
N
BR-W
G-R
Y-R
R
G
3 4 10 11 3
RA 17 6
5 A 3 A 1 A 2 A
W-L
J D
R-Y
G-R
R
9 2 1 2
T/C RR
T/C FR
RELAY
RELAY
R-Y
FS1 US1 FT1 3
F
R-Y
R-Y
L-W
BR-W
L-R
2
1 5 FT1 F 1 3 4
B FT1 7 D 3
BUZZER
EF1
BACK
G
L-W
B RH
STARTER L-W L-R
D 6
RELAY F 2
1C 1 B C 3 B 2
SOLENOID
W-B
W-B
1
SOLENOID
1
W-B
B
H
H
2 C C 2
EF2 12 US1 1 FT1 8
STARTER
W-B
W-B
W-B
8 FT1 8 FT1
7-11
ELECTRICAL SHIFT TORQUE CONVERTER (D2 PEDAL)
7-12
4 6
FL AM1 IG1 B-Y B-Y
40A 10 2 G EF1
W-L W-L AM1 ST1 B-W 1 2
EF1 G G
3 EF1 2
1 2 3 4
IGNITION SW.
B K
10A 7.5A 7.5A
GAUGE ST SFT
1 2 3 3 2 1
B-W
L
3 3
R-G R-G C
FT2 EF3 EF1 4 EF1 8 L
W-L
G-W
B-W
B
FT2 4 FT1 4
SHIFT CONTROL
SHIFT CONTROL
3 1 2 3
B-W
4
L
D2 PEDAL 6
SW(RR)
R-G
SW(FR)
4 K K 3 4 I I 3 M
N/O RELAY N/O RELAY D
NO.2 NO.1
N 3 1N N 2
2 K K 1 2 I I 1
W-G
W-G G-W 1 2 3
1 2
R-W
B
W-L
L-B N
G
BACK LAMP
RELAY(RR)
RELAY(FR)
SHIFT SOL
SHIFT SOL
2 M M 1 O 2 O 1 P 2 P 1
1
2 FT2 F
B
EF1
G-W
RELAY
1 FT2 1
B
H 1 2 3
3 M M 4 6 O O 3 O 4 6 P P 3 P 4 2 4 6
STARTER
G-W
3 4
W-B
G-R
L-B
RELAY
R
STARTER O
R-W
(IN R/B)
2
FT1 3 G G
W-B
FT1
R-Y
W-B
L-B
3 L L 2 1 2 3
FS1 9
G-R
1
R
4 6
RELEASE
LOCK
PKB
R-Y
W-B
EF2 12 SW.
T/C RR
H P
RELAY
T/C FR
RELAY
2
BACK BUZZER(OPT)
US1
RR COMBINATION LAMP
(BACK UP LAMP)(OPT)
L 1
R-Y
1 F
BR-W
BR-W
L-W
L-R
W-B
W-B
3 D 1 2
2 F 3 4
L-W
Y
R
W-B
6 D I
C 3 B 2 C 1 B 1
W-B
SOLENOID
SOLENOID
8 FT1 US1 1 FT1 8

OPS ECU
W-B
W-B
C 2 C 2
3 4 10 11
W-B
W-B
J 17 J 11 J 10 J 4 J 3 17
G-R
BR-W
Y-R
FT1 8 FT1 8 FT1 8 FT1 8

G
J
FUEL (2Z)
4 6
FL AM1 IG1 B-Y B-Y 2
10 A EF1
40A 2 4
W-L W-L AM1 ST1
EF1 A 1 1 A
FL HEAD IGNITION SW.
40A C C
DPF 1
FL GLOW 7.5A B
80A IGN
1 1
C C
B-O
EXCEPT DPF
1
B-O
1 2
3 4
C
B-O
B-O
B-O D
1 D D 4
RELAY
1
1 B E
3 D D 2
B-Y
G-R
1
TEMPERATURE
E 1 F F
SWITCH
WATER
TCV
BODY BODY BODY
GROUND GROUND GROUND
7-13
COMBINATION METER
7-14
4 6
FL AM1 IG1 B-Y B-Y
40A 10 2 A EF1
W-L W-L AM1 ST1
EF1 A
FL HEAD
40A IGNITION SW.
FL GLOW
80A 10A
GAUGE
R-G
3 EF3
R-G
B 6 COMBINATION METER
SEDIMENTER
AIR CLEANER
LOCK INDICATOR
WATER TEMP.
FUEL
HOUR METER
LOW LPG
CHARGE
(DIESEL)
(VSCS)
CHECK
(DIESEL)
GLOW
OPS
SAS
OIL
(GASOLINE)
1 C 9 B 3 C C B 12 6 C 8 C 7 C 3 B 2 B 13 C 2 C 7 B 10 C 1 B 12 C 8 B 8 B B 4
(DIESEL)
B-L
4
LG-R
LG-B
R-W
P-G
Y-B
Y-R
R
Y
V
FS3 1
10 EF2 FS1 10 7 EF2 EF3 6 FT1 1 FS2 1 EF3 4 5 EF3 5 EF3 10
Y-B
B-Y
G
P-G
LG-R
SX1 1
Y-B
LG
Y-R
R
R
V
Y
SAS RELAY
R-L
HOUR METER
CONNECTOR
OIL PRESSURE SW.
LPG PRESSURE SW.

3(2Z)
L-O
V-G
P-L
V-R
(IN R/B)
OPS-LAMP RLY
WATER TEMP.
(AIR CLEANER)
E 2 1G 1H J 1 L 1 N 1 P 1 T 7(1DZ-II) U 16
VACCUM SW.
SENDER
LEVEL SW.
LEVEL SW.
W-B
W-B
GLOW VSCS
W-B
F 2
TIMER ECU
12 EF2
FUEL K 1 L 2 Q 1
2G
B-Y
3 SENDER
W-B
9 D 12 D D D 11 1 I
SX1 2
W-B
W-B
W-B
W-B
FT1 8
Y
W-B
SAS SAS ALT

ECU ECU
FS3 2
W-B
BODY GROUND
7-15
2
2 3 4 6 7 8 9 12
4
A B
3
1 2 3 4 6 7 8 10 12 13
9 11 12
C D
1
2 2 1
2
E F G H
1 1 1
I (4Y, 2Z, 1DZ-II) J K
1 2 1 1 1
L N P Q
3
7 16
T (2Z) T (1DZ-II) U

7FDF OPS S

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7FDF OPS S

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Tillägg för OPS (fr.o.

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I : Inspection. Repair or Replacement if required.

Control block diagram

Name of each part

(7) (8) (9)

(5) (6) (1)

(1) OPS controller (9) Backward tilt switch

(2) Seat switch (10) Unload valve

(3) Forward switch (11) Lift lock valve

(4) Reverse switch (12) Tilt control valve

(5) Forward interrupt relay (13) OPS lamp

(6) Reverse interrupt relay (14) OPS lamp relay

(7) Lower switch (15) OPS buzzer

(8) Forward tilt switch (16) Plug-in analyzer

Function of each part

(2) Seat switch

Output from controller

Oil Control Valve

Unloading solenoid valve

Open this valve to

Lift lock solenoid valve Tilt control solenoid valve

1-ton series 2-ton series 3-ton series J3.5-ton series

Relief pressure setting Lift 17800 (182) 18700 (191) ← ←

Flow divider flow rate L/min 13.0 ← 15.2 ←

(1) Unloading valve

Hydraulic circuit control

Tilt control SOL

Full open circuit for

1. Tilt stop circuit

2. Tilt semi-open circuit

Tilt Cylinder 3. Tilt full open circuit

Key-off lift lock

Load handling operation is prohibited when operator leave the

Att lever Arm pad

Fork automatic leveling switch

Lever for fixing rotation of lever box

Lever for fixing lever box

Engine hood opening procedure

(7) (8) (9)

(5) (6) (1)

(1) OPS controller (9) Backward tilt switch

(2) Seat switch (10) Unload valve

(3) Forward switch (11) Lift lock valve

(4) Reverse switch (12) Tilt control valve

(5) Forward interrupt relay (13) OPS lamp

(6) Reverse interrupt relay (14) OPS lamp relay

(7) Lower switch (15) OPS buzzer

(8) Forward tilt switch (16) Plug-in analyzer

OPS PLUG-IN ANALYZER

Menu name Content of function Reference page

Monitoring input voltage value from the sensors and the

ACTIVE TEST Forced operation of solenoids and warning lamps. 1-12

Indication of OPS controller abbreviation number and

<Blank> <No function>

Determine an item for selection.

5. "LANGUAGE SET" screen

6. "MAIN MENU" screen

ANALYZER MENU Display contents and function Page

2. ANALYZER MENU screen

"1 DIAG MEMORY"

"2 IN/OUT MONITOR" (Excluding the mini-lever

Name of each part　