Toyota 5FBCU15

FOREWORD
Thjs manual covers the service procedures of the TOYOTA BATTERY

FORKLIFT 5FBCU15 -- 30 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of July 1995. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due t o change in disign and specifica-
tions. Any change or modifications thereafter will be informed by
Toyota Industrial Vehicles' Parts & Service News.
TOYOTA MOTOR CORPORATION

SECTION INDEX
NAME 1 SECT1
e
x m
CC
MULTIDISPLAY FUNCTIONS
ELECTRICAL SYSTEM TRouBLEsHooTlNG m A
MOTOR
DRIVE UNIT
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY & FRAME
y
MAST
CYLINDER
OIL PUMP
p a
APPENDIX
GENERAL
Page
EXTERIOR VIEWS ........................................ 0-2
VEHICLE MODEL ................................................ 0-3
FRAME NUMBER ............................................... 0-4
HOW TO READ THIS MANUAL ......................... 0-5
EXPLANATION METHOD ..................................... 0-5
TERMINOLOGY .................................................. 0-6
ABBREVIATIONS ................................................ 0-6
LIST OF ABBREVIATIONS AND SYMBOLS ............. 0-7
OPERATIONAL TIPS .......................................... 0-8
CIRCUIT TESTER ............................................... 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE .......................................................... 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ........................................................ 0-11
TIGHTENING TORQUE TABLE ............................... 0-12
PRECOAT BOLTS ............................................... 0-13
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE .................................... 0-13
WIRE ROPE SUSPENSION ANGLE LIST ............. 0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ...................................... 0-14
COMPONENTS WEIGHT .................................... 0-15
RECOMMENDED LUBRICANTS
AND CAPACITIES ...................................... 0-16
GREASE ON MICRO SWITCH FOR
INSTALLATION ......................................... 0-17
INSTRUCTION OF OIL CHECK LEVEL
IN HYDRAULIC OIL TANK ........................... 0-17
LUBRICATION CHART .................................. 0-18
PERIODIC MAINTENANCE ............................. 0-19
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ..................................... 0-24
EXTERIOR VIEWS
I I
Front View
I
Rear View
VEHICLE MODELS
Load Capacity Model
Types on Spec.
1-ton
series
STD capacity
battery
2-ton
compartment
STD spec. series
models
3-ton
series
High capacity 2-ton

% series
I -ton
series
STD capacity
battery
2-ton
compartment
Dust proof series
models
%ton
series
High capacity 2-ton

series
% These high capacity (battery compartment) models are not established in EEC specification.
FRAME NUMBER
Above side frame of LH
Stamping Form
Models Remark
[( ) showing EEC specifications for ECI
5FBCU15-10011
1-ton series 5FBCU1 5
(5FBCU15 @ 10011)
5FBCU18
5FBCU25-10011
5FBCU20
(5FBCU25 @ 1001 1 )
2-ton series 5FBCU25
5FBCHU20 5FBCHU25-10011
5FBCHU25 (5FBCHU25 @ 1001 1)
5FBCU30-10011
3-ton series 5FBCU30
(5FBCU30 @ 1001 1 )
305FBCU15-10011
1-ton series 30-5FBCU 1 5
(305FBCU1 5 @1001
I 1)
30-5FBCU 1 8
305FBCU25-10011
30-5FBCU20
(305FBCU25 @ 1001 1)
2-ton series 30-5FBCU25
30-5FBCHU20 305FBCHU25-10011
30-5FBCHU25 (305FBCHU25 @ 1001 1 1
305FBCU30-10011
3-ton series 30-5FBCU30
(305FBCU30 @ 1001 1)
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Ex~lanationof each ooeration step with a photo or illustration.
Pattern B: ~xplanationof operatiin procedure by indicating step numbers in one illustration, fol-
lowed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T = N - m (kgf-cm) [ft-lbfl
If a place or part cannot be indi-

cated directly, the part name is
described on the either side of
the illustration.
Example: 1 Piping
I I
Oil Pump Disassembly Procedure
Disassembly Procedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 2 l o O p e r a t i o n explained on a laterpage
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 1I 4
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit:19.12 mm (0.7528 in)
2. How t o read components figures (Example)
( 1 ) The components figure use the illustra-
tion in the parts catalog for the vehicle
model. Please refer t o the catalog for
checking the part name.
The number at the right shoulder of each FIG number in parts catalog
components figure indicates the Fig.
number in the parts catalog.
3. Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation:
Cleaning and washing of removed parts as required
@ visual inspection (Partially described)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to observe them.
Note:
Important items of which negligence may cause accidents or matters in operation procedure re-
quiring special attention.
Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly SST Special service Tool
LH Left hand STD Standard
OPT Option T = Tightening torque
01s Oversize 0O T Number of teeth (00 )
PS Power steering U IS Undersize
RH Right hand W/ With
Society of Automotive
SAE
Engineers (USA)
- - - ---- -- -- - - - - - --
0-7
LIST OF ABBREVIATIONS AND SYMBOLS

Symbol Name Symbol Name Symbol Name
BATT Battery FRY Flasher Relay MScH Charger Magnet Switch
Bz Buzzer H Horn MW Field Weakning Contactor
CADIP DriveIPump Absorber ,,,L Back-up Lamp, LH PBcpu Computer Print Board
Capacitor ,.L
,, Back-up Lamp, RH PBsps SPS Print Board
CH Charger LC-L Clearance Lamp, LH PL, Working Pilot Lamp
CHI, Forward Chime Clearance Lamp, RH RF Fan Resistor
CHI, Reverse Chime LF-L Flasher Lamp, LH RFW Field Weakning Resistor
CSDIP DriveIPump Current LF-,, Flasher Lamp, LH (Rear) RG Regenerative Resistor
Sensor LF-R Flasher Lamp, RH RADIP Drivelpump Absorber
CS, Power Steering Current L,-, Flasher Lamp, RH (Rear) Resistor
Sensor LH-L Head Lamp, LH SA Surge Absorber
DcH Charger Diode LH-R Head Lamp, RH SDD Drive SIT Driver
DC-SDD DC-DC Converter & LR-F Rotaly Forward Lamp SDP Pump SIT Driver
Source Drive (Drive) LR-R Rotaly Reverse Lamp SLL Lequid Level Sensor
DC-SDP DC-DC Converter & LSATT,,, Attachment Limit Switch SN 1 Snubber No. 1
Source Drive (Pump) No. 112 SSP Speed Sensor
DF112 FLY-WHEELDiode, LSB Brake Limit Switch SP Steering Pressure Sensor
No. 112 LSD Dead Man Limit Switch STH Thermo Sensor
DF314 FLY-WHEEL Diode No.314 LSL1/2 Lift Limit Switch No.112 SWAc Accel Switch
DG Regenerative Diode LS, Parking Brake Limit SW, Flasher Switch
DlSP Display Switch SW, Horn Switch
DMD,, DriveIPump Motor LS, Stop lamp limit Switch SW, Key Switch
DMps Power Steering Motor LST-, Stop Lamp, LH SW, Light Switch
DSBu Back-up Direction Switch LsT-, Stop Lamp, RH SW, Speed Control Switch
DSF Forward Direction Switch LS, Tilt Limit Switch TF Transformer
DSFo Forward Optional LT-L Tail Lamp, LH TG Regenerative Transistor
Direction Switch LT-R Tail Lamp, RH THR Thermal Relay
DSR Reverse Direction Switch ,L Working Lamp TM Main Transistor
F1 Drive Fuse MF Forward Contactor TMP Main Pump Transistor
F2 Pump Fuse MG Regenerative Contactor TMps Main Power Steering
F3 Power Steering Fuse MP Pump Contactor Transistor
F4 Lamp Fuse M PS Power Steering Contactor TU Timer Unit
F5 Control Circuit Fuse MR Reverse Contactor VRAD Accel Drive Vari-Ohm
F c ~ Charger Fuse MS Short Contactor
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in
load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1 Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the
parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassembly.
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Grasping the troule state

When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for remedying.
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. The should be used selectively accord-
ing t o the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured
value should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult t o observe the variation or move-
ment.
1. Difference in measurement results with the digital type and analog type
* The result may be different between measurements with the analog type and digital type. Al-
ways use a circuit tester according t o its operation manual. Cautions when the polarities are dif-
ferent between the analog type and digital type are described below.
Circuit tester range: Analog type + kohm range Digital type + 2 Mohm range
Forward direction Reverse direction
Black Red
probe probe
Measurement result example
Analog type Digital type

Continuity
No continuity
Forward shall exist
11 Kn 1
Continuity
No continuity
Reverse shall exist
00 2 MSZ
As seen from the example above, the measurement results with the analog and digital types are re-
verse. In measurement with a digital type circuit tester, therefore, use the tester probes as shown be-
iow.
Forward direction Reverse direction
2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5V, 3.OV or 6.OV is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply
voltage.
The diode characteristics are shown in the figure below.
The resistance values of the same semiconductor mea-

sured
with t w o types of circuit testers having different
Current power supply voltages are different.
in
forward This manual describes the results of measurement
direction
with a circuit tester whose power supply voltage is
3.0 V.
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Voltage in forward direction (')
3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement
range switches over the internal circuit to vary the circuit
resistance. Even when the same diode is measured, the
measurement result varies with the measurement range.
Always use the range described in the repair manual

for measurement.
Variable resistor
Resistor
Range: x 10
Red Black
0-1 1
STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the
table.
2. The nut tightening torque can judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.
Shape and class Class Hexagon head bolt

4 = 4T
GD-
5 = 5T
Bolt head No. 6 = 6T
7 = 7T Parts No.
Hexagon 8 = 8T
91 61 1-40625
head bolt
Length (mm)
No mark 4T
Diameter (mm)
Hexagon
No mark 4T
flange bolt
iameter
Hexagon
head bolt 0 Two protruding
lines
5T
Hexagon Two protruding

6T
flange bolt ines
Stud bolt
Hexagon
head bolt 0 Three protruding
lines
7T
Parts No.
92 1 32-406 1 4
Hexagon
head bolt @ Four protruding
lines
8T Length (mm)
Diameter (mml
Welded bolt 4T
k
iameter
No mark 4T
I
Stud bolt
Grooved 6T
0-1 2
TIGHTENING TORQUE TABLE
13 ) 130 1 9
16 1.5 113 f 1150 1 83 - I

I
- I
I
-
6 1 .O 6.4 1 65 1 56 in-lbf I
I
I
I
I I I I
8 1.25 16 f
I
160 1 12 I
I
I
I
I I I
10 1.25 32 j 330 f 24 - I
I
- I
I
-
5T I I I I
12 1.25 59 1
I
600 f
I
43
I
I
I
I
I
I
14 1.5 91 1
I
930 1
I
67
I
I
I
I
I
I
16 1.5 137 1 1400 1 101
I
I
I
I
6 1 .O 7.8 1 80 1 69 in-lbf 8.8 1 90 1

I
78 in-lbf
8 1.25 19 1 195 1 14 21 1 215 1 16
6T 10 1.25 39 400 29 43 440 1 32
12 1.25 72 1 730 j 53 79 1 810 j 59
14 1.5 - I
I
I
- I
I
I
- 123 / 1250 / 90
6 1 .O 11 /
I
110 /
I
8 12 /
I
120 j 9
8 1.25 25 260 f 19 28 290 21
I I I I
10 1.25 52 j 530 j 38 58 1 590 f 43
7T \ I I I
12 1.25 95 1 970 j 70 103 1 1050 1 76
I I I I
14 1.5 147 1 1500 f 108 167 1 1700 1 123
I I I I
16 1.5 226 1 2300 ) 166 - I
I
- I
I
-
8 1.25 29 f 300 1 22 33 1 330 1 24
8T 10 1.25 61 1 620 1 45 68 1 690 1 50
12 1.25 110 1 1100 1 80 120 1250 1 90
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the fol-

lowing cases.
(a) After is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable tight-
ening torque range. If the bolt moves, retighten it according
to the steps below.
2. Method for reuse of precoat bolts

( 1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Parfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth t o remove foreign matters and dirt. Also check no dent or other damage on the
contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and
tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Standard tightening torque N-m (kgf-cm) [ft-lbfl Hose inside

Nominal diameter
diameter
of screw Standard Tightening range mm (in).
7116 - 20UNF 25 ( 250) [ 18.11 24 -- 26 ( 240 -- 270) [ I 7.4 -- 19.51 6 (0.24)
9116 - 18UNF 49 ( 500) [ 36.21 47 -- 52 ( 480 - 530) [34.7 - 38.31 9 (0.35)
314 - 16UNF 59 ( 600) [ 43.41 56 -- 62 ( 570 -- 630) [41.2 -- 45.61 12 (0.47)
718 - 14UNF 59 ( 600) [ 43.41 56 -- 62 ( 570 - 630) 141.2 -- 45.61 12 (0.47)
718 - 14UNF 78 ( 800) [ 57.91 74 - 82 1 760 -- 840) 155.0 -- 60.81 1 5 (0.59)
1-1116-12UNF 118 ( 1 2 0 0 ) [ 86.81 112-123(1140--12501[82.5- 90.41 19 (0.75)
1.511 6 - 12UNF 137 (1400) [101.3] 130 - 144 (1330 -
1470) 196.2 - 106.41 25 (0.98)
PF1 14 25 ( 250) [ 18.1I 24 -- 26 1 240 - 270) I17.4 -- 19.51 6 (0.24)
PF318 49 ( 500) [ 36.21 47 - 52 ( 480 -- 530) [34.7 - 38.31 9 (0.35)
PFI I 2 59 ( 600) [ 43.41 56 -- 62 ( 570 - 630) 141.2 -- 45.61 12 (0.47)
PF314 1 18 (1200) [ 86.81 1 12 -- 123 (1140 - 1250) 182.5 - 90.41 19 (0.75)
PF 1 137 (1400) [101.31 130 - 144 (1330 -- 1470) 196.2 -- 106.41 25 (0.98)
0-1 4
WlRE ROPE SUSPENSION ANGLE LIST

Lifting Compres- Suspension Lifting Compres- Suspension
Tension Tension
angle sion method angle sion method
0O 1.OO time 0 time
L1
- 90° 1.41 time 1.OO time
by5
2' A
30 O 1.04 time 0.27 time
%
h0 1 20° 2.00 time 1.73 time

2% k0
60 O 1.1 6 time 0.58 time
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (ton) [Ibl
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0O 0O 30 O 60 O 90 O 0O 30 O 60 O 90 O
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in) [ I 9401
[48071 [683.6] [ I 3671 [ I 3231 [ I 1691 [970] [27341 [2646] 123371
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm (1.74) (1.56) (1.28)
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8)
(0.32 in)
[70781 [992.3] [ I 9851 [ I 91 81 [ I 7201 [ I 41 11 [3969] [39371 [3440] [23221
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[ I 1.691 [I 565.61 [3153] [3021] [2646] [2205] [6174] [5954] 152921 144101 -
76880 10980 21570 21280 18630 14710 43150 41 190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.51 (4.4) (4.2) (3.8) (3.0)
(0.5in)
1173871 [2469.5] 148511 [4631] [4190] 133081 [9702] 192611 [83791 166151
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [ I 23481 [ I 19071 [ I 05841 183791
COMPONENTS WEIGHT
Item Model Approx Weight kg (Ibs)
STD 6 6 (145)
1 ton series
Dust proof type 75 (165)
STD 1 0 4 (229)
Drive Motor 2 ton series
Dust proof type 1 2 0 (264)
STD 1 0 4 (229)
3 ton series
Dust proof type 1 2 0 (264)
Motor
STD 3 8 (84)
1 ton series
Dust proof type 4 2 (92)
STD 75 (165)
Pump Motor 2 ton series
STD 7 5 (165)
3 ton series
5FBCU1 5 4 4 0 (970)
5FBCU1 8 4 1 0 (904)
5FBCU20 480 (1058)
Counter Weight 5FBCU25 825 (1819)
5FBCU30 8 2 5 (18 1 9)
5FBCHU20 41 0 (904)
5FBCHU25 4 8 0 (1058)
Mast WILift bracket (with Lift cylinder,

1 ton series 3 9 0 (860)
less Back rest and forks).
[Max. Fork height = 3000mm (118 in)]
2 ton series 4 6 0 (1014)
3 ton series 6 0 0 (1323)
Note: Refer t o Page 1 - 2 for the battery weight.

RECOMMENDED LUBRICANTS AND CAPACITIES
APPLICATION TYPE CAPACITY (TOTAL)
Differential & transmission STD: Hypoid gear oil SAE85W-90 1.5 ton 7.0 Q
(VALVOLINE80W90) (1.85 US gal.)
20s: Hypoid gear oil W
(VALVOLINE80W90) 1.8 -- 3 t o n 7.5 Q
(1.98 US gal.)
Hydraulic oil STD: Hydraulic oil I S 0 VG32 (Daph- 1.5 ton

ne Fluid AW32)
* 1 6 Q (4.2 US gal.)
* 2 1 Q (5.5 US gal.)
20s: Auto Fluid
1.8- 3 t o n * 2 0 Q (5.3 US gal.)
* * 2 6 Q (6.9 US gal.)
Brake oil STD: SAE J-1703 DOT-3

(INTAC AUTOMOTIVE PRODUCTS
INC. GC325) Proper quantity
20s: GC325
Grease *** STD: MP Grease No.2

(VALVOLINE BRB GRESE)
20s: Esso Beacon 3 2 5 Proper quantity
** *
For 3000 mrn ( 118 in) maximum fork height.
*** For 6000 mm (236 in) maximum fork height.

Use where unspeicified.
HYDRAULIC OIL CAPACITY DEPENDING ON FORK HEIGHT

Model
Height [ 3000 3300 4300 5500
Remarks
Capacity or less -4000 - 5000 - 6000
5FBCU1 5 Total
16 17.5 19 21 Same as 5FB15
30-5FBCU1 5 (Q1
&
Oil tank
13 14.5 16 18 5FB20 series
(0)
5FBCU 18,20,25
5FBCUH20, H 2 5
5FBCU30 Total
20 22 24 26
(Q)
30-5FBCU 18, 20, 2 5
30-5FBCUH20,25 Same as 5FB30
30-5FBCU30
series
Oil tank
16.5 18.5 20.5 22.5
(Q 1
P.S. There are no capacity differences depending on the type of mast, such as V, FV, and FSV.
INSTRUCTION OF OIL CHECK LEVEL IN
HYDRAULIC OIL TANK
1. To check the oil level, touch the lower threaded end
portion of the cap t o retainer without screwed in.
2. +
Adjust oil amount within 0 -- 10 mm (0.39 in) dif-
ference from each of the height indication.
-
Fork Height 5500- 6500
-
-
-
Fork Height 3000 or less
GREASE ON MICRO SWITCH FOR

INSTALLATION
Put grease on roller.
LUBRICATION CHART
I 1. Chain I Inspect every 8 hours (daily)
2. Mast support bushing I1 lnspect every 40 hours (weekly)

3. Tilt cylinder front pin 111 lnspect every 170 hours (monthly)
4. Front wheel bearing IV lnspect every 1000 hours (6monthly)
5. Differential & transmission V lnspect every 2000 hours (annually)
6. Brake fluid reservoir tank 0 lnspect and service
7. Tilt steering locking mechanism Replace
8. Tilt steering universal joint
9. Oil tank 1. MP grease
10. Rear wheel bealing 2. Engine oil
1 1. Steering knuckle king pin 3. Hypoid gear oil
12. Rear axle beam front 4. Hydraulic oil
13. Rear axle cylicder rod joint (1 ton series) 5. Brake fluid
14. Rear axle beam rear
Located on right and left sides
1
Lubrication Chart
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
1 * : Flaw detector
Inspection Period Months 1 3 6 12

Item Hours 170 500 1000 2000
ELECTRICAL SYSTEM
Abnormal sound during revolution I 0 0 0 0
Loose terminal T 0 0 0 0
Insulation resistance M 0 0 0
Motor
Brush wear and sliding contact status I 0 0
Commutator fouling and damage I 0 0
Brush spring fatigue M 0
Charge I 0 0 0 0
Battery fluid level I 0 0 0 0
Battery fluid specific gravity M 0 0 0 0
Loose terminal I 0 0 0 0
Battery Abnormality at top of battery and
battery case
I 0 0 0 0
Insulation resistance M 0 0 0
Cell voltage measurement after
charging
M 0
Timer operation I 0 0 0 0
Terminal loosening I 0 0 0 0
Charger Operating voltage measurement M 0 0 0
Magnet switch function, contact
fouling and roughening
I 0
Loose contact, damage and wear I 0 0 0 0
Auxiliary contact function, fouling and
I 0 0 0 0
wear
Magnet
Arc chute installation status I 0
contactor
Timing and functioning I 0
Loose coil installation I 0
Loose main circuit lead installation I 0
Timing and operating function I ' 0 0 0 0
Microswitch
Damage and loose installation I 0 0 0 0
I-
Item - Hours 170 500 1000 2000
Direction lever Operating conditions and damage I 0 0 0 0
Operation I 0 0 0 0
Controller Inside fouling and damage C 0 0 0 0
Overcurrent limit valve M 0
Fuse Loosening I 0 0 0 0
Damage of wiring harness and loose
clamp
I 0 0 0 0
Wiring
(including Loose connection and taping status I 0 0 0 0
charging cord) Battery connector damage and
connection status
I 0 0 0 0
Accelerator Operating and damage I 0 0 0 0
POWER TRAIN
Oil leak I 0 0 0 0
Differential,
Oil level I 0 0 0 0
Transmission
Loosening of nuts and bolts T 0
TRAVELING EQUIPMENT
Tire cuts, damage and uneven wearing I 0 0 0 0
Loose rim and hub nuts T 0 0 0 0
Tire groove depth M 0 0 0 0
Metal chips, pebbles and other foreign
matter trapped in tire grooves
I 0 0 0 0
Wheels
Rim and disc wheel damage I 0 0 0 0
Abnormal sound and looseness of
I 0 0 0 0
front wheel bearing
Abnormal sound and looseness of rear
wheel bearing
I 0 0 0 0
Cracks, damage and deformation of
Front axle I 0
housing
Cracks, damage and deformation of
Rear axle I 0
beam
Item Hours 170 500 1000 2000
STEERING SYSTEM
Play and looseness I 0 0 0 0
Steering wheel
Function I 0 0 0 0
Oil leak I 0 0 0 0
Steering valve
Looseness of mounting T 0 0 0 0
Oil leak I 0 0 0 0
Power steering
Damage of power steering hose I 0
King pin looseness I 0 0 0 0
Knuckle
Cracks and deformation I 0
BRAKING SYSTEM
Play and reserve M 0 0 0 0
Brake pedal
Braking effect I 0 0 0 0
Pull margin I 0 0 0 0
Braking effect I 0 0 0 0
Parking brake
Rod and cable looseness and damage I 0 0 0 0
Ratchet wear and damage I 0
Brake pipe and
hose
Leakage, damage and mounting status I 0 0 0 0
Brake fluid Fluid level I 0 0 0 0
Master cylinder
or brake valve Function, wear, damage, leak and
I 0
and wheel cyl- mounting looseness
inder
Clearance between drum and lining M 0 0 0 0
Wear of shoe sliding portion and lining I 0
Drum wear and damage I 0
Brake drum
Shoe operation condition I 0
and brake shoe
Anchor pin rusting I 0
Return spring fatigue M 0
Automatic adjuster function I 0
Deformation, cracks and damage I 0
Backing plate
Loose mounting T 0
Item Hours 170 500 1000 2000
MATERIAL HANDLING SYSTEM
I Abnormality of fork and stopper pin / I 1 0
Misalignment between left and right
/ Forks
fork fingers
I 0
Cracks at fork root and welded part I*

Deformation and damage of each part
and crack at welded part
Mast and lift bracket looseness
Wear and damage of mast support
Mast and fork
bush
bracket
Wear, damage and rotating condition
of rollers
Wear and damage of roller pins
Wear and damage of mast strip
Tension, deformation and damage of
chain
Chain and Chain lubrication
chain wheel Abnormality of chain anchor bolt
Wear, damage and rotating condition
of chain wheel
Various Abnormality and mounting condition
I 0 0 0 0
attachments of each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
mounting
Deformation and damage of rod, rod
Cylinder screw and rod end
Cylinder operation
Natural drop and natural forward tilt
(hydraulic drift)
I Oil leak and damage I I I o ~ o I o I o
Wear and damage of pin and cylinder
Cylinder bearing
/ Lifting speed / I " I o o I o
Uneven movement I 0 0 0 0
Oil pump Oil leak and abnormal sound I 0 0 0 0
Oil level and contamination
Hydraulic oil
Tank and oil strainer
tank
I Oil leak I 0 0 0 1 0
-
- Inspection Period Months 1 3 6 12
Item --++ Hours 170 500 1000 2000
Loose linkage I 0 0 0 0
Control lever
Operation I 0 0 0 0
Oil leak I 0 0 0 0
Oil control Relief pressure measurement M 0
valve Relief valve and tilt lock valve
I 0 0 0 0
functions
Oil leak I 0 0 0 0
Hydraulic Deformation and damage I 0 0 0 0
piping Loose joint T 0 0 0 0
Hoise tension and twisting I 0 0 0 0
SAFETY DEVICES, ETC.
Cracks at welded portion I 0 0 0 0
Head guard
Deformation and damage I 0 0 0 0
Loosening of mounting T 0 0 0 0
Back-rest
Deformation, crack and damage I 0 0 0 0
Lighting
Function and mounting condition I 0 0 0 3
system
Horn Function and mounting condition I 0 0 0 0
Direction
Function and mounting condition I 0 0 0 0
indicator
Instruments Functions I 0 0 0 0
Back u p buzzer Function and mounting condition I 0 0 0 0
Rear-view Dirt, damage I 0 0 0 0
mirror Rear reflection status I 0 0 0 0
Seat Loosening and damage of mounting I 0 0 0 0
Damage and cracks of frame, cross
I 0
Body members, etc.
Bolt looseness T 0
Other Grease up L 0 0 0 C
0-24
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Inspection (operating hours or Months 1 3 6 12
months, whichever is earlier) Hours 170 500 1000 2000
Brake fluid • •
Hydraulic oil • •
Hydraulic oil return filter
a a a
(New veh~cle)
Differential and transmission oil •

Wheel bearing grease •
Master cylinder rubber parts •
Wheel cylinder rubber parts •
Reserve tank hose
a
(Every 2 years)
Power steering hose

a
(Every 2 years)
Internal rubber parts of power steering system

a
(Every 2 years)
Material handling hose

a
(Every 2 years)
Chain
a
(Every 3 years)
-
BATTERY
Page
GENERAL ............................................................1-2
CAPACITY ON SPEC .......................................... 1-2
WEIGHT OF BATTERY WICASE ............................. 1-2
RECOMMENDED BATTERIES ................................. 1-2
BATTERY COMPARTMENT &
MINIMUM WEIGHT REQUIRED ....................... 1-5
BATTERY COMPARTMENT SIZE
ADJUSTMENT ................................................. 1-6
BATTERIES SUITABLE TO BATTERY
ROLL OUT SPEC. COMPARTMENT ................ 1-8
BATTERY WEIGHT SUPPLEMENT
ADJUSTMENT BY SUB-WEIGHT ..................... 1-9
TROUBLE SHOOTING ......................................... 1-12
SERVICE STANDARDS ....................................... 1-I3
BATTERY ASSY .................................................. 1-I4
REMOVAL.INSTALLATION ................................... 1.14
INSPECTION ....................................................... 1-15
1-2
GENERAL
CAPACITY ON SPECIFICATIONS
STD battery High capacity
Model
36 V 48 V 36 V 48 V
5FBCU1 5
595 425 680 51 0
30-5FBCU1 5
5FBCU1 8
680 51 0 935 680
30-5FBCU1 8
5FBCU20
. 680 510 935 610
30-5FBCU20
5FBCU25 680 557 935 680
Capacity 5FBCU25 - -
680 935
AH16HR (Compact model)
5FBCU30
30-5FBCU30 '
5FBCHU20
935 1020
30-5FBCHU20
. 5FBCHU25
30-5FBCHU25
5FBCHU25 - -
935 1020
(Compact model)
WEIGHT OF BATTERY WICASE

Approx. weight battery Approx. weight battery
Model ASSY Wlcase Model ASSY Wlcase
kg (Ibs) kg (Ibs)
5FBCU1 5 5FBCHU20
830 (1840) 1360 (3000)
30-5FBCU1 5 30-5FBCHU20
5FBCU20 5FBCHU25
1090 (2400) 1360 (3000)
30-5F BCU20 30-5FBCHU25
5FBCU25
1090 (2400)
30-5FBCU25
5FBCU30
1360 (3000)
30-5FBCU30
RECOMMENDED BATTERIES
The recommended Batteries are shown in the next table. Those batteries satisfy the minimum weight
required for counter balance. For that reason, the sub-weight are unnecessary. (The maximum capacity
batteries are also given for reference.)
Note:
In UL-EE specifications, a battery side cover and an insulated cover on the rear of the battery hood
are installed; thereby it is unnecessary to use a battery (with cover) for EE use.
Installed battery Battery case

Single cell dimensions Inside dimensions
Type Voltage Capacity
Manufacturer Model mm (in) mm (in)
AH16HR
V Length Width Height Length Width Height
159 165 575 660 862 575
36 EXlDE 18E85-17 680 (6.26) (6.50) (22.64) (25.98) (33.94) (22.64)
t t 18E100-17 800 t 578

(22.76)
. 1
554
t GNB 18-75C-17 600 t (21.81
t t 1 8-85C- 1 7 680 t T t
160 166 575
5FBCU1 5 t C&D 18C75-17 600 (6.30) (6.54) (22.64)
t t 1 8C85-17 680 t t t
157 127 574
48 EXlDE 24E75-13 450 (6.18) (5.00) (22.60)
578
t t 24E 1 00- 1 3 600 t (22.76)
554
t GNB 24-75C-13 450 t t (22.60)
t t 24-85C-13 510 t t t
158 128 575
T C&D 24C75-13 450 (6.18) (5.04) (22.64)
t t 24C85-13 510 t t t
[MAXI
159 165 578
36 EXlDE 8E1 low-' 880 (6.26) (6.50) (22.76)
t t 24c85-17 1 680 1 166

(6.54) / 160
(6.30) / 1
Installed battery Battery case
Single cell dimensions Inside dimensions
Type Voltage Capacity
Manufacturer Mode' mm (in) mm (in)
AHI6HR .
V Length Width Height Length Width Height
222 159 575
36 EXlDE 18E75-23 825 (8 74) (6 26) (22 64)
t t 18E85-23 935 t t t
554
t GNB 18-75C-23 825 T (21 81)
t t 18-85C-23 935 t t t
204 160 575
t C&D 18C85-2 1 850 (8 03) (6 30) (22 64)
223
5FBCU20 t t 18C85-23 935 (8 78) t
165 159 575
25 48 EXlDE 24E75-17 600 (6 50) (6 26) (22 64)
T t 24E85-17 600 t t t
554
t GNB 24-75C- 17 600 t (21 81)
C&D 24C85-19 765 (7 28, (6 30) (22 64)

A *
24C85-21 850 (iz) t t
[MAXI 1
279 159 578
~ F B C H U ~ 3~6 EXlDE 8E 540 ( 10 98) , (6 26) (22 76)
203 159
5FBCU30 48
A
24E 1 1OW-2 1 1 100 ( 7 99, (6 26, T 7
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight t o satisfy the minimum required weight by refer-
ring t o the table below.
Compartment dimensions mm (in) Minimum required

Maximum battery
Front to rear
length X
I
I
Width Y /
I
Height Z
battery weight
(with case)
kg (Ib)
weight (with case)
kg (Ib)
830
(1840)
Battery Compartment Shape

1-6
BATTERY COMPARTMENT SIZE ADJUSTMENT

The battery compartment is made adjustable in both the length and width direction.
1. Length (To front and back)
Since TI 6 plate
is mounted with
a bolt, the compart-
ment length is
adjustable in t w o
stages by removing
this plate.
With TI6 Plate mounted:

Compartment length = 691 mm (27.20")
Without T I6 Plate:
Compartment length = 698 mm (27.48")
Note:
Adjust so the space between the battery compartment and the battery is under 12.7 mm (112" )
2. Width (To right and left)
W (Battery compartment width)

+
r
a C
-
Battery Stopper RH
Battery stopper LH
(Bolted to frame)
Battery compartment width: W is adjustable in 6 stages with different combinations of battery stopper
LH.
Note: Adjust so the space between the battery and battery compartment is under 12.7 mm (112")
BATTEROES SUITABLE TO BATTERY ROLL OUT SPEC. COMPARTMENT
The batteries mountable on battery-rollout specification are limited since the battery compartment length
and width differ from standard models. A recommended list of mountable batteries are shown in the
table below.
Capacity Length Width Height

Voltage Manufacturer TYpe (AHI6HR) mm (in) mm (in) mm (in)
690.6 982.7 574.8-
18E75-23 825
(27.19) (38.69) (22.63)
EXlDE
690.6 982.7 574.8
18E85-23 935
(27.19) (38.69) (22.63)
684.3 979.4 574.8
36 V C&D 18C85-23 935
(26.94) (38.56) (22.63)
685.8 973.1 574.8
18-75C-23 825
(27.00) (38.31 (22.63)
GNB
685.8 973.1 574.8
18-85C-23 935
(27.00) (38.31 (22.63)
685.8 982.7 574.8
24E75-17 600
(27.00) (38.69) (22.63)
EXlDE
685.8 982.7 574.8
24E85-17 680
(27.00) (38.69) (22.63)
684.3 979.4 574.8
24C75-17 600
(26.94) (38.56) (22.63)
48 V C&C
684.3 979.4 574.8
24C85-17 680
(26.94) (38.56) (22.63)
679.5 973.1 574.8
24-75C-17 600
(26.75) (38.31) (22.63)
GNB
679.5 973.1 574.8
24-85C- 17 680
(26.75) (38.311 (22.63)
36 690.6 982.7 577.9

EXIDE 18E11OW-23 1210
V (27.19) (38.69) (22.75)
A
X 48 690.6 982.7 577.9
EXlDE 24E110W-17 880
V (27.19) (38.69) (22.75)
Note: The following matters must be observed when mounting batteries other than the above.
1. Battery weight: Over 1090 kg (2403.45 Ib)
2. Space between battery and battery compartment
(UL Standards) to be under 12.7 mm (112")
BATTERY WEIGHT SUPPLEMENT ADJUSTMENT BY SUBWEIGHT
It will be possible to mount a battery that does not satisfy
minimum battery weight by adding a subweight in the bat-
tery compartment.
The subweight must be procured locally and will not be op-

tionally set.
Taps are provided at two places on the forklift body for at-
taching the subweight. Subweight reference diagrams,
mounting methods, principal battery subweights and required
weights are shown:
1. Sub-weight reference diagram Unit: mm

(in)
Thickness Weight
T19mm 72 kg
(0.748 in) (158.76
T 50 mm 192 kg
(1.969 in) (423.36
Nozzle way for
welding flame
cutting.
dl/ o
400
(15.748)
m
I
L
f-'
20 -
7 I
-
(0.7W& b
6 +*
i
.J
@F
,
0
*+ 3 be. i
OO?.@~~
3s
i
d
P
P
-
fu
N i
0
r\
m - i
0
CO
b
i
-2 i
0
m
m i
i
i
i
I
500 (19 685)

870 (34.252)
2. Mounting method Unit: mm
(in)
h x 1 \i (Frame)
(Sub-weight)
(Sub-weight)
A-A section for T 1 9 mm (0.748) sub-weight A-A section for T 50 mm (1.969 in) sub-weight
* Tapped holes were already bored in frame.
3. Principal Battery Sub-weight and Required Weight.

A: T I 9 mm (0.748 in) 72 kg (158.76 Ib)
B: T 5 0 mm (1.969 in) 192 kg (423.361b)
Minimum Battery Mounted-Battery (Subweight required) Loadable

Weight subweight
Vehicle battery Battery Case
Size Voltage weight lacking width
tY Pe weight W x L x H mm Manufacturer Battery type Size mm
(W x L x H in1 (V) W X L x H mm kg (~bs) kg (Ibs) (in1
kg (~bs) IWxLXHin)
811 X597x575 83
18-75C-15 131,93x 23,50x 22,641 725 (1598) 105 (231) 13.27)
B
811x597~575 83
36 18-85C-15 i31,g3x23,50x22,64) 790 (1741) 40 (88) 13.27)
A
830 (18401 GNB
30-5FBCU15 i $ ~ ~ , " ~ ~ ~ ~ ' ~ 0 3 ) 81 1 x 597x 575 83
8-75B-1 131.93X23.50~22.64)
725 (1598) 105 (231 r3,27,
B
685 x 848 x 575 32
48 24-85C-11 126.18x25.51 x22,64)
778 (1716) 52 (114) A
5FBCU 992x710~585 970X 508x 575 100

(2000) (39.06 x 27.95 x 23.03) GNB 36 18-85C-17 ~38,19x20,00x22,64,
899 (1981) 11 (24) 13,941
A
30-5FBCU18
970X 508 x 575
8-85C-1 (38.19X 2 0 . 0 0 ~22.641
899 (1981) 191 (420)
li.gl B
973X 568x 575 76
18-75C-19 ,
138,31 22,36x 22,641
938 (2069) 152 (334) 12.99)
B
973 x 568 x 575 76
18-85C-19 ,38,31 22,36x 22.64)
1023 (2256) 67 (147) (2,991
A
5FBCU20 36
973 x 568 x 575 76
30-5FBCu20 18-75B-1 938 (2069) 152 (334) (2,99,
B
992X710x585 138.31 X22.36x22.64)
OgO (2400) (39.06 x 27.95 x 23.03) GNB
5FBCU25 973 x 629x 575 45.5
8-75c-21 1041 (2294) 49 (108) A
30-5FBCU25 138.31x --
24.76%22.64) ~-
973x629x575 45.5
8-75B-21 1041 (2294) 49 (108)
138.31 X 24.76X 22.64) A
970x 597x 575 61.5
24-75C-15 138,19x23,50x22,64~
958 (2111) 132 (2901 12,42)
970 x 597 x 575 61.5
48 24-85C-15 138,1gx 23,50, 22,641
1044 (2302) 46 (101 (2.42)
A
970x 597 x 575 61.5
24-75B-1 (38.19~23.50~22.64) 958 (21 ) 32 (290) 12.42)
TROUBLESHOOTING
Pole plate corrosion

\
\\ lnsufflc~entcharge
\-No operation for \ Repetillon of

overdischarge
Shorting between
and overcharge
cells
Excessive
charg~ng
current
temperature
Incomplete
terminal
Improper water
connection
supply
Overcharge
Deposition of fallen
-acting substance In Duty terminal or plug-
Short circuit Loosened or corroded

and decrease connections
1-13
SERVICE STANDARDS
Specific gravity in fully charged state (OC) 1.280 (20)
Specific gravity in fully discharged state (OC) 1.150 (20)
Discharge end voltage 36 V specification 32.0
V 48 V specification 42.5
Electrolyte Sulfuric acid diluted with distilled water
Fluid t o be spplied Distilled (deionized) Water
Insulation resistance MO I or more
DISPLAY INDICATION
1. The display indicates the remaining battery charge
level in 1 0 stages. When the remaining charge drops
below 20 %, the indication flashes the warn the timing
for charging.
2. When the battery is discharged fully ( 1 0 0 %), the

overdischarge alarm function operates as follows:
OVERDISCHARGE ALARM FUNCTION

1. Material handling with traveling becomes impossible.
If simultaneous operation is attempted, priority is
given t o traveling and material handling is not ef-
fected. (For prevention of battery from damage by
large current flow)
2. When material handling is attempted, all indicators on

the display flash and the buzzer sounds t o alarm over-
discharge.
Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on how-
ever, material handling operation can be performed.
BATTERY ASSY
REMOVAL. INSTALLATION
Removal Procedure
1 Place the mast in vertical position.
2 Disconnect the battery plug.
3 Pull the-steering unlocking lever to tilt the steering forward
4 Place the seat t o the foremost position.

(When the deadman seat is used, remove the seat together with the seat stand.)
5 Release the battery hood catch.

(For the battery roll-out spec. model, release the battery stoppeer. For the dust-proof spec. model,
remove the battery side cover, too.)
6 Open the battery hood as holding the handle on RHS and hook the hood stay.
7 Hoist the battery Assy W/Case to relocate. (Case of the battery roll out spec., removable sidewise.)
Installation Procedure
Follow the reverse sequences of the removal.
INSPECTION
1 Electrolyte inspection
( 1 ) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.
2 Inspection o f electrolyte specific gravity

( 1 ) Use a hydrometer and measure the specific gravity
of the electrolyte
Specific gravity in fully charged state:

1.280 (at 2 0 O C)
Specific gravity in fully discharged state:
1.150 (at 2 0 OC)
The specific gravity of the electrolyte is expressed
by the value at 2 0 O C as the standard.
Specific gravity conversion equation
,S, = S t + 0.0007'(t-20)
:S
,, Specific gravity at 2 0 O C
S t : Specific gravity at t O C
t : Temperature at the time of measurement
H o w t o use the hydrometer

@ Insert the nozzle of the hydrometer into the wa-
ter supply port and suck the electrolyte into the
outer cylinder.
@ Let the hydrometer in the outer cylinder float
correctly without contact with the top, bottom
and side wall of the outer cylinder, and read the
graduation at the using electrolyte surface as
shown at left after disappearance of bubbles in
the sucked electrolyte.
@ After the measurement wash outside and in-
Hydrometer side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.
1
3 Insulation resistance inspection
Duter tube - Use an insulation resistance meter (megger) and mea-
sure the resistance between the battery and battery
case.
Insulation resistance: 1 M Q or more
Note:
If the insulation resistance is less than 1 MQ, remove
the battery from the vehicle and wash it with water.
Dry the battery case the roughly, and measure the
insulation resistance again. Install the battery on the
vehicle after checking that the insulation resistance
is 1 M Q or more.
* Battery control table
Prepare the control table for each battery t o record and retain the inspection result.
CONTROL CIRCUIT
Page
MCS I11 CONTROLLER ....................................... 2-2
GENERAL ........................................................... 2-2
SPECIFICATIONS ................................................. 2-3
COMPONENTS ................................................... 2-4
CONTROL PANEL ASSY ...................................... 2-9
OCL VALUE (OVER CURRENT LIMIT VALUE) .......... 2-39
ACCELERATOR POTENTIOMETER
ADJUSTMENT ................................................2-41
BRAKE SWITCH & STOP LAMP SWITCH
ADJUSTMENT ................................................ 2-41
PARKING BRAKE SWITCH ADJUSTMENT ....... 2-42
SEAT SWITCH ADJUSTMENT FOR
BATTERY ROLL OUT (OPT) ......................... 2-43
MATERIAL HANDLING SWITCH
ADJUSTMENT ................................................ 2-43
MATERIAL HANDLING CHOPPER SWITCH (OPT)
ADJUSTMENT ............................................... 2-44
DIRECTION SWITCH .......................................... 2-45
REMOVAL-INSTALLATION ................................... 2-45
DISASSEMBLY -ASSEMBLY .................................. 2-46
INSPECTION ...................................................... 2-47
POWER STEERING CONTROLLER ..................... 2-48
COMPONENTS ................................................... 2-48
REMOVAL.INSPECTION.INSTALLATlON (STD) ....... 2-49
REMOVAL-INSPECTION-
INSTALLATION (WIEHPS) ................................. 2-51
MCS-I11 CONTROLLER
GENERAL
The 5FBCU series is provided with the diagnostic (self-diagnosis) function for automatically detecting
any abnormality in the main travelinglmaterial handling circuit, operating system such as the ac-
celerator and sensors to sound the buzzer (peep, peep) and to display the abnormal portion by the cor-
responding error code on the multidisplay.
A t the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken to ensure safety.
When the display is set to the analyzer (fault analysis) mode, defect detection and functional check of
the main drivelmaterial handling circuit, operating systems, and sensors are performed.
See the Multidisplay section (page 3-3) for the diagnosis. See the Multidisplay section (page 3-71 for
the analyzer.
Drive Control Panel ASSY
Material Handling Control Panel ASSY Material Handling Control Panel ASSY (with Chopper)
SPECIFICATIONS
Portion 1 t o n series 2 t o n series 3 ton series
F1 (Drive circuit) 275 A 325 A t
F 2 (Material handling circuit) 1 225 A I 325 A I c 1

Fuses F 3 (PS circuit) I 75 A I t I + 1
F 4 (For lamps) I 10 A I C
I t
I
F5 (Control circuit) I 10 A 1 t I t 1
T M (For traveling)
Transistors TMP (For material handling: OPT) TSM 0 0 3 (3 pcs.) c c
TG (For regeneration preexcitation) E T I8 8 c t
TM ,,(For PS : OPT) # IM1100H-025 t c
DAD (For traveling) 30MF40 t t
DAP (For material handling: OPT) 30MF40 t t
IDG (For regeneration)

D F I (DM flywheel) SR250L-6s + C
Diodes
DF2 (DM flywheel) SR250L-6s +- C
I D F ~(PM flywheel) 1 20M30 I t I 4- 1

/ D F (PM
~ flvwheel: OPT) I 70M30 1 +- I +- I
I D F ~ (PS flywheel) I # IM1100H-025 I + I t I
CSD (For traveling) HS800RT c c
Current
CSP (For material handling: OPT) HS800RT t c
sensors
CS, (For PS: OPT) MBP20A-1 OMJN C +-
CAD (Absorber for traveling) I 60pF ( 2 pcs.) 1 +- +-

I
I I
Capacitors CAP
(Absorber for material handling: OPT)
RAD (Absorber for traveling)
60pF ( 2 pcs.)
1 .5Q 2 2 0 W t c
RG (For regeneration) 0.6Q 120W t t

Resistors
RAP
1.5Q 220W c c
(Absorber for material handling: OPT)
MF.MR
(For forwardireverse traveling)
1 ME250
1
MG (For regeneration) ME251 c t
MS (Bypass) ME251 +- t
M W (For field weakening) ME251 +- +
MP (For material handling) 1 ME251 I

MPS (For PS) ME252 +- t
# : The PS transistor and diode are integrated.

COMPONENTS
Drive Control Panel Components
240 1
Resistor Panel Components
2401
Material Handling Contactor Components
z
%
?.
E
I
al
3
-
-.
Q
3
(C1
0
0
3
B
2
z
z
\
0
z
0
'El
u
e
0
0
3
'El
0
3
tD
2
V)
MF-MR Contactor Components
MG-MS.MPsMW Contactor Components

- -
CONTROL PANEL ASSY

Removal-Installation
Control Panel ASSY Removal Procedure
Removal Procedure
2 Remove the control panel cover
3 Remove the cover. (Dustproof model only)
4 Disconnect the wiring.
5 Remove the drive control panel ASSY.
6 Remove the material handling control panel ASSY.
The installation procedure is the reverse of the removal procedure.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose,
the control panel elements may be damaged.
Inspection
Some components parts can be inspected after removing from the vehicle while others can only be in-
spected on the vehicle.
As the CPU board and DC-SD board require battery voltage application, they must be inspected while
being mounted on the vehicle. (Use SST 09240-1 3300-71 .)
lnspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (always inspect before starting control panel inspection.)
(1) Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
Measurement terminals Controller side of battery plug - Body

The resistance should be as high as possible, but it varies greatly, depending on
Standard
the vehicle use status, place and weather. (Approx. 1 Ma)
Measuring the Insulation Resistance

2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor)
(OPT)
( 1) lnspection method
Disconnect the wiring of CAD and CAP after discharging the CAD and CAP with a resistor of
about 100 Q.
Inspection point Measurement terminals Circuit tester range

CAD
Both terminals of CAD (DAD side - T M side)
(Drive control panel)
Q x lK
CAP
Both terminals of CAP (DAP side - TMP side)
(Material handling control panel)
Standard
When circuit tester probes are brought into contact w i t h both terminals of CAD or CAP, the pointer deflects
once t o the 0 Q side and gradually deflects toward the side t o indicate finally.
CAD lnspection CAP lnspection

3. TM (main transistor for drive circuit) and TMP (main transistor for material handling circuit)
Disconnect wiring from each of TM and TMP.
Inspection point Measurement terminals Standard Circuit tester range
Between D and S
D: - probe - S: +
probe
w C!
D: +probe - S: - probe
TM
w n
(Drive control panel) D: - probe - G: + probe
Between D and G Continuity
TMP D: + probe - G: - probe Q x IK
shall exist
(Material handling
Continuity
control panel)
Between G and S
G: - probe - S: + probe shall exist
G: + probe - S: - probe
w n
If any one of TMs or TMPs is found defective as a result of inspection, replace all TMs or TMPs as a
set.
I I
TM lnspection TMP lnspection
4. DRD (Direction of Reverse Conductive Diode)

(1) lnspection method
Remove the DRD.
DRD
Forward Anode: - probe - Cathode: + probe Approx. 1.6 k 8
il x l K
Reverse Anode: + probe - Cathode: - probe
u
Conduction No Conduction
5. TG (regenerative transistor)
Disconnect the wiring from TG.

Continuity
B: - probe - C: + probe
Between B and C shall exist
B: +
probe - C: - probe
@J Q
Q x lK
03 Q
Between C and E
C: - probe - E: + probe Continuity
C: + probe - E: - probe
shall exist
I I
TG lnspection
6. DFI aDF2 (flywheel diodes No.1 and No.2)

Disconnect the wiring from D F I and DF2.

D F I .DF2 Forward Anode: - probe - Cathode: + probe Approx. 3kQ
Q x lK
(Traveling ~0ntf-01
panel) Reverse Anode: + probe - Cathode: - probe 00 Q
DFl lnspection
7. DG-DF3 (regeneration diode and flywheel diode No.3 in material handling panel (with chopper))
Disconnect the wiring from DG and DF3.

DG
Forward Anode: - probe - Cathode: + probe Approx. 3 kfJ
DF 3 O x lK
(Material handling Reverse Anode: + probe - Cathode: - probe wn
control panel)
Q
DG lnspection DF3 lnspection
8. DF3 (chopperless material handling panel flywheel diode No.3)

( 1 1 lnspection method

DF 3 Forward - probe - Cathode: + probe
Anode: Approx. 30 kQ
0 x 1K
(Contractor panel) Reverse Anode: - probe - Cathode: - probe w 0
DF3 lnspection
9. DAD (drive circuit absorber diode).DAP (material handling circuit absorber diode)
Disconnect the wiring from DAD and DAP.

DAD
Forward Anode: - probe - Cathode: + probe Approx. 6 kO
DAP O x 1K
(Material handling Reverse Anode: + probe - Cathode: - probe 03 f-l
control panel)
DAD Inspection DAP Inspection
10. MF (forward traveling contactor).MR (reverse traveling contactor).MS (bypass contactor)

MG (regeneration contactor)-MW(field weakening contactor)
MP(materia1handling pump contactor)
( 1 lnspection method
Measure the coil resistance of each of MF-MR-MS-MGsMWand MP.

(In drive control
panel)
MF coil MF coil connector
MR coil MR coil connector
MS coil MS coil connector Approx. 2 0 52
at 20°C
MG coil MG coil connector
(68OF)
(In material handling
control panel)
MW coil MW coil connector
MP coil MP coil connector
MF Coil lnspection MR Coil lnspection
I 1
MS Coil lnspection MG Coil lnspection
MW Coil l n s ~ e c t i o n MP Coil lnspection

1 1. RG (regeneration resistor)
( 1 ) lnspection method
Disconnect the wiring from RG.

RG Both terminals of RG Approx. 0.6 Q Q x I
RG Inspecting the Continuity of RG
12. RAD(drive circuit absorber resistor)-RAP(materia1handling circuit absorber resistor)

Disconnect the wiring from RAD and RAP.

RAD Both terminals of each of
Approx. 1.5 Q Q x l
RAP RAD and RAP
Inspecting the Continuity of RAD Inspecting the Continuity of RAP

13. RFW (field weakening resistor)
(1 ) lnspection method

RFW Both terminals of RFW See the table below 9 x 1
(H):High capacity vehicle

* : Compact specification
"2.5 ton
1 ton series 2 ton series (H) 3 ton series
RFW
"2.5 ton
vehicle
Identification Resistance
Part No. 36 V 48 V 36 V 48 V 36 V 36 V 48 V
symbol mS1
A 24291 -1 3300-71 5.428
F 24292-1 3300-7 1 1 7.188 0 0

X No resistor 03 0
(Dustproof specification)
I
I
I
RFW
1
I
I
RFW Inspecting t h e Continuity of RFW

14. CPU board.DC-SD board
When the cause of a trouble is judged to exist in the CPU board or DC-SD board, apply the battery
voltage, connect SST09240-13300-71, and measure the applied voltage and resistance at each
connector.
Caution:
Always disconnect the battery plug before removing or installing the CPU board and DC-SD board.
Note:
Always measure the applied voltage and resistance at the respective portion before replacing the
CPU board or DC-SD board which is judged to be causing a defect as a result of troubleshooting.
Use SST 09240-1 3300-71 for measurement.
(1 SST connection method
@ I the key switch to OFF.
Turn
@ I
Disconnect the battery plug.
Disconnect the CPU board and DC-SD board connectors (CN101 to CN 107.CN1 1 1
and CN112).
@ Connect the SST. (If connectors A and B are connected disconnect them beforehand)
@ Connect the connector A and B.
If the connection of the connector A and B are undone, inspections on both main circuits
Travel and Hydraulics can not be performed.
/
ConnectorB
Connecting the SST

( 2 ) Lists o f measurement methods and standards
@ Explanation o n list f o r m a t
rCircuit tester ( + ) probe

r Circuit tester ( - ) probe
connector pin No.
Connector No. * ~onnectorl~o. Conditions Standard Remarks
-
I
CN102-1 CN102-9 SWky: ON
V) I (N,,GND) I s w ~ ~ :OFF
t T I t
k 3 i g n a l (part) name Conditions for measurement
Level No.
Lists
C N l 01 connector Basic conditions (battery plug O N - S W k y ON)
Connector No. * Connector No. Conditions Standard Remarks

CNIOI-I
Unused
CN101-2 I
CN101-3 I CN101-20
(15, + 3 0 V )
I
I (N1,GND)
Approx. 18 +3V
CN101-4 I CN101-20
Approx. 18 *3V
(15,+30V) (N1,GND)
CN101-5 CN101-20 SWky ON Approx. 4 8 V/36 V Voltage after
(10, C36 V ) I (NI, GND) SWky OFF OV key switch
CN101-6 CN101-20
(32, CHOP + I
I
(N1, GND)
5 * 0.25 V
CN101-7
(3O,VDD+) I
CN101-20
(N1,GND)
5 * 0.25 V
CN101-8 CN101-20
( ,- 5V) I (N1,GND)
Unused - 5V - - 6V
4
CN101-9 I CN101-20 SWky ON Approx. 4 8 V/36 V

I
(14, VBKY) I ( N I , GND) SWky OFF 0V
CN101-10
(12,VBKY2) I Unused
CNIOI-I1 CN101-20 SWkyON Approx. 4 8 V/36 V Voltage after

(43, K 3 6 V ) I ( N I , GND) SWky OFF 0V key switch
I
CN101-12 I
I Unused
CN101-13 I
Connector No. ++ Connector No. Conditions Standard Remarks
I
CN101-14 1 CN101-20
ov
(11, GND) 1 ( N I , GND)
CN101-15 I Unused
CN101-16 I CN101-20
I ov
(11, GND) I ( N I , GND)
I
CN101-17 I CN101-20
(33,CHOP-) (N1,GND)
Traveling in stopped state 4V - 5V
CN101-18 CN101-20
(31, VDD-) I ( N l , GND)
Traveling in stopped state 4V - 5V
CN101-19 1 Unused
CN101-20 I Panel N l Battery plug OFF
I on
( N I , GND) 1 terminal SWky OFF
CN101-21 I CN101-20
Approx. 4 8 V/36 V
(13, VBBT) I ( N l , GND)
CN101-22 1 CN101-20
Approx. 4 8 V/36 V Battery voltage
(41, B36 V ) I ( N l , GND)
CN102 Connector Basic conditions (battery plug ON-SWky ON)

CN102-1 1 CNlO2-9 SWky ON Approx. 4 8 V l 3 6 V Voltage after
(43, K36 V ) I ( N l , GND) SWky OFF 0V key switch
CN102-2 CN102-9
(41, B36 V ) I ( N l , GND)
I
CN102-3 I Unused
I
I 3 6 V vehicle:
CNIO2-4 CH102-9 21 *
3V
(P8, RCKI) I ( N l , GND) 4 8 V vehicle:
I
I 28 f 3 V
CN102-5 CN102-9
Approx. 4 8 V/36 V
(P9, RCK2) I ( N I , GND)
CN102-6 CN102-9
ov
(N2, TMS) I ( N I , GND)
I
CN102-7 I CN102-9
I Unused Approx. 48 V/36 V Battery voltage
(41, B36 V ) I ( N l , GND)
CN102-8 I CN102-9
(41, D 3 6 U) I ( N I , GND)
Connector No.
CN 102-9
-I Connector No.
Panel N 1
Conditions
Battery plug OFF
Standard Remarks
SWky OFF
0 Q
(N1, GND) terminal
CN102-10 I Unused
I 3 6 V vehicle:
I
CN102-11 I CNl02-9 21f3V
I
(P8,TMD) I (N1,GND) 4 8 V vehicle:
I 28f3V
I
CN102-12 I CN102-9
Traveling stopped state - 5- 6V
(92, TMG) I ( N l , GND)
CN103 Connector Basic conditions (battery plug ON.SWky ON)
Connector No.
CN103-1
- Connector No.
Panel
Conditions
Battery plug OFF
Standard Remarks
on
(11, GND) I N 1 terminal SWky OFF
I Battery plug OFF
I
SWky OFF
CN103-2 CN103-9
Measure the resistance with CN 103-9 Approx. 2 0 Q MP contactor
(5,MPI (l.M+I
as the positive side (circuit tester neg-
I
I ative probe).
I
CNIO3-2 1 CN103-1
Measure the voltage applied to the
MP coil with CN 103-2 as the positive Approx. 4 6 V l 3 4 V MP coil
(51MP) I (I GND)
I side (circuit tester positive probe).
I
I Battery plug OFF

I
CN103-3 I CN103-9
SWky OFF
Measure the resistance with CN 103-9 Approx. 2 0 Q M W contactor
(7,M W ) (1. M + )
as the positive side (circuit tester neg-
I
I ative probe).
I
CN103-3 I CN103-1
MW coil with CN 103-3 as the positive Approx. 4 6 V l 3 4 V MW coil
(" MW) I GND'
side (circuit tester positive probe).
I
I Battery plug OFF, SWky OFF
CN 103-4 I CN 103-9 Measure the resistance with CN 103-9
Approx. 2 0 n MS contactor
(6, MS) j (1, M + ) as the positive side (circuit tester neg-
I ative probe).
I
CN103-4 CN103-1
MS coil with CN 103-4 as the positive Approx. 4 6 V / 3 4 V MS coil
(6,MS) (1I , GND)
I
I Battery plug OFF, SWky OFF Measure
I
CN103-5 I CN103-9 the resistance with CN103-9 as the
Approx. 2 0 Q MG contactor
(4, MG) M+)
(I, positive side (circuit tester negative
I probe).
I
I Measure the voltage applied to the
CN103-5 I CN103-1
(4,MG) ,
I
I
(11,GND)
MG coil with CN 103-5 as the positive Approx. 4 6 V / 3 4 V
MG coil
Connector No. - I
Connector No. Conditions
Battery plug OFF, SWky OFF Measure
Standard Remarks
I
CN103-6 1 CN103-9 the resistance with CN103-9 as the
Approx. 2 0 9 MR contactor
(3, MR) I (1, M + positive side (circuit tester negative
I
I probe).
I
CN103-6 CN103-1
MR coil with CN103-6 as the positive Approx. 46 V / 3 4 V MR coil
(3,MR) I (11,M+)
I side (circuit tester negative probe).
I
CN103-7 CN103-9 the resistance with CN103-9 as the
Approx. 2 0 D MF contactor
(2, MF) I (1, M + positive side (circuit tester negative
I
I probe).
I
CN103-7 I CN103-1
Measure the voltage applied to the MF
coil with CN 103-7 as the positive side Approx. 4 6 V / 3 4 V MF coil
(2, MF) 1 (11, GND)
I (circuit tester positive probe).
I
CN103-8 I CN103-1
I Approx. 0 V
(PS, VBPS) I (11, GND)
CN103-9 CN103-1 Contactor
SWky ON
(1, M + ) I (11, GND)
Approx. 4 6 V / 3 4 V
power supply
CN103-10 I CN103-1 SWky ON Approx. 48 V l 3 6 V Voltage after
(10, C36 V ) I (11, GND) SWky OFF OV key switch
I
CN103-11 I
( . M+KY) I
I
CN103-1 Unused
I
CN103-12 1 CN103-1
Approx. 4 8 V l 3 6 V
(43.VBKY2) (11,GND)
CN103-13 1 CN103-1
Approx. 1 V TG base
(91,TGB) I (11,GND)
I
CN103-14 I CN103-1
Approx. 0 V TG emitter
(P10, TGE) (1 1, GND)
CN103-15 I CN103-1
Approx. 4 8 V/36 V
(P2, VBP2) I (11, GND)
CN103-16 I CN103-1
I Approx. 4 8 V/36 V
(13, VBBT) I (11, GND)
2-24
CN104 Connector Basic Conditions (battery plug ON.SWky ON)

CN104-1 j Panel N1
ov
(74, GND) 1 terminal
CN104-2 CN104-1
(74, GND) I (74, GND)
ov
I
CN104-3 I CN104-1 Greater than 0 V and
(76, THC) (74, GND) less than 5 V
CN104-4 / CN104-1
Material handling stopped state 4 v -5v
(36, VDP-) 1 (74, GND)
CN104-5 1 CN104-1
(31, VDD-)
I
1 (74, GND)
Traveling stopped state 4 v -5v
CN104-6 I CN104-1
Approx. 1 8 =k 3V
(15,+30V) (74,GND)
CN104-7 CN104-1
Traveling stopped state Approx. 1.2 V
(71, CSD) I (74, GND)
I
CN104-8 I CN104-1
I Material handling stopped state Approx. 1.2 V
(72, CSP) 1 (74, GND)
CN104-9 I CN104-1
5 * 0.25 V - +5V
(32, + 5 V ) 1 (74, GND)
CN104-10 j CN104-1
5 * 0.25 V +5V
(75, + 5 V ) I (74, GND)
I
CN104-11 I CN104-1
(I
1, GND) / (74, GND)
ov
CN104-12
Unused
( ,GND)
CN104-13 I CN104-1 SWky ON Approx. 4 8 V/36 V
I
(14, VBKY) 1 (74, GND) SWky OFF 0V
CN104-14 I CN104-1
5 * 0.25 V
(35, VDP + I j (74, GND)
CN104-15 / CN104-1
5 f 0.25 V
(30, VDD + ) 1 174, GND)
CN104-16 I CN104-1
I
(33, CHOPD) 1 (74, GND)
4 v -5v
CN104-17 CN104-1
(38, CHOPP) 1 (74, GND)
4 v -5v
CN104-18 1 CN104-1
12V f 0.6V +12V
(73, + 1 2 V ) 1 (74, GND)
CN104-19 CN104-1
12 f 0 . 6 V +12V
(73, + 1 2 V ) (74, GND)
CN104-20 1 CN104-1
5 f 0.25 V +5V
(37, + 5 V ) I (74, GND)
&
CN105 Connector Basic conditions (battery plug ON, SWky ON) GND of CN105 is at CN105-3,
CN105-8 and CN105-9. Any GND may be used for the voltage check, but use wired GND pins for con-
-
tinuity check.
Connector No. Connector No. Conditions Standard Remarks

I
CN105-1 j CN105-6 the resistance with CN105-6 as the
Approx. 20 Q MPS
(8, Mps) I1 (1, M +) positive side (circuit tester negative contactor
I probe).
I
Measure the voltage applied t o MPS
CN105-1 CN105-9
with CN 105-1 as the positive side Approx. 4 8 V/36 V Mps coil
(8, Mps) I1 (51, GND)
(circuit tester negative probe).
* 0.25 V
I
CN105-2 I CN105-9 LSAT2OFF 5

I
(69, LSAT2) 1 (51, GND) LSAT2ON ov
CN105-3 1 CN105-9
ov
( , GND) 1 (51, GND)
CN105-4 CN105-5
Without traveling OV
(82, SS-) I (81, S S + )
I
CN105-5 I CN105-4
I Without traveling OV
(81, S S + ) 1 (82, SS-)
CN105-6 CN105-9 Contactor
SWky ON Approx. 4 6 V l 3 4 V
(1,M+) / (51,GND) power supply
CN105-7 1 CN105-9 LSAT3OFF 5 * 0.25 V
( ,LSAT3) 1 (51, GND) LSAT3ON OV
I
CN105-8 I CN105-9
ov
(51, GND) 1 (51. GND)
CN105-9 1 Panel N1
ov
(51, GND) 1 terminal
CN105-10 I Unused
Connector No. c* Connector No. Conditions Standard Remarks
CN105-I 1 I CN105-9 LS, OFF 5 * 0.25 V
(66, LSPB) 1 (51, GND) LS, ON OV
CN105-12 / CN105-9 LSAT, OFF 5 * 0.25 V
(63, LSAT1) I (51, GND) LSATl ON OV
CN106 Connector Basic conditions (battery plug ON-SWky ON)
Connector No. c* Connector No. Conditions Standard Remarks

CN106-1
I
1 CN105-9 DSR OFF 5 * 0.25 V
(46, DSR) 1 (51, GND) DSRON 0V
CNIO6-2 CN105-9 DSF OFF 5* 0.25 V
(45, DSF) 1 (51, GND) DSF ON OV
5 * 0.25 V
I
CN106-3 I CN105-9 SWAc OFF
(64, SW), / (51, GND) SWAc ON 0V
CN106-4 I CN105-9 LS, OFF OV
(65, LS,) 1 (51, GNDI LS, ON 5 * 0.25 V
CN106-5 I CN105-9 LSD OFF 5 * 0.25 V
I
(67, LSD) 1 (51, GND) LSD ON OV
CN106-6 CN105-9
(191, TMD + ) 1 (51, GND)
4 v -5v
CN106-7 CN105-9
4 v -5v
- 9 4 , T M P + ) II
( 1 (51,GND)
CN106-8 I CN105-9
(53, POT +
I
1 (51, GND)
3 v -5v
CN106-9 CN105-9 0V -
Approx.
(193, BMP) 1 (51, GND) 4 8 V/36 V
CN106-10 1 CN105-9
t
(190, BMD) I (51, GND)
CN106-11 CN105-9
(196, BMPS) / (51, GND)
t
CN106-1 2 j CN 105-9 Shall vary smoothly according to trav-
(52, POTA) I (51, GND) eling speed acceleration.
CN106-13 CN 105-9 Greater than 0 V and
(192,TMD+) 1 (51,GND) less than 5 V.
CN106-14 CN105-9 Greater than 0 V and
(195, TMP+I / (51, GND) less than 5 V.
CN106-15 CN105-9 LS,, OFF 5 * 0.25 V
(60, LSLl) (51, GND) LS,, ON OV
CN106-16 I CN105-9 LS, OFF 5 * 0.25 V
(61, LS,) I (51, GND) LS, ON OV
5 * 0.25 V
I
CN106-17 1 CN105-9 SWsc OFF
(77. SWSC) 1 (51, GND) SWsc ON OV
CN106-18 1 CN105-9 LS, OFF 5 * 0.25 V
(68, LS,) (51, GND) LS, ON 0V

I
CN107-1 1 CN107-6
0 - 1 v
(141, SMTDA) 1 (17, GND)
CN107-2 1 Cannot be measured with a circuit
(142, SDTMA) I tester.
I
CN107-3 I CN107-6 Approx. 4 8 V l 3 6 V
(14,VBKY) / (74,GND)
Unused
ov
CN107-4 CN107-6
(144,SMTDK) 1 (74,GND)
0 v
CN107-5 I Cannot be measured with a circuit
I
(143, SDTMK) I tester.
-
CN107-6 Panel N1
(17, GND) / terminal
Battery plug OFF, SWky OFF 0 SZ
CN107-7 I Unused
CN107-8 CN107-6
(16,+30V) I (17,GND)
18 +3V

I
CN111-1 I
Unused
CN111-2 I
CN111-3 I CN111-20
I Unused Approx. 18 & 3 V
(15,+30V) I (N1,GND)
I
CN111-4 I CN111-20
(15, + 3 0 V ) / ( N l , GND)
Unused Approx. 1 8 +3V
CN111-5 CNlll-20 Approx. 4 8 V/36 V
Unused
(10, C36 V ) I ( N l , GND) ov
CN111-6
(37, CHOP + ) I
1
I
CN111-20
( N I , GND)
5 * 0.25 V
CN111-7 1 CN111-20
(35, VDP+) / ( N I , GND)
5 f 0.25 V
CNlll-8 CNlll-20
( ,- 5V) I ( N l , GND)
Unused - 5V - - 6V
I
CN111-9 I CN111-20
I Unused Approx. 4 8 V/36 V
(14, VBKY) I ( N I , GND)
CNI11-10 Unused
CN111-11 1 CNlll-20 SWky ON Approx. 48 V/36 V
(43, K 3 6 V ) ( N I , GND) SWky OFF 0V
CNlll-12
Unused
CN111-13 I
I
CN111-14 I CN111-20
(11, GND) I ( N I , GND)
Unused OV
I
CN111-15 I Unused
CN111-16 I CN111-20
Unused OU
(11, GND) I ( N l , GND)
CNlll-17 I CN111-20
(38, CHOP-)
I
I (N1, GND)
Material handling stopped state 4V - 5V
I
CN111-18 I CNlll-20
(36, VDP-) ( N l , GND)
Material handling stopped state 4V - 5V
CNlll-19 I Unused
CN II1-20 Panel N 1 Battery plug OFF
0n
( N I , GND) I terminal SWky OFF
CNlll-21 CN111-20
Unused Approx. 4 8 V l 3 6 V
(13, VBBT) I ( N l , GND)
CN111-22 I CN111-20 Battery
(41, 8 3 6 V ) / ( N I , GND)
Approx. 4 8 V/36 V
voltage
CN1 1 2 Connector Basic Conditions (battery plug ONmSWky on).

CN112-1 I CN112-9
Unused
Approx. 4 8 V/36 V
(43, K36 V ) I ( N l , GND) OV
CN112-2 CN112-9
Unused Approx. 4 8 V/36 V
(41,B36V) I (N1,GND)
I
CN112-3 I Unused
I
CN1 12-4 I CN112-9
10- 25V
(P14,RCKl) (N1,GHD)
CN112-5 CN112-9
Approx. 4 8 V
( P I 5, RCK2) I ( N l , GND)
CN112-6 I CN112-9
I ov
(N2, TMPS) I ( N I , GND)
CN112-7 CN112-9
(41, B36 V ) I (N1,GND)
Unused Approx. 4 8 V
CN112-8 CN112-9
Unused Approx. 4 8 V
(41, B36 V ) 1 ( N l , GND)
CN112-9 I PanelN1
I Unused Shall not be open.
( N I , GND) 1 terminal
CN112-10 Unused
CN112-11 CN112-9
(P14, TMPD) I ( N I , GND)
10 - 25V
CN112-12 CN112-9
(93, TMPG) I ( N l , GND)
Material handling stopped state -5 - - 6V
2-30
15. Display
If the cause of a trouble is judged t o exist in the display, apply the battery voltage and measure the
voltage applied t o the connector.
I 1
Measuring the Voltage
CN120 Connector Basic condition (battery plug ON)

CN120-9 j CN 120-19
(16, + 3 0 V ) 1 (17, GND)
Approx. 2 3 - 24 V
CN 120-1 0 1 CN 120-20
I Approx. 4 8 Vl36 V
(104, BL) I ( N l , GND)
Disassembly
The control panel is overhauled infrequently. Defective part replacement according t o the cause of the
trouble by inspection is performed in most cases. Please perform correct operation by referring t o the
component parts drawing, assembly drawing and internal connection diagram.
Cautions for Parts Replacement
Tighten the bar and harness set nuts and screws t o the specified torques, and always coat locktite.
Looseness or insufficient tightening will cause other troubles.
When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indi-
cating the mounting position. A t the time of reassembly, prevent incorrect installation or wiring by
referring t o the memo or tag. lncorrect installation or wrong wiring will cause other troubles.
Always coat silicone grease on parts which have been coated with silicone grease. Omission of
coating may cause overheating.
After reassembly, check no contact of the bars and cables at other than the contact portions. Before
installation on the vehicle, check continuity at points with a circuit tester. (See page 2-38 for the
inspection points with the circuit tester.)
TG (Regenerative Transistor) Installing Direction

If TG is installed in the opposite direction, B (base) and E (emitter) are reversed t o cause no function-
ing.
Correct mountlng d~rection lncorrect mounting direction
TG Installing Direction
Assembly
MR MF DG DF2 DF1 SN 1 STH CAD
CN106 CN1 0 4 CPU BOARD

DCISD BOARD
CN101
CN 102
I I
Drive Control Panel Assembly Drawing
Material Handling Control Panel Assembly Drawing (STD)
I
CSD
\
DAP
DCISD BOARD
\
Material Handling Control Panel Assembly Drawing (with Material Handling Chopper)
Control Panel Parts Tightening Torques
ltem Tightening torque N - m (kgf-cm) [ft-lbfl

M5 2.13-2.75(22-28)11.59-2.O3I
Main terminals
TM M4 8 - 1.77 (12
I.? - 18) 10.87 - I.301
For installation M5 2.1 3 - 2.75 (22 - 28) [I.59 - 2.031
Main terminals M6 3.14 - 3.73 (32 - 38) [2.32 - 2.751
DF 1 .DF2
For installation M6 5.10 - 5.69 (52 - 58) L3.76 - 4.201
Main terminals M6 2.16 - 2.75 (22 - 28) [1.59 - 2.031
DG
For installation M20 21.28-21.87(217-223)[15.70-16.131
DAD For installation M6 2.13 - 2.75 (22 - 28) L1.59 - 2.031
Main terminals M5 2.13 - 2.75 (22 - 28111.59 - 2.031
TG
For installation M5 2.1 3 - 2.75 (22 - 28) [ I.59 - 2.031
(Material handling control panel)
Item Tightening torque N. m (kgf-cm) [ft-lbfl

STD (chopperless)
DF3 Main terminals 1 M6 1 2.13 - 2.75 (22 - 281 11.59 - 2.031
OPT (with chopper)
M5 2.13 - 2.75 (22 - 28) 11.59 - 2.031
Main terminals
TMP M4 1.18 - 1.77 (12 - 18) I0.87 - 1.301
For installation M5 2.13 - 2.75 (22 - 28) [I.59 - 2.031
DAP For installation M6 2.13 - 2.75 (22 - 28) 11.59 - 2.031
Main terminals M6 2.16 - 2.75 (22 - 28) 11.59 - 2.031
DF3
For installation ~ 2 0 21.28-21.87(217-223)[15.70-16.131
(Power steering control panel)
Main terminals M5 1.96 - 2.94 (20 - 30) [ I.45 - 2. 171

1.96 - 2.94 (20 - 30) [ I .45 - 2.1 71
TMPS
For installation M5
Control Panel Internal Wiring Diagrams
"Code in ( indicates wire color
MR MF DG DF2 DF1 SN1 STH CAD
CN106 CN 1 0 4 CPU BOARD

CN107 \ CN105 \ CN103 / DCISD BOARD
CNlOl
CN 1 0 2
Drive Control Panel Internal Wirrng Diagram

"Code in ( ) indicates wire color I
C N l 10
1 (BR) (L1 \
CSP TMP
DC/SD BOARD
CN112 CNl11 \
I I
Material Handling Control Panel Internal Wiring (with Material Handling Chopper)
Continuity Check with Circuit Tester
00
CAD CAD
Kn
SIT SIT SIT
(Drive c o n t r o l panel)
0 0 RF
C N 4 9 (48'4
P58 Pi2 N i
C N 4 6 (36V)
iT 2 3T
F l 2754. (MAX) 3 2 6 (MAX)
~
(Material handling control panel [w/ chopper])

F2 2 2 5 A (MAX) 3 2 5 A (MAX)
. I
(Material handling control panel
I
[STDI)
Continuity lnspection Points
Inspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe
Inspection points Standard Circuit tester

P2: + probe - N1: - probe Approx. 1 0 to 25 Q
Between P2 and N 1 Q x lK
P2: - probe - N 1: + probe * c o n
P12: + probe - N l : - probe Approx. 1 0 to 25 Q

Between P I 2 and N 1 Q x 1K
P I 2: - probe - N 1: + probe * m Q
Tester probes may be used in either

Between P2 and frame co Q Q x 1K
direction.
Between N1 and Tester probes may be used in either
mQ Q x 1K
frame direction.
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects t o 0 and then returns.
OCL VALUE (OVER CURRENT LIMIT VALUE)
1. Drive circuit OCL value measurement
( 1) With the vehicle in the driven state, lock front and rear wheels and connect the ammeter and
shunt as shown below. Measure the drive motor lock current.
Standard OCL value
1.5 ton series: 4 4 0 * 50 A
2.0 and 3 . 0 ton series: 6 2 0 f 6 0 A
Ammeter:
..... '
5 0 mV, 7 5 0 A
Shunt:
5 0 mV, 7 5 0 A
Measuring the Drive Circuit OCL Value
( 2 ) Judgement method If the OCL value is outside the standard range, the current sensor (CS) or
CPU board may be defective. Judge the defective part according t o the following procedure:
a Jack up the vehicle until the drive wheel leaves the ground, and support both sides of the
vehicle w i t h wooden blocks.
@ Measure the current sensor output voltage. (Offset voltage: measured value B) Conditions:
Battery plug ON, SWky ON Measurement terminals: CN104(7)72 + - CN104(1)74 -
Standard: Approx. 1.2 V
*Use a digital voltmeter
@ Operate the accelerator pedal t o start bypass traveling. Read the ammeter in this state.
(Measured value A )
@ Measure the current sensor output voltage in bypass traveling state at the CPU board con-
nector. (Measured value C ) Measurement terminals: CN104(7)72 + - CN104(1)74 -
*Use a digital voltmeter.
@ Calculation Measured value C - Measured value B = D (calculated value D) Convert cal-
culated value D into converted value E using the following equation. 1V = 100A
@ Judgement Compare converted value E and measured value A in 3 . If the difference is
within 5%, the current sensor is judged normal. If the current sensor is judged normal, re-
place the CPU board as it is considered defective.
2. Material Handling Circuit OCL Value Measurement
The OCL value cannot be measured by the following reason
When the cylinder in the hydraulic system reaches to the stroke end, the pressure build up even
greater accompanied by the uprising of electric current.
The relief value in the oil control valve, however, will prevent the system from further uprising.
OCL value is set greater than the maximum current value corresponding to the stroke end.
There is no more current rise after the relief; therefore the OCL value cannot be measured.
ACCELERATION POTENTIOMETER
ADJUSTMENT
Make adjustment in the state of acceleration potentiometer
wlfront toe board.
1. Operate the accelerator pedal and check if the accelera-

tion switch is turned ON and OFF.
Measurement terminals: 51 and 64 Standard
When the pedal is not depressed:
When the pedal is depressed: 0 S;t
2. Acceleration potentiometer installation adjustment
(1) Insert a 1.5 rnm (in) thickness gauge between the ac-
celerator link stopper and toe board.
(2) Temporarily install the potentiometer so that the
switch (SWAc)is set to ON.
(3) Inspect the switch (SWAc)ON and OFF changeover
points.
When 1.0 m m (0.04 in.) thickness gauge is inserted:
OFF
When 2.0 mm (0.08 in.) thickness gauge is inserted:
ON
Set screw
(4) After the end of switch ON-OFF adjustment, fully
-- -
T = 1.57 2.35 N-rn tighten the set screws.
( 16 24 kgf-cm)
l1.76 1.74 If-lbfl
BRAKE SWITCH & STOP LAMP SWITCH

I
ADJUSTMENT
1. Adjust protrusions of the brake switch (LSB)and stop
lamp switch (LSsT)
Specification Switch Dimension A mm (in)
LSB 23 (0.91
STD
LSST 23 (0.91)
Rustproof LSB 25 (0.98)

(Cold storage) LSST 23 (0.91)
I
--
Pedal play 3 7 mm
(0.12 0.28 in)
2. After installing LSB and LSsT, check switch ON and
OFF.
(1) As depressing the brake pedal, check t o see whether
both switches function properly within "B" stroke
range, i.e. inspect conduction at each switch con-
nector.
*
B stroke range : 3 -- 7 mm
(0.2 -- 0.28 in.)
Brake ~ e d a l
Switch Not operated Operated

LSB 0 Q (ON) a 52 (OFF)
LSST ~0 Q (OFF) 0 Q (ON)
If the switch operation improper, adjust by shifting the

switch bracket position.
(2) Adjust the brake arm and each switch ON and OFF tim-
ings.
Switch (0.12 in) (0.24 in)
If the ON-OFF timing adjustment t o the standard fails, ad-

just the installation of switch bracket and the protrusion.
PARKING BRAKE SWITCH ADJUSTMENT

1. Inspect ON and OFF of parking brake switch (LSPB).
Standard
Lever state Returned Pulled

LSPB 09 a9
2. Adjust the LSPBinstallation state.
(1) lnspect the LSPBinstallation state on the bracket.
The LSpBinstallation state on the bracket. The LS,
should be set at the rear end of the oblong hole.
(2) Return the lever and check that the lever is in con-
tact with the stopper.
(3) lnspect and adjust the clearance between the
bracket B portion and lever C portion. Clearance
standard
A = 1.0 k 0.2 mm (0.04 +0.008 in)
If the standard is not satisfied, loosen the LS,
wlbracket set screw and adjust the mounting posi-
tion.
SEAT SWITCH ADJSUTMENT FOR

BATTERY ROLL OUT (OPT)
Adjust the seat switch as shown.
T = 3.92 -
C = 2 -- 3 mm (0.08 -- 0.12 in) when unseated.
5.88 N.m ( 4 0
4.34 ft-lbf]
--
6 0 kgf-cm) [2.89 -
(H) = 3 0 mm (1.18 in)
(L) = 2 4 mm (0.94 in)
MATERIAL HANDLING SWITCH

ADJUSTMENT
1. Adjust the ON timing of switch (LSL1)when the control
lever is operated. The switch shall be turned ON at
dimension A at the tip end of the control lever.
Standard
A = 5 - 2 0 mm (0.2 -- 0.79 inj
If the standard is not satisfied, make adjustment by the
roller protrusion and mounting position.
MATERIAL HANDLING CHOPPER SWITCH
(OPT) ADJUSTMENT
1. Adjust the ON timing of material handling chopper
s w i t c h (LS,,).
(1) Adjust protrusion ( D l o f roller o f LSL2.Dimension D is
the reference value for installation.
D = 2 5 m m ( 0 . 9 8 in)
(40 -- -
T = 3.92
12.39
5.88 N
60 kgf-cm)
4.34 ft-lbfl
(2) Pull the lift lever t o the stroke end.

(In this state, t h e ciearane between t h e s w i t c h roller
and t h e plate will be as s h o w n in the table.)
Reference value:
Specification Dimension B rnm (in)

STD 4.5 f 0.5 (0.177 f 0.02)
Cold storage 20s 3.5 f 0.5 (0.138 f 0.02)
(3) Return the lever by "C" dimension, and adjust w i t h

t h e adjust screw so t h a t t h e s w i t c h LS2 will t u r n o f f
Lift lever Lever Neutral o n "C" position.
C = 1 5 f 5 m m (0.61 in.)
Levers end
DIRECTION SWITCH
REMOVAL-INSTALLATION
1 Battery plug
Direction Switch Removal Procedure
Removal Procedure
2 Remove the steering rear cover.
3 Disconnect the direction switch connector.
4 Remove the steering tilt lever.
5 Remove the steering front cover and display.
6 Remove the direction switch.
DISASSEMBLY-REASSEMBLY
I
I
Direction Switch Disassembly Procedure
1 Remove the plate.
2 Remove the microswitch wlwire harness. [Point 11
3 Remove the micro switch base.
4 Remove the cam roller and spring.
5 Remove the direction lever wlknob.
6 Remove the cam.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operation
[Point 1 I
1. Install the microswitches in the correct positions.
2. When replacing a microswitch, connect the cables ac-

cording t o the cable colors in the figure.
INSPECTION
DSFo After assembling the direction switch, check conduction of

each microswitch before installing the direction switch.
Standards Lever position

Inspection
Neutral Forward Reverse
point
DSF w n on 00 n
DSR 00 n n
00 o0
DSFO w n on w n
DSBU w n n
00 on
POWER STEERING CONTROLLER
COMPONENTS
PS Contactor Panel (STD) PS Controller (EHPS)
2402 2401
.
L
2102.01151 L... ... A
2401-13%
PS Contactor Panel (Dust Proof) PS Contactor
EQ-+
CY* I
I
I
L... ... A
240347M
REMOVAL-INSPECTION-INSTALLATION (STD)
1 Battery plug
PS Controller (STD) Removal Procedure
Removal Procedure
2 Remove the side cover RH.
3 Remove the contactor panel cover.
4 Disconnect the wiring connectors and cables.
5 Remove the PS controller.
Inspection
1. P22-N 1 voltage measurement
Battery plug ON.SWky ON
Measurement terminals P22 - N1

Circuit tester range DC 50
Standard Battery voltage
Measuring the voltage between P22 and N 1
2. Mpscontactor coil conduction measurement

Battery plug OFF-SWky OFF
Measurement terminals Both terminals of connector (CN53)of MpsContactor

Circuit tester range a x 1
Standard Approx. 20 Q (at 20 OC)
Measuring the Conduction of Mps Coil

REMOVAL.INSPECTION.INSTALLATlON (WI EHPS)
I
1 Battery plug
I
I
PS Controller (EHPS Vehicle) Removal Procedure
Removal Procedure
3 Remove the contactor panel cover
4 Disconnect the wiring connector.
5 Remove the PS controller.
Installation
Procedure the installation procedure is the reverse of the removal procedure.
EHPS Controller Voltage
Measurement If t h e cause o f a trouble is judged t o exist i n t h e EHPS controller, measure the battery
voltage and measure t h e voltage and conduction a t each connector o f t h e EHPS controller.
CN27
No. Circuit connecting destination Potential

1 SWky 43
2 Steering torque sensor 162
Connector of Controller 3 Steering torque sensor 161

4 Display 151
5 Steering torque sensor 163
No. Circuit connecting destination Potential

1 DMps terminal A P2 1
2 DMps terminal B P22
3 BATT @ P1
4 BATT @ N1
Measurement terminals
CN28 Connector Basic conditions (Battery plug ONeSWky ON)
Connector No. I * Connector No. I Conditions Standard Remarks

I
CN27-1 I CN38- 4 SWky: ON Battery voltage
(43, SWky) (N1) SWky: OFF OV
I Steering wheel fully operated
I
CN27-2 ICN27-5 (held at stroke end) 9.8 V or more
/
(162, torque sensor) (163, torque sensor) Steering wheel not operated 2.5 V or less
I (straight traveling position)
I
CN27-3 I CN27-5 SWky: ON 12 * 0.8V

(161, torque sensor)! (163, torque sensor) SWky: OFF OV
I
CN27-4 I CN27-5 SWky: ON 0V
(I
51, display ) 1 (163, torque sensor) SWky: OFF 5V
2-53
C N 3 8 Connector Basic c o n d i t i o n s (battery p l u g O N - S W k y O N )

I
CN38-1
(P21, DMps , CN38-4
(N1)
- Battery voltage
terminal A ) I
I
I Steering wheel n o t operated Battery voltage
CN38-2
(P22, DMps
II CN38-4
(N1) Steering wheel fully operated Approx. 0 V
terminal B) I
I (held stroke end)
Inspection
1. TMps
D i s c o n n e c t t h e w i r i n g f r o m TMps.

aQ
Between C 2 C2E1: - probe - E2: + probe
Continuity
E l and E2 C2E1: +
probe - E2: - probe
shall exist
TMPS Q x l K
Between G2: - probe - E2: + probe aQ
G 2 and E2 G2: + probe - E2: - probe ma
Forward:
Continuity
Anode (C2E1) @ probe - cathode ( C I ) @ probe
DF4 shall exist Q x l K
Reverse:
aQ
Anode (C2E1) @ probe - cathode ( C I ) @ probe
Inspecting the Conduction of TM, TMPS
Caution:
When shifting to check C2E1-E2 from G2-E2 short connect G2-E2 to avoid the possibility of conti-
nuity on both directions.
Never touch to G2 terminal with a naked hand.
\
TMps
EHPS Control Panel Assembly Drawing
EHPS Control Panel Part Tightening Torques

Item Tightening torque N - m (kgf-cm) [ft-lbfl
Main terminals M5 2.45 (25) i1.811
TMPS
Set screw M5 2.45 (25) l1.811
Harness M4 1.47 (15) iO.721
Fuse (F3) set nut M8 9.81 (100) [7.241
Resistor M3 0.69 (7) lO.511
MULTIDISPLAY FUNCTIONS
Page
DIAGNOSIS ........................................................ 3-2
GENERAL ........................................................... 3-2
ANALYZER ......................................................... 3-7
GENERAL .......................................................... 3-7
USING THE ANALYZER MODE .............................. 3-9
METHOD FOR SELECTING EACH ITEM .................. 3-12
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM ...................................................... 3-17
MASK FUNCTIONS ............................................ 3-31
PASSWORD INPUT METHOD ............................... 3-33
DIAGNOSIS
GENERAL
The 5FBCU Series has the self diagnostic function, which automatically detects errors in the main drive
and material handling circuits, operation systems such as the accelerator, sensors, etc., and sounds
the buzzer while displaying these errors by corresponding error codes on the multi-display.
A t the same time, safe operation is ensured by automatic stopping traveling, stopping material han-
dling and traveling speed control.
Depending on the trouble only the error code appears on the multi-display. Although the vehicle may
be operated, make necessary repairs as soon as possible.
The self diagnosis mode may be switched to the analyzer (error analysis) mode, in which failure is de-
tected and, the main drive and material handling circuits, each operation system, sensors, etc. are
checked for functions.
Use these functions fully for early detection and elimination of electrical system troubles.
1. Error code display

The error code appears in part @ in the illustration,
@ Error code
and the warning sound bleeps. Make repairs soon ac-
A
cording to the error code displayed by self diagnosis
while referring to "Troubleshooting" in Repair Manual.
Hours used indication

(Example figure shown)
Error Code Display

Diagnostic Error Code List
Error
Faulty portion Fault mode Phenomenon in vehicle
code
A0 MCS main circuit Overheat Lowering of traveling speed
Stop of traveling and

A1 MCS main circuit Overvoltage
material handling
A2 CPU board Abnormal temperature rise (Display only)
A4 Acceleration potentiometer
Traveling accelerator Traveling stop
*1 abnormality
Material handling switch

Material handling switch Material handling
*1 abnormality
*'
A7
"2
Parking brake application
failure warning
Departure from vehicle
without pulling the parking
brake
(Display only)
A8 Drive motor fuse F1 Fuse open Traveling stop
Temperature sensor
AA CPU board (Display only)
abnormality
Analog input detection

AE CPU board (Display only)
Excessive processing time
CPU processing data Stop of traveling and

AF CPU board
abnormality . material handling
I I I
* 1. May occur because of improper operation and not because of fault
'2. Valid/invalid selectable by the display mask function
Error Fault mode Phenomenon in vehicle
Faulty portion
code
Traveling SIT short or open

circuit
CO Main driving circuit Traveling stop
Traveling DClSD board
abnormality
Current sensor ha~ness

C1 Driving current sensor Traveling stop
short- or open circuit
Lowering of traveling speed

C2 Prohibition of simultaneous
Drive motor Overheat
"3 traveling and material
handling
Controller temperature Temperature sensor open

C3 Display only
sensor circuit
Acceleration potentiometer
C4 Traveling accelerator Traveling stop
short- or open circuit
MS contactor drive circuit Coil chopper transistor short-

C6 Traveling stop
(CPU board) or open circuit
C7 Direction switch Switch short Traveling stop
C8 Speed sensor Sensor harness open circuit Traveling stop
MFaMR contactor drive Coil chopper transistor short

Traveling stop
circuit (CPU board) or open-circuit
Traveling and material

CE CPU board ROM abnormality
handling stop
Traveling and material

CF CPU board 3 RAM abnormality
handling stop
'3. Only in vehicle with motor overheat alarm function (option)

Error
code
1 Material handling SIT short

I Eo or open circuit Material han-
Main material handling circuit Material handling stop
"4 dling DC/SD board abnormal-
"4
I Material handling current
sensor
Current sensor harness short
or open circuit
Material handling stop '
Overheat
I I The direction switch is al- / 1

I I ready set to F or R or the I
E3
"6
/ Return to neutral warning
acceleration switch is on
when the key switch or
Traveling stop
deadman switch is turned
on.
E4 I Circuit breaker Traveling stop
Regenerative diode short cir-

E5 Regenerative diode Traveling stop
cuit
Switch 1 harness open cir-

E6
I Lift switch cuit Switch 2 harness short
circuit
Material handling stop

Brush wear Simultaneous traveling and
material handling prohibition

Brush wear Simultaneous traveling and

E9 Simultaneous traveling and
PS motor Brush wear
"5
EE I Display-MCS communication
system
MCS receiving data abnor-
mality
"4. Only in vehicle with material handling chopper (option)

(Display only)
"5. Only in vehicle with motor brush warning device (option)

"6. In UL and USA specifications only
Error
code
Excessive CPU processing

EF CPU board (Display only)
time
Power steering (only in

Fo Power steering abnormality (Display only)
EHPS)
Display-MCS communication
Communication failure (Display only)
system
F2 Communication data error (Display only)
system
F3 Echoback error (Display only)
system
Power control memory value

F4 Display (Display only)
inconsistency
ab- (Display only) (Automatic

Charger (on-vehicle type Charging timer
F5 charging impossi-
only) normality
ble)
Charger (on-vehicle type Charging safety timer opera-

F6 Charging stop
only) tion
Charger (on-vehicle type

F7 Charging starting failure (Display only)
only)
Charger (on-vehicle type

F8 Charging end failure (Display only)
only)
ANALYZER
GENERAL
The 5FBCU series has the analyzer for function check of and defective part detection in of the main
drive and material handling circuits, operating system such as accelerator and sensors by switching
the multidisplay into the analyzer mode for quick and easy servicing.
Use these functions fully for early solution of troubles in the electrical system.
General Description of Analyzer Functions

The analyzer supports controller system inspection and locating of defective parts by making full use
of the computer function of the MCS-I11 controller and the communication function between MCS-I11
and multidisplay.
(1 Monitoring the history of past errors (diagnosis monitor)
(2) Testing the connections and insulation defects of wiring and connectors (Switch input test)
(3) System check with actual travel and material handling operations (test operation)
3-8
Test items by analyzer

Category Class Description
1 Simple test Past diagnosis display and continuous quality

check for main circuits, switch systems and
sensor systems
-
2 Test operation Test operation while checking analog input

Simple test and (voltage, current values (motor current, accelerator input
test operation and temperature voltage, etc.) and error occurrence
display)
3 Test operation Test operation while checking analog input
(traveling speed values (traveling speed) and error occurrence
display)
1 Diagnosis Past error display with hour meter readings at

2 Diagnosis monitor monitor the time of error occurrences
1 Switch ONIOFF Display of each switch onloff state

information display
2 Buzzer check Information of one switch onloff state by

buzzer sound
3 Switch input test

3 Momentary Testing defective contacts of wirings and
interruption test connectors
4 Short circuit test Testing defective insulation of wirings and

connectors
USING THE ANALYZER MODE
Preparation for analyzer mode
Caution:
Jack up the vehicle always until the drive (front)
wheels depart the ground, support both sides of the
frame with wooden blocks, and lower the fork fully for
safety.
1. Set the battery plug to ON

Preparing for the Analyzer Mode
Diagnosis error display 2. Set the key switch to ON.

If diagnosis error code "AF", "CE", "CF", "EE",
"Fl", "F2" or "F3" is displayed, the analyzer mode
cannot be used.
I
Diagnosis Error Display
Switching to the analyzer mode

The multidisplay is generally set to the diagnosis mode.
This display is protected by mask functions to prevent the important internal data from being de-
stroyed by incorrect user operation.
Switching to the analyzer mode, therefore, requires password entry from the switch panel.
1. Primary password entry
Short bleep
Operate the display switch panel according to the se-
quence shown in the illustration.
Within 10 seconds
If not operated within 10 seconds, the mode returns t o

the ordinary traveling/material handling mode (diagno-
Short bleep
sis mode).
Within 10 seconds Keep pressing the switch in the final step for 2 sec-
onds. The intermediate mode screen is displayed.
0 Short bleep
If the operation is mistaken halfway, set the key
switch to off once and repeat the operation from the
I
Within 1 0 seconds
Press
Simultaneously.
Note:
beginning.
Your finger must be used for the panel switch operation.

If sharpened tools are used instead, it would be a cause of
Keep pressing for 2 sec.
damage on switch.
1 Short bleep
KI
lntermediate
Primary Password Entry
2. lntermediate mode display
Transition to the analyzer, hour meter start or MCS-Ill

tuning mode occurs from this mode.
lntermediate Mode Display
3. Analyzer mode input

Within 10 seconds
Operate the display switches in the sequence shown in
/=I Short bleep

the illustration.
1Within 10 seconds
[v) Press
sirnutanaously
Short bleep
Analyzer Mode Input

4. Analyzer activation
Lighting for 2 seconds followed by
flashing 5 times
The display changes as illustrated and the analyzer is
activated.
Then the initial screen is displayed.
Then the initial screen appears.

If the analyzer cannot be activated b y the operation
above, turn the key switch OFF once and repeat f r o m
the primary password input again. If n o t activated b y
Version display repeated operation, system abnormality may exist.
Activating the Analyzer
5. Initial screen
Flashing
Transition t o each analyzer mode occurs from this
I screen.
\ \ p /
I-/ 11
-
'
I-! I-!
1 \ \
[ RnL
A
r
I-
Anl: analyzer
Initial Screen
METHOD FOR SELECTING EACH ITEM
Each item can be selected by adjusting the speedometer display t o the corresponding category and
class numbers.
1. Item selection from analyzer activation state (initial screen) (Example: 12)
Step Operation method Screen display
0 --
Flash~ng
Indicates the ready
r End of analyzer activation - F\ ;\ - IZ T X - . : ) state for category
E
0
Q)
1- )-I I
I number input.
V)
-
s
?='
-
s
Anl analyzer
@ ,he numeral Increase by 1 Display the desired Flashlng

category number -- - :
-L$--
- -
- :
\'% ,
I ')-I
t
-
.0
rn ~OJ ,I C h/
, \
l1
+
0 [ XnL ] I 11
-
a,
a,
--
- -
--
-
V) The numeral decrease by 1
6 o Press this s w i t c h Flash~ng The category

o)
a,
c
.
m
'
when the desired
category number is
--
- -- -
--
T z-=- number is
determined and
o displayed. r D-i class number input
/I /
/-\ 11
is enabled.
[ run --
- - - - -.
@ The numeral Increase by 1 Display the desired Flashing

class number. -- -
-- -
- -\ -T--
I , ,
s / I , \ 11
-
.0
0
-
c
.
a,
'
[ run I
- -
The numeral decrease by 1 ==
=
-
:
= --: 1
Q)
V)
Press this s w i t c h Flashing stops when

w h e n the desired the class number is
class number is determined t o
displayed. complete item
'0' selection.
2. To select another item from one item
( 1) To select another class in the same category (Example: 12+ 13)

0
State of testing a certain item ( 12 )
Q,
2
0
V)
--
Press this switch t o Flash~ng The item selection

end the test. =.=== -- screen is displayed
--
t o enable class num-
ber input.
I h!
' 1 , \
[ run
0 Display the desired

The numeral increase by 1
I
class number. --
--
Flashing
t
\
----
I , .
-.
-,7;.,,
I The numeral'decrease by 1 I 4
@ I Press this switch Flashing stops when

when the desired the class number is
class number is dis- determined t o com-
played. plete item selection.
(2) To select an item i n a different category (Example: 13+New item)
0
State o f testing a certain item (13 )
t
a,
F
0
- 0)
-
.+
.-
(IJ
-8
0 Press this switch t o The item selection

end the test. Flash~ng screen is displayed
---
- -
--- t o enable class num-
-- - .
+J
0)
"a,
+
-0
8
@ Press this switch t o
set class number 0.
Returns t o the initial
screen upon ana-
Lu - . - - --
_ --
- -
-
-. - -- - - -
\ I / / lyzer activation
j-/ I-/ ' when class number
0 is set.
1-\-
I /I I I II
[ RnL ]i 1'
I
--
-1
-- //
@
.-V) Select the desired item according t o the
L
al procedure f r o m "1. Analyzer activation
2 .=$
3
state (initial screen)".
c 0
cn
al
V)
-
m v,
OE
5 .ale
8 B
2 :"-"
g ?
L 0
0 0
+
'- 0
3 +
rn-0
g .Ga,
V)
E
2 2l
E;
ao
- - - -
3. Ending analyzer mode (transition to diagnosis mode)

0
State o f testing a certain item ( 1 11 Category Subcategory
C
0)
20
tn
-
c-a
-
.C
.-
-C [T-m ESY (s~rnplrf~ed)
test- 00
0 Press this switch t o The item selection

end the test. Flashlng screen is displayed
--
t o enable class
number input.
I 1-I
C
tn
0)
C
"
y.
0 Press this s w i t c h Returns t o the initial

u
s and set class
w Flashlng screen upon
number 0.
--t;
-- -
--=-
-
-=- - analyzer activation
when class number
\ i i /
, I\
,I ,
0 is set.
DW/ D-0 I
1I
/-,
! I
[ RnL ) I,
--J
--
8
@ Press this s w i t c h "n" flashes.
a, and set category Flashlng
2
0
number 0. Analyzer mode
tn completion
u confirmation
IT
0)
L
Y: Yes t o end the
0)
N
analyzer mode
->
((1
s
a mode
8
-
0
.+
0 Press this switch "Y" flashes.
and select Y (end Flashlng
U Select~onof "Y"
-
al
al
tn
the analyzer mode).
\
f / /
-
-7 1 /
u
8
al
I,
L
/ / I \
a
N
-
>
c-a
Select~onof "n"
[ End I
-
4 - ---- - -
8 Press this switch t o
Q, end the analyzer
U
mode.
E
L
Q,
N
>.
-
m
C
m
CC
0
U
s
W
When the switch in step (6) is pressed in step (4) (flashing of "n"), the display returns t o (1) (initial
screen).
It is also possible t o end the analyzer mode by setting the key switch t o OFF.
FUNCTIONAL EXPLANATION OF EACH TEST ITEM
Category 1 Class 1 Simple test
The simple test consists of 3 5 test items ESY-01 t o ESY-35, each with its o w n screen.
Simple test item selection method

Category Subcategory
1. Initial display
T
I
ESY (simplified) test -00
Initial Display
2. Switch operation method

@ Next test Item
1 Press @: Proceeding t o the next test item

t \ (Ex. ESY01+02)
r= Press @: Returning t o the preceding test item
[ ] m- +@ Retest
(Ex. ESY 25+24)
i lyT
@ Test end
J
Press @:
Press @:
Repeating the same test item
Ending the simple test (returning t o the

@ Precedlng test Item
class selection screen)
Switch Operation Method

3-1 8
Simple Test Function Map

Category 1 Class 1
Test No. Description
ESY-01 Automatic check of main circuits, current and speed sensor etc.
The most recent diagnosis error code and
ESY -02
corresponding hour meter reading
The second most recent diagnosis error code and
ESY -03
The third most recent diagnosis error code and
ESY -04
The 4th most recent diagnosis error code and
ESY -05
ESY-06 Reading the memory of Past corresponding hour meter reading
diagnosis error (10 most
recent errors) The 6th most recent diagnosis error code and
ESY-07
ESY -08
ESY -09
ESY-10
ESY-11
Detected voltage value display Voltage detected before key switch SWk
ESY-l (to enable judgement on the (intermediate tap)
performance of the detecting
function based on the Voltage detected after key switch SWk
ESY-l
difference from the actual (intermediate tap)
value measured with a
ESY-14 multimeter) Voltage detected at P2 terminal
Automatic judgement on
abnormality or defective Check of accelerator switch SW,, and drive accel
ESY-15 adjustment of the drive vari-Q VRA
accelerator by accelerator Check of drive accelerator sensor
operation
Test No. Description
Automatic judgement on temperature sensor quality or judgement based on the

ESY-16
difference between the detected temperature value and actual temperature
ESY-l Judgement On the qua'ities Of ONIOFF of forward contactor MF

the contactor and contactor
drive circuit b y visual check on
ESY -1 8 contactor closing and opening ONIOFF o f reverse contactor MR
b y outputting each contactor
ONIOFF signal
ESY-19 ONIOFF of regenerative contactor MG
ESY - 2 0 ONIOFF of pump contactor MP
ESY - 2 1 ONIOFF of Bypass contactor MS
ESY-22 ONIOFF of Field Weakening contactor MW
ESY - 2 3 ONIOFF o f PS contactor M p s
Judgement On the of ONIOFF of forward direction switch DS,

ESY-24
s w i t c h and s w i t c h detecting
circuit b y ONIOFF state
ESY-25 display of each s w i t c h and ONIOFF of reverse direction s w i t c h DSR
buzzer sound
ESY - 2 6 ONIOFF of accelerator switch SW

,,
ESY -27 ONIOFF of brake switch LS,
ESY - 2 8 ONIOFF of speed control switch SW,
ESY -29 ONIOFF of parking brake limit switch LS,
ESY - 3 0 ONIOFF of lift limit switch LS,,
ESY - 31 ONIOFF of lift limit switch LS,
ESY - 3 2 ONIOFF of tilt limit s w i t c h LS,
ESY -3 3 ONIOFF of deadman limit s w i t c h LSD
ESY - 3 4 ONIOFF of attachment limit switch ,L

,S,
ESY -35 ONIOFF of attachment limit switch,,,L

S
,
Test No.: ESY-01
The following items are checked automatically and the results are displayed:
@ Main drive circuit and main pump circuit check ........................................... COaEO
@ Drive current sensor and pump current sensor zero point check ..................... C1 . E l
@ Speed sensor discontinuity detection ......................................................... C 8
@ CPU processing check ............................................................................. AF-CE.CF
F]
1. If the check result is normal, 0 0 is displayed on the
Error code speedometer.
ESY -02 Retest I
2. If abnormal, the corresponding error code is displayed
with buzzer sounding.
3. If multiple errors occur, they are displayed sequen-
ESY -00
i l I tially.
Test end Action: lnvestigate the error position by referring to the

troubleshooting
Display and Switch Operation
Test No.: ESY-02 to 1 1
Past diagnosis errors are displayed.
ESY-02: Most recent error

I I
I I
I I
I I
ESY-11: Oldest error
1. Select the function by pressing the switch.
I Next test Item -

-
-
-
-
- --
-
( 11 ESY-xx is displayed with blinking three times on
the hour meter.
Retest (2) The error occurrence time and error code are dis-
played on the hour meter and speedometer, re-
spectively.
I t es t item Time of eiror duration
Simplifted test end Action: Investigate the error position by referring to the
troubleshooting
Test No.: ESY-12 to 14
The voltage at the voltage input terminal is measured and

displayed.
ESY-12: Voltage at battery terminal (intermediate tap)

I Display is ESY 1 2 and ESY 13 only
(0:OK H:NG) Ij
Ii
!I
l1
ESY-13: Voltage at key switch terminal (intermediate tap)
ESY-14: Voltage at P2 terminal
1. Select the function by pressing the switch.
( 1 ) ESY-xx is displayed with blinking three times on

the hour meter.
I
I
Voltage 48.0 V
Next test item

II (2) The voltage is displayed on the hour meter.
[
t
] [T] 1 Retest
(3) Measure the input voltage at each terminal with a
multimeter, and check the difference from the dis-
played value.
Standard (See page 2-20.)
VBBTIVBKY: Within
VBP2: Within
*
1%
*
5%
(4) When the displayed voltage is 54V or less, check

Simplified test end I the difference between VBBT and VBKY.
Preceding test item
Action: @ Abnormality of trimmer potentiometer in CPU

Display and Switch Operation Replace the CPU board.
+
Note:
Never tamper with the trimmer potentiometer.
@ When the voltage is 0 , check the harness.

Test No.: ESY-15
~ ~ e p . c! t i g ~, Adjustment
~ g condition
The potentiometer voltage with satisfaction or dissatisfac-
Indicate at
the s y i t c k Q N 4- (No display : OK H :
(0 display OK)
-f--
tion of the specified range and the properness of the corre-
sponding switch ONIOFF state are displayed.
ESY-15: Accel potentiometer (SWAc.VRA)
1. Press the switch t o select the function.
( 1) ESY-15 is displayed with blinking 3 times on the

hour meter.
/ Potentiometer voltage
Accelerator potentiometer
Next test item (2) The potentiometer type and potentiometer volt-
age are displayed on the hour meter.
(3) The speedometer displays whether the potenti-

ometer voltage is within the specified range and
whether the switch onloff state is proper.
Actions: @ Check the potentiometer installation state.

@ Check the harness.
@ Replace the potenitiometer.
Simplified test end I
Preceding test item @) Replace the CPU board.

Test No.: ESY-16
Temperature sensor check
The temperature detected by the thermistor on the CPU board is displayed. The properness of the tem-
perature and voltage range is checked and displayed.
Press the switch t o select the function.

Therernistor voltage Temperature range
(0 : OK H : NG)
\ -
(0:OK H:NG)
(1) ESY-16 is displayed with blinking 3 times on the
hour meter.
(2) The temperature on the CPU board is displayed on

the hour meter.
(3) The speedometer displays whether the rempera-

ture range is normal and whether the thermistor
voltage is normal.
Actions: @ Check the ambient temperature of the CPU

ESY-17 Retest
board by comparison with the data measured
by the thermometer. Within f 5OC.
ESY 1 5

Test No.: ESY-17to23
Contactor closing test
ESY-17: Forward contactor (MF) test

ESY-18: Reverse contactor (MR) test
ESY - 1 9: Regenerative contactor (MG test
ESY-20: Pump contactor (MP) test
ESY-21: Bypass contactor (MS) test
ESY-22: Field Weakening contactor (MW) test
mF : Contactor MF ESY-23: PS contactor (Mps) test
Next test item 1. Press the switch t o select the function.

I
(1) ESY-xx is displayed with blinking three times on
the hour meter.
, Retest
(2) The contactor code is displayed on the hour

meter.
I Preceding test item
Simplified test end (3) Visually check closing or opening of each contac-
I I tor.
Actions: @ Check welding of the contactor.
@ Check the resistance of the contactor coil.
Check the voltage at the time of contactor
closing.
(The contactor is defective if it is 20 V or
more. 1
Test No.: ESY-24 to 35
Switch ONIOFF and buzzer check
ESY-24: Forward direction switch (DS,)

ESY-25: Reverse direction switch (DS,)
ESY-26: Accelerator switch (SW,)
ESY-27: Brake switch (LS,)
ESY-28: Speed control switch (SW,) (Not in US specification)
ESY-29: Parking brake limit switch (LS,)
ESY -30: Lift limit switch 1 (LS,, 1
ESY -3 1 : Lift limit switch 2 (LS,) (Only in vehicle with material handling chopper)
ESY-32: Tilt limit switch (LS,)
ESY -33: Deadman limit switch (LSD)
ESY-34: Attachment limit switch L ()S
,,,
ESY-35: Attachment limit switch 2 (LSATT2)
2 1. Press the switch to select the function.
(1) ESY-xx is indicated with blinking three times on

the hour meter display.
(2) The switch code is indicated on the hour meter

display.
(3) When the selected switch is set to ON, F on the

hour meter display is changed 0 and the buzzer
sounds.
Actions: @ Check the switch.

DS,: Forward switch 0: ON
F: OFF
@ Check the switch harness.
@ Check the CPU board.
Next test item
@ Replace the CPU board.
I Preceding test item

Simplified test end

Category 1 Class 2 Test operation (voltage.current or temperature display)
In the test operation, traveling and/or material handling are possible while monitoring the analog input
value of each sensor.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed to en-
able very infrequent troubles t o be confirmed.
Analog input items to be monitored
No. Item Description

0 Drive motor current A Abnormality of current sensor or current detecting circuit,
deviation of OCL value or abnormal forklift load
1 Pump motor current A Abnormality of current sensor or current detecting circuit or
abnormal forklift load
2 Battery terminal Abnormality of voltage detecting circuit (excessive charge
voltage V indicator display error)
3 Key switch terminal voltage Abnormality of voltage detecting circuit (excessive charge
V indicator display error)
4 P2 terminal voltage V Abnormality in voltage detecting circuit (contactor opening
or incorrect detection of A1 error)
5 Accelerator potentiometer Abnormality of acceleration sensor, or abnormality in accel-
voltage V eration potentiometer detecting circuit (maximum speed)
6 Atmospheric temperature Abnormality of thermo sensor or abnormality in thermo sen-
OC sor detecting circuit
7 Controller thermo sensor Abnormality of thermo sensor or abnormality in thermo sen-
voltage V sor detecting circuit
Reference:
Temperature conversion
The analog input value is displayed in the test operation
The error code is displayed w h e n an error occurs and is retained until the error clear switch is pressed.

Display in normal state: 12
Display In error state: error code ( 1 ) The test No. is displayed on the hour meter.
( 2 ) The current value, etc. during the test operation

are displayed on the hour meter.
Displaved upon ( 3 ) 1 2 (Category 1, class 2) is displayed on the

speedometer in normal state.
(4) If an error occurs, the error code is displayed on

Preeding Analog input display
item No. (300A)
the speedometer and is retained until the error
clear switch is pressed.
Action: lnverstigate the error position and the part show-

ing an abnormal value by referring to the trouble-
shooting procedure.
Number marked% is increases by 1 .
I
Test operation
Error clear
end
i
Number marked% is decremented 1
Category 1 Class 3 Test operation (traveling speed display)
Traveling while monitoring the traveling speed value input from the speed sensor is possible during the
test operation.
If a diagnosis error occurs during traveling and/or material handling, the error code is displayed t o en-
able very infrequent troubles t o be confirmed.
No. Item Description

1 Traveling detected speed Check if the drive wheel traveling speed are deviated from
value the displayed values. (km/h)
2 Traveling detected speed Check if the drive wheel traveling speed are deviated from
value the displayed values. (milelh)
Display i n normal state: 13
Display in error state: error code
( 1 ) The test No. is displayed on the hour meter.
( 2 ) The traveling speed or speed sensor input data is

displayed on the hour meter.
(3) When an error occurs, the error code is displayed

on the speedometer and is retained until the error
clear switch is pressed.
Moniter No. Speed sensor display
Action: lnverstigate the error position and the part show-
ing an abnormal value by referring to the trouble-
shooting procedure.
Number increases by 1
I
Test operation .Error clear

end
Number decremented by 1

Category 2 Class 1 / Diagnosis monitor
Past errors ( 1 0 items in total) are displayed with the corresponding hour meter readings.
Use this test when the user found an error during operation but failed in regeneration.
1. Press the switch t o select the function
+
;
" ,-,-
- ---
-
------=a
- -- -
(1 ) The serial number of error occurrence is displayed
on the battery charge indicator.
(2) The time of error occurrence is displayed on the

hour meter.
ln~tlalscreen display
(3) The error code is displayed on the speedometer.
10th latest error E~~~~code
Latest error Action: Investigate the error position by referring to the
troubleshooting procedure.
Hour meter readrng upon error occurrence
Latest error dlsplay
Dtagnosrs
monltor end
Second latest error

Category 3 Class 1 Switch input test: ONIOFF information display
The ONIOFF state of every switch is displayed t o allow confirmation at a glance.
A level line in the battery charge indicator or a level line in the power control level gauge corresponds
t o each switch.
The corresponding position comes on when a switch is ON.
L ~ g h at
t the parking
brake release (ON)
-
Initial Display Screen
Display and switch table
Deadman switch (LSD)

0- Speed control switch (SWsc)
- I
P
-
-Parking brake limit switch
Accelerator switch
Brake switch
(LSpB)
(LS,)
(SWAc)
LReverse direction switch (DSR)
Forward direction switch (DSF)
Lift limit switch 1 (LS,,
Lift limit switch 2 (LSL2)
Tilt limit switch (LST)
Attachment limit switch (LSATT)
1 Attachment limit switch 2 (LSA~~2)
1. The corresponding part is lit, when a switch is set t o
ON.
Action: If the switch ONIOFF state differs from the dis-

play, check,and repair the switch, harness or CPU
Switch input . board.
test end
Switch Operation
Category 3 Class 2 Switch input test: Buzzer check
The ONJOFF state of each switch is informed by the buzzer
Uses:
(1 Tuning of limit switch or potentiometer
(2) Switch ONJOFF check in a place where the display is invisible
0 1. Press the switch t o select the switch t o be tested.
(1) See page 3-28 "Display and Switch Table" for

the types of switches.
2. Operate the switch and check if the buzzer sounds.
Action: If the switch ONIOFF state differs from the buzzer

indication, check and repair the switch, harness
or CPU board.
Upper switch in the list
Switch input Buzzer

test end stop
Lower switch in the list

Category 3 Class 3 Switch input test: Momentary interruption test
I
Memory interruption (open-circuit) in the switch input line is checked
1. Set the switch to be checked to ON.
I
1 2. Press a switch to match the display with the desired
switch to be checked.

the switch types.
(2) When the buzzer is sounding, stop it by pressing

the stop switch.
3. Shake or apply vibration to the wiring to be checked.
1 Upper switch in the list

(1) The buzzer sounds if momentary interruption
(open-circuit) occurs.
Action: Repair the switch or harness.

S w ~ t c hinput
test end stop
I
L
Lower Switch in the list
D~spiayand Switch Operation

I
1
Category 3 Class 4 Switch input test: Short-circuit test
Short-circuit in the switch input line is checked.
1. Set the switch to be checked to OFF
2. Press the switch to match the display with the desired

switch to be checked.

the switch types.
(2) When the buzzer is sounding, stop it by pressing

Upper switch in the list the stop switch.
3. Shake or apply vibration to the wiring to be checked.

Switch input Buzzer
(1) The buzzer sounds if short-circuit occurs.
test end stop
Action: Repair the switch or harness.
I Lower swltch In the list I

I
I
MASK FUNCTIONS
The digital multi-display has built-in mask functions for vehicle maintenance and specification setting
by the service man in addition to the general functions displayed in the owner's manual for use by gen-
eral users.
To prevent destruction of important internal data by incorrect use of mask functions by the user, the
mask functions are protected to prohibit use unless the password is input from the switch panel. The
password is described in this manual and repair manual, but is not described in the vehicle owner's
manual.
Display Mask Functions (11

Time of use
Name Function A t board Upon
Other
replacement delivery
Corrects the battery
Only when the
Battery charge meter when the
battery is not
(mountedlnot discharge characteristic
mounted.
mounted) is different from that of
the standard battery. 0
Material handling Only when the
chopper Sets the data showing material handling
(providedlnot use of the material chopper is
provided) handling choppers. provided.
(option input) 0
Soft start adjustment
made by the trimmer
on the conventional When requested by
MCS tuning the user.
control board is made
possible by switch
operation.
When tires are
Tire constant changed to a
rewriting
Speedometer correction 0
different type.
Selects the unit for Only for display in
Unit changeover
speed and distance mile.
(km or mile)
display. 0
Charge counter Resets the charge When the battery
reset counter t o zero. is replaced.
Parking brake
warning when
application failure Only when warning
the parking brake When requested by
warning IS unnecessary.
warning is the user.
(validlinvalid)
unnecessary. 0
(option input)
Stops warning when a
Battery fluid level battery without Only when warning
warning electrolyte level is invalid.
(validlinvalid) warning terminal is 0
used.
Time of use
Name Function At board Upon
Other
replacement delivery
''Itage selection Only for 48V

Sets the data according When the battery
(36Vt48V) specification
to the battery voltage. is replaced.
(option input) 0
Motor brush
Sets the data showing
warning Only when warning
whether motor brush
(providedtnot not provided.
warning is provided or
provided)
not provided. 0
(option input)
Enables simultaneous
Demonstration
traveling and material When a
mode
handling operations demonstration is to
(validtinvalid)
before starting the hour be made.
(option input)
meter.
Sets the data such as Vehicle with the
Speed control
speed control switch speed control
switch set
setting which varies switch
(option input)
with the destination. 0
Starts counting by the
Hour meter start
hour meter. 0 0
-
Display Mask Functions (2)

The following mask functions are provided for the manager of the user. The dealer should advise the
manager of the user how to operate as required.
Name Function
Displays the check result of each vehicle part by
Analyzer
the corresponding numeric code.
Locks the switch panel to accept no switch in-
put for other than the password and hour meter
Switch panel lock (lock/unlock)
changeover (option), or unlocks the locked
state.
Temporarily cancels brush wear warning.
Temporary cancellation of brush wear warning
(The password input is accepted only during
(settreset)
brush wear warning.)
PASSWORD INPUT METHOD
Password list
Primary password Intermediate mode Secondary password Processing
L
i
.
il
-i
-m Analyzer mode
/Start
U
- I Hour meter start
W
i-A
' (
LX
J ' MCS-III tuning
mode F/
i---i
Tire diameter constant
Pr~rnarypassword
acceptance mark
\
E l - 5.z rewrite mode
0-
/
( kmlh
'-B
L
-+
Irl
,-ad
km -
Unit changeover
mile
~lmultaneously~
press for 2 sec,
Hours used indication [Xj -+
k l Charging counter start
b --
d; : :2
mounted
- Not
lLi Battery fluid level

warning
-- -- Valid * Invalid
- U
N Switch panel lock
Unlock * Lock
El
Temporary cancella-
tion o f brush wear
warning (set * reset)
For items marked jStartl in t h e processing column (analyzer mode, MCS-Ill tuning mode, and tire diam-
eter constant rewrite model, follow the operation procedure described later after inputting the second-
ary password. For other items, processing is completed automatically here b y inputting u p t o the sec-
ondary password.
Note:
Your finger must be used for the panel switch operation.
If sharpened tools are used instead, it would be a cause of damage on switch.
1. Hour meter start

The hour meter does not start counting when a new vehicle is delivered. Always start the hour
meter when the vehicle is to be delivered from the dealer to each user. See the password list for
starting the hour meter.
Note:
Once the hour meter is started, it cannot be stopped. Hour meter starting is necessary also after re-
placement of the meter control board ASSY.
2. MCS-Ill tuning mode

When restriction of the maximum speed or weakening of the regenerative braking force is key in
the password and start the MCS-Ill tuning mode. Then turning is possible similarly as power con-
trol adjustment.
The 11 items shown below can be adjusted:
Item Tuning mode display

(1 Regenerative braking torque C1
(2) Material handling chopper soft start *1 C2
(3) Material handling chopper duty after activation *1 C3
(4) Battery charge meter correction C4
(5) Maximum traveling speed limiter C5
(6) Attachment power control 1 " 1" 2 C6
(7) Attachment power control 2 *1*2*4 C7
(8) Lifting power control " 1" 2 C8
(9) Tilting power control *1 C9
(10) Lift interrupt set level "3 CA
( 11 Material handling chopper duty in 1 st stage *1 CC
(12) Spare CE
(13) Spare CF
Note:
ltems marked * 1 are invalid in models without the material handling chopper. (Display appears.)
ltems marked *2 are invalid in the UL-EE specification even hen the material handling chopper is pro-
vided. (Display appears.)
Item marked "3 is invalid in easy models of U L and USA specifications. (Display appears.)
The item marked "4 is provided in preparation for special orders as its main harness is different.
MCS-111 Tuning mode Initial Level Setting List
Tuning mode Level (0 Initial setting)

Item
display 1 2 3 4 5 6 7 8
Regenerative braking torque: Weak Strong
C1 Varying the regenerative braking * a
w C
torque in switchback operation

Material handling chopper soft
small Great
start: * a
C2 m
Varying the degree of rise of the
material handling chopper duty
Material handling chopper duty
after activation: Small Great
C3 Varying the initial duty in soft 4 .
)
start of the material handling

chopper
C4
Battery charge meter correction:
Correcting the decreasing rate of
battery charge meter reading
-SIOW
a
QUIC~
-
Low No
C5
Maximum traveling speed limiter:
Limiting the maximum traveling
speed
-speed Ilmlt
C6
Attachment power control 1:
Varying the pump motor revolv-
ing speed when attachment
-Low Hlgh
switch 1 is ON
C7
Attachment power control 2:
ing speed when attachment
-Low Htgh
switch 2 is ON
Lifting power control: L OW ~lgh
C8 Varying the pump motor revolv- -=
ing speed during lifting
C9
Tilting power control:
ing speed
-L OW
0
~lgh
-
Lift interrupt set level: 100 %
NO
Small
Varying the operation timing (dis- alarm
CA v
charge level) for overdischarge
alarm function
Material handling chopper duty in
CC
Ist stage:
Varying the duty of material han-
-small Great
0
dling chopper 1st speed
(1) Tuning method
@ lnput the primary password and secondary password.
I
Password lnput
@ When the power control select switch is pressed, the tuning mode is indicated by the
speedometer on the display and the power control level indicates the current tuning
level of the mode.
As the tuning mode is changed sequentially (C1 C2
+ C3) each time the power con-
+
trol select switch is pressed, select the desired tuning mode.

@ Carry out tuning by pressing the level setting (UP or DOWN) switch.
To increase the tuning level: Press the UP switch.
To decrease the tuning level: Press the DOWN switch.
The tuning level is indicated on the display.
If another item is to be tuned in succession, repeat steps @ and I 0.
Tuning mode
UP switch
/ I
Power control Hour meter

select switch select switch
\
Down swrtch Tuning level Hours used indication
MCS-Ill Tuning
@ Use one of the three methods as shown below for returning from the tuning mode.
Press the hour meter select switch to return to the standard display (speed display).
Turn the key switch to the OFF position.
Leave the state unchanged. (Automatic returning to the standard display occurs in 2
minutes if no operation is made.)
3. Tire diameter coefficient rewriting
The speedometer indication is influenced subtly by the tire type (tire diameter).
Setting for a new vehicle is made according t o the tires installed on the vehicle. When tires are
replaced with other tires in a different size (new tires), set the tire diameter constant rewriting.
Also perform this setting when tires are exclusively worn or when special tires are used.
Select any of the three following methods for setting:
Method A: When replaced w i t h new tires in a different size (excluding special tires)
Method B: When replaced with special tires When the installed tires are worn t o make the speed-
ometer indication be felt incorrect.
Method C: When tires are worn t o make the speedometer indication be felt incorrect while the
outside diameter of the tire in the new state is known.
(1 Tire constant rewriting method (method A )

@ lnput the primary password and secondary password
El-
m
pi]
Primary password Secondary password
Password lnput
@ Select the tire constant from the tire constant list shown below.
5FBCU18 5FBCU30
Vehicle model 5FBCU1 5 5FBCU20 5FBCHU20
5FBCU25 5FBCHU25
Tire constant 25 47
@ On the display, the speedometer indicates the current tire constant ( 2 numeral digits)
and the hour meter indicates the tire mark indicator.
Each time the power control select switch is pressed, the 10's digit or 1's digit of the
tire constant blinks alternately. The blinking numeral is incremented or decremented
when the level setting (UP or DOWN) switch is pressed. Set the tire constant selected in
step @. (The tire constant can be set between 00 and 99.)
T o increase the tire constant: Press the UP switch. (Increments by 1 each time.)
To decrease the tire constant: Press the DOWN switch. (Decrements by 1 each time.)
I Up switch Tire constant I
Power control
select switch select switch ,, ,,
\ /
Indicator
D o w n switch
Rewriting the Tire Constant
@ Select any of the three following methods for returning from the tire constant rewriting
mode.
Press the hour meter select switch t o return t o the standard (speed) display.
Turn the key switch t o the OFF position.
Leave the state unchanged. (Automatic returning t o the standard display occurs in 2
minutes if no operation is made.)
Tire constant rewriting method (method B)

@ Obtain the tire constant as follows:
Set the no load state, measure dimension A
in the figure, and calculate tire constant W
by the following equation:
W = 0.55A (mm) - 1 0 0
(W = 14A (in) - 100)
Count fractions of 5 and over as 1 and disre-
gard the rest.
@ Input the primary password and secondary
password. (See method A.)
@ Then, follow steps 3 and 4 in method A.
Use the value calculated from the actually
I measured value as the tire constant.
Measuring the Tire Dimension
(3) Tire constant rewriting method (method C)
@ Obtain the tire constant as shown below.
Calculate tire wear C by the following equa-
tion:
k$hL
c II >Worm state
C = Tire radius in new state - radius of
worn tire
@ Calculate tire constant W by the following
equation:
1
W = W' - - C (mm)
2
Initial (new) state
(W = W' - 12.7 C (in))
W' = Tire constant in new state
Measuring the Tire Wear
@ Input the primary password and secondary
password. (See method A.)
@ Rewrite the tire constant according to steps
3 and 4 in method A by using the tire con-
stant calculated from the tire wear.
4. Battery electrolyte level warning

The warning function can be enabled or disabled by
password input. If A1 is indicated on the speed display
portion, the warning function is enabled. If A 0 is indi-
cated, this function is disabled.
5. Switch panel lock

The switch panel can be locked or unlocked by pass-
word input. If P I is indicated on the speed display por-
tion upon password input, the switch panel set to the
locked state. If PO is displayed, the switch panel is un-
locked.
6. Motor brush warning temporary cancellation

The motor brush warning state can be temporarily can-
celled or reset from cancellation by password input. If
H I is indicated on the speed display portion upon
password input, the brush warning state is set to tem-
porary cacellation (Temporary cancellation can be set
only while the brush warning signal is generated.) If
HO is displayed, the brush warning state is reset from
temporary cancellation.
3-40
7. Option input mode
Primary password Intermediate mode Secondary password Processing
Effective -
Demonstration mode
lneffective
-
Parking brake applica-
tion failure warning
Effective lneffective
Prlrnary password
acceptance mark
rn 36V -
Voltage selection
48V
[ol --=--=--
Irl
El
+ElMaterial handling
-
@
chopper
Provided Not pro-
Hours used indication vided
Set -
Speed control switch
Reset
Motor brush warning

Set * Reset
These are passwords for option items newly added in the 5FBC series.
As these are set according t o the specifications at the time of n e w vehicle delivery, no setting is re-
quired unless any change is made.
These items should be set in any of the following cases:
When the display board is replaced
When a demonstration is t o be made
When the parking brake application failure warning is t o be reset
Note:
When changing the setting for other than the demonstration mode and parking brake application fail-
ure warning related parts shall be replaced with those for the set specification. When changing the bat-
tery voltage, the following parts shall be replaced.
There are differences between models in use.

Field weakening
In detail, reference should be made to Section 2, Control Panel, Inspection 13, RFW.
resistors
Page 2.18.
The pump is used selectively according to the voltage only in 2- and 3- ton series
Oil pump
dustproof models. In other models, the same oil pump is used irrelevant to the voltage.
Auxiliary electri-
Aux. electrical equipments other than the chime are in accordance with the voltage specs.
cal equipments
( 1) Demonstration mode switching effectivelineffective.
For the transportation reason, the condition of the truck before starting the hourmeter has
been so arranged that the parking application failure warning and the simultaneous opera-
tions of the traveling and material handling should be preset t o "lneffective".
This condition, however, is changeable t o "Effective" by turning the demonstration mode on
the mask function.
This changeover, in especial, in useful for the demonstration of the New Trucks, where the
warning and simultaneous operation are in need.
lneffective + Effective changeover
1:: t
Transition to next option
Effective +
\
End
lneffective changeover
Demonstration mode : Effective Demonstration mode : Ineffective
Demonstration Mode Effectivellneffective Selection
Use the UP or DOWN switch for selection.

Press the UP switch t o change from ineffective t o effective. Press the DOWN switch t o change form
effective t o ineffective. Pressing the UP switch in the effective state or the DOWN switch in the inef-
fective state causes no change. When the power control select switch is pressed, the next option item
is selected.
When the hour meter changeover switch is pressed, the mode returns from option input t o normal dis-
play.
Note:
It takes about a second after pressing the select (UP or DOWN) switch until display change.
(2) Parking brake application failure warning effectivelineffective selection
The method is the same as that for demonstration mode selection in item ( 11.
lneffective - Effective changeover
I r *
rm
,["'1 WI-- End
Transition t o next optlon
Effective - lneffective changeover
Parking brake application failure alarm : Parking brake application failure alarm
Effective lneffective
Parking Brake Application Failure Warning Effectivellneffective Selection
( 3 ) Voltage selection
The method is the same as that for demonstration mode selection in item (11.
36 V - 48 V changeover
End
Transition
48 V - 36 V changeover
-
\ ---2w&-------
-- - --- -- -
.- - -d
48 V specification
Voltage Selection
(4) Material handling chopper providedlnot provided selection
The method is the same as that for demonstration mode selection in item (1) above.
Not provided + Provided changeover
I
I +
,m [OJ-+ End
* I
Provided + Not provided changeover
P-rmp ] 1;Ij [ P-CHL~P )
With material handling chopper Without material handling chopper
Material Handling Chopper ProvidedJNotProvided Selection
(5) Speed control switch setlreset selection

The method is the same as that for demonstration mode selection in item (1). The operation,
however, shall be made after pressing the speed control switch to on.
Reset + Set changeover
f I 4
, [n )-+End
6 I
Set + Reset changeover
5LJSEr
Switch : Set Switch : Reset
Speed Control SetiReset Selection

( 6 ) Motor brush warning setlreset selection
The method is the same as that for demonstration mode selection in item ( 1) .
Reset - Set changeover
I r \
I
Trans~t~on
to next optlon
Set - Reset changeover
*
brS-Er
1
1 1l1
1
I
- f = = = = =
W ~ t hmotor brush warnlng Without motor brush warnlng
Motor Brush Warning SetIReset Selection
When the power control select switch is pressed, the mode returns t o demonstration mode enableldis-
able selection in item (1).
(Sequential changeover in the order of item ( 1 item (2) ... item (6) + item (1) ...)
+ -+
When setting is completed, press the hour meter changeover switch t o return t o the ordinary display
(or turn the key switch t o OFF).
ELECTRICAL SYSTEM TROUBLESHOOTING
Page
GENERAL .......................................................... 4-2
TROUBLESHOOTING EXPLANATION ............... 4-2
DRIVE SYSTEMmMATERIAL HANDLING
SYSTEM TROUBLES ...................................... 4-4
WHEN DIAGNOSTIC ERROR CODE IS
DISPLAYED ................................................. 4-4
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (DRIVE SYSTEM) .................... 4-71
DISPLAYED (MATERIAL HANDLING
SYSTEM) ..................................................... 4-106
TROUBLESHOOTING-OTHERS ....................... 4-1 12
TROUBLESHOOTING RELATED TO
MULTI-DISPLAY AND MCS
COMMUNICATION SYSTEM ...................... 4-113
STEERING SYSTEM TROUBLES ....................... 4-114
DIAGNOSIS ERRORS ..................................... 4-114
DISPLAYED (STD) ....................................... 4-117
DISPLAYED (WIEHPS) ................................ 4-1
19
GENERAL
This troubleshooting is to pursue the causes of diagnostic error indicated by the error code on the mul-
tidisplay and other electric troubles for quick repair.
Measuring instruments such as the megger and m~~ltimeter

are used for the error check. Some error
items may be checked by the analyzer on the vehicle.
Descriptions in this manual are for the mechanics who have mastered handling of measuring instruments,
can read wiring and connection diagrams accurately and can make actual measurements using the con-
nector drawing.
Please make use of the attached connection diagram, connector drawing and connector terminal ar-
rangement.
TROUBLESHOOTING EXPLANATION
1. Drive system - material handling system troubles
(1) When an error code is displayed:

See the "Diagnosis Errors" section (page 4-41.
(2) When no error code is displayed:
@ Drive system abnormality
See the "When Diagnostic Result is Not Displayed (Drive System" section (page 4-71).
@ Material handling system abnormality
See the "When Diagnostic Result is Not Displayed (Material Handling System)" section (page
4-1 06).
2. Trouble shooting-other
See the "Trouble shooting-other" section (page 4-1 12)
3. Troubleshooting related to multi-display and MCS communication system

See the "Multi-display . MCS Communication System" section (on page 4-1 13).
4. Steering system troubleshooting

(1) When an error code is displayed:
See the "Diagnosis Error" section (page 4-1 141.
(2) When no error code is displayed (STD):
See the "No Diagnosis Error" section (page 4-1 17).
(3) When no error code is displayed (wIEHPS1
See the "No Diagnosis Error" section (page 4-1 19)
3. TROUBLESHOOTING EXPLANATION
YES
Are CO and C 1 displayed -
Action for error code CO
alternately?
I
1NO (only C1 error)
Check the wiring between
CN 1 0 4 and drive current
sensor
k40 Test again after correction
ANL1 1 : Simplified test 0 Traveling current sensor defect

Is C1 displayed? o Open circuit or defective connector contact be-
a g e - , tween CN104 and traveling current sensor
lnspection 1
Was switch back operation CSD output voltage check
performed when C1 error CN104-7 (71)
occurred? 5 voltage check
CN104-1 (74) or more)
IY ES OK A p p r o . 1.2 V I ~
Measure with a
To A on next page 0 CPU board defect circuit tester.
0 Drive motor defect (short circuit)
t
Repair or replace.
Indicates the item that can be checked by the analyzer.

(Single frame is used when analyzer check is impossible.)
Potential level Analyzer test item

4
I
lnspection 1 ANL 1 1 : Simplified test
CSD output vpltage check (ESY01
CN104-7 (71) + Tester probe ( + is C1 displayed?
5 Voltage check Page 3-1 7
CN 1 04-1 (74)
A 1
-- Tester probe (-1
1 1
'7
I
Test item description page
Connector No.
DRIVE SYSTEM . MATERIAL HANDLING SYSTEM TROUBLES
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED
ERROR CODE AO: MCS MAIN CIRCUIT OVERHEAT
Related portion /
CN104-10 (75, + 5V) -

CPU
board CN104-3 (76, THC)
---
Connector STH
STH
Temperature sensor
@ Overheat (continued use with overload)
@ Temperature sensor defect
@ Temperature sensor wiring and connector contact defect
@) CPU board defect
1 Continued use of vehicle with overload

IYESd Stop the vehicle and restart traveling 30
minutes later
NO
Inspection 1 NG
Disconnect connector STH and check the -Temperature sensor defect
resistance of temperature sensor. (2 kQ
or more)
OK (Less than 2 kQ)
0 Defective contact between CN 104 and connector STH

0 CPU board defect
Inspection 1 Temperature sensor resistance check
Battery plug OFF, connector STH disconnection
Measurement terminals Both terminals of connector STH (sensor side)
Circuit tester range 0 x 1
Standard Less than 2 kQ
Connector STH
Connector STH Measuring the Temperature Sensor Resistance
OK (less than 2 kQ) --+ CPU board defect or defective contact between CN 104 and connector STH
NG (2 kQ or above) --+ Temperature sensor defect
4-6
ERROR CODE A l : MCS MAIN CIRCUIT OVERVOLTAGE
CPU CN103-I 5 (P2, VBP2)

board
P2
Estimated causes
@ Battery plug disconnection during regenerative operation
/ @ CPU board defect
1 @ Connection of other than specified battery voltage t o battery plug
The battery plug is discon-

Recovery t o normal state by
nected during regenerative
battery plug reconnection
operation
Inspection 1 0 Connection of high voltage power to

battery plug
1 (Other than
I battery voltage)
OK (Battery voltage)
CPU board defect

Inspection 1. P2 - N 1 voltage check
Battery plug ON
Measurement terminals ~ 2 @
- NIB
Circuit tester range DC50 V
P2-N 1 Measuring the Voltage between P2 and N1
OK (battery voltage) -, CPU board defect

NG (above battery voltage) -, Incorrect battery or external reason (high voltage connection t o bat-
tery plug)
ERROR CODE A2: CPU BOARD ABNORMAL TEMPERATURE RISE
CPU board
Temperature sensor
Estimated causes
I @ CPU board temperature at 80°C (176OF) or above
I @ Overheat (continued use with overload)
1 @ Temperature sensor defect (CPU board defect)
Abnormally high CPU board temperature YES Leave the vehicle unoperated for some
[at 80°C (176OF) or above] time (about 3 0 minutes)
I
Test the vehicle with normal load after

Continued use of vehicle with overload
stopping for 30 minutes
0
1 ""
CPU board defect
* The CPU temperature sensor is included on the CPU board. CPU board defect is conceivable
when this error code (A21 is displayed.
ERROR CODE A4: ACCELERATION POTENTIOMETER INSTALLATION DEFECT
Related portion
CPU
CN106-12 (52, POTA)
-
board CN105-8 (51, GND)
CN106-3 (64, SWAC)
-
-r ---
Acceteration
pofentiometer
Estimated causes
@ Acceleration potentiometer defect (between 6 4 and 51 )
@ Acceleration potentiometer installation adjustment defect
@ Accelerator switch wiring short circuit (between 6 4 and 51)
@) CPU board defect
Is the battery plug connected

while the accelerator pedal is
depressed?
Is the normal state recovered
when the accelerator pedal is
released? I-YES Normal
ANL31: Switch input test 1
k
Is the accelerator switch turned
Not light
ON or OFF when the accelera- CPU board defect
tor pedal is not depressed? (Switch OFF)
See page 3-28
1 Light (Switch ON)
0 Carry out ANL31: Again after disconnecting

the acceleration potentiometer connector.
I
ANL31: Switch input test

Is the accelerator switch turned
Light Accelerator switch wiring short circuit
ON or OFF when the accelera-
tor pedal is not depressed? (Switch ON) (Short circuit between 6 4 and 51)
See page 3-28
I
Not light (Switch OFF)
Inspection 1
Individual acceleration poten-
tiometer inspection
NG
(Always 0 Q)
- Acceleration potentiometer defect
co Q in ordinary state and
OK 0 Q in operated state
Installation adjustment defect

Inspection 1 . lndividual acceleration potentiometer measurement
Individual acceleration potentiometer removal
Measurement terminals ) GND ( 51 )

Acceleration potentiometer S W ~ c ( 6 4 -
Circuit tester range Q x l

Standard co Q in ordinary state and 0 Q in operated state
Acceleration Potentiometer Checking the Conduction of Acceleration Potentiometer
OK (co s2 in ordinary state and 0 Q in operated state) Installation adjustment defect

+
NG (Always 0 Q ) -+ Acceleration potentiometer defect

ERROR CODE A6: MATERIAL HANDLING SWITCH INSTALLATION ABNORMALITY
CNl I
CN105-2 (69, L S A T ~ ) c
CN105-12 (63, LSATI)
CN106-15 (60, LSLI)

Lift tilt
CPU attachment
board CN106-16 (61, LST) switch
CN106-18 (68, LSLP) -
-.
CN105-3 (51, GND)

- -
CN39
@ Defect of each material handling switch
@ lnstallationladjustment defect of each material handling switch
@ Short circuit of each material handling switch wiring
@ CPU board defect
Is the battery plug connected Recovered t o the normal

YES- state when the material YES-~ormal
while any material handling
lever is operated? handling lever is released
1

Is each material handling switch
ON or OFF when the - Light * T o A on next page
corresponding material handling (Switch ON)
lever is not pulled?
See page 3-28
I Not light (Switch OFF)
CPU board defect

A
(When LS2 is ON)
11 Recheck after disconnecting

- /I
L-
CN39 Light
ANL31: Switch input test Wiring short circuit (between 6 8 and 51)
See page 3-28 (Switch ON)
I Not light (Switch OFF)
Inspection 1
LSLZindividual check
NG
(0 Q at switch
- L S L replacement
~
OFF)
I OK
(m Q at switch OFF)
Installation readjustment
(When LSi is ON)
I'
Recheck after disconnecting
CNll
See page 3-28
lnspection 2
-II1
Light
(Switch ON)
Not light (Switch OFF)

Wiring short circuit (between 60 and 51)
LSLI replacement
LSLI individual check (0Q at switch
1
OFF)
1
I
OK
(m Q at switch OFF)
Installqtion readjustment
For LST, LSATI, LSAT:! and L S A T ~carry

, out troubleshooting in the same way as for LSLI.
lnspection 1. LSL2individual check
LSL2individual removal
Measurement terminals LSL2terminals

Standard co Q at s w i t c h OFF and 0 Q in operated state
i
Checking the Conduction of L S L ~
OK ( w fl at switch OFF) + Installation readjustment

NG (0 Q a t s w i t c h OFF) + LSL2replacement
lnspection 2. LSLl individual check

LSLl individual removal
Measurement terminals LSLl terminals

Standard S w i t c h OFF: co Q Operated state: 0 Q
Checking the Conduction of LSLl
OK (co Q at switch OFF) + Installation readjustment

NG (0 Q at s w i t c h OFF) -+ LS,, replacement
ERROR CODE A7: PARKING BRAKE ALARM
Related portion
CN105-11 (66, LSPB) - Parking
CPU
CN105-3 (51, GND)
- -
CN15
brake
switch
board
CN106-5 (67, LSD)
n ,
Deadrnan
switch
L
Y
" Deadman brake

Deadrnan seat :
@ Parking brake switch defect

@ Parking brake switch installation adjustment defect
@) Parking brake switch wiring short-circuit
@ Deadrnan switch defect
@ Deadman switch installation adjustment defect
@ Deadrnan switch wiring short circuit or disconnection
@ CPU board defect
Left the vehicle without pull- YES Recovered t o normal state when
YES Normal
ing the parking brake? the parking brake is pulled?
I I
NO
NO
Is the parking brake switch

Not light
ON or OFF when the parking -To A on next page
brake is pulled? (Switch ON)
Switch OFF (Light)
OFF when sitting on the oper- :To B on next page

(Switch OFF)
ator's seat?
11 See page 3-28
/
I
Not light (Switch ON)
CPU board defect

I Disconnect parking brake
switch connector CN15.
/I Not light ,Wiring short circuit
(between 66 and 51 )
the parking brake lever is pulled?
Light (Switch OFF)
lnspection 1
Individual parking brake switch Switch replacement
check
I (co
oK
Q at switch OFF)
Installation adjustment defect
B1 (For deadman seat switch)
lnspection 2
Switch replacement
lndividual seat switch check co Q at switch ON)
( 0 fl at switch ON)
Wiring disconnection
-
( ~ ~ 1 0 6 - 5CN22)
CN105-3 - CN22
B2 (For deadman brake)
lnspection 3
lndividual deadman switch
check
NG
(a 52 at switch ON)
- Switch replacement
OK
( 0 52 at switch ON)
v
Switch installation adjustment
defect
Disconnection between
(CN106-5 - C~29)
CN105-3 - CN29
lnspection 1. Individual parking brake switch check
Parking brake switch individual removal
Measurement terminals Both terminals of parking brake switch connector

Standard m O at switch OFF
I
Parking Brake Switch Checking the Conduction of Parking Brake Switch
OK (co O at switch OFF) + Installation readjustment

NG (0 Q at switch OFF) + Switch replacement
lnspection 2. Individual seat switch check

Battery plug OFF
Measurement terminals Both terminals of seat switch connector

Standard 0 O at switch ON
Seat Switch Checking the Conduction of Seat Switch
OK (0 Q at switch ON) + Wiring disconnection (CN106-5 - CN22.CN105-3 - CN22)

NG (co Q at switch ON) -t Switch replacement
Inspection 3. Individual deadman switch check
Battery plug OFF
Measurement terminals Both terminals o f deadman s w i t c h connector

Standard 0 Q at s w i t c h ON
Deadrnan Switch Checking the Conduction of Deadrnan Switch
OK (0 Q at switch ON) + Wiring disconnection (CN106 - CN29-CN105 - CN29) or installation

adjustment defect
NG (oo Q at switch ON) + Deadman switch replacement
ERROR CODE A8: TRAVELING FUSE ABNORMALITY
CN103-15 (P2, VBP2) P2

0
CPU
board
CN100-2 (43, K36V)
Key switch
CN101-21 (13, VBBT)
Estimated causes
@ Drive fuse (F1) open
@ P2 wiring disconnection
@) Battery cable disconnection
@ CPU board defect
Inspection 1 NG
F 1 replacement OK - ~ o r m a l
Traveling fuse iF1) Check (aQ)
I I
lnspection 3
P2 Contact between
t resistance measurement P2 wiring and N1
N1
1 OK (Other than 0 Q)
0 P2 wiring route correction
lnspection 2
P2
Battery cable disconnection
t voltage check
N1
0 P2 wiring (CN103-5 - P2) disconnection

0 CPU board defect
lnspection 1 . Traveling fuse (F1 check
Battery plug OFF
Measurement terminals Both terminals of F1
Standard 00
F1 Checking the Conduction of F1
OK (0 52) + To inspection 2
NG (oo 52) + F1 replacement + To inspection 3
lnspection 2. P2 - N1 voltage check

Battery plug ON
Measurement terminals ~ 2 @
- NI@

P2.N 1 Measuring the Voltage between P2 and N1
OK (battery voltage) -t P2 wiring disconnection (CN103-P2) or CPU board defect

NG (0V ) + Battery cable disconnection
ERROR CODE AA: CPU BOARD TEMPERATURE SENSOR OUTPUT ABNORMALITY
CPU board
Temperature sensor
Estimated causes
1
I @ CPU board disconnection
ERROR CODE AE: EXCESSIVE AID PROCESSING TIME
Estimated causes
@ CPU board defect
CPU board replacement for AE display
ERROR CODE AF: CPU PROCESSING DATA ABNORMALITY
Estimated causes
@ CPU board defect
CPU board replacement for AF display

ERROR CODE CO: MAIN DRIVE CIRCUIT ABNORMALITY
CN104-9 (32, + 5V) ICN101-6 (32, + 5V) CN102-6 IN1, TMS)

I
CN104-16 (33, CHOPD) CN101-17 (33, CHOPD) CN102-5 (P9. RC2)
CPU I
CN104-15 130, VDD+) 1CN101-7 130, VDD+) DC/SD
board
I board
I CN102-1 1 1P8, TMD)
I
CN104-5 (31, VDD-) I C ~ 1 0 1 - 1 8(31. VDD-1 CN 102-4 (P8. RC 1 )
P2
0
R
DRD" D
A
D DAD n
I G
i
CN116 CN109
Estimated causes
' @ T M defect
@ Main drive circuit connection defect
@ RAD wiring disconnection, connector disconnection or defective contact
@) TM-DCISD wiring disconnection or defective contact
@ CPU-DCISD wiring disconnection
@ Defective contact of each connector
a Drive DCISD board defect
@ CPU board defect

Connector (CN102.CN104)
Traveling test after
disconnection and TM
correction
connection loosening check
Inspection 1 Inspection 4
MS contac-
*P8 Check welding of MS
5 voltage check contactor
N1 (Less than 1 0 V) replacement
1OF (10 V or more)
1- 1
1
1
I Inspection 2
5 continuity check
a k D
(using SST)
,
I
NG Wiring dis-
(a n, connection
1 lnspection 5
TM wiring
Individual TM-DRD check
after disconnecting
, TM
wiring and copper bar
OK
k*
NG TMandDRD
replacement
To A on next
page for
checking the
cause of TM
I-
lnspection 3 breakdown.
lnspection 6
CPU
NG Wiring dis- P2 NG To B on
5 continuity check
(a Q) connection 5 continuity check next page
DCISD
DAD cathode (heat sink)
(using SST)
1 OK io n)
lnspection 7
OK (Approx. 1 .5 Q)
DCISD defect
CPU board defect CN102-5
5 continuity check
DAD cathode (heat sink) NG, is con-
CN1 02-4 Q) nection
$continuity check
TM (Dl
* Conditions for lnspection 1 (using SST)
Battery plug ON, SWky OFF, direction
switch OFF, and accelerator switch OFF OK (0 n)
* * The standard voltage between P8 and N 1 Drive DCISD defect

is as follows. It is different from the criteri-
on in troubleshooting:
C Vehicle
36V vehicle
48V vehicle
Standard
21 +
28-+ 3 V
3 V
lnspection 8
Discoloration or loosening of DF1 set screw or copper bar
lndividual DF 1 check
Approx. 3 kQ
Reverse: oo Q 1
lnspection 9
Loosening of DAD lead or round terminal
lndividual DAD check
0
0
I OK
I
Loosening of CAD wiring
Forward: Approx. 6 kQ
Reverse: oo Q
Loosening of TM copper bar terminal

j
lnspection 1 0
lndividual RAD check after
NG RAD defect
disconnecting CN 1 16
OK (Approx. 1.5 Q)
main circuit and
CN109-CN116
lnspection 1. P8-N 1 Voltage check
Battery plug ON, SWky OFF, direction switch OFF, acceleration switch OFF
Measurement terminals PB@ - NIB

Standard 36 V vehicle: 21 t- 3 V, 48 V vehicle: 28 t 3 V
P8.Nl Measuring the Voltage between P8 and N1
OK (10 V or more) + To inspection 2 The standard voltage between P 8 and N 1 is as

NG (less than 1 0 V ) To inspection 4
+ shown above, but the criterion for troubleshoot-
ing is 1 0 V or more.
-
lnspection 2. TM-DCISD continuity check
Battery plug OFF, SST connection
Measurement terminals TM - DCISD

Circuit tester range Q x 1K
Standard 0 Q
OK (0 Q )
+ To inspection 3
NG (aQ ) + Wiring disconnection
Checking the Continuity between TM and DCISD

lnspection 3. CPU-DCISD continuity check
Measurement terminals CPU - DC/SD

Circuit tester range Q x l K
Standard 0Q
OK (0 Q ) + DC/SD board defect or CPU board defect

NG (oo Q ) + Wiring disconnection
Checking the Continuity between CPU and DCISD Board
lnspection 4. MS contactor welding check

Battery plug OFF
OK + To inspection 5
MS contactor NG + MS contactor replacement
Checking the Welding of MS Contactor

Inspection 5. Individual TM-DRD check
Battery plug OFF, copper bar disconnection
Between D and S
DO-S@
DO-SO
Measurement terminals Between D and G
DO-GO
DO-G@
Between G and S
GO-S@
GO-SO
Circuit tester range 52 x 1K
Between D and S DO-S@:mP

D@-S@:mQ
DO-G@:mQ
Standard Between D and G
D @ - G @: Continuity shall exist
G @ - S @: Continuity shall exist
Between G and S
G@-S@:m52
TM Checking the Continuity of TM
OK += To inspection 6
NG += To inspection 8
DRD (Direction of Reverse Conductive diode) check

Battery plug OFF. Remove the DRD.
Forward: Anode @ - Cathode @

Reverse: Anode @ - Cathode @
Circuit tester range 52 x 1K
Forward: Approx. 1.6 kS2

Standard
Reverse: co 52
Cathode Anode
Red probe
Conduction No Conduction
Inspection 3. P2-N 1 resistance measurement
Battery plug OFF
1
Measurement terminals P 2 - N1
Standard Other than 0 Q
P2.Nl Measuring the Resistance between P2 and N1
OK (Other than 0 Q ) P2 wiring pinching

-+
NG (0 Q ) Contact between P2 wiring and N1

-+
lnspection 6. P2-DAD Cathode (heat sink) continuity check
Battery plug OFF
Measurement terminals P2 - DAD cathode (heat sink)

Standard Approx. 1.5 Q
Checking the Resistance between P2 and DAD
OK (Approx. 1.5 Q) -t To inspection 7

NG (co Q) To inspection 1 0
-)
lnspection 7. (CN102-5 - DAD cathode CN 102-4 - TM (D)) Continuity check

CN102-5 - DAD cathode (heat sink)

CN102-4 - TM(D)
Circuit tester range n x l

Standard 0Q
-
r I OK -t Drive DC/SD board defect

NG + Wiring disconnection
Checking the Continuity between CN102 and DAD/TM

lnspection 8. Individual DF 1 check
Battery plug OFF, DF1 wiring disconnection
Anode - - Cathode +
Circuit tester range

Forward:
Reverse: 8
Anode + - Cathode -
Q x lK
8
Standard
Reverse: co Q
DF 1 Measuring the Conduction of DF1
OK (forward: Approx. 3 kQ, reverse: co Q ) -t To inspection 9

NG -+ Discoloration or loosening of DF1 set screw or copper bar
lnspection 9. lndividual DAD measurement

Battery plug OFF, DAD wiring disconnection

Forward
Reverse 8
Anode - - Cathode +
Anode + - Cathode -
n x IK
8
Forward: Approx. 6 k n
Standard
Reverse: co Q
DAD Measuring the Conduction of DAD
OK (Forward: Approx. 6 kQ, reverse: oo O) + Loosening of CAD wiring or copper bar

NG + Loosening of DAD lead or round terminal
Inspection 10. Individual RAD measurement

Battery plug OFF, CN116 disconnection
Measurement terminals RAD connector terminals
Standard Approx. 1.5
RAD Measuring the Conduction of RAD
OK (Approx. 1.5 Q) -+ Disconnection between main circuit and CN 109 - CN 1 1 6

NG (00 Q) + RAD defect
ERROR CODE C1: DRIVE CIRCUIT CURRENT SENSOR ABNORMALITY
CN104-7 (71, CSD)

Drive
CPU CN104-18 (73, + 12V) current
board sensor
CN104-1 (74, GND)
Connector
CSD
Estimated causes
@ Drive current sensor defect
@ Disconnection or defective connector contact between CN104 and traveling current sensor
@ TM short circuit
@ MG welding
@ Speed sensor defect
@ Short circuit or defective connector contact between CN105 and speed sensor
a Drive motor defect (short circuit)
@ CPU board defect
Are CO and C 1 displayed

Action for error code CO
alternately?
NO (only C1 error)
I I I I
Check the wiring between
CN104 and drive current NG - Test again after correction
sensor
I
ANL 11: Simplified test (ESY0 1 ) 0 Traveling current sensor defect

Is C1 displayed? 0 Open circuit or defective connector contact between
I See page 3- 1 7 CN 104 and traveling current sensor
NO
Inspection 1
Was switch back operation CSD output voltage check NGo, CSD defect
performed when C1 error NO CN 104-7
(2.0 v 0 Wiring defect
occurred? 1 voltage check
CN 104-1 or more)
I 1 OK (Approx. 1.2 V )
To A on next page 0 CPU board defect

0 Drive motor defect (short circuit)
A
--
Is MG welded? 1 YES - 0 MG contactor replacement
NO
0 Speed sensor defect

Is the speedometer reading 0 Short circuit of wiring between CN105 and
abnormally low? speed sensor
(Does it exceed 5 kmlh?) 0 CPU board defect
Normal
ANL13: Test operation (No. 1 )

Is the speedometer reading
stable?
Not
stabilized - 0
0
Speed sensor defect
Defective contact of connector between
CN 105 and speed sensor
(Doesn't it suddenly drop
below 5 krnlh?) 0 CPU board defect
See page 3-24
I
I
CPU board defect
Inspection 1. CSD output voltage measurement
Battery plug ON, SWky ON, SST connection
Measurement terminals ~ ~ 1 0 4 --
7 ~0 ~ 1 0 4 - 1 0
Standard Approx. 1.2 V
I I
CSD Measuring the Output Voltage of CSD
OK (Approx. 1.2 V ) -+ CPU board defect or drive motor defect (short circuit)
NG (2.0 V or more) -+ CSD defect, or wiring defect
lnspection 2. MG contactor welding check

Battery plug ON
OK + To ANL13: Test operation
--- MG contactor
NG + MG contactor replacement
\\
\
\
\
I I
Checking the Welding of MG Contactor

ERROR CODE C2: TRAVELING MOTOR ABNORMAL TEMPERATURE RISE
Related portion
CN106-6 (191, T D + )
-
Drive
CPU motor
board temperature
CN106-13 (192, T D + ) sensor
*
CN43
Estimated causes
@ Drive motor overheat
I @ Drive motor temperature sensor defect

I
@ Short circuit of wiring between CN106 and drive motor temperature sensor
I
1 @ CPU board defect
Stop the vehicle and traveling test after

waiting 3 0 minutes
Inspection 1.
Disconnect CN106 and measure the tem-
perature sensor resistance
0 Sensor defect
CN106-6 (191)
Less than 0 Wiring short circuit
5 measure resistance
CN106-13 (192) approx. 1 0 kQ
(using SST).
OKl
(Approx. 1 0 kQ or more)
CPU board defect

Inspection 1. Drive motor temperature sensor resistance measurement
Battery plug OFF, CN 106 disconnection
Measurement terminals CN106-6 - CN106-13
Circuit tester range a x IK

Standard Approx. 1 0 kfl or more
OK (Approx. 10 kQ or more) CPU board defect

+
NG (Less than approx. 1 0 kQ) Sensor defect or short cir-

-+
cuit in wiring
Measuring the Resistance of DMD Temperature Sensor

ERROR CODE C3: CONTROLLER TEMPERATURE SENSOR ABNORMALITY
CPU
board
@ Controller temperature sensor abnormality
@ Defective contact between C N 1 0 4 and connector STH
@ Open circuit between CN 1 0 4 and controller temperature sensor
@ CPU board defect
I Inspection 1 I
check disconnection of
Display check after correction
connector CN 1 0 4 and
connector STH.
0
OK
ANL 12: Test operation (No. 7) Inspection 2

Disconnect connector STH
Is the temperature sensor YES- Temperature
and measure the resistance of
voltage 0 V ? No- sensor defect
(0 V ) temperature sensor. Is it
See page 3-24
between 1 0 Q and 1 0 kQ?
NO YES
(Other than 0 V ) (Between 1 0 Q and 1 0 kQ)
7
CPU board defect 0 Wiring disconr!ection
0 Defective connector contact
lnspection 1. CN104 connector and connector STH disconnection check
I '
I I I
CN 104 Connector STH
OK -, To ANL12: test operation

NG + Display check after correction
lnspection 2. Temperature sensor resistance measurement

Battery plug OFF
Measurement terminals Both terminals of temperature sensor connector STH

I
Standard Between 10 fl and 10 kn
__Z
\
Connector STH
I
Connector STH Measuring the Resistance of Temperature Sensor
YES (Between 1 0 Q and 1 0 kQ) + Wiring disconnection or defective connector contact

NO -+ Temperature sensor defect
ERROR CODE C4: TRAVELING ACCELERATOR ABNORMALITY
CN25
r 7
CN106-8 (53. POT+)
CN106-12 (52, POTA)

Acceleration
CN105-8 (51, GND) potentiometer
CN106-3 (64, SWAC)

--
- L
@ Acceleration potentiometer defect

@ Short circuit or open circuit in wiring between CN 1 0 5 . CN106 and acceleration potentiometer
@ Defective contact of CN105 - CN106 . CN25 and accelerator connector
@ CPU board defect
Check disconnection of CN105 - CN106 . Traveling test after correction

CN25 and accelerator connector
OK
(acceleration potentiometer check)

Check the potentiometer voltage when the 'To A on next page
accelerator pedal is not depressed. (0.0 V )
1 OK (0.1 V or more)
NG
Check the potentiometer voltage when the To B on next page
accelerator pedal is fully depressed. (4.6 V or more)
4 OK (4.5 V or less)
ANL11: ESY-15
Check the potentiometer voltage when the NG Disconnection between
switch is turned from OFF t o ON while ( " ~ o turned
t ON or CN106-3 and CN105-8
depressing the accelerator pedal gradually. 1.4 v or more)
See page 3-21
* The acceleration potentiome-
OK (1.3 V or less) ter is defective if the switch
is not turned ON.
7
CPU board defect
Inspection 1 Does the acceleration
Acceleration
Disconnect the acceleration potentiometer resistance vary NO-- potentiometer
potentiometer and check it from 0 O to about 2 to 4 kQ
replacement
individually. , when it is turned?
YES
Adjustment defect. Readjust it.
B
Recheck after disconnecting the acceleration
potentiometer connector.
ANLI 1: ESY-15
(acceleration potentiometer check) - Short circuit of wiring between
Check the potentiometer voltage when the CN106-12 and CN106-8
(4.6 or morel
accelerator pedal is not depressed.
See page 3-21
OK ( 0 V )
lnspection 2
Disconnect the acceleration potentiometer,
and check it individually.
Does the acceleration potentiometer voltage

vary from 0 O to about 2 t o 4 kO when it is
turned?
NO - Acceleration potentiometer
replacement
YES
1
Adjustment defect
lnspection 1. Individual acceleration potentiometer measurement
Battery plug OFF
Measurement terminals Terminals of acceleration potentiometer connector
Standard Variation from 0 Q t o about 2 - 4 k0
Acceleration Potentiometer Measuring the Resistance of Acceleration Potentiometer
YES (Variation from 0 Q t o about 2 -

4 kQ) + Acceleration potentiometer adjustment defect
NO + Acceleration potentiometer replacement
lnspection 2. Individual acceleration potentiometer check

Same operation as inspection 1
ERROR CODE C6: MS CONTACTOR DRIVER ABNORMALITY
CPU board
internal junction
Estimated causes
@ CPU board defect
Replace the CPU board when C 6 is displayed.

ERROR CODE C7: DIRECTION SWITCH ABNORMALITY
-
CN106-1 (45, DSF)
CPU CN106-2 (46, DSR) D~rection

-
board switch
CN105-3 (51, GND)
CN9
@ Direction switch abnormality
@ Short circuit or disconnection in wiring between CN 105 . CN106 and direction switch
@ CPU board defect
Check if CN105 or CN 106 connector is

Confirmation test after correction
disconnected.
When the direction lever is operated to NO 0 Direction switch defect

the forward or reverse position, is the 0 Short circuit or disconnection of wiring
opposite direction also set to ON?
YES
CPU board defect

ERROR CODE C8: SPEED SENSOR ABNORMALITY
Related portion
CN105-4 (82, SS-) T
CPU Speed
board sensor
CN105-5 (81, SS+)
CN21
Estimated causes
@ Speed sensor defect (coil disconnection)
@ Disconnection in wiring between CN 1 0 5 and speed sensor
@ Connector contact defect
@ CPU board defect
Check disconnection of CN 1 0 5 or CN21 NG w Traveling test after correction

connector.
OK
Inspection 1
Individual speed sensor check after
disconnecting CN2 1
NG
(Other than 7 0 0
-
Ql
Rotation sensor defect
OK (Approx. 7 0 0 Q )
CPU board defect

Inspection 1. Individual speed sensor measurement
Battery plug OFF
Measurement terminals Terminals of speed sensor connector
Circuit tester range Slxl

Standard Approx. 700 Sl
Speed Sensor Measuring the Resistance of Speed Sensor
OK (Approx. 700 Q) + CPU board defect

NG (Other than 700 0) Speed sensor replacement
+
ERROR CODE CA: FORWARD REVERSE CONTACTOR DRIVER ABNORMALITY
CPU board
internal junction
Estimated causes
@ CPU board defect
Replace the CPU board when CA is displayed.
ERROR CODE CE: CPU ROM ABNORMALITY
@ CPU board defect
Replace the CPU board when CE is displayed.
ERROR CODE CF: CPU RAM ABNORMALITY
@ CPU board defect
Replace the CPU board when CF is displayed.

ERROR CODE EO: MAIN MATERIAL HANDLING CIRCUIT ABNORMALITY
I
CN104-20 (37, + 5V) I CN111-6 (37, + 5V) CN112-6 (N2, TMPS)
CN104- 17 (38, CHOPP) ! CN1 11-1 7 (38, CHOPP) CN112-5 ( P I 5, RC2)
CPU CN104- 14 (35, VDP+) I CN111-7 (35, VDP+) CN112-12 (93, TMPG)
CN104- 4 (36, VDP-) I CN111-18 (36, VDP-1 CN112-11 (P14, TMPD)
I -- CN112-4 (P14, R C l )
I Material
handling
panel
-
PI1
0
TMP - C?
CN118 CN109
Estimated causes
@ TMP defect
@ Main material handling circuit connection defect
@ Open circuit, connector disconnection or defective contact in RAP wiring
@ Disconnection or defective contact of wiring between TMP and DCISD
@ Disconnection of wiring between CPU and DCISD
@ Defective contact of each connector
@ Material handling DCISD board defect
@ CPU board defect

Check disconnection of
each connector and Material handing opera-
loosening of TMP tion after correction
connection.
lnspection 1
*PI 3
t voltage check
N1
OK
OK ( * * 1 0 V or more) v
lnspection 2
placement
5 continuity check To A on
DCISD (using SST) next page
Q
for checking
the cause of
OK (0 8 each) TMP break-
lnspection 5 down.
NG To B on
resistance
lnspection 3 next page
measurement
CPU I DAP cathode (heat sink) I
$ continuity check
DCISD (using SST) 1 OK (Approx. 1.5 8)
Q OK ( 0 8 each)
0
0
DCISD board defect
CPU board defect
I
t continuity check
DAP cathode (heat sink)
CN 1 12-4
$ continuity check
I--
I
NG Wiring dis-
(a 8)
connection
* Conditions for lnspection 1

Battery plug ON, SWky OFF OK ( 0 8 )
* * The standard voltane between P I 3 and N 1
is a&follows. It is different from the criteri- 0 Material handling DCISD defect
on in troubleshooting. 0 CPU board defect
When brush worn

Vehicle Standard
(error code E8 is displayed)
3 6 V vehicle 16k 3V 21 + 3.V
4 8 V vehicle 21 k 3 V 28+ 3 V
Inspection 7 NG Loosening or discoloration of DF3 installing
Individual DF3 check screw or copper bar
OK
Inspection 8 NG
Loosening of DAP lead terminal
Individual DAP check
OK
0 Loosening of CAP wiring

0 Loosening of TMP copper bar
lnspection 9
Disconnect CN1 1 8 and
check the RAP
individually.
/
b.RAp
OK (Approx. 1.5 Ql
defect
main circuit and CN109,
CN118
lnspection 1 . P13-N 1 voltage measurement
Battery plug ON, SWky ON
Measurement terminals ~ 1 3 -0 NI@
3 6 V vehicle: 1 6 k 3 V, 4 8 V vehicle: 2 1 k 3 V
Standard For an E8 error (at the time of brush wear)
3 6 V vehicle: 21 k 3 V, 4 8 V vehicle: 2 8 k 3 V
P I 3.N1 Measuring the Voltage between P I 3 and N1
OK ( 10 V or more) + To inspection 2 The standard voltage between P I 3 and N 1 is as

NG (less than 1 0 V ) + To inspection 4 shown above, but the criterion for troubleshoot-
ing is 1 0 V or more.
lnspection 2. TM-DCISD continuity check

Measurement terminals TMP - DCISD

Circuit tester range Q x lK
Standard on
'
OK ( 0 Q) + To inspection 3
CN112 NG (aQ ) + Wiring disconnection
Checking the Continuity between TMP and DClSD

lnspection 3. CPU-DCISD continuity check
Measurement terminals CPU - DCISD

Standard 0 Q
-
OK (0 L?) + DCISD board defect or CPU board defect
CNlll 1.1 NG (co L?) + Wiring disconnection
I 16171 I I111
/ 1171181 1201 122
II
CN104 1
112/314/516/7/8/9/10
111 ~ 1 3 ~ 1 4 / 1 5 ~ 1 6 ~ 1 7 ~ 1 8 / 1 9 ~ 2 0
I t t-
Checking the Continuity between TM and DCISD
lnspection 4. Individual TMP check

Battery plug OFF, TMP wiring and copper bar disconnection
Between D and S
8 8
D - -
D + -S
+
S
-
Measurement terminals Between D and G

8 8
D - -
D + - G
G+
-

Between G and S
8 8
G - -
G + -S
L? x 1K
S+
-
Between D and S
8 8
D - -
D + -S
S+ : c o Q
-:Coil
Standard Between D and G

8
D --G@:coQ
D + - G @ : Continuity shall exist
Between G and S
8 8
G - - S + : Continuity shall exist
G + - S -:coil
TMP Measuring the Resistance of TMP
NG + T o inspection 7
Inspection 5. P I 1 -DAP cathode (heat sink) continuity check

Battery plug OFF
Measurement terminals P I 1 -DAP cathode (heat sink)
Standard Approx. 1.5 0
Checking the Continuity between P I 1 and DAP
NG ( w Q) -
OK (Approx. 1.5 Q) +To inspection 6
T o inspection 9
lnspection 6. CN112-5 - DAP Cathode and CN112-4 TMP (D) continuity check
Battery plug OFF
CN112-5 - DAP cathode (heat sink)

CN 1 12-4 - TMP(D)
Standard 0Q
OK (00)+ Material handling DCISD defect or CPU board

defect
NG, (oo Q) +Wiring disconnection
Checking the Continuity between CN11 2 and

DAP.CN112 and TMP
lnspection 7. Individual DF3 measurement

Battery plug OFF, DF 1 wiring connection

Forward:
Reverse: 8 8
Anode - - Cathode +
Anode + - Cathode -
n x IK
Forward: Approx. 3 k n
Standard
Reverse: m n
I I
DF3 Measuring the Resistance of DF3
OK (Forward: Approx. 3 kQ, reverse: co Q) + To inspection 8

NG +Discoloration or loosening of DF3 set screw and copper bar
Inspection 8. Individual DAP measurement

Battery plug OFF, DAD wiring disconnection

Forward:
Reverse:
Anode
Anode
n
8- - Cathode +
+ - Cathode -
x IK
8
Forward: Approx. 6 kfl
Standard
Reverse: D
DAP Measuring the Resistance of DAP
OK (Forward: Approx. 6 kQ, reverse: co Q) + Loosening of CAP wiring or TMP copper bar terminal
NG + Loosening of DAP lead or round terminal
Inspection 9. Individual RAP measurement
Battery plug OFF, CN 1 18 disconnection
Measurement terminals RAP connector terminals
RAP Measuring the Resistance of RAP
OK (Approx. 1.5 Q ) + Main circuit -CN109 - CN1 18 open circuit

NG (00 Q ) + RAP defect
ERROR CODE E l : MAIN MATERIAL HANDLING CIRCUIT CURRENT SENSOR
ABNORMALITY
- CN104-8 (72, CSP)

Material
t
CPU CN104-19 (73, + 12V) handling

board current
CN104-2 (74, GND) sensor
CN 1 10 Connector
-
CSP
Estimated causes
@ Material handling current sensor defect
@ Defective contact between CN104, CN 1 1 0 and connector CSP
@ TMP short circuit
@ CPU board defect
YES
To action for EO
NO (only E l error)
Inspection 1
CSP output voltage check
C N1 0 4 - 8
NG -
(2.0 V or
0
0
CSP defect
Wiring defect
2 voltage check
CN104-1 more)
OK (Approx. 1 . 2 V )
CPU board defect

Inspection 1. CSP output voltage measurement
Measurement terminals ~ ~ 1 0 4 --8 ~0 ~ 1 0 4 - 1 0

Standard Approx. 1.2 V
CSP Measuring the CSP Output Voltage
OK (Approx. 1.2 V ) -, CPU board defect

NG (2.0 V or above) CSP defect or wiring defect
ERROR CODE E2: MATERIAL HANDLING MOTOR ABNORMAL TEMPERATURE RISE
Related portion
CN106-7 (194, T P + )
Material
CPU handling
board motor
temperature
C N l 0 6 - 1 4 (195, TP-1 . sensor
L-
CN41
Estimated causes
@ Material handling motor overheat
I @ Material handling motor temperature sensor defect
I @ Short circuit in wiring between CN106 and material handling motor temperature sensor
@ CPU board defect J

YES Material handling operation after stopping
the vehicle for 3 0 minutes
NO
Inspection 1 NG ,0 Sensor defect

Disconnect CN 106 and measure the
(Less than 0 Short circuit of wiring
resistance between pin 7 and pin 14.
approx. 1 0 kQ)
OK
(Approx. 1 0 kQ or more)
7
CPU board defect
Inspection 1 . Material handling motor temperature sensor resistance measurement
Battery plug OFF, CN 106 disconnection
Measurement terminals CN106-7 - CN106-14

Standard Approx. 1 0 kQ or more
OK (Approx. 1 0 kQ or above) -+ CPU board defect

NG (Less than approx. 1 0 kQ) -+ Sensor defect or short cir-
cuit of wiring
Measuring the Resistance of Temperature Sensor

ERROR CODE E3: RETURN TO NEUTRAL SYSTEM ABNORMALITY (FOR U.S.A.)
Related portion
CN105-3 (51, GND) - Deadman

CN106-5 (67, LSD) switch
CN29 -
CPU
board CN106-1 (45, DSF) -
CN106-2 (46, DSR) Direction
' switch
CN105-3 (51, GND)
- A
CN9
@ When the direction switch is at F or R, the key switch is turned ON with the accelerator .
pedal depressed or the deadman switch is turned ON.

@ Direction switch defect
@ Wiring short circuit
@ CPU board defect
Does the error display dis-

appear when the direction
switch is set t o N and the Traveling test
accelerator switch is
turned to OFF?

Is the deadman switch YES
when the direction switch
turned ON or OFF?
is set to N (neutral)?
See page 3-28
NO YES
Inspection 1 Deadman After disconnecting

Individual deadman switch NG=-switch direction connector CN9.
check rep'acement
OK YES NO
\
0 CPU board defect 0 Wiring short circuit Direction switch internal
0 Disconnection in wiring 0 CPU board defect defect
t o CN29 or between
CN22 and CN105.
Inspection 1. Individual deadman switch check
Battery plug OFF, C N 2 9 disconnection
Measurement terminals Both terminals of deadman switch connector
Circuit tester range Q X I
Switch OFF: J
!
Standard
Switch ON: 0D
'CN29 Connector Checking the Continuity of Deadman Switch
OK (Switch OFF: w Q,switch ON: 0 Q) + CPU board defect, or CN29lCN22-CN105 wiring discon-
nection
NG + Deadman switch replacement
ERROR CODE E5: REGENERATIVE DIODE (DG) ABNORMALITY
Related portion
@ Regenerative diode (DG) short circuit
@ Short circuit between P5 and N1
Inspection 1 NG -0 Loosening of DG mounting screw or

Individual DG check copper bar
OK
lnspection 2
Disconnect CN 1 03 0 Panel internal wiring pinching
P5 0 Conductive foreign material between
(Approx.
S voltage check copper bars
N1
continuity shall exist
CPU board defect

lnspection 1. Individual DG measurement
Battery plug OFF, DG wiring disconnection

Forward:
Reverse: 8
Anode - - Cathode +
Anode + - Cathode -
Q x lK
8
Standard
Reverse: co Q
DG Measuring t h e Resistance of DG
OK (Forward: Approx. 3 kQ, reverse: oo Q) + To inspection 2

NG +Discoloration or loosening of DG set screw or copper bar
lnspection 2. P5-N 1 continuity check

Battery plug OFF, CN 103 connector disconnection
Measurement terminals P5 - N1
Conduction P5 @ - N1 @ : oo Q,P 5 @ - N 1 @ : Continuity shall exist
I I
P5-N 1 Checking t h e Continuity between P5 and N1
OK (P5 @ - N 1 @ : oo Q, P5 @ - N 1 @ : Continuity shall exist) -+ CPU board defect

NG (Approx. 0 Q) + Panel wiring pinching, or entrance of conductive substance between copper bars
ERROR CODE E6: MATERIAL HANDLING SWITCH ABNORMALITY
Related portion
CN11
7
CN106-15 (60, LSLI) Material
handling
CN105-9 (51, GND) - switch
- No. 1
CPU (LSL1)
board -
i.
Material
CN106-18 (68, LSLZ) -
handling
switch
No.2
-
CN39
(LSLZ)
Estimated causes
@ Material handling switch No. 1 (LSu) defect (open)
@ Material handling switch No. 1 (LSLI) wiring disconnection
@ Defective adjustment of LSLI or L S u
@ CPU board defect
CN 105 and CN 106 connector NG Material handling operation after

disconnection check correction
I
k
ANL31: Switch input test 0 LSLI open
Is LSLI set to ON with L S L kept
~ at OFF 0 LSLI wiring disconnection
when the material handling lever is pulled Not light 0 LSLI.LSL~adjustment
slightly? (Switch OFF)
See ~ a a e3-28
OK (Light)
(Switch ON)
CPU board defect

ERROR CODE E7: DRIVE MOTOR BRUSH WEAR ALARM
Related portion
-
CPU CN106-10 ( 190, BMD)
board
@) Drive motor brush wear
@ Drive motor brush detector defect
@ CN106- CN43
@ CPU board defect
NG
Drive motor brush inspection Traveling test after brush replacement
OK
Inspection 1 NG
C N 4 3 (motor side connector) . (0 P),The brush wear indicator wire
$ continuity check short-contacts to "A" terminal.
Drive motor terminal A
OK (m P)
Inspectian 2
CN106-10
$ continuity check
NG
(0 P) - The harness wire short-contacts
to P 4 level.
P4
OK (aP)
7
CPU board defect
* If brush wear warning is set by the option input (display mask function) in a vehicle without brush
wear warning, E7 is displayed when the key switch is turned to ON.
In that case, set to no brush wear warning.
lnspection 1. Brush wear detector continuity check
Battery plug OFF
Measurement terminals CN43 (motor side connector) - Drive motor terminal A

Standard a S-2
CN43 Connector. Motor terminal A Checking the Continuity at Brush Wear Detector Portion
OK (a9 ) + To inspection 2
NG (08) The brush wear indicator wire short-contacts t o "A" terminal.
-+
lnspection 2. Wiring check

Battery plug OFF
Measurement terminals CN106-10 - P 4
Circuit tester range ~ x l
Standard m8
CN106 Connector.P4 Checking the wiring
OK (a9)-+ CPU board defect

NG (09 ) The harness wire shorts-contacts t o P4 level
-+
ERROR CODE E8: MATERIAL HANDLING (PUMP) MOTOR BRUSH WEAR ALARM
n
CPU
CN106-9 (193, BMP)
board
-
CN41
Estimated causes
@ Material handling motor brush wear
@ Material handling motor detector defect
@) CN106-CN41
1 @ CPU defect
Material handling motor brush inspection / NG .-Traveling test after brush replacement
1 Inspection 1 I
CN41 (motor side connector) NG ,The brush wear indicator wire
5 ( 0 9) short-contacts t o "A" terminal
Material handling motor terminal A
I
lnspection 2
CN106-9 The harness wire short-contacts
$continuity check to P I 2 level.
PI2
1 OK (aPi
CPU board defect
Battery plug OFF
Measurement terminals CN41 (motor side connector) - Material handling motor terminal-A
Standard WP
CN41 Connector.Motor Terminal A Checking Continuity at Brush Wear Detector Portion
OK ( W 52) + To lnspection 2
NG ( 0 P) + The brush wear indicatior wire short-contacts t o "A" terminal.

Battery plug OFF
Measurement terminals CN106-9 - PI2

Standard 00 CJ
CN106 Connector.Pl2 Checking the wiring
OK (a9) + CPU board defect

NG ( 0 P) + The harness wire short-contacts t o P I 2 level.
4-68
ERROR CODE E9: PS MOTOR BRUSH WEAR ALARM
Related portion
- -
CPU CN106-11 (196, BMPS)
board
-
CN45
@ PS motor brush wear
@ PS motor brush detector defect
@ CN106-CN45
@ CPU board defect
PS motor brush inspection

NG - 0 PS operation after brush replacement
OK
-
Inspection 1
CN45 (motor side connector) NG
1continuity check 0 The brush wear indicator wire
( 0 9) short-contacts t o "A" terminal.
PS motor terminal A
OK (aSt)
lnspection 2
CN106-11
NG Wiring short-contacts between CN 106
1 continuity check
P22 (STD) ( 0 Q) and P22 (STD) or P21 (with EHPS)
P21 (with EHPS)
OK (aQ )
CPU board defect
Battery plug OFF
Measurement terminals CN45 (motor side connector) - PS motor terminal A
Standard a 8
\
CN45 Connector.PS Motor Terminal A Checking the Continuity at Brush Wear Detector
OK (a8) + To inspection 2
NG (0 8) + The brush wear indicator wire contacts t o "A" terminal.

Battery plug OFF
CN106-11 - P22 (STD)

CN106-11 - P21 (With EHPS)
Standard as2
Checking the Wiring (STD) Checking the Wiring (with EHPS)
OK (0 8) -+ CPU board defect

NG (co 8) -+ Wiring short-contacts between CN 1 0 6
and P22 (STD) or P21 (with EHPS).
ERROR CODE EE: MCS RECEIVING DATA ABNORMALITY
Related portion
I
C N 1 0 7 - 2 ( 1 4 2 , SDTMA) 1 -
Multi-
CPU display
board DlSP
C N 1 0 7 - 5 (14 3 , SDTMK)
T- -
CN1
-
CN120
.
@ Multi-display defect
@ CN 1 0 7 -C N 1 - C N 1 2 0 contact defect
@ Disconnection of wiring between CN 1 0 7 and multi-display
@) CPU board defect
C N 1 0 7 disconnection check, wiring

NG
disconnection check and display side Display check after correction
connector check
OK
0 CPU board defect

0 Multi-display board defect
(Replace the CPU board first)
ERROR CODE EF: CPU PROCESSING TIME ABNORMALITY
Estimated causes
@ CPU board defect
Replace the CPU board when EF is displayed.

WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (DRIVE SYSTEM)
1. The vehicle does not move at all. (The multi-display is kept off even when the key
switch is turned ON.)
1CN102-1 DC/SD CN101-3, 4

A board .
P1 CN101-14
I-
CPU
board
CN104-11
CN1 04-6
@ The battery voltage is not applied.
@ The voltage after the key switch is not applied.
@ The DCISD 25 V power is not supplied.
lnspection 1 0 Battery connector defect

CN101-22 (41, B36V) 0 Blown fuse F5
3 voltage check 0 Internal open circuit in battery
CN101-20 ( N l , GND)
1 OK (Battery voltage)
lnspection 2
CN102-1 (43, K36V) 0 Key switch defect
3 voltage check 0 Wiring defect
CN102-9 ( N l , GND)
I I 0 DCISD
lnspection 5 defect
lnspection 3 lnspection 4 Disconnect CN1 0 4 0 Wiring
CN104-6
(15, + 3 0 V )
3 voltage check
Disconnect CN107
CN 104-6
(15, +30V)
from CPU
CN104-6
(15, +30V)
- v).
NG
(0
defect
(short
circuit)
CN104-11 3 voltage check 3 voltage check between
(N1, GND) CN104-11 CN104-1 1 CNlOl
(N1, GND) (N1, GND). and
CN104
CPU
25 V ) / (Approx. 25 V ) 25 V)
0
board
defect
CPU board defect 0 Display defect CPU board defect 0 Display
0 Defective wiring (short circuit) defect
between CN107 and display
0 CPU board defect
lnspection 1. Battery voltage measurement
Battery plug O N
Measurement terminals CNlOl(22) 41 @ - CN101(20)Nl@
Circuit tester range DC 5OV
OK (Battery voltage) + To inspection 2

NG (0 V ) -, Battery connector defect, blown F5 fuse, or bat-
tery internal wiring disconnection
Measuring the Battery Voltage
lnspection 2. Voltage measurement after SWky

Battery plug ON, SWky O N
Measurement terminals CNI 02(1)43@ - CN102(9)NI@

NG (0 V ) -t SWky defect, or wiring defect
Measuring the Voltage after SWky

lnspection 3. DCISD supply voltage measurement
Measurement terminals ~ ~ 1 0 4 ( 6 ) 1 5-@~ ~ 1 0 4 ( 1 1 ) ~ 1 @
Standard Approx. 2 5 V
OK (Approx. 25 V ) -+ CPU board defect

NG (0 V ) + To inspection 4
Measuring the DCISD Supply Voltage
lnspection 4. DCISD Supply voltage measurement

Battery plug ON, SWky ON, CN107 connector disconnection
Measurement terminals cN104(6)15@ - C N 1 0 4 ( 1 1 ) ~ 1 @
OK (Approx. 25 V ) Display defect, or CN107- display

wiring defect (short circuit)
NG (0 V ) -t To inspection 5
Measuring the DCISD Supply Voltage

Inspection 5. DCISD Supply voltage measurement
Battery plug ON, SWky ON, CN104 CPU board side connector disconnection
Measurement terminals CN104(6)15@ - C N I O ~ ( I 1 ) ~ 1 @
OK (Approx. 25 V ) + CPU board defect

NG (0 V )+ DCISD defect, or CN101 -CN104 wiring defect
(short circuit)
Measuring the DClSD Supply Voltage

2. The vehicle does not move at all. (The MF (MR)) Contactor is not closed when the
direction lever is set to forward (reverse).
Related portion
CN106-1 (45, DSF)
CN106-2 (45, DSR) Direction

switch
CN105-3 (51, GND)
CN9
CPU
CN103-9 (1, M + )
-
board CN103-7 (2, MF) -
Connector
MF
-
CN103-6 (3, MR)
-
T Connector
MR
w
@ Battery overdischarge
@ No input of direction switch signal
@ Open circuit in MF or MR contactor coil
@) CPU board defect
lnspection 1
P2
$ voltage check
1 0 Battery overdischarge
N1

Is the direction switch turned NO o Direction switch defect
ON and OFF by the direction *o Defective wiring between DSF-DSRand
lever? Not turned CN106.CN105
See page 3-28 ON and OFF.
YES
(Turned ON and OFF)
Is the MF-MR contactor closed? NG - Inspection 2

MF.MR contactor coil con-
tinuity check.
NG MR-MF
Qireplacement
(CO
OK OK (Approx. 2 0 Ql
CPU board defect 0 CPU board defect
0 Disconnection of wiring
between CPU board and
contactor
lnspection 1. Battery voltage measurement
Battery plug ON
Measurement terminals - NI@

~ 2 @
P2-N 1 Checking the Battery Voltage
OK (15 V Battery voltage or more)

+ ANL31: Switch input test
shown above, but the criterion in
NG (0 V ) + Battery overdischarge
lnspection 2. MF.MR contactor coil continuity check

Battery plug OFF, or MF.MR connector disconnection
Measurement terminals Both terminals of MF.MR connector
Standard Approx. 2 0 fl (at 20°C)
MR
MF connector MR connector
MF.MR Connector Checking the Continuity of MF.MR Coil
OK (Approx. 2 0 9 ) + CPU board defect, wiring disconnection (between CPU board and MF.MR
contactor)
NG (00 L?) + MF-MR contactor replacement
3. The vehicle does not move at all. (The MFIMR contactor is closed when the acceler-
ator pedal is depressed, but the M G contactor is not closed.)
Related portion
1
CN106-8 (53, POT') c
--
CN106-12 (52, POTA)
- Acceleration
CN105-8 (51, GND)
- potentio-
meter
CN106-3 (64, SWAC)
CN25
CN103-5 (4, MG)
Connector
Estimated causes
@ The accelerator switch signal is not input.
I @ CPU board defect
1 @ Acceleration potentiometer defect
1 @ MG contactor defect
I
I @ Wiring disconnection
Is the accelerator switch NO - 0 Acceleration potentiometer defect

0 Disconnection of wiring between
acceleration potentiometer and CN 106.
YES Light (Switch ON)
Is the MG contactor closed?

NG - Inspection 1
MG contactor coil conduction
measurement.
NG MG contactor
nrreplacement
OK OK (Approx. 2 0 Q)

o Disconnection of wiring between
CN 1 0 3 and MG contactor
Inspection 1. MG contactor coil continuity check
Battery plug OFF, MG connector disconnection
Measurement terminals Both terminals of MG connector
Standard Approx. 20 Q (at 20°C)
MG connector
M G Connector Checking the Continuity of MG Coil
OK (Approx. 20 Q) -, CPU board defect, or disconnection of wiring (between CPU board and con-
tactor)
NG (00 Q) -t MG contactor replacement
4. The vehicle does not move at all. (The M G - M F and MR contactors are closed.)
(For other than U.S.A.)
CN106-8 (53, POT+)

- 7
CN106-12 (52, POTA)

CPU Acceleration
board CN105-8 (51, GND) potentio-
meter
CN 106-3 (64, SWAC)
--- - -
CN25
Estimated causes
@ The acceleration potentiometer signal is not input.
@ CPU board defect
@ Motor circuit abnormality
ANL12: Test operation (No. 5) Acceleration potentiometer defect

Acceleration potentiometer (Approx. 1.0 V Disconnection of wiring between
voltage check acceleration potentiometer and CN
or-less at full
See page 3-24 acceleration)
Inspection 1
I
Disconnect wiring of
(Approx. 1.0 V or more
at
0K full acceleration)
P4, P5, P6 and P7. NG o Open circuit in armature coil

P4 P6 ,( 8) 0 Open circuit in field coil
$ I continuity check
P5 P7
Y
OK (Approx. 0 8 ) * Approx. 0 8 is the motor

t coil resistance very close to
CPU board defect 0 8.
Inspection 1. Drive motor continuity check
Battery plug OFF, cable disconnection from P 4 to P7
Armature coil: P 4 - P5
Field coil: P 6 - P7
Standard Approx. 0 fl
Cables of P4 t o P7 Checking Continuity of the Drive Motor
OK (Approx. 0 Q ) + CPU board defect

NG (aQ ) + Armature coil disconnection or field coil disconnection
4. The vehicle does not move at all. (The MG, MF and MR contactors are closed.) (For
U.S.A.)
ri Related portion
Acceleration
potentio-
CN105-8 (51, GND) meter
CN106-3 (64, SVVAC)
CPU
board
-
CN106-4 (65, LSB) - Brake
CN105-9 (51, GND)
-
- switch
CN6
Estimated causes
@ The acceleration potentiometer signal is not input.
ANL 1 2: Test operation (No.5) 0 Acceleration potentiometer defect

Acceleration potentiometer (Approx. 1.0 v 0 Disconnection of wiring between
voltage check or less at full acceleration potentiometer and CN 1 0 6
See page 3 -2 4 acceleration)
(Approx. 1 . 0 V or more
at full acceleration)
1
ANL31: Switch input test Inspection 1
Is the brake switch turned
ON when the pedal is not dis-
pressed.
Not lig%
(Switch
ON)
Disconnect wiring of
P4, P5, P6 and P7.
P4 P6
-
NG
0 Open circuit
in ..armature
coil
3 3 check continuity "0 open circuit
See page 3-28 in field coil
P5 P7
I
1
Light (Switch OFF)
OK (Approx. 0 Q)
*
To A on next page CPU board defect
* Approx. 0 Q is the motor

coil resistance very close to
0 Q.
Is the switch kept ON when Not light
the brake pedal is returned C Pedal return failure
manually? (Switch ON)
Light (Switch OFF)
Inspection 2.
Individual brake switch
inspection
NG - Switch replacement
OK
Brake switch installation adjustment defect

4
Readjustment
Is the brake switch turned Not light

OFF when the brake pedal is -- Normal
not depressed? (Switch ON)
1 Light (Switch OFF)
0 Connector CN6 defective contact

0 Wiring disconnection (between brake switch and CPU)
0 CPU board defect
Inspection 1. Drive motor continuity check
Battery plug OFF, cable disconnection from P 4 to P 7
Armature coil: P4 - P5
Field coil: P6 - P7
Standard Approx. 0 0
P4-P7 Cables Checking the Continuity of Drive Motor
OK (Approx. 0 Q ) CPU board defect

+
NG (00 Q ) Disconnection of armature coil or field coil

+
lnspection 2. Individual brake switch check

Battery plug OFF, SWky ON
Measurement terminals Connector CN6
Switch OFF: 00
Standard
Switch ON: co i
2
Brake Switch (LS,) Checking the Continuity of LS,
OK + Brake switch installation adjustment defect

NG + Switch replacement
ANL11: ESY21 0 MS contactor coil defect
MS contactor operation
0 -
Wiring defect (MS contactor CN 103)
(If NG even after checking and replacing
check the above, CPU board should be judged
See page 3-1 7 defective. )
0 CPU board defect
OK

Is the brake switch ON or
OFF when the brake pedal is
not depressed?
Isn't the switch kept ON
when the brake pedal is
Switch OFF
I-
Switch
ON Pedal return
defect
(Switch ON)
0 CPU board defect Inspection 2

0 Drive motor defect Individual brake switch
replacement
inspection
on
nent
0 Connector contact defect

0 Disconnection of wiring
lnspection 1. Drive circuit OCL value measurement
See the OCL value measurement (page 2-39) in the controller section.
lnspection 2. Individual brake switch check

Battery plug OFF
Measurement terminals Both terminals of brake s w i t c h connector

Standard Switch OFF: co fl
I I I
Brake Switch Connector Checking the Continuity of Brake Switch
OK (Switch OFF: co Q) -+ To inspection 3

NG (Switch OFF: 0 Q) -+ Brake switch replacement
lnspection 3. Brake switch installation adjustment check

See the brake switch adjustment (page 2-42) in the controller section
5. Normal speed control fails. (No acceleration) (For U.S.A.)
Related portion
CN106-12 (52, POTA)

- Acceleration
potentio-
CN105-8 (51, GND)
- meter
CPU CN106-3 (64, SWAC)

board
CN25
CN103-9 (1, Mi)
CN 103-4 (6, MS)
Connector MS
@ Insufficient acceleration potentiometer signal
@ Drive OCL value drop
II 0 Acceleration potentiometer defect

ANL12: Test operation (No.5) o Wiring defect (acceleration potentiom-
Acceleration potentiometer
voltage check 2.5 V at full
See page 3-24 acceleration)
OK
(Approx. 2.5 V or more
at full acceleration)
Inspection 1 0 Drive circuit current sensor (CSD) defect

Drive circuit OCL value
0 CPU board defect
measurement
OK (Within + 5%)
11 11
ANL11: ESY21
MS contactor defect
MS contactor operation check u side
(O t ' 5%) * Wiring
' 0
o defect (MS contactor -CN 103)
If NG even after checking and replacing the
(Within + 5%) above, the CPU board should be judged
defective.
0 CPU board defect 0 CPU board defect
0 Drive motor defect
Inspection 1. Drive circuit OCL value measurement
See the OCL value measurement (page 2-39) in the controller section.
6. The maximum speed is not attained. (For other than U.S.A.)
-- Related portion I
CN106-8 (53, POT+)
CN106-12 (52, POTA)

- Acceleration
CN105-8 (51, GND)
- potentio-
meter
CPU
CN106-17 (77, SWSC) -- Speed
control
--
board CN105-3 (51, GNDI
switch
CN103-9 (1. M + )
- 7
CN103-3 (7, M W )
- -
CN 1 1 0 Connector
MW
CN103-4 (6,MS)
Connector
MS
Estimated causes
@ No speed control switch signal input
@ Weakening field operation defect
@ MS contactor not closed
@ Wheel diameter setting error
* The maximum speed is not attained when the speed control switch is ON or when the maximum
speed limiter is set to valid (display mask function tuning mode C5).
(The tortoise mark is displayed in this state.)
ANL12: Test operation (No. 5) 0 Acceleration potentiometer
defect
0 Wiring defect (acceleration
See page 3-24
potentiometer -
CN 106)
OK 2.5 V or more at
full acceleration j
1I
ANL31: Switch input test 0 Speed control switch defect
Speed control switch ON-OFF check 0 Wiring defect (speed control
See page 3-28 switch - CN106.CN105)
I1
OK (Switch OFF)
t
lnspection 1 NG MW contactor
M W contactor operation NG
check
MW contactor coil continuity ,( Sl) replacement
measurement
See page 3-1 7
/ OK (Approx. 2 0 Q)
0 CPU board defect

0 Wiring defect (MW contactor - CN103)
I
r-
Inspection 2
Check loosening of weaken-
Traveling test after correction
ing field resistor installation
and wiring.
Weakening field resistor part NG Traveling test after replace-

No. check (See page 2-17) -merit with the correct part.
I
OK
MS contactor operation check

See page 3-1 7
NG
- lnspection 3
MS contactor coil continuity
measurement. (00
NGm
Q)
MS contactor
replacement
0
1 OK (Approx. 2 0 Q)
wiring defect (MS contactor - CN103)

0 CPU board defect
Tire wheel diameter check

(See the mask function P3-31.) 1 NG
___t
Traveling test after wheel
diameter setting.
(The maximum speed may
not be attained depending
CPU board defect, Drive on the tire material and run-
motor defect ning resistance)
lnspection 1. MW contactor coil continuity check
Battery plug OFF
Measurement terminals Both connectors of MW connector

Standard Approx. 2 0 (at 20°C)
MW connector MW
MW Connector Checking the Continuity of MW Coil
OK (Approx. 20 Q ) CPU board defect, or disconnection of wiring (between CPU board and
-+
contactor).
NG (co Q ) -+ MW contactor replacement
lnspection 2. Field weakening resistor (RFW) installation and wiring check

Battery plug OFF
RFW
I
\
Checking Field Weakening Resistor Installation and
Wiring
OK -+ Field weakening resistor part No. check (See page 2-1 7 )

NG -+ Traveling test after correcting installation and adjustment
Inspection 3. MS contactor coil continuity check
Battery plug OFF
Measurement terminals Both terminals of MS connector

Standard Approx. 20 D (at 20°C)
I I I
MS Connector Checking the Continuity of MS Coil
OK (Approx. 20 Q) + CPU board defect, or wiring disconnection (between CPU board and con-
tactor)
NG $2) + MS contactor replacement
6. The maximum speed is not attained. (For U.S.A.)
Estimated causes
@ Weakening field operation defect
@ MS contactor not closed
@) Wheel diameter setting error
* The maximum speed is not attained when the maximum speed limiter is set to valid (display mask
function tuning mode C5).
(The tortoise mark is displayed.)
ANL12: Test operation Acceleration potentiometer defect
(No. 5) Acceleration poten- 0 Wiring defect (acceleration poten-
tiometer voltage check 2.5 V at full tiometer -CN106)
See page 3-24 acceleration
I'
OK 2.5 V or
more at ful
acceleration
T
I
ANL11: ESY-22
M W contactor operation
check
NG - lnspection 1
MW contactor coil continuity
check
.
,(
NG,
Q)
MW contactor
replacement
See page 3-1 7
o Wiring defect (MW contactor - CN103)

0 CPU board defect
I
lnspection 2
Check the weakening field
resistor of installation and
wiring
NG
I
Traveling test after correction
Weakening field resistor part Traveling test after replace-

No. check (See page 2-1 7) ment with the correct part.
OK
See page 3-1 7
0 CPU board defect

0 Wiring defect (MS contactor - CN103)
Tire wheel diameter check NG Traveling test after wheel
(See the mask function P3-31) diameter setting
(The maximum speed may
not be attained depending
OK on the tire material and road
1 resistance.
0 CPU board defect
0 Drive motor defect
lnspection 1. M W contactor coil continuity check
Battery plug OFF
Measurement terminals Both terminals of M W connector
Standard Approx. 20 0 (at 20°C)
M W Connector Checking the Continuity of M W Coil
OK (Approx. 20 Q) CPU board defect, or wiring disconnection (between CPU board and contactor)
-+
NG (co Q) -+ M W contactor replacement
lnspection 2. Field weakening resistor (RFW) installation and wiring check

Battery plug OFF
RFW
Checking the Field Weakening Resistor Installation

and wiring
OK -t Field weakening resistor part No. check (See page 2-1 7 )

NG -+ Traveling test after correcting installation and wiring
inspection 3. MS contactor coil continuity check
Battery plug OFF
Measurement terminals Both terminals of MS connector

Standard Approx. 20 ( a t 20°C)
MS Connector Checking the Continuity of MS Coil
OK (Approx. 20 Q ) CPU board defect, or wiring disconnection (between CPU board and
contactor)
NG (oo fl) -+ MS contactor replacement
7 . Regenerative braking is ineffective in switchback operation.
(1) Regenerative contactor (MG) is not opened just after switch back.
Related portion
CN105-4 (81, S S c )
Speed sensor
CN105-5 (82, SSP)
CN21
CPU
board
CN103-9 (1. M + )
CN103-5 (4, MG)
Connector
MG
Estimated causes
@ Insufficient vehicle speed
I @ No speed sensor signal input

I
NG ,Check according to "6. The maxi-
Traveling speed check
I Maximum mum speed is not attained."
speed is
less than 5
ANL13: Test operation (No. 1 ) 0 Speed sensor defect

Speed indication check 0 Wiring defect (speed sensor -
See page 3-1 7 CN106.CN105)
(If NG still after checking and replacing
the above, the CPU board should be
judged defective.)
ANL11: ESY-19
NG 0 MG contactor defect
MG contactor operation check
-0 CPU board defect
See page 3-1 7
0 CPU
t
board defect
(2) Transition t o plugging occurs soon. (The MG contactor is closed just after switch back.)
Related portion
CN105-4 (81, S S + )
CN105-5 (82, SS-)
CPU CN103-15 (P2, VBP2)

board P2 Collector
CN103-13 (91, TGB)
CN103-14 (P10, TGE)
P5
(1 Emitter
I
CN109
I
RG
@ Pre-excitation circuit defect
@ Regeneration diode (DG) open
@) Speed sensor signal defect
Check wirings of the generation transis-

tor (TG) and regeneration resistor (RG). P- Traveling test after correction
Inspection 1
TG (emitter) NG
$ continuity check -To A on next page
(Other than
P5 Approx. 0.6 Q )
OK (Approx. 0.6 Q)
TO B on nextipage
lnspection 2
Disconnect CN 1 17 and measure the Regeneration resistor (RG) defect
(Other than
OK (Approx. 0.6 Q)
Wiring disconnection (CN107 -CN 109)
I Inspection 3 I
c h i c k the regeneration transistor (TG)
Regeneration transistor (TG) defect
after disconnecting wirings from its base
I and emitter. I
Inspection 4 NG 0 Regeneration diode (DG) open

Check continuity from N1 t o P3. 0 Loosened wiring or copper bar of
(* Q, regeneration diode (DG)
OK ( 3 kQ)
ANL13: Test operation (No. 1 ) 0 Speed sensor defect

NG 0 Wiring defect (speed
Speed indication check
* sensor-CN 106-CN 105)
See page 3-24
* If NG still after checking and replacing
the above, the CPU board should be
OK
judged defective.
CPU boa'rd defect
lnspection 1. TG emitter - P5 continuity check

Battery plug OFF, RG connector CN117 disconnection
Measurement terminals TG (El - P5

Standard Approx. 0.6 n
Checking Continuity between TG and P5
OK (Approx. 0.6 Q) To inspection 3

+
NG (Other than Approx. 0.6 Q To inspection 2

+
lnspection 2. lndividual RG measurement
Battery plug OFF, CN1 1 7 connector disconnection
Measurement terminals Both terminals of CN 1 17 connector (RG side)
Measuring the Continuity of RG
OK (Approx. 0.6 8 ) -, Wiring disconnection (CN107 - CN109)

NG (Other than approx. 0.6 8 ) + RG defect
lnspection 3. lndividual TG check

Battery plug OFF, TG wiring disconnection
Between B and C
'8'8
B + - C -

Between C and E
"8-'8
C + -
Q x l K
E -
Standard
Between B and C
8 8
B - - C + : Continuity shall exist
B + -C-:mQ
Between C and E
8 8
C - - E + : m Q
C + - E - : Continuity shall exist
I
Checking the Continuity of TG
NG + TG defect
Inspection 4. DG circuit continuity check (P3-N1

Battery plug OFF
Measurement terminals - NI@

~ 3 @
Circuit tester range O x lK
Standard 3 kO
P3.Nl Checking the Continuity between P 3 and N1
OK + To ANL13: Test operation

NG + Open circuit in DG or loosening of copper bar
8 . The vehicle travels only in the forward or reverse direction.
- CN106-1 (45, DSF)

-
CPU
board
CN106-2 (46, DSR)
- Direction
switch
CN105-3 (51, GND)
-
CN9
@ No direction switch signal input
@ Open circuit in MF or MR contactor coil
I ANL31: Switch input test

Is DSFIDSRturned ON and
OFF when the direction lever 0 Direction switch defect
NG
is operated t o the forward -0 Wiring defect (DSFIDSR -
and reverse positions CN106lCN105)
See page 3-28
OK
ANL11: ESY-17-18
MF or MR contactor NG MF or MR con-
operation check MF or MR contactor coil con- ,( Q) tactor
See page 3-1 7 tinuity measurement replacement
I
0
l°K
CPU board defect 0
JOK (Approx. 2 0 Q l
CPU board defect

0 Wiring defect (MFIMR - CN103)
Inspection 1. MF or MR contactor coil continuity check
Battery plug OFF
Measurement terminals Both terminals of MF or MR connector

Standard Approx. 20 Q (at 20°C)
MR
MF connector MR connector
MF.MR Connector Checking the Continuity of MF.MR Connector
OK (Approx. 20 Q) + CPU board defect, or wiring disconnection (between CPU board and
contactor)
NG (00 Q) + MF or MR contactor replacement
9 . The speed limiter is ineffective.
(1 The vehicle speed rises to the maximum speed.
Related portion
CN106-17 (77, SWSC) -

Speed
CN105-3 (51, GND) control
- switch
CN2
CPU
board
CN105-4 (81, SS+)
Speed
CN105-5 (82, SS-) sensor
CN21
Estimated causes
@ No speed control switch signal input
@ Wheel diameter setting error
@) Speed sensor signal defect

NG 0 Speed control switch defect
Check ONIOFF of speed control switch.
See page 3-28
0 Wiring defect (speed control switch -
CN10611 05)
OK (ON)
, l Tire wheel diameter check a
-;venilg test after wheel diameter
~ o regular
t Setting
ANL13: Test operation (No. 1 )

NG 0 Speed sensor defect
Speed indication check
See page 3- 1 7
( G flucr~
~ Wiring
~ ~ (speed sensor -
~defect
I tuation of CN 105)
0
l°K
CPU board defect
speed indi-
cation whi-
le at a
constant
speed.)
(2) The limited speed is abnormal.
Related portion
CN105-4 (81, S S t )
CPU CN105-5 (82, SS-)
board
7 CN21
Estimated causes
I @ Speed sensor signal defect
Tire wheel diameter check NG Traveling test after wheel diameter
OK (tire size
ANL13: Test operation (No. 1) 0 Speed sensor defect

Speed indication check (Great flue- 0 Wiring defect (speed sensor -
See page 3-24 tuation of CN105)
speed indi- 0 CPU board defect
cation whi-
t
CPU board defect
le at a
constant
speed.)
4-106
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED

(MATERIAL HANDLING SYSTEM)
1 . The material handling motor does not run.
(1) When material handling chopper is provided. (Option)
CN105-2 (69, LSATZ)

CN105-12 (63, LSATI)
-
CN106-15 (60, LSLI)
-
CN106-16 (61, LST)
- L~ft.tilt
CN105-3 (51, GND)
- - attachment
switch
CPU CNll
board --
CN106-18 (68, LSLZ)
L
-
CN39
CN103-9 (1, M + )
CN103-2 (5, MP)
CN110 Connector
MP
Estimated causes
@ F 2 fuse open
@ Display mask function setting error
@ Material handling switch defect
@ MP contactor coil defect
@ Pump drive motor abnormality
F 2 fuse replacement
To A on next page
Is the MP contactor closed Is MP closed on when the
when the key switch is NG material handling lever is NO
turned to the ON position OFF^ pulled, and open when the
material handling lever is
returned
OK (ON) YES
i
Display mask function is not
set to "Material handling
chopper" by option input
setting.
7
NG 0 Material handling switch
Check ON/OFF of each defect
material handling system 0 Wiring defect (each material
switch. handling switch -
CN 105lCN 106)
OK
0 CPU board defect

0 Material handling
motor defect
B
MP contactor operation check

NG - Inspection 2
MP contactor coil continuity
NG- MP contactor
M, replacement
See page 3-1 7 check
I' I I
OK OK (Approx. 20 M)

o Wiring defect (MP contactor coil - CN1 10)
lnspection 1. F2 fuse continuity check
Battery plug OFF
Measurement terminals Both terminals of F 2 fuse

Standard 0Q
F 2 Fuse Checking the Continuity of F 2 Fuse
OK ( 0 O) + MP closing check at SWky ON

NG (oo O) + F2 fuse replacement
Inspection 2. MP contactor coil continuity check

Battery plug OFF
Measurement terminals Both terminals of MP connector
Standard Approx. 2 0 0 (at 20°C)
MP connector MP
MP Connector Checking the Continuity of MP Coil
OK (Approx. 2 0 Q) -+ CPU board defect, or wiring disconnection (between CPU board and contactor)
NG (a O) -+ MP contactor replacement
( 2 ) When the material handling chopper is not provided. (Standard)
Related portion
Estimated causes
@ F2 fuse open
@ Material handling motor defect
@) Material handling switch defect
@ MP contactor coil defect
Inspection 1 NG
F2 Fuse continuity check *F2 fuse replacement
(00 Q)
OK (0 Q)
Is MP contactor closed when the 0 Pump motor defect

material handling lever is pulled? 0 Pump motor cable disconnection
t
To A on next page
ANL3 1: Switch input test
Check ONIOFF of each
material handling switch
NG
- 0 Material handling switch
defect
0 Wiring defect (each material
handling switch -
CN 1051CN106)
OK
MP contactor operation check

NG
- Inspection 2
MP contactor coil continuity
check
,(
NG MP contactor
drreplacement
1 OK (Approx. 2 0 Q )

0 Wiring defect (MP contactor coil - CN1 10)
Caution:
Never touch the material han-
dling lever during MP contac-
tor operation check.
Otherwise, the mast and fork
begin t o move when MP con-
tactor is closed.
lnspection 1. F 2 fuse continuity check
Battery plug OFF
Measurement terminals Both terminals of F 2
Standard on
F2 Fuse Checking the Continuity of F2 Fuse
OK (0Q ) -, Check MP closing at SWky ON

NG (co Q ) -, F 2 fuse replacement
Inspection 2. MP contactor coil continuity check

Battery plug OFF
Measurement terminals Both terminals of MP connector

Standard Approx. 20 Q (at 2 0 ° C )
MP connector MP
MP Connector Checking the Continuity of MP Coil
OK (Approx. 2 0 $2) -+ CPU board defect, or wiring disconnection between CPU board and contactor
NG (co Q ) -, MP contactor replacement
TROUBLESHOOTING - OTHERS
Battery capacity is not indicated correctly.
mask function check

Is the 36 V/48 V selection set t o the cor-
rect battery voltage?
1YES
P- Set it correctly.
Display mask function check

H
Is "the standard battery -"battery-less"
selection set t o "battery-less"?
NO
- Set t o battery-less.
I YES
I
P-
Is the speed control switch setting
correct? Set it correctly.
USA: Invalid
Others: Valid
I YES
A
The indication is lit The indicator is off
although the battery although the battery
has been discharged. charge still remains.
0 0
Adjustment of turning Adjustment of tuning
mode C 4 mode C 4
0 Adjust toward high- 0 Adjust toward low-
er figure than pre- er figure than pre-
sent set valve. sent set valve.
TROUBLESHOOTING RELATED TO MULTI-DISPLAY AND MCS
COMMUNICATION SYSTEM
ERROR CODE F1: FAILURE IN COMMUNICATION BETWEEN MULTIDISPLAY AND MCS
Check CN 107 and harness.
Check the multidisplay connector and
harness.
NG - Retest after repair
Page 2-27
OK
V
0 CPU board defect
0 Multidisplay or controller defect
ERROR CODE F2: FAILURE IN COMMUNICATION BETWEEN MULTIDISPLAY AND MCS

Check the rnultidisplay connector and
harness.
Page 2-27
OK
v
0 CPU board defect
ERROR CODE F3: POWER CONTROLLER MEMORY VALUE IN CONSISTENCY

Check the multidisplay connector and
harness.
Page 2-27
OK
0 CPU board defect
ERROR CODE F4: POWER CONTROLLER MEMORY VALUE ABNORMALITY

0 Multidisplay controller defect
STEERING SYSTEM TROUBLES
DIAGNOSIS ERRORS
ERROR CODE: FO (WITH CONTACTOR)
FO is not displayed for a trouble on the PS side.
Estimated causes
I @ Display subharness defect
@ Display defect I
ERROR CODE: FO (WITH EHPS)
--
-
%
4x
e
P22
I
b g-
(U
5;
TMps
-
-
- BATT 4I CN27-4 (151.L I 3 F '
-
- 3ISP
CSm
(b
PBEHPS
I
-
I
Estimated causes
@ PS board defect
@ Display defect
@ Connector and wiring defect
1 @ TMps defect
I Check connector and

1 -w Recheck by operation after correction.
Does the PS motor keep running when

TMps defect (short circuit)
the SWky is turned t o OFF?
No I
To A on next page
Does the PS motor run when the steering
PS board defect
wheel is not operated after SWky ON?
( ~ ~ ON)k y
Does the PS motor run when the steering
CN27(4)151 (harness side-board side)
wheel is operated after SWky ON?
vv
$ Voltage measurement
0 V on both harness
side and board side 5 V on harness side t
1 and 0 V on board 5 V on both harness
0
0
Display defect
Wiring
disconnection
side
I
CN27 defect
+
side and board side
PS board defect
Inspection 2.
SWky ON
CN27(1)43 (harness side.board side)
$ Voltage measurement
CN38(4)N1
/
NG NG
O/ t
Battery voltage on both Battery voltage on harness 0 V on both harness side
harness side and board side side and 0 V on board side and board side
0
t
CN38 defect
1
CN27 defect
1
Wiring disconnection
0 PS controller internal
wiring defect
0 PS board defect
lnspection 1. Display signal voltage check
Battery plug ON, SWky ON, CN27 connection
Measurement terminals CN27(4)151 - CN27(5)163

Standard 0 V on both harness side and board side
CN27 Connector Measuring the Display Signal Voltage
OK (0 V on both harness side and board side) + Display defect

NG ( 5 V on harness side and 0 V on board side) + CN27 defect
NG ( 5 V on both harness side and board side) + PS board defect
lnspection 2. PB board signal voltage check

Battery plug ON, SWky ON, CN27 connection, C N 3 8 connection
Measurement terminals CN27(1)43 - CN38(4)N1

Standard Battery voltage on both harness side and board side
CN27.C~38Connectors Measuring the PS Board Signal Voltage
OK (battery voltage on both harness side and board side) +CN38 defect, PS controller internal
wiring defect, or PS board defect
NG (battery voltage on harness side and 0 V on board side) -+ CN27 defect
NG (0 V on both harness side and board side) + wiring disconnection
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (STD)
1. The steering wheel is heavy. (The PS motor does not run when the direction switch
is closed after SWky is turned to ON.)
-
-
P22
"4s
Estimated causes
@ CPU board defect
@ Direction switch defect
@) Mps contactor defect
@ Connector and Wiring defect
Check connector and wiring NG )

Recheck operation after
connections. correction.
I I
Is the PS contactor closed Inspection 1. 0 Blown F 3

when the direction switch is YES P22 NG 0 Cable defect
closed after the SWky is f Voltage measurement -0 Contactor
turned t o ON? N1 contact
I I defect
1 OK (battery voltage)
t
0 Motor cable or connector defect
k-
0 Motor defect
lnspection 2
M, contactor coil continuity Mps contactor defect
check
OK 120 011
0 CN53 defect
0 Wiring disconnection
0 Direction switch defect
0 CPU board defect
lnspection 1. Main PS circuit voltage measurement
Measurement terminals ~ 2 2 -0 NI@
P22.Nl Measuring the Main PS Circuit voltage
OK (Battery voltage) + Motor cable or connector defect, or motor defect

NG (0V ) + F3 fuse defect, wiring disconnection, or contactor contact defect
lnspection 2. Mps contactor coil continuity check

Battery plug OFF
Measurement terminals Both terminals of Mps connector C 5 3
Circuit tester range Ox I

Standard Approx. 2 0 Q (at 20°C)
53 connector
CN53 Connector Mps Coil Continuity Check
OK (Approx. 20 Q ) + CN53 defect, wiring disconnection, direction switch defect, or CPU board
defect
NG (00 Q) Mps contactor defect
+
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (WIEHPS)
1. The steering wheel is heavy. (The PS motor does not run when the steering wheel
is operated after the SWky is turned to ON.)
Estimated causes
@ F 3 open
@ PS controller internal wiring defect
1 @ PS motor defect
1 @ PS pump defect
1 @ PS board defect
I@ Steering Pressure sensor (SP) defect
1a TMps defect
[ /
Check connector and wiring connections.
NG-I Recheck by operation after correction.
NG
I I
P-
Inspection 1.
o Blown F 3
CN38(1)P21
0 CN38 defect
5 Voltage measurement
0 PS controller internal wiring defect
CN38(4)N1
1 I
OK (battery voltage)
t
To A on next page
lnspection 2.
0 CN38 defect
Release the steering wheel.
0 PS controller internal wiring defect
CN38(2)P22
0 Motor cable connector defect
Voltage measurement
0 Motor defect (The motor circuit is
CN38(4)N1
open if the measured voltage is 0 V.)
I OK (Battery voltage)
lnspection 3.
Operate the steering wheel t o the stroke 0 Motor defect
end. 0 PS pump defect (The pump or motor
CN38(2)P22 may be seized if the measured voltage
5 Voltage measurement is about half of the battery voltage.)
CN38(4)N1
I OK (battery voltage)
lnspection 4.
CN27(3)161 NG 0 CN27 defect
5 Voltage measurement 0 PS board defect
CN27(5)1 6 3
OK ( 1 2 V )
lnspection 5.
CN27(2)1 6 2
Voltage measurement
CN27(5)163
OK (Shall vary from 2.5 V or less t o 9.8 V or more.)
is released
9.8 V: Voltage when the steering wheel
0 PS circuit TMps defect is operated t o the stroke end.
0 PS circuit current sensor defect
0 PS board defect
lnspection 1. Main PS circuit voltage measurement (11
Measurement terminals CN38(1 )P21 - CN38(4)N1
CN38 Connector Measuring the Main PS Circuit Voltage ( 1 )
OK (Battery voltage) To inspection 2

-+
NG (0 V ) F 3 fuse defect, CN38 defect, PS controller internal wiring defect

--+
lnspection 2. Main PS circuit voltage measurement (2)

Battery plug ON, SWky ON, C N 3 8 connection, steering wheel in neutral position
Measurement terminals CN38(2)P22 - CN38(4)N1
CN38 Connector Measuring the Main PS Circuit Voltage (2)
OK (Battery voltage) To inspection 3

-+
NG (0 V ) CN38 defect, CPU board defect, motor or cable connector defect

-+
lnspection 3: Main PS circuit voltage measurement (3)
Battery plug ON, SWky ON, C N 3 8 connection, steering wheel at stroke end
Measurement terminals CN38(2)P22 - CN38(4)N1

C N 3 8 Connector Measuring the Main PS Circuit Voltage (3)

NG (About half of battery voltage) -+ Motor defect or PS pump defect
lnspection 4. Steering Pressure sensor operating voltage measurement (1)


Standard Approx. 12 V
CN27 Connector Measuring the Pressure Sensor Operating Voltage
OK (Approx. 12 V ) -r To inspection 5
NG (0 V ) -r C N 2 7 defect or PS board defect
Inspection 5 . Steering Pressure sensor operating voltage measurement (2)
Circuit tester range DCIO V

Standard Variation from Approx. 2.5 V to 9.8 V or more
I
CN27 Connector Measuring the steering Pressure Sensor Operating
Voltage
OK (Variation from approx. 2.5 V t o 9.8 V or more) -t PS circuit TMps defect, PS circuit current
sensor defect, or PS board defect
NG -t Steering Pressure sensor defect
2. The PS motor keeps running after SWky ON. (STD with contactor)
Estimated causes
I @ PS contact welding
1 @ CPU board defect
Does the motor stop upon SWky OFF? - 1 Welding of contactor contact.
I
YES
\
CPU board defect
2. The PS motor keeps running after SWky ON. (with EHPS)
CN27-3 (161. SST)

CN27-2 (162. SST)
P B ' ~ (163.~ SST)
CN27-5 ~ SP
~
Estimated causes
@ PS board defect
@ Steering Pressure sensor defect
Check steering Pressure sensor connector

connection.
- 1 Recheck operation after recheck.
Inspection 1.
CN27(2)1 6 2 o Steering Pressure sensor defect
$ Voltage measurement 0 Wiring defect
CN27(5)163
1 OK (from 2.5 V or less t o 9.8 V or more)
PS board defect
Inspection 5. Torque sensor operating voltage measurement (2)
Measurement terminals CN27(2)1 6 2 - CN27(5)1 6 3
Standard From 2.5 V or less t o 9.8 V or more
I I
CN27 Connector Measuring the Torque Sensor Operating Voltage
OK (Approx. 2.5 V or less t o 9.8 V or more) -, PS board defect

NG -t Torque sensor defect, or wiring defect
MOTOR
Page
DRIVE MOTOR ................................................... 5-2
GENERAL ........................................................... 5-2
SPECIFICATIONS ................................................ 5-3
COMPONENTS ................................................... 5-4
DISASSEMBLY .INSPECT10NmREASSEMBLY ............ 5-8
PUMP MOTOR ................................................... 5-11
GENERAL .......................................................... 5-11
SPECIFICATIONS ................................................ 5-12
COMPONENTS ................................................... 5-13
REMOVAL.INSTALLATI0N ................................... 5-15
DISASSEMBLY.INSPECTI0N.REASSEMBLY ............ 5-16
POWER STEERING MOTOR ............................... 5-19
GENERAL .......................................................... 5-19
SPECIFICATIONS ................................................ 5-19
COMPONENTS ................................................... 5-20
DISASSEMBLY.INSPECTI0N.REASSEMBLY ............ 5-22
MOTOR BRUSH WEAR AND OVERHEAT
WARNING (OPTION) ......................................... 5-25
GENERAL ........................................................... 5-25
DISPLAY ERROR CODES AND ACTIONS ................ 5-27
INSPECTION ...................................................... 5-28
DRIVE MOTOR
GENERAL
Drive Motor Sectional View ( 1 ton series, STD)
Drive Motor Sectional View (2.3ton series, STD)

SPECIFICATIONS
5FBCU1 8-20-25.30
5FBCU1 5
5FBCHU20.25
TYpe DC series-wound 4-
Nominal voltage V 36/48 c
Rated output kW 5.517.0 7.019.0

Insulation class H +
Brush size mm 28.6 x 38.1 x 12.7 28.6 x 44.5 x 15.9

(width x length x thickness) (in) (1.126 x 1.50 x 0.50) (1.126 x 1.752 x 0.626)
Number of brushes 8 c
30-5FBCU 18.20.25.30
30-5FBCU1 5
30-5FBCHU20.25
DC series-wound 4-
I Nominal voltage v I 36/48 1 4- I

I Rated output kW I 4.516.0 I 6.018.0 I
Insulation class H 4-
Brush size mm 28.6 x 38.1 x 12.7 28.6 x 44.5 x 15.9

(width x thickness x length) (in) (1.126 x 1.50 x 0.50) (1.126 x 1.752 x 0.626)
COMPONENTS
1401
Drive Motor Components (STD)

Drive Motor Components (Dustproof)
Drive Motor ASSY Removal Procedure
Removal Procedure
1 Remove the mast ASSY.
(See page 13-5 "V MAST ASSY Removal & Installation".)
2 Remove the battery hood W/ driver seat.
3 Remove the battery ASSY.

(See page 1-5 "BATTERY ASSY Removal & Installation" .)
4 Jack up the vehicle.
5 Drain differential oil.
6 Disconnect the drive motor wiring.
7 Disconnect the brake pipe.
8 Remove the front toe-board.
9 Disconnect the parking brake wires.
10 Remove the drive motor set bolts
11 Remove the front axle bracket set bolts. [Point 11
12 Remove the drive unit & drive motor.
1 3 Disconnect the drive unit and drive motor. [Point 21

Point Operation
[Point 1 I
Removal:
Remove the reamer bolts (2 pcs. each at top and bottom on
one side)
SST 0 9 3 1 0-22000-7 1
[Point 21
Removal.lnstallation:
Slightly suspend the drive motor with a hoist.
DISASSEMBLY-INSPECTION-REASSEMBLY
Note:
Measure the insulation resistance of each motor cable and motor unit before starting disassembly.
Standard: 1 MQ or more
4 Raise the brush
1 Remove the brush cover and motor cover.
2 Remove the bracket No. 1. [Point 1I
3 Raise the brush.
4 Remove the drive armature ASSY. [Point 21
5 Remove the brush and bracket No. 2. [Point 31
6 Remove the brush holders ASSY. [Point 41
7 Remove the yoke ASSY. [Point 51
Assembly Procedure
The assembly procedure is the reverse of the disassembly procedure.
Note:
Measure the insulation resistance between each motor cable and motor case.
Field coil continuity inspection. Terminals t o be measured: E and IF
Standard: 0 Q (multimeter range: Q)
Point Operations
[Point 1 I
Disassembly: Punch a match mark.

Reassembly: Align the match marks.
[Point 21
Disassembly:
1. Extract the armature straight without damaging the ar-
mature coil and field coil.
2. Remove the armature bearings.
SST 09950-20017
(or SST 09950-4001 0)
Inspection:
1. If the commutator surface is roughened, correct it with
sandpaper (around # 600)and clean it carefully. If heavi-
ly roughened, correct it w i t h a lathe.
Commutator outside diameter
I
1 ton series 2-3 ton series
mm (in) mm (in)
Standard 106 (4.1 7) 130 (5.12)
Limit 97 (3.82) 121 (4.76)
2. Carry out undercutting of mica when the commutator

is corrrected.
Undercut depth
Standard: 1.2 mm (0.047 in)

Limit: 0 . 8 mm (0.031 in)
3. Measure the insulation resistance of the armature coil.
Standard: 1 MQor more

[Point 31
Disassembly:
Arrange the removed brushes for easy discrimination of the
mounting positions.
Inspection:
Brush wear and contact state.
Vehicle
mm (in) mm (in)
[Point 41
Disassembly:
Arrange the removed brushe holder for easy discrimination
of the mounting positions.
Inspection:
1. Install the armature and brushes. Attach a spring scale
to the brush spring and measure the force on the ins-
tant when the spring departs from the brush.
Vehicle Standard (max.) N (kgf) [Ibfl

1 ton series 12.7 (1.3) 12.91
2.3 ton series 15.7 (1.6) 13.51
2. Measure the insulation resistance between the brush

holder and bracket.
[Point 51
Inspection:
1. Use compressed air for cleaning.
If the dirt is difficult to be removed, wipe the field coil
with soft cloth wetted with gasoline so as not to damage
it.
2. Field coil continuity inspection.
Terminal to be measured: E and F
Standard: 0Q
3. Inspect the field coil insulation.

Between E/F terminal and yoke

PUMP MOTOR
GENERAL
I I
Pump Motor Sectional View (STD)

5-1 2
SPECIFICATIONS
5FBCU 18.2025.30
5FBCU1 5
5FBCHU20.25
TYpe DC series-wound C
Nominal voltage V 36148 c
Rated output kW 6.218.3 10.0113.0

Insulation class H c
Brush size mm 28.6 x 38.1 x 12.7 4-

(width x length x thickness) (in) (1.126 x 1.50 x 0.50)
30-5FBCU1 8.20.25.30
30-5FBCU1 5
30-5FBCHU20.25
Type DC series-wound c
Nominal voltage V 36/48 +
Rated output kW 5.017.0 9.211 2.3

Brush size mm 28.6 x 38.1 x 12.7 4-

(width x thickness x length) (in) (1.126 x 1.50 x 0.50)
COMPONENTS
1 1 1402
Pump Motor Components (STD)

Pump Motor Components (Dustproof)
O 0 l
1 Battery plug
2 Side cover (LH)
Removal Procedure
2 Remove the side cover (LH).
3 Disconnect the oil pump ASSY.
4 Disconnect the pump motor ASSY wiring.
5 Remove the pump motor ASSY W/ bracket.
6 Remove the pump motor.
Note:
2
3 Raise the brush
1 Remove the brush cover and motor cover
2 Remove the bracket No. 1. [Point 11
3 Raise the brush.
4 Remove the drive armature ASSY. [Point 21
5 Remove the brush and bracket No. 2. [Point 31
7 Remove the yoke ASSY. [Point 51
Assembly Procedure
Note:
Standard: 1 M52 or more
Field coil continuity inspection. Terminals to be measured: A and F
Standard: 0 52
Point Operations
[Point 1 I

[Point 21
Disassembly:
1. Extract the armature straight without.
Damaging the armature coil and field coil.
2. Remove the armature bearings
SST 09950-2001 7
(or SST 09950-4001 0)
Inspection:
1. If the commutator surface is roughened, correct it with
sandpaper (around # 600) and clean it carefully. If
heavily roughened, correct it with a lathe.
Standard 106 (4.17)
2. Carry out undercutting of mica when the commutator

is corrected.
Undercut depth
Standard: 1.2 m m (0.047 in)

Limit: 0.8 m m (0.031 in)
3. Measure the insulation resistance of the armature coil.
Standard: 1 MR or more
[Point 31
Disassembly:
Arrange the removed brushes for easy discrimination of the
mounting positions.
Inspection:
Brush wear and contact state
1 ton series 2.3 ton series

mm (in) mrn (in)
New brush length 38.1 (1.500)
Wear limit 21.1 (0.831)
[Point 41
Disassembly:
Arrange the removed brushe holder for easy discrimination
of the mounting positions.
Inspection:
t o the brush spring and measure the force on the in-
stant when the spring departs from the brush.
Vehicle Standard (max.) N (kgf) [Ibfl
1 ton series 12.7 (1.3) [2.91
2.3 ton series t
2. Measure the insulation resistance between the brush

holder and bracket.
[Point 51
Inspection:
1. Use compressed air for cleaning.
If the dirt is difficult t o be removed, wipe the field coil
with soft cloth wetted with gasoline so as not t o dam-
age it.
2. Field coil continuity inspection.
Terminal t o be measured: A and F
Standard: 0 Q (multimeter range: Ql

3. Inspect the field coil insulation.
Between AIF terminal and yoke

POWER STEERING MOTOR
GENERAL
Power Steering Motor Sectional View
SPECIFICATIONS
Vehicle type 5FBCU1 30-5FBCU1 5

5FBCU1 8.20.25.30 30-5FBCU 18.20.25.30
Item 5FBCHU20-25 30-5FBCHU20.25
TYpe Permanent magnet type enclosed motor
Nominal voltage V 36/48 +
Rated output kW 0.710.9 +
Brush size mm 15.8 x 28.4 x 9.5 C
(width x length x thickness) (in) (0.622 x 1 .I

18 x 0.374)
Number of brushes 4 +
COMPONENTS
I 1
Power Steering Components
REMOVAL INSTALLATION
1 Hydraulic oil
2 Side cover RH
3 Toe board
Removal Procedure
1 Drain hydraulic oil from the oil tank.
3 Remove the toe board.
4 Remove the battery, and remove the step. (Only in 2 and 3 ton series)
5 Disconnect the power steering motor wiring.
6 Disconnect the suction hose.
7 Disconnect the high pressure hose.
8 Remove the power steering motor Wlpower steering pump.
9 Disconnect the power steering motor and power steering pump.
Note:
2 Raise the brush
1 Remove the brush cover.
2 Raise the brush
3 Remove the brush and bracket No.1. [Point 11
4 Remove the bracket No.2. [Point 21
5 Remove the power steering armature ASSY. [Point 31
Assembly Procedure
Note:
Standard: 1 M Q or more
Point Operations
[Point 1I

Reassembly: . Align the match marks.
[Point 21

Reassembly: Aligh the match marks.
Inspection:
Brush wear and contact state.
New brush length: 2 8 . 4 mm (1.1 1 8 in)

Wear limit: 20.4 mm (0.803 in)
[Point 31
Disassembly:
1. Extract the armature straight without damaging the
armature coil or commutator.
Permanent magnets in stator will have tendency to resist
armature removal.
2. Armature bearing removal.
SST 09950-2001 7
(or SST 09950-4001 0)
Inspection:
1. If the commutator surface is roughened,, correct with
sandpaper (around # 600) and clean it carefully.
If heavily roughened, correct it with a lathe.
Standard: 57.2 mm (2.252 in)

Limit: 54.6 mm (2.150 in)
2. When the commutator is corrected, undercut the mica.
Under cut
Standard: 0.8 mm (0.031in)

Limit: 0.3 mm (0.012in)
/
\
Mica
[Point 41
Inspection:
t o the brush holder, and measure the force when the
spring departs from the brush.
Standard: -
4.9 - 8.8 N (0.5 0.9 kgf) [1 .I - 2.0lbfl
2. Insulation resistance between the brush holder and

bracket.
Standard: 1 M!2 or more

MOTOR BRUSH WEAR AND OVERHEAT WARNING (OPTION)
GENERAL
1. Brush wear warning
(1) Drive, pump and PS motors
When the brush is worn to the limit level, conductors embedded in brush will contact commuta-
tor surface and result in voltage signal.
This signal is sent to the CPU board for warning by displaying the corresponding error code. A t
the same time, the motor is protected by limiting the traveling speed.
2. Overheat warning
(1) Drive and pump motors
The thermistor installed on the brush holder detects the brush temperature. When the motor tem-
perature rises to the limit level, warning is made by displaying the corresponding error code.
If used further the motor is protected by restricting the traveling speed (for drive motor over-
heat) or the material handling speed (for pump motor overheat).
(2) PS motor
The overheat warning function is not provided for the PS motor.
1 Drive motor
Location of BWI brushes
(+I
0
1 ton series
Brush
Commutator
Field coil
(->
BWI detection circuit
2.3 ton series
BWI : Brush-Wear Indicator
BWI brush
Pump motor
t
- - BWI detection circuit
BWI brush
PS motor
(-1 0
BWI detection circu~t
BWI brush
Warning function Motor Error code Vehicle operation
Traveling speed restriction and
Drive motor E7 prohibition of simultaneous traveling
and material handling
Brush wear warning
Pump motor E8 t
PS motor E9 t
Drive motor C2 Traveling speed restriction
Overheat warning
Pump motor E2 Material handling contactor opening
1. Actions t o be taken when brush wear warning occurs

(1) Replace the brushes as soon as possible.
(2) The warning may be reset as a temporary action before brush replacement. (See page 3-40 for
the resetting method.)
(3) Temporary resetting of warning
The restriction of vehicle operation such as traveling speed restriction caused by an error is lifted.
Error code display and buzzer sounding occur, however, for 3 seconds each time the key switch
is turned ON.
After the brush replacement, return the warning reset switch t o the set position.
Note:
When any brush needs replacement, always replace all brushes at the same time. No adjustment
is necessary at the time of replacement.
2. Action t o be taken when overheat warning occurs

(1) Stop the vehicle as soon as possible, and leave it for cooling for some time. (The resting period
is about 20 minutes.) The normal state is regained when the temperature drops.
I
INSPECTION /
Drive motor
Pump motor 1. Inspect the brush wear warning devices.
(1) Drive and pump (material handling) motors. In nor-
mal state, connector pin No.3 and motor terminal A
JBf~ ~ (Drive)
4
CN41 (Pump)
3u are connected. They are disconnected after brush
wear warning (signal generation).
Note:
If the warning is issued though the brush is not worn
(disconnected state above), limit switch defect, har-
ness internal open circuit or connector disconnection
may be the reason.
(2) PS motor
In normal state, the positive terminal of the PS mo-
tor power connector and brush warning connector
are connected. They are disconnected after brush
wear warning (signal generation).
CN45 Note:
(Brush warning connector) If the warning is issued though the brush is not worn
(disconnected state above), harness internal open cir-
cuit or connector disconnection may be the reason.
c
2. lnspect the overheat alarm device.
Drive motor (1) Measure the resistance when the motor is in cold
Pump motor state.
Between connector pins No.1 and No.2
Standard: 180 - 2 2 0 kQ
[Atmospheric temperature:
45OC ( 1 13OF) -- 10 ° C (50°F)1
CN43 (Drive)
CN41 (Pump)
DRIVE UNlT
Page
GENERAL ......................................................... 6-2
SPECIFICATIONS ................................................. 6-4
COMPONENT ....................................................... 6-5
DRIVE UNIT ASSY ............................................... 6-7
REMOVAL.INSTALLATION ..................................... 6-7
DISASSEMBLY -INSPECTION-REASSEMBLY ............. 6-8
GENERAL
1 ton series (Drive unit sectional view)
I I
Differential Sectional View
2-3ton series (drive unit sectional view)
I
Transmission Sectional View

SPECIFICATIONS
1 ton Series 2 ton Series 3 ton Series
STD Dustproof STD Dustproof STD Dustproof
Ring gear tooth number 35 +- +
Drive pinion tooth

6 t e
number
Gear ratio (Differential) 5.833 t +
Number
4 4 t
gears
Pinion gear
Number
10 t t
tooth
Number
2 t t
Side gear - gears

Number
14 t t
tooth
Drive gear tooth number 24 20 22 17 22 17
Output gear tooth
66 70 60 65 60 65
number
Gear ratio
2.750 3.500 2.727 3.824 2.727 3.824
(Transmission)
Drive unit oil capacity
7.0 (1.85) 7.5 (1.98) c
L? (US gal)
COMPONENTS
1 ton series
Refer to
4101
FIG;3305
2.3 ton series
4101
Refer to
FIG.3305
94512-01400 4101-130
6-6
1 ton series
9161 1-60820 3305
91611-61030
FIG.4101
R e f e r to
FIG.4101
3305-013
2-3ton series
3305
R e f e r to
FIG 4101
3305-014
DRIVE UNIT ASSY
1 Mast ASSY
2 Battery hood W/ driver seat
3 Battery ASSY
Drive Unit ASSY Removal Procedure
Removal Procedure
(See page 13-5 " V M A S T ASSY Removal . Installation".)
2 Remove the battery hood w/ driver seat.

(See step 1 t o 7 on page 1 -1 4 "BATTERY ASSY Removal & Installation".)
4 Remove the drive motor ASSY.

(See step 4 t o 1 3 on page 5-6 "DRIVE MOTOR ASSY Removal & Installation".)
5 Remove the axle shaft.
6 Remove the drive unit ASSY.
Note:
Check the drive unit oil lever and hydraulic oil level.
Check no oil is leaking from each joint.
6-8
Note:
Before disassembling the differential case, measure the runout at ring gear back side and ring gear
backlash.
Run out limit: 0.1 m m (0.004 in)

Backlash: 0.2 - 0.3 m m (0.008 - 0.012 in)
Drive Unit ASSY Disassembly Procedure
1 Remove the thrust screw. (Only in 1 ton series) [Point 1I
2 Remove the bearing cap. [Point 21
3 Remove the adjusting nut. [Point 31
4 Remove the differential case ASSY. [Point 41
5 Remove the differential case bearing. [Point 51
6 Remove the differential upper case. [Point 61
7 Remove the side gear, differential pinion gear. [Point 71
8 Remove the differential ring gear. [Point 81
9 Remove the drive pinion ASSY. [Point 91
10 Remove the output gear. [Point 101
11 Remove the drive pinion, remove the retainer from the bearing. [Point 111
12 Remove the shim, spacer. [Point 121
1 3 Remove the pilot bearing. [Point 131
14 Remove the drive pinion bearing inner race. [Point 141

Point Operations
[Point 1 I
Inspection:
Thrust screw cap inspection.
Standard length: 13 m m (0.51 in)

Wear limit: 11.5 rnm (0.453in)
Reassembly:
Cost liquid seal on the thrust screw before installing it.
Adjustment:
1. Thrust screw to cap clearance adjustment.
Clearance: 0.2 - 0.3 m m (0.008- 0.012 in)

2. Fully tighten the thrust screw and loosen it by 118
turn.
[Point 21
Disassem bly-Reassembly:
The case and bearing cap are machined as a pair, they are
not interchangeable between the left and right sides.
Always punch the match mark for reinstallation at the orig-
inal position.
Adjustment:
Adjust the ring gear back lash, Temporary tighten the set
bolt.
[Point 31
Adjustment:
1. Adjust the ring gear back lash.
(1) Apply the dial gauge vertically to the rear surface of
the ring gear.
(2) Alternately tight the adjusting nuts on the left and
right sides.
SST 09330-300 10
(3) Measure the thrust clearance and tighten the adjust-
ing nuts until the thrust clearance becomes 0.
(4) Tighten the adjusting nuts on both sides by one
notch each.
(5) Apply the dial gauge vertically to the tooth surface
of the ring gear.
(6) Measure the backlash by moving the ring gear to the
left and right.
Backlash standard: 0.2 - 0.3 mrn

(0.008- 0.012in)
Adjustment:
2. If the measured backlash is outside the above standard
range, adjust the backlash according to the following
procedure.
( 1 ) If the measured backlash is greater than the stan-
dard:
After loosening the adjusting nut on the ring gear
tooth surface side, tighten the adjusting nut on the
ring gear rear surface side to bring the ring closer to
the drive pinion.
( 2 ) If the measured backlash is smaller than the stan-
dard:
After loosening the adjusting nut on the ring gear
rear surface side, tighten the adjusting nut on the
ring gear tooth surface side to move the ring gear
away from the drive pinion.
( 3 ) To adjust the backlash, loosen the adjusting nut on
one side by one notch and tighten the adjusting nut
on the other side by one notch to gradually shift the
differential case while watching the dial gauge read-
Ing.
Adjustment:
3 . Check the side bearing preload by means of drive pin-
ion starting torque.
Starting torque:
6.37 -- 15.20 N.m (65 -- 155 kgf-cm)
[4.70 -- 1 1.21 ft-lbf]
Correct teeth contact

Adjustment:
r 4. Check the tooth contact.
I I Small end I I ( 1 Uniformly coat red lead thinly on both faces of 7 to
8 gear teeth, and turn the ring gear forward and
backward several times after installing a box wrench
on the output gear lock nut. Judge the gear teeth
contact by observing the pattern formed on the gear
teeth. If the tooth contact is not correct, make ad-
justment according to the "Drive Pinion Protrusion
Adjustment" and "Ring Gear Backlash and Differen-
tial Case Bearing Starting Torque Adjustment" pro-
cedures.
(2) Correct teeth contact
The pattern should be slightly leaning to the inside cir-
cle of the ring gear with respect to the center of the
tooth length, as shown.
( 3 ) Heeal contact
Move the drive pinion croser t o the ring gear by
decreasing the drive pinion adjusting shim thickness.
Then move the ring gear away from the pinion to ad-
just the backlash.
(4) Toe contact
Move the pinion away from the ring gear by increas-
ing the drive pinion adjusting shim thickness. Then
move the ring gear closer to the pinion to adjust the
backlash.
Flank
(5) Flank contact (low shallow contact)
contact Move the pinion away from the ring gear by increas-
move the ring gear closer to the pinion to adjust the
backlash.
(6) Face contact (high shallow contact)

Face Move the pinion closer to the ring gear by decreas-
contact
move the ring gear away from the pinion to adjust
the backlash.
[Point 41
Installation:
When installing the differential case ASSY, make the ring
gear contact the drive pinion.
[Point 51
Disassembly:
Remove the differential case bearings.
SST 09950-2001 7
eta Installation:
Install the bearing t o the differential case ASSY.
,-"-
SST 0 9 6 0 8 - 3 5 0 1 4
[Point 61

[Point 71
Inspection:
1. Wear o f spider
Standard outside diameter: 22.00 mm (0.8661 in)

2. Wear of thrust washer (for drive pinion)
Standard thickness: 1.6 mm (0.063 in)

3. Wear o f thrust washer (for side gear)

Installation:
Install the thrust washer w i t h its oil groove facing the side
gear.
[Point 81
Disassembly:
Remove when any defect is found in the drive pinion, ring
gear or differential case.
Reassembly:
1. Be sure to clean and degrease the bolts and bolt holes.
2. Coat thread tightener (08833-00070) on the bolt
threaded portion and tighten them to the specified
torque.
[Point 91
Reassembly:
1. Measure the drive pinion bearing starting torque.
Starting torque: 10.79 -

1 3 . 2 4 N-m
(110 -- 135 kgf-cm)
17.96 -- 9 . 7 7 ft-lbfl
Projection Adjust Shims 2. When the starting torque is not within the above
range, adjust the shim thickness after assembly with
Thickness the specifed tightening torque, measure the starting
Shim part No.
mm (in) torque again.
No.1 41 21 3-20540-71 0.03 (0.001 2)
3. Decrease the shim thickness if the starting torque is
No.2 41 21 6-20540-71 0.10 (0.0039)
less than the specified level, and increase the shim
No.3 41 217-20540-71 0.15 (0.0059) thickness if above the specified level.
No.4 41 21 8-20540-71 0.35 (0.0138)
No.5 41 21 9-20540-71 0.45 (0.01 77)
4. Caulk the lock nut.

(1) Be sure to caulk at t w o places.
(2) A in the illustration shall be in close contact.
Reassembly:
5. Installation the drive pinion ASSY.
(1 The bolt and hole shall be cleaned and degreased.
(2) Coat thread tightener (08833-00070) on the bolt
theads, and tighten the bolt to the specified torque.
[Point 101
Installation:
1. Always use a new lock nut.
2. After tightening the lock nut, tap the shaft with a plas-
tic hammer and recheck the tightening torque.
3. Lock the lock nut after checking the starting torque.
[Point 1 1 I
Disassembly:
Use a press to extract the drive pinion.
Disassembly:
Bearing outer race (front side-rear side)
SST 09320-23000-71
[Point 121
Disassembly:
Record the number of shims and thickness.
[Point 131
Disassembly:
Uncaulk the and of the drive pinion.
SST 09950-2001 7
Installation:
1. Pilot bearing
SST 09608-3001 2
2. Caulk three places at the tip end of the drive pinion.
[Point 141
Disassembly:
Drive pinion bearing inner race (front side)
SST 09950-2001 7
Installation:
Drive pinion bearing inner race (front side)
SST 09370-20270-7 1
FRONT AXLE
Page
GENERAL ........................................................... 7-2
SPECIFICATIONS ............................................... 7-3
COMPONENTS ................................................... 7-4
FRONT AXLE SHAFT-HUB ................................. 7-5
REMOVAL.INSTALLATION ................................... 7-5
DISASSEMBLY .ASSEMBLY .................................. 7-9
FRONT AXLE ASSY ........................................... 7-11
REMOVAL.INSTALLATION ................................... 7-1 1
7-2
GENERAL
1 ton series (Front axle sectional view)

I I
SPECIFICATIONS
Vehicle series
1 t o n series 2 t o n series 3 ton series
Front axle shaft type 314 floating type Full floating type +
Front axle suspension Fixed t o frame + t
Front axle shaft outside diameter m m (in) 40 (1.57) c c
Number of axle shaft spline teeth 31 c c

COMPONENTS
1 ton series 2 ton series
FRONT AXLE SHAFTmHUB
REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl
T = 107.89
(1100
l79.59
--- 196.13
2000)
144.701
1 ton series
T = 294.20
(3000 ---
[217.05
588.40
6000)
434.101
2.3 ton series
2 Differential oil
Front Axle Shaft Hub Removal Procedure
Removal Procedure
1 Remove the front wheels. [Point 11
2 Drain differential oil. [Point 21
3 Remove the front axle shaft. [Point 31
4 Remove the front axle hub. [Point 41

Point Operations
[Point 1I
Removal~lnstallation:
Carefully remove - install because the wheels are heavy
[Point 21
Removal:
Drain differential oil
Oil amount:
1 ton series 7 . 0 l (1.85 US gal)
2 . 3 ton series 7 . 5 t (1.98 US gal)
[Point 31
Removal:
When removing the axle shaft, carefully prevent the oil
seals from being damaged.
Installation:
Use a new packing.
I [Point 41
Removal:
1. Remove the stopper bolt, and remove the bearing lock
nut.
SST 09509-55020
Removal:
2. Remove the front axle hub.
SST 09310-10160-71
Installation:
1. Fill grease in the axle hub.
2. Return the adjusting screw to the position where the

brake shoe is contracted slightly.
3. Coat grease on the outer bearing, and inset it to the

hub.
4. After checking correct positioning of the brake shoe,

install the axle hub ASSY t o the front axle.
1.2 ton series
SST 09370-1 0410-71
3 ton series
SST 09421 -33020-71
5. When driving in the bearing, apply the SST perfectly to

the bearing to make the SST push the whole hub so
that the hub will not be returned by reaction.
6. Assemble the lock nut.

[ I ton series1
(1) Tighten the lock nut.
SST 09509-55020
Installation:
(2) Assemble the lock nut stopper bolt.
(3) Coat thread tightener (08833-00070) on the bolt
threads.
12.3 ton series1
( 1 ) Install the bearing ring to the axle shaft.
(2) Use the SST to fully tighten the bearing lock nut,
-
and loosen it by 1 I1 2 1 I6 turn.
SST 09509-55020
(3) Set a spring scale to the axle hub bolt and measure
the preload.
Preload: 25.5 -72.6 N

(2.6 -7.4 kg)
[5.73 -16.31 Ib]
After the end of preload adjustment, find the place

where the.bearing stopper hole matches the lock nut
screw hole. Match them perfectly to insert the tip
end of the bolt surely.
Coat thread tightener (08833-00070) on the stop-
per bolt, and tighten the stopper bolt.
DISASSEMBLY-ASSEMBLY
Note:
Inspect each part, and disassemble only when the bearing, axle hub or brake drum is found defective.
T = N.m (kgf-cm) [ft-lbfl
1 ton series
2 . 3 ton series
Front Axle Shaft & Hub Disassembly Procedure
1 Remove the oil seal. [Point 11
2 Remove the bearing. [Point 21
3 Remove the hub bolts. [Point 31

Point Operations
[Point 1 I
Reassembly:
Coat grease thinly on the outside of the oil seal.
1 ton series
SST 09608-3501 4
2.3 ton series
SST 091 60-101 70-71
SST 09320-1 0410-71
[Point 21
Disassembly:
1 ton series
SST 09608-3501 4
2.3 ton series
Remove the bearinu with the brass rod.
lli
1 ton series
SST 09608-3501 4
2.3 ton series
Remove the bearing with the brass rod.
[Point 31
Disassembly:
1. Remove a hub bolt only when it is found defective.
2. Use a press or a brass bar t o remove the hub bolt.
Reassembly:
1. Coat thread tightener (08833-00070) on the brake drum
set nut before tightening.
FRONT AXLE ASSY
Removal Procedure
(See step t o on page 13-5 "V MAST ASSY Removal & Installation".)
2 Remove the battery hood w / driver seat.

(See page 1-1 4 "BATTERY ASSY Removal & Installation".)
4 Jack up the vehicle.
5 Drain differential oil.
6 Remove the axle shafts.
7 Disconnect the brake pipe.
8 Remove the front toe-board.
9 Disconnect the parking brake wires.
1 0 Remove the differential housing set nuts.
11 Remove the front axle bracket set bolts. [Point 11
1 2 Remove the front axle ASSY.

7-1 2
POINT OPERATION
[Point 1 I
Removal:
Remove the reamer bolts (2 pcs. each at top and bottom on
one side)
SST 0931 0-22000-7 1
REAR AXLE
Page
REAR AXLE ASSY .............................................. 8-2
GENERAL ............................................................8 - 2
SPECIFICATIONS ................................................. 8-3
COMPONENTS ................................................... 8-4
REMOVAL INSTALLATION ................................... 8-6
rn
STEERING KNUCKLE .......................................... 8-9

REMOVAL .INSTALLATION ................................... 8-9
REAR AXLE CYLINDER ....................................... 8- 13
GENERAL ............................................................ 8- 13
SPECIFICATIONS ................................................. 8- 13
COMPONENTS .................................................... 8- 14
REMOVAL .INSTALLATION ................................... 8-16
(1 TON SERIES) ................................................... 8-17
DISASSEMBLY .INSPECT10 NsREASSEMBLY
(2.3TON SERIES) ................................................ 8-19
8-2
REAR AXLE ASSY

GENERAL
1 ton series
1 2.3 ton series

SPECIFICATIONS
-
Vehicle model 5FBCU1 5 5FBCU18
Item 30-5FBCU1 5 30-5FBCU18
Type Eliot type
Rear axle
Suspension Center supported swing type
Toe in mm (in) 0 (0)
Camber 0
Wheel alignment
Caster 0
King pin inclination 0
Minimum turning
Outer 1685 (66) 1 740 (68.5)
radius mm (in)
Tire size 1 4 x 4-112 x 8 16 x 5 x 10-112
Vehicle model 5FBCU20 5FBCU25 5FBCU30

Item -
30-5FBCU20 30-5FBCU25 30-5FBCU30
TYpe Eliot type
Rear axle
Suspension Center supported swing type
Camber 0
Wheel alignment
Caster 0
Minimum turning
Outer 1765 (69.5) 1790 (70.5) 1960 (66)
radius mm (in)
Tire size 16 x 5 x 10-112 c c
Vehicle model 5FBCHU20 5FBUHU25

Item \ 30-5FBCHU20 30-5FBCHU25
Type Eliot type
Rear axle
Suspension Center support swing type
Camber 0
Wheel alignment
Caster 0
Minimum turning
Outer 1920 (75.5) 1940 (76)
radius mm (in)
Tire size 16 x 5 x 10-112 c

8-4
COMPONENTS
1 ton series
01
DZ-e AC
8 I
8 I
8 I
I-.. 42K ,,,J
4301 -100
-
2-3ton series
(FRONT)
t
(REAR)
DZ-@
Note:
Always use wooden blocks or other stands to support the frame underside on the left and right sides.
Always apply the parking brake and chock the front wheels.
Make the height of the weight bottom surface above the ground to 400 -
500 mm (15.75 - 19.69
in) to make operation easy.
For 1 ton series
Removal Procedure
1 Remove the balance weight.
2 Check the front wheels.
3 Jack up the frame and support it with a stand or wooden blocks.
4 Remove the rear wheel. [Point 1 I
5 Disconnect the power cylinder piping.
6 Remove the rear axle bracket.
7 Remove the rear axle ASSY. [Point 21
8 Remove the rear axle cushion rubber [Point 31

Point Operations
[Point 1I
Removal:
After setting the wooden blocks, check sure contact.
Installation: Adjust the rear wheel starting force.

(See page 8- 1 1
1. Hook a spring scale to a rear wheel and measure the rear

axle hub preload.
Rear axle preload

1 ton series:
6.9 -- 19.6 N (0.7 -- 2.0 kgf) [I.5 -- 4.4 Ibfl
2.3 ton series:
9.8 -- 29.4 N (1.O -- 3.0 kgf) 12.2 -- 6.6 Ibf]
[Point 21
Removal: Remove according t o the following procedure:
1. Sling the rear axle beam with wires at the left and right
and slightly suspend with a hoist.
2. Remove the rear axle support set bolts (4 pcs.).

3. Operate the hoist slowly and remove the rear axle.
If the cushion rubber sticks to the frame and does not
come off, separate them by prying with a bar inserted
between the beam and frame.
1 [Point 31
t Upper side Installation: Install the cushion rubber in the correct direc-
tion.
Place the "UP" mark on the upper side.
(Thicker side up)
Installation: Match the taper of the beam side pin with the
taper of the cushion rubber, and push the
cushion rubber fully against the beam.
STEERING KNUCKLE
1 Front wheels
2 Jack up
Removal Procedure
2 Jack up the frame and support its bottom with a stand or wooden blocks.
3 Remove the hub cap. [Point 11
4 Remove the rear wheel Wlouter bearing. [Point 21
5 Remove the inner bearing and oil seal from the steering knuckle. [Point 31
6 Remove the bearing from the wheel.
7 Remove the tie rod ASSY. [Point 41
8 Remove the king pin lock bolt, and remove the king pin. [Point 51
9 Remove the steering knuckle and thrust bearing. [Point 61
10 Remove the oil seal and bearing from te rear axle beam. [Point 71
Note:
Supply MP grease through the king pin grease fitting.
The tightening torque for each portion is as follows:
Unit: N.m (kgf-cm) [ft-lbfl
King pin lock bolt and nut 19.61 - 31.38 (200 - 320)[14.47- 23.151
1 ton series: 68.65 - 98.067 (700 - 1000)
150.65 - 72.351
2.3ton series: 147.10 - 1 96.13 (1 500 - 2000)
Tie rod end castle nut
[I08.53 - 144.701
[Point 1 I
Installation: Fill MP grease in the cap.
Installation: Install by tapping the cap flange portion.
[Point 21
Installation: Fill grease in the hub and knuckle spindle.
Installation: SST 09370-20270-7 1

Installation: Adjust the rear wheel starting force.
1. Temporarily tighten the castle nut while rotating the

wheel.
Temporary tightening torque

1 ton series:
11.77 -
32.36 N - m (120 -
3 3 0 kgf-cm)
[8.68 -
23.88 ft-lbf]
2 - 3 ton series:
14.71 -
44.13 N - m (150 -
4 5 0 kgf-cm)
r10.85 -
32.56 ft-lbf]
After temporary tightening, rotate the wheel by 3 to 5

turns.
2. Set a spring scale at the outer periphery of the wheel,

and measure the starting force.
Starting force
1 ton series:
6.9 -
19.6 N (0.7 - 2.0 kgf) [1.5 - 4 . 4 Ibf]
2.3 ton series:
9.8 -
29.4 N (1.0 - 3 . 0 kgf) [2.2 - 6 . 6 Ibf]
3. If the measured value does not satisfy the standard,
make adjustment by tightening or loosening the castle
nut.
[Point 31
Removal: SST 09950-4001 0

(or SST 09950-2001 7 )
Installation: SST 09370-20270-71
[Point 41
Removal: SST 096 10-2001 2

[Point 51
Inspection: Measure the king pin outside diameter.
Standard outside diameter:

28.0 mm (1.102 in)
limit outside diameter:
27.8 mm (1.094 in)
Installation: Align the king pin cut groove and lock bolt hole,
tighten the lock bolt, and lock by tightening the
lock nut.
[Point 61
Installation: Adjust the steering knuckle starting force.
1. Insert the shim on the upper side of the thrust bearing

and install the king pin.
2. Set a spring scale on the tip end of the knuckle and meas-
ure the starting force.
Starting force: 29 - 4 9 N (3 - 5 kgf) [6.6 - 1 1 Ibf)

3. If the measured value does not satisfy the standard,
make adjustment by changing the shim.
Shim thickness: 0.1-0.2-0.5 and 1.0 mm

(0.22.0.44.1 .Iand 2 . 2 in)
[Point 71
Installation: Pay attention t o the relative positions of the

needle bearing and oil seal i n the assembled
state.
SST 09620-30010
8-1 3
REAR AXLE CYLINDER

GENERAL
1 ton series
2.3 ton series
SPECIFICATIONS
Vehicle model
1 ton series 2.3 ton series
Item
Rear axle cylinder type Double action 4-
Piston seal type Seal ring 4-
Rod seal type U-packing 4-
Piston stroke (All stroke) mm (in) 1 5 0 (5.90) 1 4 8 (5.83)

Cylinder bore mm (in) 60.3 (2.375) 76.2 (3.000)
Piston rod diameter mm (in) 4 0 (1.57) 5 0 (1.97)
8-1 4
COMPONENTS
1 ton series
8-1 5
2.3 ton series

REMOVAL- INSTALLATIQN
1 Balance weight
2 Front wheels
Removal Procedure
3 Jack up the frame and support it with a stand or wooden blocks.
4 Remove the rear wheel.
5 Remove the piston rod end pin.
6 Remove the pipe clamp set bolt.
7 Disconnect the rear axle cylinder pipe.
8 Remove the fitting.
9 Remove the rear axle cylinder ASSY.
Note:
Supply MP grease through the piston rod end pin grease fitting.
Unit: N-m (kgf-cm) [ft-lbfl
Cylinder ASSY set bolt

1 ton series: 49.03 - 68.65 (500 - 700) 136.18 - 50.651
2.3 t o n series: 166.71- 21 5.75 (1700 - 2200) [ I 23.00 - 159.1 71
DISASSEMBLY .INSPECTION .REASSEMBLY (1 TON SERIES)
1 Remove the rod guide.
2 Extract the piston rod. [Point 11
3 Remove the cylinder. [Point 21
Note:
Coat hydraulic oil befor reassembly.
Point Operations
[Point 1 I
Inspection: Measure the piston rod outside diameter.

40.0 mm (1.575)
Limit outside diameter:
39.92 mm (1.5717)
Inspection: Measure the piston rod bend.
Limit bend: 0 . 5 mm (0.020 in)
[Point 21
Inspection: Measure the cylinder bore.
Standard bore: 6 0 . 3 mm (2.374)

Limit bore: 60.65 mm (2.3878 in)
8-1 9
DISASSEMBLY -INSPECTION.REASSEMBLY (2-3

TON SERIES)
1 Remove the tie rod.
2 Remove the rod guid.
3 Extract the piston rod. [Point 11
4 Remove the cylinder. [Point 21
Note:
Coat hydraulic oil before reassembly.
Tie rod nut tightening torque T = 88.3 - 95.1 N - m ( 9 0 0 - 9 7 0 kgf-cm)[65 - 7 0 ft-lbfl
Point Operations
[Point 1I

50.0 mm (1.969 in)
49.92 mm (1.9654 in)
Limit bend: 0.5 mm (0.020 in)
[Point 21
Standard bore: 76.2 mm (3.000 in)

Limit bore: 76.55 mm (3.0138 in)
STEERING
Page
GENERAL ........................................................9-2
SPECIFICATIONS ...............................................9-4
COMPONENTS ................................................... 9-4
MAST JACKET ASSY & STEERING
POST ASSY ..................................................... 9-7
rn ................................... 9-7
HYDROSTATIC STEERING VALVE ASSY .......... 9-11

DISASSEMBLY INSPECTION -REASSEMBLY ............ 9-12
rn
RELIEF PRESSURE MEASUREMENT ....................... 9-16

OIL PRESSURE SENSOR (FOR EHPS) ..................... 9-17
9-2
GENERAL
Hydrostatic Steering Valve
SPECIFICATIONS
Item
Vehicle models
5FBCU1 5 5FBCU18 - 30
Diameter m m (in) 3 8 0 (14.96) c
Steering
wheel Play m m (in)
At idling 2 0- 40
(0.79 - 1.57)
C
Power steering type Hydrostatic power steering c
Displacement
46.3 (2.82) 73.8 (4.50)
Hydrostatic cm31rev (in3/rev)
steering valve Relief valve set pressure 5880 If: 4 9 0 (60 + 5) 7850 + 4 9 0 (80 + 5)
kPa (kgf/cm2) [psi] 1850 + 701 11140 + 701
Relief valve type Built-in type +
COMPONENTS
Steering Post Components
MAST JACKET ASSY & STEERING POST ASSY
Removal Procedre
2 Remove the steering wheel. [Point 11
3 Remove the cover.
4 Remove the turn signal switch ASSY.
5 Remove the tilt lock lever.
6 Remove the display ASSY.
7 Remove the direction switch.
8 Remove the tension spring. (large)
9 Remove the tilt lock components. [Point 21
10 Remove the mast jacket ASSY. [Point 31
11 Remove the post ASSY.
The installation procedure is the reveerse of the removal procedure.
Point Operations
[Point 1 I
Removal:
SST 09609-2001 1
(or SST 09950-5001 0 )
[Point 21
Tilt lock bolt Collar Lock nut Removal-Installation:

Tilt lock bolt (left handed screw)
Installation:
Loosen the lock nut by one turn after tightening if fully.
[Point 31
Installation:
1. Coat grease on the universal joint spline.
2. Do not forget to use the bushing when installing the
set bolt and nut.
DISASSEMBLY -INSPECTION .REASSEMBLY
1 Remove the tilt steering shaft Wlshaft stopper. [Point I]
2 Remove the universal joint. [Point 21
3 Remove the steering shaft stopper. [Point 31
4 Remove the snapring.
5 Remove the main shaft.
6 Remove the bearing.
7 Remove the jacket.
Assembly Procedure
Point Operations
[Point 1 I
Reassembly:
Match the bolt holes in the mast jacket and shaft stopper
Installation:
Shaft bend
Bend limit: 1.5 mm (0.059 in)
[Point 21
Reassembly:
Match the bolt set groove on the steering shaft with the
bolt hole in the universal joint.
[Point 31
Disassembly:
SST 0941 1-41800-71
Reassembly:
1. Steering shaft stopper
SST 09700-30200-7 1
2. Snap ring
SST 09905-0001 2
HYDROSTATIC STEERING VALVE ASSY
Unit: N - m (kgf-cm) [ft-lbfl
1 Battery plug
Removal Procedure
2 Remove the rear toe board.
3 Remove the front toe board.
4 Disconnect the sensor harness. (for EHPS)
5 Disconnect the pipings.
6 Remove the hydrostatic steering valve ASSY.
DISASSEMBLY- INSPECTION-REASSEMBLY
Unit: N - m (kgf-cm) [ft-lbfl
1 fitting
- --
1 Remove the fitting. [Point 11
2 Remove the end cap. [Point 21
3 Remove the spacer, the gerotor, the drive and the wear plate. [Point 31
4 Remove the retaining ring. [Point 41
5 Remove the seal stopper Wlseal.
6 Remove the needle bearing.
7 Remove the sleeve and spool set. [Point 51
8 Remove the relief valve. [Point 61
Note:
Wash each part with clean hydraulic oil before assembly.
Unit: N.m (kgf-cm) [ft-lbfl
End cap set screw 31.09 (317) [22.931

pcmp
P
\
port fitting
Point Operation
[Point 1 I
Reassembly: A check valve is built in the pump port fitting.

Install the fitting in the correct position.
[Point 21
Disassembly.Reassembly: Install w i t h the end cap facing

upwards as illustrated, and fix
the flange portion in a vise. Use
aluminium places pads for pro-
tection and do not tighten the
vice excessively.
Reassembly: Tighten the screws in accordance w i t h the

order numbers as shown i n the illustration.
Tighten all the seven screws with the preli-
minar, tightening torque of 16.97 N-m (173
kgf-cm) 112.52 ft-lb] and then tighten again
evenly w i t h the standard torque.
[Point 31
Reassembly: Reassemble according t o the following pro-

cedure.
1. Install spacer plate. Align bolt holes in wear plate w i t h

tapped holes in housing.
2. Rotate spool and sleeve asesmbly until pin is parrallel

with port face.
Drive
with Port Face

3. Install drive, make sure you engage drive with pin. To
assure proper alignment, mark drive as shown. Note rela-
tionship between slotted end of drive t o splined end of
Gerotor star valley A
drive when marking.
4. With seal side of meter toward spacer plate, align star

valleys (ref. A) on drive (ref. B). Note the parallel rela-
tionship of reference oines A, B, C, and D. Align bolt
holes without disengaging meter from drive.
Port face
I I [Point 41
Disassembly: Place housing on a clean soft cloth t o protect
surface finish. Use a thin bladed screwdriver
t o pry retaining ring from housing, as shown.
I I
[Point 51
Reassembly: Reassemble according t o the following pro-

cedure.
1. Assemble spool and sleeve carefully so that the spring

Spring
Slot slots line up at the same end. Rotate spool while sliding
Identification
parts together. Some spool and sleeve sets have identi-
fication marks, align these marks as shown in figure.
Test for free rotation. Spool should rotate smoothly in
sleeve w i t h finger tip force applied at splined end.
2. Set springs back t o back with the notched portions at

both ends facing downward.
3. Install pin through spool and sleeve assembly until pin
becomes flush at both sides of sleeve.
Pin
c
4. Position the spool and sleeve assembly so that the spli-
ned end of the spool enters the end of housing first, as
shown.
Be extremely careful that the parts do not tilt out of posi-
tion while inserting. Push parts gently into place with
slight rotating action, keep pin nearly horizontaal. Bring
the spool assembly entirely within the housing bore until
the parts are flush at the end of housing. With the spool
assembly in this flush position, check for free rotation
within the housing by turning with light finger tip force
at the splined end.
[Point 61
Plug Disassembly: Do not remove the relief valve unless it is esti-

mated t o be defective.
The valve seat cannot be removed.
Relief valve
Disassembly: Measure the plug screwed-in depth before
disassembly.
Valve seat
Resassembly: Reassemble by adjusting t o the screwed-in

depth of the plug measured before disas-
sembly. After installing the steering valve
ASSY on the vehicle, measure the relief pres-
sure. If it is not within the standard range,
adjust it by changing the screwed-in depth
of the plug.
RELIEF PRESSURE MEASUREMENT
1. Measure the power steering relief pressure.
( 1 ) Disconnect the steering valve piping (at one place

shown in the figure: pump port) and install the SST.
Then set an oil pressure gage.
SST 09450-2361 0-71
Plug size: PT 118
( 2 ) Start the engine and turn the steering wheel slowly

clockwise and counterclockwise.
(3) Start the engine, rotate the steering wheel and mea-
sure the relief pressure when the relief occurs.
Standard relief pressure

1 ton series
5880 + 4 9 0 kPa ( 6 0 f 5 kgf/cm ) [850 + 7 0
2
psi1
2.3 ton series
7 8 5 0 f 4 9 0 kPa (80 + 5 kgf/cm ) [I1 4 0 + 7 0
2
psi1
OIL PRESSURE SENSOR
SPECIFICATIONS
Maximum pressure kPa (kgf/cm2) [psi] 9810 (100) [I4201
Rated output kPa (kgf/cm2) [psi] Approx. 29 (0.3) 14.31
Driving voltage V 12
ON state V 10 or more
Output
OFF state V 2 or less
1. Bring the tester probes into contact w i t h CN27.
2. Turn the key switch t o ON.
3. Inspect the voltage when the steering wheel is in the neu-

tral position (PS motor in stop state).
CN27-2 -- CN27-5
Standard: 2 V or less
4. Operate the steering wheel and check the voltage.
Standard: 10 V or more
5. If any the above standards is not satisfied replace the

oil pressure sensor.
BRAKE
Page
SPECIFICATION ................................................ 10-2
FRONT BRAKE ..................................................... 10-3
GENERAL .......................................................... 10-3
COMPONENTS ..................................................10-5
DISASSEMBLY .INSPECTION .ASSEMBLY .............. 10-7
BLEEDING AIR FROM BRAKE SYSTEM ................. 10-10
TEST (Function Test of Automatic Adjuster) ......... 10-10
MASTER CY LlNDER .......................................... 10-I 2
GENERAL .......................................................... 10- 1 2
COMPONENTS .................................................. 10-1 3
REMOVAL .INSTALLATION .................................. 10- 1 4
DISASSEMBLY . ASSEMBLY ................................. 10- 1 5
PARKING BRAKE .............................................. 10-16
COMPONENTS .................................................. 10-16
REMOVAL INSTALLATION .................................. 10-17
rn
DISASSEMBLY . ASSEMBLY ................................. 10-18

ADJUSTMENT ...................................................10-19
BRAKE PEDAL ...................................................10-20
COMPONENTS .................................................. 10-20
ADJUSTMENT ................................................... 10-20
SPECIFICATIONS
Item 1 ton series 2.3 ton series
Foot brake type Hydraulic internal expansion duo servo type
Parking brake type Mechanical internal expansion friction type

Brake drum inside diameter mm (in) 254 (10.00) 310 (12.20)
Brake lining Material Resin mold (non-asbestos)
Brake lining dimensions 279 x 48.5 x 5 343 x 6 0 x 5.7

(Length x Width x Thickness) mm (in) (10.98 x 1.909 x 0.1 93) (13.50 x 2.36 x 0.22)
Wheel cylinder bore mm (in) 22.2 (0.8741 28.5 (1.12)
Master cylinder bore mm (in) 19.05 (0.750) 25.4 (1.OOO)

FRONT BRAKE
GENERAL
1 ton series
Wheel cylinder section

10-4
2-3ton series
Wheel cylinder section

COMPONENTS
1 ton series (BRAKE ASSY) N-m (kgf-cm) [ft-lbfl
02[LH]
0 1 [RH]
~O[RH]
3 1 [LH]
10-6
2-3ton series (BRAKE ASSY) N.m (kgf-cm) [ft-lbfl
02[LH]
---
I---
I T = 17.65 26.48
I (180 270)
113.02 19.531
31[LH]
10 15
A
Y- I
AN
I
! I
L,, ,
,J
I I
I I
L-- ,,J
4715-0716
DISASSEMBLY-INSPECTION-ASSEMBLY
1. Front axle hub

2. Brake fluid draining
Front Brake ASSY Disassembly Procedure
1. Remove the front axle hub. (See page 7-61 [Point 11
2. Drain brake fluid from the reservoir tank.
3. Remove the anchor to shoe spring. [Point 21
4. Remove the fitting cable, cable guide and adjust lever.
5. Remove the adjuster spring and adjusting screw. [Point 31
6. Remove the shoe hold down spring and cup. [Point 41
7. Remove the primary shoe wlparking lever. [Point 51
8. Remove the secondary shoe. [Point 51
9. Remove the parking lever.
10. Remove the parking brake cable.
1 1. Remove the backing plate. [Point 61
1 2. Remove the wheel cylinder ASSY
13. Disassemble the wheel cylinder ASSY. [Point 71
Assembly Procedure
Note:
Coat new brake fluid sufficiently before assembling the wheel cylinder ASSY.
Do not use the old self-lock nut, but use a new one.
Point Operation
[Point 1 I
Inspection: lnspect uneven wear of the inside surface of

the brake drum.
1 ton series
Standard inside diameter: 2 5 4 m m (10.00 in)
Wear limit: 2 5 6 m m (10 . 0 8 in)
2-3 ton series
Standard inside diameter: 3 1 0 m m (12.20 in)
Wear limit: 3 1 2 m m ( 12.28 in)
[Point 21
Disassembly: SST 0 9 7 1 7-2001 0
Inspection: lnspect the spring free length.

1 ton series
Free length: 1 0 2 m m (4.02 in)
2-3 ton series
Free length: 1 2 4 m m (4.88 in)
1 - 2 - 3ton series
Limit free length: Replace if there is any clearance
in the coil.
Assembly: SST 0 9 7 1 8-20010
[Point 31

1 ton series
Free length: 7 9 m m (3.11 in)
2-3 ton series
Free length: 88 m m (3.46 in)
1 - 2 . 3 ton series
Limit free length: Replace if there is any clearance
in the coil.
Assembly:
Sufficiently clean the threaded part of the adjusting
screw, and coat chassis grease (grease containing mo-
lybdemul disulfide).
Fully compress the spring at the time of installation.
[Point 41
Disassembly~assembly:SST 0951 0-31 960-71

1 ton series
Free length: 25.7 mm (1 .012 in)
2-3 ton series
Free length: 25.7 mm (1 .012 in)
[Point 51
Inspection: lnspect the brake shoe lining thickness.

1 ton series
2-3 ton series
Wear limit: 2.0 m m (0.079 in)
[Point 61
Assembly:
1. Coat liquid packing (08826-00080) on the joint face be-
tween the backing plate and front axle bracket to
eliminate any clearance.
2. Before assembling the brake shoe, coat castle non-melt
lube (08887-01406) on the following places:
Six contact faces of brake shoe.
Anchor pin.
[Point 71
Inspection: Inspect wear of the inside surface of the wheel

cylinder.
Cylinder t o piston clearance

1 ton series:
Limit: 0.125 mm
(0.00492 in)
2-3 ton series:
Limit: 0.145 mm
(0.00571 in)
BLEEDING AIR FROM BRAKE SYSTEM

1. Add brake fluid t o the reservoir tank.
2. Bleed air from the master cylinder

3. Bleed air from the wheel cylinder.
Note:
When bleeding air from the wheel cylinder, start from the
far side of the master cylinder.
During air bleeding, carefully add the brake fluid to prevent
it from running out from the reservoir tank.
TEST (Function Test of Automatic Adjuster)
Operation Sequence
Function Test (Function Test of Automatic Adjuster)
1. Brake shoe diameter adjustment
(1 Adjust the installed brake shoe outside diameter at 1.0 mm (0.039 in) less than the brake drum
inside diameter by turning the adjusting screw.
2. Adjusting screw function test

(1) Push the fitting cable toward the shoe on the rear side and release it.
(2) See the adjusting lever then comes into mesh with the next tooth of the adjusting screw.
(3) When returned, see that the adjusting lever returns to the original position by feeding one tooth
of the screw.
3. lnspect the following points in case of any malfunctioning:

(1) The adjusting lever shall be in vertical contact with the adjusting lever tooth.
(2) The adjusting lever shall be in contact at 5 -7 mm (0.20 - 0.28 in) above the center line of
the adjusting screw.
Note:
If either (1) or (2) is defective, the adjusting screw fails in making adjustment because of improver
meshing of the adjusting lever and tooth.
Braking force inspection and adjustment

1. Force inspection
(1 1 lnspect the braking force with the brake tester or by the traveling test.
Initial braking speed kmlh (mph) Braking distance

No load status
3 6 V vehicle 4 8 V vehicle m (ft)
1 ton series 1 4 (8.7) 1 6 (10) 5.0 (19 7 ) or less
2 ton series 1 4 (8.7) 1 6 (10) 5.0 ( 197) or less
3 ton series 1 3 (8.1) 1 6 (10) 5.0 (197) or less
2. Adjustment
(1 Make the following adjustment when the depressed brake pedal height above the toe board is
insufficient:
Repeat forward and backward traveling, and adjust the brake shoe clearance.
The adjusting screw makes adjustment only when the brake pedal is depressed backward trav-
eling.
(2) Insufficient braking is caused by adjuster malfunction, insufficient lining contact, foreign matter
adhesion on the lining, or brake fluid leakage. Remove the brake drum and inspect the inside.
(3) If the braking performance is uneven or depressed brake pedal height is insufficient, same de-
fect as in 12) is conceivable.
MASTER CYLINDER
GENERAL
Master Cylinder Sectional View

COMPONENTS
1 Brake fluid
2 Toe board
Master Cylinder Removal Procedure
Removal Procedure
1 Drain brake fluid from the reservoir tank.
2 Remove the rear and front toe boards.
3 Disconnect the brake piping (reservoir hose and outlet pipe).
4 Remove the brake pedal return spring.
5 Disconnect the brake pedal arm and master cylinder clevis.
6 Remove the master cylinder.
Note:
Do not loosen the push rod clevis lock nut except for brake pedal play adjustment.
Bleed air from the brake system always after the end of operation. (See page 10-10)
I I
Master Cylinder Disassembly Procedure
1 Remove the union.
2 Turn up the boot toward the clevis side.
3 Remove the hole snap ring and push rod.
4 Remove the piston and spring.
5 Remove the cap.
6 Remove the cylinder cup.
Assembly Procedure
Note:
Clean each part (except for rubber parts), and clean it sufficiently by air blowing.
At the time of assembly, coat brake fluid on the cylinder inner parts.
10-16
PARKING BRAKE
COMPONENTS
PARKING BRAKE
I
Parking Brake Lever Removal Procedure
Removal Procedure
1 Remove the parking brake lever bracket set bolts.
2 Disconnect the parking brake cable from the lever bracket.
3 Remove the parking brake lever.
Note:
Always adjust the parking brake lever operating force after installation.
10-1 8
Parking Brake Lever Disassembly Procedure
1 Remove the pin and disengage the hook.
2 Remove No. 1 link and parking brake lever wlknob.
3 Remove the pin, and remove the parking brake plate.
4 Remove the parking brake knob. [Point I ]
5 Remove the knob (adjusting screw, etc.). [Point 21
6 Remove the parking brake rod and clevis. [Point 31
Assembly Procedure
Point Operation
[Point 1 I
Water I' '%i,:,,, Disassembly: When removing the parking brake lever knob,
immerse the lever knob portion in hot water (70 to 80°C
(158 -
176OFI) for 10 to 2 0 seconds, and pull the knob off
toward the lever side.
(lOO°C (212OF) or above is not allowed.)
[Point 21
Assembly:
After tightening knob B, return it by a half turn (clearance
C = 0.6 mm (0.024 in)) and tighten knob A.
A t the time of assembly, coat grease and Locktite.
D portion: 08833-00070
E portion: Fill MP grease
[Point 31
Assembly: When assembling the parking brake rod and cle-

vis, coat MP grease thinly on the E portion.
ADJUSTMENT
1. Parking brake lever operating force adjustment
(1) Hook the spring scale on the top of the lever knob
and pull it back t o measure the operating force.
Standard operating force
1 ton series: 196 - 245 N (20 - 25 kg)
144 - 55 Ib]
2-3 ton series: 254 - 294 N (25 -3 0 kg)
[55 -6 6 Ib]
(2) If the operating force does not satisfy the standard,

adjust it by turning the adjusting screw at the tip
end of the brake lever.
Make the adjustment while the brake is in released
state.
Clockwise turn: The operating force increases.
Counterclockwise turn: The operating force de-
creases.
BRAKE PEDAL
COMPONENTS
ADJUSTMENT
1. Brake pedal height and play
( 1 ) Adjust the brake pedal height from the upper surface
of the toe board to the following value by turning the
stopper bolt.
Pedal height B:
136 mm (5.35 in) - 141 mm (5.55 in)
With pad A:
141 mm (5.55 in) - 145 mm (5.71 in)
(2) Adjust the master cylinder push rod length to adjust

the pedal play.
Pedal play:
3 - 7 mm (0.12 - 0.28 in)
(3) Manually move the master cylinder push rod to con-
firm the free state.
(4) Check the depressed brake pedal height.
Standard A
1 ton series:
Not less than 9 0 mm (3.54 in)
(With Pad 9 5 mm (3.74 in)
\ / / I Floor clearance 2 - 3 ton series:
Not less than 82 mm (3.23 in)
(With Pad 87 mm (3.43 in)
2. Brake switch adjustment

See the controller section for the brake switch adjust-
ment method. (See page 2-42)
BODY
Page
BODY FRAME .................................................... 11-2
COMPONENTS .................................................. 11-2
BATTERY HOOD ................................................ 11-7
REMOVAL.INSTALLATI0N ................................... 11-7
BALANCE WEIGHT ............................................ 11-8
COMBINATION METER ...................................... 11-9
DISASSEMBLY-ASSEMBLY .................................. 1 1-1 0
11-2
BODY FRAME
COMPONENTS
1 ton series
Frame & Weight Components

2 ton series
Frame & Weight Components

2 ton series (USA spec.)
Battery Roll Out Spec. Structure

1 - 3 ton series
Battery Hood Components

11-6
1 - 3 ton series 1 - 3 ton series
5702 5301
Refer to FIG.5702
r--
I
L
. --J 5301-212
sm-mm
Combination Meter Instrument Panel & Floor Compartment
1 - 3 ton series
Overhead Guard
BATTERY HOOD
Battery Hood Removal and Installation
Removal Procedure
1 Release the hook and hood catch.
2 Open the battery hood, and remove the torsion bar stopper screw.
3 Remove the torsion bar.
4 Remove the battery hood wlseat.
11-8
BALANCE WEIGHT
REMOVAL-INSTALLATION Unit: N.m (kgf-cm) [ft-lbf]
6.5 - 255.0
1 Battery plug dlsconnect~on
4 (1 800
I130 --1881
2600)
Balance Weight Removal and Installation
Removal Procedure
2 Remove the rear cover
3 Temporarily hoist the balance weight using wire ropes.
4 Remove the balance weight set bolts.
Caution:
When installing and removing the balance weight, operate safely by referring to the following
points.
Use a wire rope whose diameter over 8 mm (0.31 in).
Inspect the wire ropes sufficiently for the following points before actually using them:
Excessive number of cut strands
Excessive deformation and rusting
Use a host or chain block with sufficient strength.
The hoisting angle should be restricted within 30°.
Always hoist vertically. Do not attempt hoisting in an oblique direction.
When moving the hoisted weight, the height above the ground should not exceed 30 cm (11.8 in)
COMBINATION METER
The combination meter has the diagnosis (self-diagnostic) function and analyzer (failure analysis) func-
tion in addition t o general indication of the traveling speed, battery charge, hour meter, etc.
See the respective sections for the details of these additional functions.
Travel speed limiter set indicator

Battery electrolyte level warning I Praking brake indicator
Battery charge indicator \ I / Speedometer
\
Multiway hour meter
I 1
Display
Level setting switches
/ \
Power control Hour meter
select switch select switch
Switch panel
Combination Meter
Combination Meter Disassembly and Assembly
1 Remove the cover sheet.
2 Remove meter board.
3 Remove the panel ASSY.
4 Remove the window plate, glass, etc.
Assembly Procedure
Page
HYDRAULIC CIRCUIT ........................................ 12-2
COMPONENTS .................................................... 12-3
NATURAL DROP TEST .......................................12-4
NATURAL FORWARD TILT TEST ...................... 12-4
OIL LEAK TEST ...................................................12-5
HYDRAULIC CIRCUIT
Pump motor for steering
'Oil tank in detail:
Face for oil tank cover
To oil
General External Appearance
Filter Cover Suction Filter Drain Plug

COMPONENTS
1 ton series 4507
4507-140
2-3ton series 4507
4507-141
NATURAL DROP TEST
1. Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 - 1.5 m (40 - 60
in), and stop the engine.
2. Draw a line on the inner and outer masts, and measure

the gap in 15 minutes.
Vehicle model Natural drop amount
1 ton Series 9 0 mm (3.54 in)
NATURAL FORWARD TILT TEST

load on the fork. Lift the fork about 50 cm (20 in) and
turn the key switch off.
2. Measure the tilt cylinder rod extension in 15 minutes.
Vehicle model Natural forward tilt amount


OIL LEAK TEST
LIFT CYLINDER
load on the fork. Lift the fork by 1 -1.5 m (40 -
60
in) and turn the key switch off.
2. Gently tilt the mast fully forward and turn the key switch
off. After 5 minutes, disconnect the oil control valve and
return hose. Measure the oil leakage amount in one
minute by placing a measuring cylinder at the fitting.
Standard oil leakage amount (at lift port):

6 -1 6 cc (0.37 -
0.98 in 3)
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
Port for oil leak measurement
TILT CYLINDER
load on the fork. Lift the fork by about 5 0 cm (20 in)
and turn the key switch off.
2. After 5 minutes, disconnect the oil control valve and

return hose. Measure the oil leakage amount in 1 minute
by placing a measuring cylinder at the fitting.
Standard oil leakage amount

(total o f lift and tilt):
14 - 34 cc (0.85-2.07 in 3 )
3. The leakage amount at the tilt port is the total leakage

- leakage at the lift port.
NOTE:
If the natural drop is great though the oil leakage amount
is within the standard, the lift cylinder packing is
defective.
/ Port to; oil leak measurement

I
MAST
Page
V MAST ASSY ..................................................13-2
COMPONENTS ...................................................13-2
REMOVAL.INSTALLATION .................................. 13-5
MAST DISASSEMBLY-
INSPECTION.REASSEMBLY .............................. 13-7
LlFT BRACKET DISASSEMBLY-
lNSPECTlON.REASSEMBLY ............................... 13-9
MAST ADJUSTMENT .......................................... 13-1 1
CHAIN ................................................................ 13-17
INSPECTION ..................................................... 13-17
REASSEMBLY .................................................... 13-17
ADJUSTMENT ............................................. 1 3-18
FORK ................................................................. 13-18
REMOVAL. INSTALLATION .................................. 13.1.8
INSPECTION ...................................................... 1 3-18
FV MAST ASSY ................................................ 13-19
COMPONENTS ................................................... 13-19
MAST ADJUSTMENT ..........................................13-21
FSV MAST ASSY .............................................. 13-25
COMPONENTS ...................................................13-25
MAST ADJUSTMENT .......................................... 13-27
LlFT CYLINDER ROD SHIM
ADJUSTMENT ................................................ I 3-31
V MAST ASSY
COMPONENTS
1 ton series 6101
20
6101-413
2 . 3 ton series 6101
20
6101-407
-
1 2 ton series
3 ton series
REMOVAL. INSTALLA
1 Mast position
5 Piping
Removal Procedure
1 Set the most vertical and lower the bottom position.
2 Disconnect the chain.
3 Remove the chain wheel. [Point 11
4 Remove the lift bracket. (Raise the inner mast until it comes off from the lift bracket, and slowly
move the vehicle in the reverse direction depart from the lift bracket. Then stop the engine.)
5 Disconnect the piping.
6 Slightly hoist the mast.
7 Remove the mast support caps.
8 Remove the tilt cylinder front pin. [Point 23
9 Remove the mast ASSY

Note:
Apply MP grease on the interior surface of the mast support bushing, inner surface of the mast sup-
port cap and tilt cylinder front pin.
Mast support cap set bolt tightening torque:
T = 68.65 - 107.87 N-m (700 - 1100 kgf-cm) [50.65 -
79.59 ft-lbfl
If any of the mast ASSY, outer mast, inner mast and lift cylinder is replaced, it is necessary to inspect
and adjust uneven motion of the lift cylinder. See the lift cylinder rod shim adjustment section (on
page 13-31) for the inspection and adjustment method.
Adjust the chain tension. (See page 13-18)
Point Operations
[Point 1I
Removal: Use the SST for removal if the fitting is tight.

SST 09950-4001 0
Installation: Install the chain wheel w i t h its side having

greater radius at the periphery of its hole fat-
ing the boss of the mast side pin.
[Point 21
Removal: SST 09810-201 72-71

MAST DISASSEMBLY- INSPECTION- REASSEMBLY
2 Hoses and flowregurator housing.
1 Remove the hose cover.
2 Remove the hoses and flowregurator housing.
3 Remove the cylinder rod end set bolt and disconnect the rod end. [Point 11
4 Remove the cylinder support. [Point 21
5 Remove the cylinder bottom set bolts and remove the lift cylinder.
6 Slide the inner mast in the lowering direction and remove the lift rollers.
7 Remove the mast strip. [Point 31
8 Remove the outer mast.
Point Operations
[Point 1 I
Disassembly: Shim adjustment has been made at the lift

cylinder rod end for prevention of cylinder un-
even motion between the left and right sides.
Take a note on which side the shim adjust-
ment is made and the number of shims used.
[Point 21
Disassembly: Take a note on the number of cylinder sup-

port shims used.
Reassembly: When the mast or cylinder is replaced, make

shim adjustment at the cylinder support. With
the cylinder rod end iserted to the inner mast,
eliminate the clearance between the cylinder
support and outer mast by inserting shims.
The shim thickness should be slightly thicker.
[Point 31
Inspection: Measure the mast strip thickness.
Thickness limit: A = 2.7 mm (0.106 in)

B = 1.3 mm (0.51 in)
--- - --
LIFT BRAKET DISASSEMBLY. INSPECTION. REASSEMBLY
1 Remove the lift rollers. [Point 11
2 Remove the side rollers. [Point 21
3 Remove the back rest.
Note:
Back rest set bolt tightening torque T = 99.54- 184.86 N-m (1015 - 1885 kgf-cm)
[73.44 -
136.38 ft-lbfl
13-10
Point Operations
[Point 1 I
Disassembly: SST 09950-40010
[Point 21
Reassembly: Do not mistake the side roller mounting

direction.
The side where the chamfering radius of the
roller outer circumference shall face the front
side.
13-1 1
MAST ADJUSTMENT (V MAST)

Mast Lift Roller Adjustment
lnner mast
This roller
1. lnner mast roller clearance adjustment

( 1 1 Measure the clearance with the mast overlap at near
450 mm (17.72 in).
(2) Shift the inner mast t o one side to bring the roller into
contact with the outer mast, and adjust the clearance
between the roller side face and mast at the closest
position on the opposite t o the following value by in-
serting the inner mast roller shim.
Standard clearance A = 0 -
0.8 mrn
(0 - 0.031 in)
Shim thickness: 0.5 and 1 .O rnm
(0.020 and 0.039 in)
I
(3) Distribute the shim thickness equally t o the left and
Shim right rollers. (See the "mast roller removal-installa-
tion" section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
This roller
fi
Outer mast
Inner mast
2. Outer mast roller clearance adjustment

(1) Measure the clearance w i t h the mast overlap at near
450 m m ( 17.72 in)
(2) Shift the inner mast t o one side t o bring the roller into
contact with the outer mast, and adjust the clearance
between the roller side face and mast at the closest
position on the opposite side t o the following value
by inserting the outer mast roller shim:
Standard clearance B = 0 -
0 . 5 mm
(0 -
0 . 0 2 0 in)
Shim thickness: 0 . 5 and 1.0 mm
(0.020 and 0 . 0 3 9 in)

Shim right sides. (See the "mast roller removal~installation"
section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
II
Mast Roller Removal- Installation
1. Remove the lift bracket. (See the mast ASSY removal

procedure steps 1 to 4 on page 13-5.)
2. Jack up the vehicle and support the tires with wooden

blocks. Lock the front and rear tires to prevent rotatiotn.
3. Tilt the lift cylinder.

( 1 ) Remove the hose cover at the bottom of the mast and
disconnect the lift cylinder hose on the LH side.
(2) Remove the lift cylinder bottom set bolts.
(3) Sling the innder mast upper tie beam with a wire and
slightly hois it.
(4) Remove the lift cylinder rod end set bolts, and dis-
connect the rod end by hoisting the inner mast.
(5) Remove the lift cylinder support.
( 6 ) Tilt the lift cylinders LH and RH and tie them with
ropes t o the outer mast tie beam.
-
4. Remove the mast rollers.
I (1) Lower the hoisted inner mast slowly until mast rollers
Shim
are visible, and support the bottom with wooden
blocks.
(2) Remove the inner mast rollers and shims.
(3) Remove the outer mast rollers and shims.
(3) Remove the outer mast rollers and shims.
5. The installation procedure is the reverse of the removal

Shim procedure.
Lift Bracket Roller Adjustment
100 mm (3.44 in)
Bring into contact Bracket
Outer mast
Inner mast
1. Lift roller and side roller clearance adjustment

(11 Measure the clearance when the center of the lift
bracket upper side roller is 100 m m (3.93 in) from the
top of the inner mast.
(2) The upper lift rollers need no adjustment because they
are fixed by snap rings.
(3) Measure the clearances at the middle and lower lift
rollers after removing the side rollers.
Shift the lift bracket t o one side t o bring the roller into
contact with the inner mast, and measure the clear-
ance between the roller side face and the mast at the
closest position on the opposite side t o the follow-
ing value by inserting the lift roller shim.
Standard clearance C = 0 -
0 . 8 mm
(0 -
0.031 in)
Shim thickness: 0 . 5 and 1 .O mm
(0.020 and 0 . 0 3 9 in)
right sides. (For the shim replacement procedure, see
the lift bracket disassembly section on page 13-9.)
(5) Install the side rollers.
(6) Side roller adjustment shall be made after adjusting

the middle and lower lift rollers.
Bring the side roller on one side into contact with the
mast side surface, and make adjustment by shim in-
sertion t o make the clearance between the side roller
and inner mast side surface on the opposite side satis-
f y the following standard.
Standard clearance D = 0 - 0 . 6 mm
(0 - 0 . 0 2 4 in)
Shim thickness: 0 . 5 and 1 .O rnrn
(0.020 and 0.039 in)
(7) The shim thickness shall be distributed equally into
the left and right sides. (Shim replacement is possi-
ble on the vehicle. For the side roller installation, see
the lift bracket disassembly section on page 13-9.)
2. After the adjustment, the lift bracket should move

smoothly along the overall mast length.
Mast Strip Adjustment
Bring into contact
1. Mast strip clearance adjustment

(1) Measure the clearance with the inner mast at the bot-
tom position.
(2) With the inner mast in contact with the outer mast
roller, adjust the clearance between the mast strip and
inner mast the following value by inserting the mast
strip shim. (The shim replacement procedure is the
same as that described in the "mast roller
removal. installation" section on page 13-1 3.)
Standard clearance E = 0.5 -

I.O mm
(0.020 -
0.039 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and
0.039 in)
Shim
(3) After the adjustment, the mast should move
smoothly.
Note:
Make sure the direction of taper of the mast strip to install.
The higher tapered side should be faced out side. (See the
upper illustration)
CHAIN
INSPECTION
1. Inspect the chain elongation.
SST 09631 -22000-71
Note:
When inspecting the chain elongation, use the SST
above and inspect without removal from the vehicle.
Standard chain link pitch.
1 ton series: 15.88 mm (0.6252 in) (Type: BL534)
2 ton series: 19.05 mm (0.7500 in) (Type: BL634)
3 ton series: 25.4 mrn (1.000 in) (Type: BL823)
REASSEMBLY
Applicable FV: Lift bracket

mast and V: Lift bracket FSV: Inner mast
FSV: Lift bracket
portion
Center of Center of Front of

vehicle
0 vehicle 0
vehicle
Cotter pin Coner pin Coner pin

Sketch
Install with the cotter pin on the Install with the cotter pin on the lnstall with the cotter pin on the
vehicle center side. vehicle center side. vehicle front side.
Chain Adjusting Nut Tightening Sequence
1 Tighten nut a
and 0.
Tightening torque T = 49.03 - 78.45 N - m (500 - 800 kgf-cm)
136.18 -
57.88 ft-lbf]
13-18
ADJUSTMENT
1 Place the vehicle on a flat ground, and set the mast in the vertical position.
2 After moving the fork up and down several times without a load, check that the chain tension on
the left and right sides are equal.
3 Turn the adjusting nut so that the fork bottom surface is about t o come into contact with the ground
surface without slackening the chain.
4 Check the chains for equal tension on the left and right sides.
5 Check that the chains are no twisted.
6 Check that the maximum fork height is as specified.
FORK
REMOVAL
1. Position the fork at 20 c m (7.9 in) above the ground.
2. Place a wooden block under the notched portion of the

fork rail.
3. Unlock after lifting the fork stopper pin, and shift the fork
blades one b y one t o the center.
4. Gradually lower the fork and remove it.
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1. Inspect the fork.
Fork tip end limit misalignment: 10 mm (0.39 in)
Note:
If the tip end limit misalignment is exceeded, inspect the bend,
fork mounting looseness and lift bracket finger bar distortion
for each blade.
FV MAST ASSY
MAST ADJUSTMENT (FV MAST)
Mast Lift Roller Adjustment (FV)
lnner mast
This roller
1. lnner mast roller clearance adjustment

( 1 ) Measure the clearance with the mast overlap at near 450 mm (17.72 in). .
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and adjust
the clearance between the roller side face and mast at the closest position on the opposite side
to the following value by inserting the inner mast roller shim.
Standard clearance A = 0 -
0.8 mm (0 -
0.031 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
n This roller
Bring into contact

/ \
ill
&3 Bring into contact
Outer mast
Inner mast
2. Outer mast roller clearance adjustment

( 1 ) Measure the clearance with the mast overlap at near 4 5 0 m m (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the outer mast, and adjust
the clearance between the roller side face and mast at the closest position on the opposite side
t o the following value by inserting the outer mast roller shim:
Standard clearance B = 0 -0 . 5 mm (0 -
0.020 in)
Shim thickness: 0 . 5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally t o the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
Lift Bracket Roller Adjustment (FV)
100 mm (3.94 in)

(1 Measure the clearance when the center of the lift bracket upper side roller is 100 mm (3.94 in)
from the top of the inner mast.
(2) The upper and middle lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift roller, shift the lift bracket t o one side to bring the roller into contact with the
inner mast, and adjust the clearance between the roller side face and the mast at the closest
position on the opposite side t o the following value by inserting the lift roller shim.
0.5 m m (0 -
0.020 in)
Shim thickness: 0.5 and 1.0 rnrn (0.020 and 0.039 in)
(4) Distribute the shim thickness equally to the left and right sides.
(5) Adjust the side rollers after adjusting the lower lift rollers. Bring the side roller on one side into
contact with the mast side surface and adjust the clearance between the side roller and inner
mast on the opposite side to the following value by inserting the side roller shim:
Standard clearance D = 0 -
0.6 m m (0 -
0.024 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(6) Distribute the shim thickness equally to the left and right side rollers.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
Mast Strip Adjustment (FV)
Bring into contact

( 1 ) Measure the clearance with the inner mast at the bottom position.
(2) With the inner mast in contact with the outer mast roller, adjust the clearance between the mast
strip and inner mast t o the following value by inserting the mast strip shim.
Standard clearance E = 0 . 5 -
1.0 mm (0.020 -
0 . 0 3 9 in)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0 . 0 3 9 in)
(3) After the adjustment, the mast should move smoothly.

- - -- --
FV MAST ASSY
COMPONENTS
I ton series 6101
20
6101-411
2.3 ton series 6101

~ I A
-
20
6101-405
1 -2ton series
- --
MAST ADJUSTMENT (FSV MAST)

Mast Lift Roller Adjustment (FSV)
Outer
Middle
lnner
This ioller
1. lnner mast roller and middle mast lower roller clearance adjustment.
(1) Measure the clearance with the mast overlap at near 450 mm (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the outer mast and the mid-
dle mast, and adjust the clearance between the roller side face and mast at the closest position
on the opposite side t o the following value by inserting the inner mast roller shim and middle
mast lower shim, respectively.
Standard clearance A = 0 - -
0.8 m m (0 0.031 in)
Shim thickness: 0.5 and 1.0m m (0.020and 0.039 in)
(3) Distribute the shim thickness equally to the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
This roller
Bring into contact
Bring into contact
2. Outer mast roller and middle mast upper roller clearance adjustment.
(1) Measure the clearance with the mast overlap at near 4 5 0 mm (17.72 in).
(2) Shift the inner mast t o one side to bring the roller into contact with the inner mast and middle
mast, and adjust the clearance between the roller and mast at the closest position on the oppo-
site side to the following value by inserting the outer mast roller shim and middle mast upper
roller shim respectively.
Standard clearance B = 0 -
0 . 5 mm (0 -
0 . 0 2 0 in)
Shim thickness: 0 . 5 and 1.0 mm (0.020 and 0.039 in)
(3) Distribute the shim thickness equally t o the left and right sides.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast and the
middle mast moves smoothly in the outer mast.
Lift Bracket Roller Adjustment (FSV)
Lower lift roller
Lift Bracket

(1) Measure the clearance with the lift bracket at the uppermost position.
(2) The upper lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift rollers, shift the lift bracket t o one side t o bring the roller into contact with
the inner mast, and measure the clearance between the roller side face and the mast at the closest
position on the opposite side t o the following value by inserting the lift roller shim.
0.5 m m (0 -
0.020 in)
Shim thickness: 0.5 and 1.0 m m (0.020 and 0.039 in)
(4) Distribute the shim thickness equally t o the left and right rollers.
(5) Adjust the side rollers after adjusting the lower lift rollers.
Bring the side roller on one side into contact with the mast side surface, and adjust the clear-
ance between the side roller and inner mast side surface to the following value by inserting the
side roller shim:
Standard clearance D = 0 -
0.6 m m (0 -
0.024 in)
Shim thickness: 0.5 and 1.0 m m (0.020 -
0.039 in)
(6) Distribute the shim thickness equally to the left and right sides.
2. After the adjustment, the lift bracket should move smoothly along the overall mast length.
Mast Strip Adjustment (FSV)
I Middle mast I

(1) Measure the clearance with the inner mast or middle mast at the bottom position.
(2) With the inner mast in contact with the middle mast upper roller, adjust the clearance between
the mast strip and inner mast to the value shown below by inserting the mast strip shim.
Then, with the middle mast in contact with the outer mast roller, adjust the clearance between
the mast strip and the middle mast to the value shown below by inserting the mast strip shim.
Standard clearance E = 0 . 5 -
1.0 mm (0.020 -
0 . 0 3 9 in)
Shim thickness: 0 . 5 and 1.0 mm (0.020 -
0.039 in)
(3) After the adjustment, the mast should move smoothly.

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required t o prevent uneven lifting on the left
and right sides due to tolerances of parts, etc.
The inspection and adjustments must be made whenever any of the following parts is repalced: Lift
cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY,
and inner mast SUB-ASSY.
1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case.
Both the left and right rods stop almost simultane-
ously with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of
the inner mast shakes at the time of stopping. To cor-
rect this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches
the SST.
SST 096 10-22000-7 1
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 and 1.0 m m (0.020 and 0.039 in)
CYLINDER
Page
LlFT CYLINDER (V)
REAR LIFT CYLINDER (FV-FSV) .................... 14-2
GENERAL ..........................................................14-2
SPECIFICATIONS ................................................ 14-4
COMPONENTS ................................................... 14-5
REMOVAL*INSTALLATION ................................... 14-8
DISASSEMBLY INSPECTION-REASSEMBLY
s
(V-FV(LH). FSV) ............................................... 14- 1 0
(FV(RH)) ....................................................... 14- 1 2
FLOW REGULATOR VALVE (V-FV-FSV) .......... 14-1 4
SAFETY DOWN VALVE (V*FV-FSV) ................ 14-16
REMOVAL.INSTALLATION .................................. 14-1 7
FRONT LIFT CYLINDER (FVmFSV)..................... 14-18
GENERAL .......................................................... 14-18
SPECIFICATIONS ................................................ 14-19
COMPONENTS ................................................... 14-20
REMOVAL.INSTALLATION .................................. 14-2 1
DISASSEMBLY .REASSEMBLY ..............................14-2 1
TILT CYLINDER (V. FVaFSV) ............................. 14-23
GENERAL .......................................................... 14-23
SPECIFICATIONS ................................................ 14-23
COMPONENTS ................................................... 14- 24
DISASSEMBLY .INSPECTION.REASSEMBLY .......... 14-27

LlFT CYLINDER (V)-REAR LlFT CYLINDER (FV-FSV)
GENERAL
Lift Cylinder (V)
Safety down valve
Rear Lift Cylinder (FV)
Safety down valve

14-3
Rear Lift Cylinder (FSV)

14-4
SPECIFICATIONS
Lift Cylinder (V)

>
Vehicle model
1 ton series 2 ton series 3 ton series
Lift cylinder type Single acting +- c
Lift cylinder bore mm (in) 44.45 (1.750) 50 (1.97) 55 (2.17)
Piston rod outside diameter

34.93 (1.375) 42 (1.65) 45 (1.77)
mm (in)
Piston seal type U packing + C
Rod seal type U packing + +
Others With safety down valve c c
Vehicle model
Lift cylinder type Single acting t t
Lift cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.1 7)

32 (1.26) 34.9 (1.374) 40 (1.57)
mm (in)
Rod seal type U packing c c
Others With safety down valve (LH) c t
Vehicle model
Lift cylinder type Single acting + +
Lift cylinder bore mm (in) 44.45 (1.750) 50 (1.97) 55 (2.17)

34.93 (1.375) 42 (1.65) 45 (1.77)
mm (in)
Piston seal type U packing +- t
Rod seal type U packing t t
Others With safety down valve t t

COMPONENTS
Lift Cylinder (V)
1 4-6

6503
1 Lift bracket
Removal Procedure
1 Remove the lift bracket. (See removal procedure steps 1 to 4 in mast removal-installation section
on page, 13-5)
2 Remove the piston rod end set bolt and cylinder bottom set bolt.
3 Disconnect the piston rod end. [Point 11
5 Disconnect the hose.
6 Remove the lift cylinder support. [Point 21
7 Remove the lift cylinder ASSY.
Note:
Perform the following operations after installing the lift cylinder:
Repeat lifting and lowering t o stroke ends without load to bleed the air and to check normal operation.
After the operation check, check the hydraulic oil level and add oil i f insufficient.
Inspect the lift cylinders for uneven movements and make adjustment if necessary. (See the lift cylinder
rod shim adjustment section on page 13-31 )
Point Operations
[Point 1 I
Removal: Hoist the inner mast (middle mast) and set the
SST to the inner mast (middle mast) tie beam.
SST 0 9 6 1 0-22000-7 1
Removal: Shim adjustment is made at the lift cylinder rod

end to prevent uneven movements of the lift
cylinders RH and LH. Take a note on which side
the adjustment is made and the number of shims
used.
[Point 21
Installation: The cylinder support shall be tightened tem-

porarily here and make shim adjustment after
rod end connection.
Adjustment: With the rod end connected, insert shims be-

tween the cylinder support and outer mast t o
eliminate the clearance. The shim thickness
shall be slightly on the thicker side.
DlSASSEMBLY.INSPECTION.REASSEMBLY (V. FV(LH)-FSV)
Note:
* Oil will leak if the U packing or dust seal at the rod guide portion is defective.
Natural drop will occur if the U packing at the piston portion is defective.
1 Remove the safetly down valve.
2 Remove the cylinder cover. [Point 11
3 Remove the piston rod Wlpiston. [Point 21
4 Remove the seals from the piston side.
5 Remove the check valve.
6 Remove the lift cylinder. [Point 31
Note:
Do not install dry parts but apply hydraulic oil before reassembly.
Cylinder cover tightening torque
1 ton series T = 1 7 0 - 237 N-m (17 3 0 - 2420 kgf-cm) 112 5 - 175 ft-lbf]
2 ton series T = 203 - 271 N-m (2070 - 2760 kgf-cm) [I50 - 200 ft-lbf]
3 ton series T = 237 - 3 0 5 N - m (2420- 3 11 0 kgf-cm) [I75 - 225 ft-lbf]
14-1 1
Point Operations
[Point 1I
Disassembly. Reassembly: SST 09620-10100-71
[Point 21
Inspection: Measure the piston rod outside diameter
Unit: mm (in)

[Point 31
Inspection: Measure the lift cyinder bore.
Unit: mm (in)
DISASSEMBLY-INSPECTION-REASSEMBLY (FV (RH))
Note:
Oil will leak if the U packing or dust seal at the rod guide portion is defective.
Natural drop will occur if the U packing at the piston portion is defective.
1 Loosen the cylinder cover. [Point 11
2 Remove the cylinder cover and piston rod Wlpiston. [Point 21
3 Remove the seal from the piston side.
4 Remove the piston. [Point 31
5 Remove the lift cylinder.. [Point 41
Note:
Do not install dry parts but apply hydraulic oil before reassembly.
Cylinder cover tightening torque
1 ton series T = 170 - 237 N - m ( 1730 - 2420 kgf-cm) [ I 25 - 175 ft-lbf]
2 ton series T = 203 - 271 N -m (2070 - 2760 kgf-cm) [ I 5 0 - 200 ft-lbf]
3 ton series T = 237 - 3 0 5 N-m12420 - 3 11 0 kgf-cm) [ I 7 5 - 225 ft-lbf]
Point Operations
[Point 1I
Disassembly. Reassembly: SST 09620-10100-71
[Point 21

(See page 14-1 1 )
Inspection: Measure the piston rod bend

(See page 14- 1 1 )
[Point 31
Disassembly- Reassembly: Follow the procedure view.
1. Fix the boss portion at the tip end of the piston rod in
a vise.
2. Used a screwdriver, and rotate the piston to remove

the wire.
3. The installation procedure is the reverse.
[Point 41
Inspection: Measure the lift cylinder bore.

(See page 1 4-1 1 )
14-14
FLOW REGULATOR VALVE ( V *FVmFSV)
Specifications
Maximum pressure kPa (kgf/cm*)[psil 20590 (210)[29901 c +-
Control flow rate Urnin (US gallmin) 5 0 (13.2) 6 0 ( 15.8) 7 0 (18.5)
Lowering Speed
Unit: rnrnlsec (fprn)
V FV FSV
Vehicle mode
No load 550 ( 108) 3 5 0 (69) 4 4 0 (87)
1 ton series
Loaded 500 (98) 4 0 0 (79) 4 7 0 (93)
No load 500 (98) 380 (75) 3 8 0 (75)

2 ton series
Loaded 500 (98) 4 8 0 (94) 4 8 0 (94)
No load 4 5 0 (88) 3 5 0 (69) 3 5 0 (69)

3 ton series
Loaded 500 (98) 4 6 0 (91) 4 6 0 (91)
I
Removal Procedure
1 Lower the fork t o the bottom
2 Remove the flow regulator valve.
Note:
Flow regulator valve tightning torque
T = 58.8 - -
68.6 N-rn (600 700 kgf-cm) [43.4 - 50.6 ft-lbfl
14-16
SAFETY DOWN VALVE (V. FV.FSV)

Safety Down Valve Sectional View (for V-FV-FSV Rear Lift Clinder)
Safety Down Valve Sectional View (for FV-FSV Front Lift Cylinder)
Specifications
V lift Cylinder and FV-FSV Rear Lift Cylinder
Piston seat flow rate Urnin (US gallrnin) 6 0 (15.8) t t
Control after piston seat tlrnin (US gallrnin) 15 (4.0) +- t
-
FV-FSV Front Lift Cylinder
Piston seat flow rate tlrnin (US gallrnin) 8 0 (21.1) +- 1 2 0 (31.7)
Control after piston seat Urnin (US gallrnin) 1 9 (5.0) C 15 (4.0)

Removal Procedure
1 Disconnect the piston rod end and hoist the inner mast. [Point 11
3 Disconnect the hoses and remove the safety down valve. [Point 21
Point Operation
[Point 1 I
Removal.installation: Sling the inner mast (middle mast)

with a wire rope, and hoist it. Set the
SST on the inner mast (middle mast)
tie beam and lower the inner mast un-
til it comes into contact with the SST.
SST 0 9 6 1 0-22000-7 1
[Point 21
Inspection: Check the safety down valve orifice for

dogging.
FRONT LIFT CYLINDER (FVmFSV)
GENERAL
Front Lift Cylinder (FV)
Front Lift Cylinder (FSV)

SPECIFICATIONS
Lift Cylinder (V)
Vehicle model
1 t o n series 2 t o n series 3 t o n series
Cylinder type Single acting + c
Lift cylinder bore mm (in) 7 0 (2.76) 7 5 (2.95) 85 (3.35)

50.8 (2.00) c c
mm (in)
Piston seal type Wear ring t t
Rod seal type U packing c +

7
Others W i t h safety d o w n valve c c

COMPONENTS
Note:
0 See the lift cylinder ASSY (V) removal section for the removal of the front lift cylinder ASSY.
Perform the following operations after installation:
Repeat lifting and lowering t o stroke ends without load for air bleeding and check normal operation.
After the operation check, check the hydraulic oil level and add if insufficient.
Adjust the lift chain tension equally on the left and right sides.
DISASSEMBLY- INSPECTION. REASSEMBLY
1 Remove the safety down valve.
2 Remove the chain wheel supporter.
3 Remove the cylinder rod guide. [Point 11
4 Remove the piston rod Wtpiston [Point 21
5 Remove the check valve.
6 Remove the lift cylinder. [Point 31

Note:
Do not reassembly dry parts, but apply hydraulic oil before reassembly.
Apply liquid packing (08833 00080) on the threaded portion of the rod guide.
Rod guide tightening torque.
1 ton series T = 305 - 373 N-m (3110 -3800 kgf-cm) [225 -
275 ft-lbf]
2 ton series T = 339 - 407 N-m (3460 -4150 kgf-cm) [250 -
300 ft-lbf]
3 ton series T = 420 - 454 N-m(4280 -4630 kgf-cm) 1310 -
335 ft-lbf]
Point Operation
[Point 1I
Disassembly. Reassembly: SST 09620- 1 0 1 00-7 1
[Point 21
Unit: mm (in)
Standard outside Limit outside

diameter diameter
1 ton series 50.8 (2.00) 50.72 (1.9968)
2 ton series 50.8 (2.00) 50.72 (1.9968)
3 ton series 50.8 (2.00) 50.72 (1.9968)
[Point 31
Inspection: Measure the lift cylinder bore.
Unit: m m (in)
Standard bore Limit bore
1 ton series 70 (2.76) 70.35 (2.7697)
1 2 ton series 1 75 12.95) 1 75.35 (2.9665) 1

3 ton series 85 (3.35) 85.40 (3.3622)
TILT CYLINDER (V. FV.FSV)
GENERAL
SPECIFICATIONS
Vehicle model
Item
Cylinder'type Double action c t
Cylinder bore m m (in) 69.85 (2.750) t 76.2 (3.00)
Piston rod outside diameter m m (In) 31.75 (1.2501 c c
Piston seal type U packin c @
Rod seal type U packin + +

14-24
COMPONENTS
(TILT BOOTS)
DH
14-25
5 Mast
Removal Procedure
1 Remove the toe boad.
2 Remove the side cover.
3 Remove the battery, and remove the step. (Only in 2 and 3 ton series)
5 Slightly hoist the mast.
6 Remove the tilt cylinder rear pin. [Point 11
7 Remove the tilt cylinder front pin. [Point 21

8 Remove the tilt cylinder ASSY.
Note:
Apply MP grease on the tilt cylinder front pin and rear pin inserting portion.
Tilt the mast slowly forward and backward a few times t o confirm normal operation.
Check the hydraulic oil level and add if insufficient.
Tile the mast fully forward and backward t o check no uneven movements between the left and right
sides. To adjust uneven movements, change the screw-in amount of the rod joint.
Point Operations
[Point 1 I
Disassembly: Use a drift pin for driving out the spring pin.
I
[Point 21
Disassembly: SST 09810-20172-71

14-27
DISASSEMBLY. INSPECTION- REASSEMBLY
1 Remove the rod guide wire. [Point 11
2 Disconnect the rod guide from the tilt cylinder.
3 Remove the rod guide and piston rod W/piston.
4 Remove the tilt cylinder [Point 21
5 Remove the piston.
6 Remove the rod guide.
7 Remove the piston rod. [Point 31
8 Remove the rod joint. [Point 41
Reassembly' Procedure
The reassembly pocedure is the reverse of the disassembly procedure.
Note:
Do not disassembly dry parts but apply hydraulic oil before reassembly.
Piston castle nut tightening torque
T = 258.0 N-m ( 2 6 3 0 kgf-cm) [ I 9 0 ft-lbfl
Rod joint lock nut tightening torque
T = 333.2 - 392.0 N-m ( 3 4 0 0 - 4 0 0 0 kgf-cm) [246-2 8 9 ft-lbf]
Point Operations
[Point 1 I
Disassembly- Reassembly: Use the pipe wrench t o remove

the ring.
[Point 21
Standard bore:
1 . 2 ton series 69.85 mm (2.75 in)
3 ton series 76.2 mm (3.00 in)
Limit bore:
1 - 2 ton series 70.20 mm (2.7638 in)
3 ton series 76.55 mm (3.0138 in)
[Point 31

31.75 mm (1.250 in)
31.67 mm (1.247 in)

[Point 41
Disassembly: Put a match mark.
Reassembly: Check the match mark.

Reassembly: When the rod or rod joint is replaced, adjust
the installed dimensions t o be equal on the left
and right sides.
Forward. Dimension A Dimension L

Mast
Backward tilt (Spacer) (Reference value)
V 5.6 92 (3.62) 467 (18.39)
FV 5.10 - 444 (17.48)
1 ton series FSV 5 . 5.5 92 (3.62) 467 (18.39)
V-FV -
10. 6 467 (18.39)
FSV
6 - 8 112 (4.41 505 (19.88)
v 6 .10 - 491 (19.33)
FV
2 ton series 6. 5 131 (5.16) 524 (20.63)
FSV 6. 5 131 (5.16) 524 (20.63)
V-FV
10 - 5 131 (5.16) 524 (20.63)
FSV
6 . 8 112 (4.41) 505 (19.88)
v 6 . 10 491 (19.33)
FV
6. 5 131 (5.16) 524 (20.63)
3 ton series -
FSV 6. 5 131 (5.16) 524 (20.63)

V.FV
10.5 131 (5.16) 524 (20.63)
FSV
OIL PUMP
Page
OIL PUMP ASSY ...............................................15-2
GENERAL ......................................................15-2
SPECIFICATIONS ............................................... 15-3
COMPONENTS ..................................................15-3
DISASSEMBLY.INSPECTION.DISASSEMBLY ......... 15-5
TEST PROCEDURE ............................................ 15-7
POWER STEERING PUMP ASSY ...................... 15-9
GENERAL .......................................................... 15-9
SPECIFICATIONS ............................................... 15-9
COMPONENTS ............................................. 15-9
REMOVAL.INSTALLATION .................................. 15- 10
OIL PUMP ASSY
GENERAL
SPECIFICATIONS
2.3 ton series (STD) 1 ton series (Dust
1 ton series (STD) 2.3 ton series (36 V, roof), 2.3 ton series
dust roof) (48 V, dust roof)
Manufacture ULTRA + 4-
Oil pump kind Double gear pump + C
Oil pump type Green pump + C
Theoretical discharge rate 27.0 (1.647) 19.5 (1.120)

25.0 (1.525)
cm3/rev (in3/rev)
Discharge rate (at pump speed 29.3 (7.7)
36.4 (9.6) 39.3 (10.4)
of 1500 rpm) elmin (US gal/rnin)
&QL R? .M;taqoo
COMPONENTS
REMOVAL . INSTALLATION
1 Hydraulic oil
2 Side frame cover LH
Removal Procedure
2 Remove the side frame cover LH.
3 Disconnect the suction pipings.
5 Remove the oil pump ASSY.
Note:
Coat paste lubricant containing molybdenum disulfide on the pump spline before installation.
Clean the surface for mounting the fitting to prevent damage on the O-ring.
DISASSEMBLY-INSPECTION. REASSEMBLY
T = N - m (kgf-cm) [ft-lbfl
T = 43 - 51 (440 - 520) 131.8 - 37.61
1 Remove the cover. [Point 11
2 Remove the seals.
3 Remove the bushing set. [Point 21
4 Remove the pump gear. [Point 31
5 Remove the body. [Point 41
6 Remove the bushing set. [Point 21
7 Remove the seals.
8 Remove the cover (mounting flange).
9 Remove the oil seal.
Note:
Wash each part, blow with compressed air and apply hydraulic oil before reassembly.
Use new seals for reassembly.
15-6
Point Operations
[Point 1 I
[Point 21
Disassembly: Make a match mark. Do not damage the

bushing.
[Point 31
Dosassembly: Make a match mark. Do not damage the

gear.
Reassembly: Aligh the match marks.
[Point 41
Inspection: Inspect the depth of flaw on the inside surface

of the body.
Limit flaw depth: 0 . 0 8 mm (0.003 in)
Gear teeth
crest contact trace
TEST PROCEDURE
Note:
A bench test is required for a strict inspection, but it is impossible in an actual service. Install the oil
pump on the actual vehicle and judge the properness of the oil pump state by checking the cylinder
operation.
1. Check on the display if the battery charge is sufficient.
2. Check if the oil control valve relief pressure is as specified.
3. Raise the hydraulic oil temperature t o 5 0 -

55OC (12 2 - 1 3 1 OF), and measure the lift cylinder
full stroke operation time calculate the lifting speed.
Lifting Speed Table
V Mast Unit: mmlsec (fpm)
5FBCU15 30-5FBCU 1 5 5FBCU18 30-5FBCU18
Full load 390 (77) 320 (63) 410 (81) 310 (61)
48V
No load 640 (126) 560 (110) 640 (126) 510 (100)
Full load 300 (59) 240 (47) 310 (61) 270 (53)
36V
No load 550 (108) 450 (88) 530 (104) 470 (92)
5FBC(H)U20 30-5FBC(H)U20 *5FBC(H)U25 30-5FBC(H)U25 5FBCU30 30-5FBCU30
Full load 400 (79) 300 (59) 360 (71) 280 (55) 310 (61) 230 (45)
48V
No load 640 (126) 510 (100) 640 (126) 510 (100) 530 1104) 430 (85)
Full load 300 (59) 250 (49) 280 (55) 230 (45) 240 (47) 190 (37)
36V
No load 530 (104) 470 (92) 530 (104) 470 (92) 450 (89) 400 (79)
* The compact models are as follows:

Full Load 2 8 0 (55)
No Load 5 3 0 (10 4 )
15-8
FV-FSV Mast Unit: mmlsec (fpm)
5FBCU1 5 30-5FBCU1 5 5FBCU18 30-5FBCU18
Full load 370 (73) 290 (57) 360 (71) 300 (59)
48V
No load 600 (118) 480 (95) 580 (114) 440 (87)
Full load 270 (53) 210 (41) 280 (55) 270 (53)
36V
No load 490 (97) 380 (75) 460 (91 ) 420 (83)
5FBC(H)U20 30-5FBC(H)U20 5FBC(H)U25 30-5FBC(H)U25 5FBCU30 30-5FBCU30
Full load 350 (69) 280 (55) 320 (63) 260 (51) 290 (57) 220 (43)
48V
No load 580 (114) 440 (87) 580 (114) 440 (87) 460 (91) 360 (71)
Full load 270 (53) 250 (49) FSV:

FV: 260
250 (51)
(49) 220 (43) 210 (41) 190 (37)
36V
No load 460 (91) 420 (83) 460 (91 ) 420 (83) 380 (75) 340 (67)
15-9
POWER STEERING PUMP ASSY

GENERAL
SPECIFICATIONS
Pump type TCP-03 1 -C
Discharge (15 0 0 rpm) Plmin (USgalImin) Approx. 5.5 (1.45)
Theoretical discharge cc (in3)/rev 4.0 (0.244)
COMPONENTS
4510
01
r---
OlKf A F
BR
tf80
L
.
.. ...J
411041Ce
15-10
1 Hydraulic oil
2 Side cover RH
3 Toe board
8
Removal Procedure
4 Remove the step.
5 Disconnect the power steering motor wiring.
6 Disconnect the suction hose.
8 Remove the power steering motor Wlpower steering pump.
9 Disconnect the power steering pump from the power steering motor
Note:
Coat paste lubricant containing molybdenum disulfide on the oldham joint before installation.
PS pump set bolt tightening torque
T = 31.4 -37.3 N-m (320 - 380 kgf-cml t23.2 -27.5 ft-lbfl
OIL CONTROL VALVE
Page
GENERAL ............................................................16-2
SPECIFICATIONS ................................................ 16-3
COMPONENTS .................................................... 16-4
OIL CONTROL VALVE ASSY ............................. 16-5
REMOVAL INSTALLATION ................................... 16-5
rn
DISASSEMBLY .INSPECTION REASSEMBLY ............ 16-6

rn
ADJUSTMENT ..................................................... 16-8

CONTROL VALVE LINK ...................................... 16-9
COMPONENTS .................................................... 16-9
16-2
GENERAL
Oil Control Valve
Hydraulic Circuit
Tilt relief valve
Inlet section. section
Main relief valve (For lift)
\ Tilt Spool section

Lift spool section
Power steering
Gouge port T-'

I
I I
Vehicle model
All models
Item
Oil control valve type Add-on type
Relief set pressure Lift 171 6 0 (175) 124901

kPa (kgt/cm2) [psi]
Tilt 15690 (160) [22801
Others Built-in tilt lock valve

COMPONENTS
OIL CONTROL VALVE ASSY
Note:
Before disconnecting the control lever link, release the residual pressure in the material handling system
piping by operating the control lever, set the mast in the neutral state and lowering the fork to the bot-
tom position.
T = N - m (kgf-cm) [ft-lbfl
Removal Procedure
4 Disconnect the control valve lever link.
5 Remove the oil control valve ASSY.
lnstallatioin Procedure
Note:
Check the hydraulic oil level, and add oil to the specified level if insufficient.
Coat grease on the oil control valve lever link.
Note:
Operate in a clean place.
As each part is finished with high precision, carefully disassemble them to prevent any damage.
1 Remove the through bolt.
2 Separate each housing.
3 Remove the O-ring, spring and check valve.
4 Remove the seal holder.
5 Remove the spring holder.
6 Remove the spool Wlspring.
7 Remove the spring. [Point 11
8 Remove the tilt lock valve (tile spool only). [Point 21
9 Remove the relief valve. [Point 31

Note:
Wash each part thoroughly, blow with compressed air and apply hydraulic oil before reassembly.
Top tie rod: T = 40.0 -

Tightening torque for each part is as follows:
-
49.4 N.m (409 -- 504 kgf-cm) [295 -- 365 ft-lbfl
Bottom t w o tie rods: T = 17.0 -- 21.0 N.m (173 214 kgf-cm) L12.5 -- 15.5 ft-lbfl
Point Operations
[Point 1I
Disassembly: Be careful as the spring may jump out.
[Point 21
Inspection: Check the tilt lock valve orifice for clogging.
[Point 31
Reassembly: When the relief valve is disassembled, always

loosen the adjust screw fully.
RELIEF PRESSURE ADJUSTMENT
Note:
Make adjustment always according to the following procedure. Random adjustment may generate
a high pressure to damage the oil pump and other hydraulic equipment.
No adjustment is required when the relief valve is not assembled or is replaced with a new part.
1 Remove the plug (9116- 18UNF-2B) on top of the oil control valve, and install an oil pressure gauge.
Oil pressure gauge: Pressure resistance at 19610 kPa (200 kgf/cm2, 2840 psi) or more.
2 Loosen the lift relief valve adjusting screw.

Loosen the lock nut, and loosen the adjusting screw to a degree not coming off from the body.
3 Adjust the hydraulic pressure.

(1 ) Turn the key switch to ON.
(2) Set the lift lever slowly to the lift position, and tighten the adjusting screw gradually before the
fork starts to rise.
(3) Lift the fork fully to the maximum height, and read the hydraulic pressure at the position. Tight-
en the adjusting screw so that the pressure at the time becomes normal.
(4) Tighten the lock nut and check the hydraulic pressure again.
4 Adjust the tilt relief hydraulic pressure.
Note:
Follow the same procedure as that for lifting.
Tilt the mast fully backward when measuring the hydraulic pressure.
Relief Pressure Table kPa (kgf/cm 2) [psi]
Lift 17 160 ( 1 75) 124901

Relief pressure
16-9
OIL CONTROL VALVE LINK

COMPONENTS
Oil Control Valve Link Components

APPENDIX
Page
SST LIST ...........................................................17-2
SERVICE STANDARDS LIST ............................ 17-5
CONNECTOR DRAWING .................................. 17-17
CPU BOARD & DCISD BOARD
CONNECTOR DRAWING ................................ I 7-23
CONNECTING DIAGRAM .................................. 17-27
WIRING DIAGRAM ............................................ 17-28
SST LIST
Section
Part Name
2 4 5 6 7 8 9 I0131416
Part No.
Illustration
Universal joint
09330-30010 flange holding 0
tool
Rear wheel
09509-55020 bearing nut 0
wrench
Front hub & drive

09608-30012 pinion bearing 0
@oos tool set
Axle hub & drive

09608-35014 pinion bearing 0 0
tool set
Steering wheel
09609-2001 1 0
puller
Pitman arm
0961 0-2001 2 0 0
puller
Steering gear box

09620-30010 0
replacer
Brake shoe return

Og7' 7-2001 0
spring remover
Brake shoe
0971 8-20010 return spring 0
replacer
a 09905-0001
Snap ring
expander, No. 1
0
Universal
09950-20017 0 0 0 0
puller
*& ez
0
g
‘, 2
- .
=
&\Jr
9&
@a
09950-40010 Puller B set 0 0 0 0
Section
Part Name
2 4 5 6 7 8 910131416
Part No.
Illustration
Front axle hub

09310-10160-71
09310-22000-71
2nd drive shaft
0 09421 -33020-71
Front axle hub
replacer
0
09450-23610-71 Adaptor 0
17-5
SERVICE STANDARDS LIST

BATTERY
Specific gravity full discharge (at 20°C) (68OF) 1.280
Specific gravity at the end of discharge (at 20°C) (68OF) 1.150
36 V model -
Final discharge voltage
48 V model -
Insulation resistance 1 MQ or more
CONTROLLER
@ and @ represent the positive (red) probe and negative (black) probe of the circuit tester

CPU board & DC-SD board See text (page 2-1 9)
PS controller See text (page 2-52)
Display See text (page 2-30)
F1 (Drive fuse) A 275 325 c
F2 (Pump fuse) A 225 325 +
F3 (Power steering fuse) A 75 c +
F4 (Lamp fuse) A 10 c t
F5 (Control circuit fuse) 10 c +
D O s o 00
TM.TMP DO So 00
conduction Q Do GO 00
Tester range DO G@ Conduction

n x IK G@ s3 @ Conduction
00
G O S O
DRD See text (page 2-1 2)
TG B@ c@ Conduction
conduction Q B@ c@ 00
Tester range c@ E@ w
Q x lK c@ E @ Conduction
DFI .DF2 Foward Anode @ probe - Cathode @ probe : About 3
conduction KQ
(Tester range Q x 1 K) Reverse Anode @ probe - Cathode probe : 00
DG.DF3 (with material handling Foward Anode @ probe - Cathode @ probe : About 3
chopper) conduction KQ
(Tester range D x 1 K Reverse Anode @probe - Cathode @probe : 00
DF3 (without material handling Foward Anode @ probe - Cathode @ probe : About 30
chopper) conduction KQ
(Tester range Q x 1 K) Reverse Anode @ probe - Cathode @ probe : 00
DAD.DAP Foward Anode @ probe - Cathode @ probe : About 6

conduction KQ
(Tester range Q x 1 K) Reverse Anode @ probe - Cathode @ probe : m
When the tester probes are brought into contact with the
CAD.CAP conduction CAD and CAP terminals, the pointer initially diflects, then
gradually returns until it finally indicates oo.
(Tester range O x IK)
(As CAD and CAP is charged by the current from the tester.)
MF.MR.MS.MG.MW.MP
Coil resistance Q 20 (20°C) (68OF)
(Tester range fl x 1
RG resistance
(Tester range n x I) n 0.6~
A ~ O U
RAD-RAP resistance
(Tester range $2x I) n A ~ O U1.5
~
RFW resistance
(Tester range nx I n See text (page 2-1 8)
OCL value
(Drive circuit) A 440 + 50 620 a 60 +
Tightening torque N.m (kg-cm) [ft-lbl
Traveling circuit
M5 2.13- 2.75 (22- 28) [ I .59-2.031

For harness set
TM M4 1.18- 1.77 (12-18) [O.87-1.301
For mounting M5 2.13-2.75 (22-28) [ I .59-2.031
For harness set M6 3.1 4 - 3.73 (32- 38) I2.32-2.751

DF 1 .DF2
For mounting M6 3.14- 3.73 (32-38) [2.32-2.751
For harness set M6 4.61 - 5.20 (47- 53) l3.40-3.831

DG
For mounting M20 21.28- 21.87 (217-223) [15.70-16.131
DAD For mounting M6 2.13- 2.75 (22-28) [ I .59-2.031
For harness set M5 2.13- 2.75 (22-28) l1.59-2.031

TG
For mounting M5 2.1 3 - 2.75 (22- 28) [I
.59-2.031
Material handling system circuit N.m (kgf-cm) [ft-lbfl
STD (Chopper-Less)
DF3 For harness set M6 2.1 3- 2.75 (22- 28) [ I .59-2.031
OPT (with chopper)
M5 2.13- 2.75 (22- 28) [1.59-2.031

For harness set
TMP M4 1.18- 1.77 (12- 18) [0.87-1.301
For mounting M5 2.13- 2.75 (22-28) [1.59-2.031
DAP For mounting M6 2.13- 2.75 (22-28) i1.59-2.031
For harness set M6 4.61 - 5.20 (47- 53) 13.40-3.831

DF3
For mounting M20 21.28-21.87(217-223)[15.70-16.131
Power steering circuit
For harness set M5 1.96- 2.94 (20-30) [1.45-2.171

TMps
For mounting M5 1.96- 2.94 (20- 30) [ I .45-2.171
Accelerator Potentio-Meter
Clearance between accelerator link 1.0 mm (0.039 in) Switch must be turned on.
stopper and toe board 2.0 mm (0.079 in) Switch must be turned off.
Tightening torque for set-screw N-m (kg-cm) [ft-lb] 1.57- 2.35 (16- 24) [ I .I
6 - 1.741
Brake Switch (LSB)

Standard type 23 (0.91
Switch roller end projection out of switch bracket
Valve for reference mm (in) Rust proof type 25 (0.98)
(Cold storage)
Non-manipulation 0
Switch ON, OFF (Continuity) !J
With manipulation m
Clearance between brake arm and stopper bolt, and 3 mm (0.12 in) 0
cl
switch ON, OFF (Continuity) 6 mm (0.24 in) 00
Parking Brake Switch (LSPB)
Non-manipulation 0
Switch ON, OFF (Continuity) s2
With manipulation 03
Clearance between lever and switch

mm (in) 1 .O-t 0.2 (0.039k 0.008)
(at lever returned position)
Material Handling System Switches
Switch (LSLI) ON timing m m (in)

Turned on at 5 -2 0 (0.20 - 0.79)
from neutral point.
Switch (LSLZ)OFF timing rnm (in)
25 (0.98)
(From bracket t o roller end) (Value for reference)
Standard type 4 . 5 k 0.5 (0.177 k 0.020)
Clearance between switch roller and
lever plate ( L S L ~ ) mm (in) Rust proof type
3.5k0.5 (0.138k0.020)
(Cold storage)
Direction Switch
Lever position
Neutral Forward Reverse
Limit switch
DSF con on 00n
DSR a n 03 n on
DSFO a Q on a n
DSBU con a n on
MOTOR
Drive Motor
Armature coil insulation resistance More than 1 MQ
Commutator outside Standard 106 (4.17) 1 3 0 (5.12)

diameter m m (in)
Limit 9 7 (3.82) 121 (4.76)
Standard 1.2 (0.047)
Undercut m m (in)
Limit 0.8 (0.031)
Field coil conduction
E -F 0
(Tester range Q x l )
Field coil insulation
resistance Field -E More than 1 MQ
F
New 38.1 (1.500) 44.5 (1.752)
Brush length m m (in)
Limit 21.1 (0.831) 24.5 (0.965)
12.7 15.7
Brush pressure (max.) N (kgf) Ilbfl (1.3) (1.6)
12.91 13.51
Brush holder insulation resistance More than 1 MQ
Pump Motor

Armature coil insulation resistance More than 1 MQ
Commutator outside Standard 72 (2.83) 106 (4.17)

mm (in)
diameter Limit 9 7 (3.82)
63.5 (2.50)
Undercut mrn (in)
Limit 0.8 (0.031)
Field coil conduction
(Tester range Q x 1) Q A -F 0
Field coil insulation

Field -FA More than 1 MQ
resistance
New 38.1 (1.500) t
Brush length mrn (in)
Limit 21.1 (0.831) t
12.7
Brush pressure (max.) N (kgf) [Ibfl 1.3 t
2.9
Brush holder insulation resistance More than 1 MQ
Power Steering Motor
Armature coil insulation resistance More than 1 MO
Commutator outside Standard 57.2 (2.252)

diameter mm (in) Limit 54.6 (2.1 50)

Undercut mm (in)
Limit 0.3 (0.01 2)
New 28.4 (1.118)

Brush length mm (in)
Limit 20.4 (0.803)
Brush pressure N (kgf) [Ibfl Standard 4.9 - 8.8 (0.5 - 0.9) 11.1 - 2.01
Brush holder insulation resistance More than 1 MO
DRIVE UNIT
Ring gear face runout on rear side
Limit 0.1 (0.0039)
mm (in)
Ring gear backlash mm (in) Standard 0.2 - 0.3 (0.008 - 0.012)

Standard 22.00 (0.8661
Spider outside diameter mm (in)
Limit 21.75 (0.8563)
Output gear & Standard 1.6 (0.063)
Thrust washer thickness
differential mm (in)
(differential pinion side) Limit 1 .O (0.039)
Thrust washer thickness mm (in) Standard 1.6 (0.063)

(side gear side) Limit 1.3 (0.051)
Standard 13.0 (0.51 2)
Thrust screw cap length mm (in)
(Only for 1 ton series) Limit 1 1.5 (0.453)
Tightening torque N.m (kgf-cm) [ft-lbfl
127.49 - 176.52
Ring gear set bolt
(1300 - 1800) [94.06 - 130.231
Output gear lock nut
343.23 -392.27
(3500 - 4000) 1253.23 -
289.401
Output gear & drive pinion ASSY set bolt

88.26 - 117.68
(900 - 1200) [65.12 -
86.821
117.68 -137.29
Bearing cap set bolt
(1200 - 1400) [86.82 -
101.291
102.97 - 127.49
Thrust screw lock nut
(1050 - 1300) I75.97 - 94.061
FRONT AXLE
Tightening torque N.m (kg-cm) [ft-lbl 1 ton series 2.3 ton series
68.65 - 88.26 166.71 - 205.94
Brake drum set nut (700 - 900) (1700 - 2100)
[50.65 - 65.1 21 1123.00 - 151.941
14.71 - 21.57
Hub bearing nut stopper bolt (150 - 220) c
110.85 - 15.921
39.23 - 53.94 58.84 - 78.45
Front axle shaft set nut (400 - 550) (600 - 800)
128.94 - 39.791 143.41 - 21.571
107.87 - 196.13 294.2 - 323.62
Front Axle hub nut (1100 - 2000) (3000 - 3300)
179.59- 144.701 [217.05 - 238.761
17-1 2
REAR AXLE
Rear axle hub and steering knuckle
Rear axle wheel starting force 1 ton series Standard 6.9 - 19.6 (0.7 - 2.0) [1.5 - 4.41
(at outer periphery of the wheel)
N (kgf) [ ~ b f ] 2.3 ton series Standard 9.8 - 29.4 (1.0 - 3.0) [2.2 - 6.61
Standard 28.0 (1.102)
King pin outside diameter mm (in)
Limit 27.8 (1.094)
Steering knuckle starting force

(at front end of knuckle)
N (kgf) [Ibf] Standard 29 - 49 (3 - 5) 16.6 - 11.01
Rear axle cylinder

1 ton series: 40.0 (1.575)
Standard 2.3 ton series: 50.0 (1.969)
Piston rod outside diameter rnm (in)
1 ton series: 39.92(1.5717)
Limit
2.3 ton series: 49.92 (1.9654)
Piston rod bend mm (in) Limit 0.5 (0.020)
1 ton series: 60.3 (2.374)
Standard
2-3ton series: 76.2 (3.000)
Cylinder bore mm (in) 1 ton series: 60.65 (2.3878)
Limit 2.3 ton series: 76.55 (3.0138)
Tightening torque Unit: N.m (kgf-cm) [ft-lbfl
Rear axle support set bolt Standard 1 17.68 - 166.71 (1200 - 1700) 186.82 - 123.01
King pin lock bolt, lock nut Standard 19.61 - 31.38 (200 - 320) 114.47 - 23.1 51
Tie rod end castle

1 ton series Standard - 98.07 (700 - 1000) i50.65 - 72.351
68.65
nut 2 - 3 ton series Standard 147.10 - 196.13 (1500 - 2000) I108.53 - 144.701
Rear axle cylinder

2 - 3 ton series Standard 88.3 - 95.1 (900 - 970) 165 - 701
tie rod nut
Rear axle cylinder

1 ton series Standard - 68.65 (500 - 700) 136.18 - 50.651
49.03
ASSY set bolt 2.3 ton series Standard 166.71 - 21 5.75 (1700 - 2200) [ I 23.00 - 159.171
STEERING
Hydrostatic steering valve ASSY
Relief valve set pressure

I
Standard
I
1 ton series: 5880 2 490 (60 k 5) 1850 + 701

I
kPa (kgf/cm2) [psi] 2.3 ton series: 7850 k 490 (80 +
5) 11140 + 701
Tightening torque Unit: N-m (kgf-cm) [ft-lbfl
I I
Steering valve set bolt Standard 44.13 - 53.94 (450 - 550) [32.56 - 39.791
Steering wheel set nut Standard 19.61 - 29.42 (200 - 300) [14.47 - 21.711
Steering valve set bolt Standard 44.13 - 53.94 (450 - 550) L32.56 - 39.791
Steering valve End cap set screw Standard 31.09 (317) [22.93]
BRAKE
Item 1 ton series 2.3 ton series
Front brake
Standard 254 (10.00) 310 (12.20)

.
Brake drum inside diameter mm (in)
Limit 256 (10.08) 312 (12.28)
Brake Shoe return spring free length 124 (4.88)

Standard 102 (4.02)
mm (in)
Adjuster actuator spring free length 88 (3.46)

Standard 79 (3.11)
mm (in)
Shoe hold down spring free length 25.7 (1.012)

Standard 25.7 (1.012)
mm (in)
Standard 5.0 (0.197) 5.6 (0.220)

Brake lining thickness mm (in)
limit 1 .O (0.039) 2.0 (0.079)
Gap between wheel cylinder and piston 0.040 - 0.0125 0.054 - 0.087
mm (in)
Standard
(0.001 57 - 0.000492) (0.00213 - 0.00343)
Parking brake
N 196 - 245 245 - 294

Brake lever opening force (kg) Standard (20 - 25) (25 - 30)
[Ibl [44 - 551 [55 - 661
Brake pedal
Brake pedal height (with pad) mm (in) Standard 141 (5.51) - 145 (5.71) 141 (5.51) - 145 (5.71)
Brake pedal play mm (in) Standard .3 - 7 (0.12 - 0.28) 3 - 7 (0.1 2 - 0.281
Depressed pedal height mm (in) Standard 95 (3.74) 87 (3.43)
Tightening torque N.m (kgf-cm) [ft-lbf]
1 17.68 - 137.29 49.03 - 78.45

Brake backing plate set nut Standard (1200 - 1400) (500 - 800)
186.82 - 101.291 136.18 - 57.881
7.85 - 11.77 17.65 - 26.48

Wheel cylinder set bolt Standard (80 - 120) (180 - 270)
[5.79 - 8.681 [13.02 - 19.531
Natural drop test
1 ton series Standard 90 (3.54) or less

Natural drop mm (in) 2 ton series Standard t
3 ton series Standard t
Natural forward tilt test
1 ton series Standard 3 0 (1.18) or less

Natural forward tilt mm (in) 2 ton series Standard 50 (1.97) or less
3 ton series Standard 60 (2.36) or less
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard 16 (0.98) or less
Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3) Standard 3 2 (1.95) or less
MAST
Mast adjustment (V mast)
Inner mast roller

Mast clearance mm (in)
Standard 0 - 0.8 ( 0 - 0.031)
rollers
Outer mast roller
clearance mm (in)
Standard 0 - 0.51 ( 0 - 0.0201
Lift
Middle and lower lift
roller clearance mm (in)
Standard 0 - 0.8 (0 - 0.031 )
bracket
rollers Side roller clearance
mm (in)
Standard 0 - 0.6 (0 - 0.024)
Mast strip t o inner mast
clearance mm (in)
Standard 0.5 - 1.0 (0.020 - 0.039)
Fork
Fork front end misalignment mm (in) Limit 1 0 (0.39)
Tightening torque Unit: N-m (kgf-cm) [ft-lbfl

Mast support cap set bolt Standard 68.65- 107.87 (700 - 1100) 150.65 - 79.591
Back rest set bolt Standard 99.54 - 184.86 (1015 - 1885) l73.44 - 136.381
Chain adjusting nut Standard 49.03 - 78.45 (500 - 800) 136.1 8 - 57.881
-
CYLINDERS
Lift cylinder
Standard 34.93 (1.375)
1 ton series
Limit 34.85 (1.3720)
v Standard 42 (1.65)
2 ton series
FSV Limit 41.92 (1 1.6504)
Standard 45 (1.77)
3 ton series
Piston rod outside diameter Limit 44.92 (1.7685)
m m (in) Standard 32 (1.26)
1 ton series
Limit 31.92 (1.2567)
Standard 34.9 (1.374)
FV 2 t o n series .
Limit 34.82 ( 1.3709)
Standard 40 (1.57)
3 ton series
Limit 39.92 (1.5717)
V-FSV 44.45 (1.750)
Standard FV 45 (1.77)
1 ton series V.FSV 44.65 (1.7579)
Limit FV 45.20 (1.7795)
Standard 50 (1.97)
Lift cylinder bore mrn (in) 2 ton series
Limit 50.20 (1.9764)
Standard 55 (2.17)
3 ton series
Limit 55.35 (2.1791
Front lift cylinder (FV-FSV)
Standard 70 (2.76)
1 ton series
Limit 70.35 (2.7697)
Standard 75 (2.95)
Lift cylinder bore m m (in) 2 ton series
Limit 75.35 (2.9665)
Standard 85 (3.35)
3 ton series
Limit 85.40(3.3622)
1 ton series
Limit 50.72(1.9968)
Standard 50.8(2.00)
Piston rod outside diameter m m (in) 2 ton series
Limit 50.72(1.9968)
Standard 50.8(2.00)
3 ton series
Limit 50.72(1.9968)
Tilt cylinder
1.2 ton series: 69.85 (1.250)
Standard 3 ton series: 76.20 (3.000)
Cylinder bore rnrn (in)
1.2 ton series: 70.20 (2.7638)
Limit 3 ton series: 76.55 (3.0138)
Piston rod outside diameter Standard 31.95 (1.250)

rnrn (in) Limit 31.67 (1.247)
Piston rod bend rnrn (in) Limit 1 .O (0.039)
Tightening torque Unit: Nern (kgf-crn) [ft-lbfl

1 ton series: 170 - 237 (1730 - 2420) [ I 25 - 1751
Lift cylinder cover Standard 2 ton series: 203 - 271 (2070 - 2760) [ I 50 - 2001
3 ton series: 237 - 305 (2420 - 31 10) [ I 75 - 2251
Flow regulator valve Standard 58.8 - 68.6 (600 - 700) [43.4 - 50.61
Front lift cylinder rod guide Standard

1 ton series: 305
2 ton series: 339
- 373 (3110 - 3800) [225 - 2751
- 407 (3460 - 41 50) [250 - 3001
3 ton series: 420 - 454 (4280 - 4630) [310 - 3351
Tilt cylinder piston castle nut Standard 258.0 (2630) [ I 901
Tilt cylinder rod joint look nut Standard 333.2 - 392.0 (3400 - 4000) [246 - 2891
OIL PUMP
Oil pump ASSY
Body inside surface flaw depth mrn (in) Limit 0.08 (0.003)
Tightening torque Unit: N.rn (kgf-crn) [ft-lbfl
Through bolt Standard 43 - 51 [440 - 520) 131.8 - 37.61

OIL CONTROL VALVE
Oil control valve
Relief set pressure Lift Standard 1 5690 (160) 122801

kPa (kgf/crn2) [psi] Tilt Standard 171 60 (175) 124901
Tightening torque Unit: N.m (kgf-crn) [ft-lbfl
Top tie rod Standard 40.0 - -

49.4 (409 504) l29.5 - 36.51
Bottom two tie rod Standard 17.0 - 21.0 (173 - 214) [12.5 - 15.51
CONNECTOR DRAWING
TAB REC
REC
&CN10&
TAB REC
TAB
TAB REC
TAB REC
TAB REC
TAB REC
TAB REC
14
TAB REC
mj -
TAB REC
TAB REC
TAB REC
TAB
TAB REC
a CN21 TAB REC

TAB REC
TAB REC
TAB REC
TAB REC
TAB REC
REC
TAB REC
TAB REC
TAB REC
(JOINT CONNECTOR 1
TAB
REC
TAB REC
TAB REC
TAB REC
CNl 00
REC
TAB REC
TAB REC
TAB REC
ElCN1l 6 Q
TAB REC
TAB REC
-
TAB REC
ONLY FOR EE DUST-PROOF Y FOR EN'S

M
@C N 5 0 Q
TAB REC
CN53
0
CN5-2
CN22-
CNlO-I
rn
N 1 06-5
CNl-1
CN47-2
NN2.-.
CN17-1C N 1 2 - 1 ~ ~ 1 3 - 1
CN100-3 J4 N24-2
CN34-2 N33- N31-2
u
I1 1 1 . SLL ( 1 10. GR)

w
CN 1 6-4
CN4- 1 CN 1 6-3 CN3-1 CN 1 6- 1
CN7- 1 CN 100-4
CN 1 00- 1 CN5- I
m 0 PI TERMINAL
(Pi.0)
CN 1 3-4 CN8-3 CN 1 00-2
CN34- b' CN8-2

( 108. BR) 1 109. G-Y)
CN33-4 A
CN37-19
(43.L )
. Y
P O R T I O N OF M A I N H A R N E S S
CN13-1 CN17-1
CN14-3 A L. CN18-3 A L.
MIdQ MIdQ
PORTION OF FR PILLAR HARNESS
CN23-2-2
w
PORTION OF RR OPTION HARNESS
CPU BOARD & DCISD BOARD CONNECTOR DRAWING
CNlOl
CNl I I
No. P No. P
1 74 11 11
2 74 12 -
3 76 13 14
4 36 14 35
5 31 15 30
6 15 16 33
7 71 17 38
8 72 18 73
9 32 19 73
10 75 20 37
CONNECTING DIAGRAM
JOINT CONNECTOR
.I (PI. R)
F3 FUSE
CW38-3
ST0 7
EE. rlln E W S I
z; 52 bF 1
WIRING DIAGRAM
I.THIS DRAWING SHOWS

OISP mmr- CASE OF FULL OPTION
S 2 . N O SPEED CONTROL SW ITCH
I N CASE OF USA ( U L ) .
USE a LOUWIK ~ E LESSR (X EHPS LESS

USE

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FOREWORD

Thjs manual covers the service procedures of the TOYOTA BATTERY

TOYOTA MOTOR CORPORATION

Load Capacity Model

High capacity 2-ton

High capacity 2-ton

Above side frame of LH

Example of description in pattern B

DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T = N - m (kgf-cm) [ft-lbfl

If a place or part cannot be indi-

Oil Pump Disassembly Procedure

2 Remove the bush [Point 2 l o O p e r a t i o n explained on a laterpage

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

3. Matters omitted in this manual

Standard: Values showing allowable range in inspection and adjustment.

LIST OF ABBREVIATIONS AND SYMBOLS

(7) Use genuine Toyota parts for replacement.

3. Grasping the troule state

Measurement result example

Analog type Digital type

The resistance values of the same semiconductor mea-

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

3. Difference in measurement result by measurement range (analog type)

Always use the range described in the repair manual

STANDARD BOLT & NUT TIGHTENING TORQUE

BOLT STRENGTH TYPE IDENTIFICATION METHOD

Shape and class Class Hexagon head bolt

Hexagon Two protruding

TIGHTENING TORQUE TABLE

16 1.5 113 f 1150 1 83 - I

6 1 .O 7.8 1 80 1 69 in-lbf 8.8 1 90 1

1. Do not use the precoat bolt as it is in either of the fol-

2. Method for reuse of precoat bolts

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

Standard tightening torque N-m (kgf-cm) [ft-lbfl Hose inside

WlRE ROPE SUSPENSION ANGLE LIST

0O 1.OO time 0 time

h0 1 20° 2.00 time 1.73 time

5FBCU20 480 (1058)

Counter Weight 5FBCU25 825 (1819)

Mast WILift bracket (with Lift cylinder,

3 ton series 6 0 0 (1323)

Note: Refer t o Page 1 - 2 for the battery weight.

Hydraulic oil STD: Hydraulic oil I S 0 VG32 (Daph- 1.5 ton

Brake oil STD: SAE J-1703 DOT-3

Grease *** STD: MP Grease No.2

*** For 6000 mm (236 in) maximum fork height.

HYDRAULIC OIL CAPACITY DEPENDING ON FORK HEIGHT

GREASE ON MICRO SWITCH FOR

I 1. Chain I Inspect every 8 hours (daily)

2. Mast support bushing I1 lnspect every 40 hours (weekly)

Inspection Period Months 1 3 6 12

Cracks at fork root and welded part I*

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Differential and transmission oil •

Power steering hose

Internal rubber parts of power steering system

Material handling hose

WEIGHT OF BATTERY WICASE

Installed battery Battery case

t t 18E100-17 800 t 578

t t 24c85-17 1 680 1 166