8FG(D)U15-32, 8FGCU20-32 Repair Manual Supplement …dealerapplications.tmhna.com/TechInfo/TechnicalDocs//service... · FOREWORD This manual covers the service procedures of the TOYOTA

8FGU 15, 18, 20, 25, 30, 328FDU 15, 18, 20, 25, 30, 3262-8FDU 15, 18, 20, 25, 308FGCU 20, 25, 30, 32

Pub. No. CE118

Supplement

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 8FGU/8FDU15 to 32 series, 62-8FDU15 to 30 series and 8FGCU20 to 32 series. Please use this manual for providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of March 2016. Please understand that disagreement can take place between the descriptions in the manual and actual vehi-cles due to change in design and specifications. Any change or modifications thereaf-ter will be informed by Toyota Industrial Equipment Parts & Service News.

For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual.

(Reference)Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 8FGU/8FDU15 to 32 series and 8FGCU20 to 32 series REPAIR MANUAL VOL.1/VOL.2 (No. CU052/CU053)

TOYOTA INDUSTRIAL EQUIPMENT 8FGU/8FDU15 to 32 series and 8FGCU20 to 32 series REPAIR MANUAL Supplement (No. CU066 and CE106)

TOYOTA INDUSTROAL EQUIPMENT 1ZS ENGINEREPAIR MANUAL (No.CE304-1)

TOYOTA INDUSTROAL EQUIPMENT 4Y ENGINEREPAIR MANUAL (No.CE663)

TOYOTA INDUSTROAL EQUIPMENT 1DZ-II ENGINEREPAIR MANUAL (No.CE664)

Foreword.fm 1 ページ２０１４年３月１２日　水曜日　午後１時３９分

i

Table of Contents1 GENERAL................................................................................................. 2

2 STEERING ................................................................................................ 5

3 MATERIAL HANDLING SYSTEM .......................................................... 17

4 OIL PUMP ............................................................................................... 22

5 OIL CONTROL VALVE........................................................................... 25

6 SAS/OPS ................................................................................................ 52

7 DISPLAY................................................................................................. 55

8 TROUBLESHOOTING.......................................................................... 152

9 WIRING DIAGRAM............................................................................... 203

10 SST LIST AND SERVICE STANDARDS LIST..................................... 217

1-2 1 GENERAL

1 GENERAL

1.1 VEHICLE MODELPneumatic Tire Models (Pn)Classification

Load Capacity Vehicle Model Transmis-sion Type Engine

Series Model

Pn1 ton series

Pn15 3000 lbs8FGU15 T/C

4YE(4YM)

Gasoline

8FDU15 T/C 1ZSDiesel

62-8FDU15 T/C 1DZ-II


4YE(4YM)

Gasoline



Pn2 ton series


4YE(4YM)

Gasoline




4YE(4YM)

Gasoline



Pn3 ton seriesPn30 6000 lbs

8FGU30 T/C4YE

(4YM)Gasoline



Pn32 6500 lbs*8FGU32 T/C 4YE Gasoline*8FDU32 T/C 1ZS Diesel

Cushion Tire Models (Cu)Classification

Load Capacity Vehicle Model TransmissionType Engine

Series Model

Cu2 ton seriesCu20 4000 lbs 8FGCU20 T/C 4YE GasolineCu25 5000 lbs 8FGCU25 T/C 4YE Gasoline

Cu3 ton seriesCu30 6000 lbs 8FGCU30 T/C 4YE GasolineCu32 6500 lbs *8FGCU32 T/C 4YE Gasoline

*: For USA, CANADA, MEXICO and HAWAII Only4YM: Option for South America1DZ-II: Standard for South AmericaT/C: Model with torque converter

1-31 GENERAL

1.2 FRAME NUMBERFrame No. Punching Position

Punching position

1

1-4 1 GENERAL

Pneumatic tire

SeriesCapacity(L.C.24inch)lbs.

Engine Vehicle model Punching format

Pn1 ton series

3000 4YE(4YM)

8FGU158FGU18-60011

3500 8FGU183000

1ZS8FDU15

8FDU18-600113500 8FDU183000

1DZ-II62-8FDU15

608FDU18-600113500 62-8FDU18

Pn2 ton series

4000 4YE(4YM)

8FGU208FGU25-60011

5000 8FGU254000

1ZS8FDU20

8FDU25-600115000 8FDU254000

1DZ-II62-8FDU20

608FDU25-600115000 62-8FDU25

Pn3 ton series

6000 4YE(4YM)

8FGU308FGU32-60011

6500 8FGU326000

1ZS8FDU30

8FDU32-600116500 8FDU326000 1DZ-II 62-8FDU30 608FDU30-60011

Cushion tire

SeriesCapacity(L.C.24inch)lbs.

Engine Vehicle modelPunching format

Detail of *

Cu2 ton series4000

4YE8FGCU20 8FGCU25-60011

(EEC spec :8FGCU25*60011)5000 8FGCU25

Cu3 ton series6000

4YE8FGCU30 8FGCU32-60011

(EEC spec :8FGCU32*60011)6500 8FGCU32

2-52 STEERING

2 STEERING

2.1 GENERALHydrostatic Steering Valve1ZS and 4YE engine

A - A

C - C

B - B

D - D

D

A

A

D

B

B

LS

C

C

2

2-6 2 STEERING

4YM and 1DZ engine (W/synchronized steering)

B-B

A

A

B

B

C-C

CC

2-72 STEERING

4YM engine (L/synchronized steering)

8

3

1. Neutral position spring

2. Housing

3. Check valve

4. Spool

5. Sleeve

6. Cardan shaft

7. Gear rim

8. Gear wheel (rotor)

9. Relief valve

1

Shock valve (No used)

9

2 5 4 6 72

2-8 2 STEERING

2.2 SPECIFICATIONSItem All modelsSteering wheel diameter

mm (in)300 (11.81)

Steering wheel play (at idling)mm (in)

20 to 50 (0.79 to 1.97)

Power steering type Hydrostatic steering

Hydrostatic steering valve (L/synchronized steering)Pn1 tonseries

Pn2 tonseries

Pn3 tonseries

Cu2 tonseries

Cu3 tonseries

Pn1 tonseries

Pn2 tonseries

Pn3 tonseries

1ZS, 4YE 1ZS, 4YE 1ZS, 4YE 4YE 4YE 4YM 4YM 4YM

Manufacturer IHC IHC IHC IHC IHC SauerDanfoss

SauerDanfoss

SauerDanfoss

Deliverycm3 (in3)/rev

96(5.86)

105(6.41)

115(7.02)

100(6.10)

100(6.10)

100(6.10)

100(6.10)

115(7.02)

Rated flow rateL (US gal)/min

- - - - -13.6

(3.59)13.6

(3.59)15.8

(4.17)

Relief set pressureMPa (kgf/cm2) [psi]

7.2 to 7.7(73.4 to78.5)

[1044 to1117]

7.8 to 8.3(79.5 to84.6)

[1131 to1204]

7.8 to 8.3(79.5 to84.6)

[1131 to1204]

6.4 to 6.9(65.3 to70.4)

[928 to1001]

8.2 to 8.7(83.6 to88.7)

[1189 to1262]

6.4 to 6.9(65.3 to70.4)

[928 to1001]

8.2 to 8.7(83.6 to88.7)

[1189 to1262]

8.2 to 8.7(83.6 to88.7)

[1189 to1262]

Hydrostatic steering valve (W/synchronized steering)

Pn1 ton series Pn2 ton series Pn3 ton seriesCu2tonseries

Cu3tonseries

4YM 1ZS,4YE 1DZ-II 4YM 1ZS,

4YE 1DZ-II 4YM 1ZS,4YE 1DZ-II 4YE 4YE

Manufacturer IHCDelivery

cm3 (in3)/rev96

(5.86)96

(5.86)96

(5.86)105

(6.41)105

(6.41)105

(6.41)115

(7.02)115

(7.02)115

(7.02)96

(5.86)105

(6.41)

Rated flow rateL (US gal)/min

13.6(3.59)

-13.6

(3.59)13.6

(3.59)-

13.6(3.59)

15.8(4.17)

-15.8

(4.17)- -


7.5 to8.0

(76.5to

81.6)[1088

to1160]

7.2 to7.7

(73.4to

78.5)[1044

to1117]

7.5 to8.0

(76.5to

81.6)[1088

to1160]

8.1 to8.6

(82.6to

87.7)[1175

to1247]

7.8 to8.3

(79.5to

84.6)[1131

to1204]

8.1 to8.6

(82.6to

87.7)[1175

to1247]

8.1 to8.6

(82.6to

87.7)[1175

to1247]

7.8 to8.3

(79.5to

84.6)[1131

to1204]

8.1 to8.6

(82.6to

87.7)[1175

to1247]

7.5 to8.0

(76.5to

81.6)[1088

to1160]

8.1 to8.6

(82.6to

87.7)[1175

to1247]

2-92 STEERING

2.3 COMPONENTS1ZS and 4YE engine [4507]

4YM and 1DZ-II engine [4507]

2

2-10 2 STEERING

PS Valve1ZS and 4YE engine [4503]

4YM engine (L/synchronized steering) [4503]

4503-036

CM

AT

AS

32

AP

CK

AV

AC

AD

CL

30

CJ

AA

31

01K=(INCL. )

01

2-112 STEERING

4YM and 1DZ-II engine (W/synchronized steering) [4503]

2

2-12 2 STEERING

2.4 HYDROSTATIC STEERING VALVE ASSY

2.4.1 DISASSEMBLY, INSPECTION AND REASSEMBLY (1ZS and4YE)

NOTICEClean dirt off from ports and joints before disassembly and operate in a clean place.

9

2

2

1

1

a

5

b

47

1

3

8

6

a: T=23 to 27 N m (235 to 275 kgf-cm) [17.0 to 19.9 ft-lbf]b: T=60 to 80 N m (612 to 816 kgf-cm) [44.3 to 59.0 ft-lbf]

Disassembly ProcedureStep 1. Remove the set bolt and end cover. [Point 1]Step 2. Remove the gear wheel set, drive shaft, and distributor plate. [Point 2]Step 3. Remove the steel ball. [Point 3]Step 4. Remove the sleeve W/ spool and bearing. [Point 4]Step 5. Remove the relief valve. [Point 5]Step 6. Remove the pin from the sleeve W/ spool.Step 7. Remove the center spring. [Point 6]Step 8. Remove the packing and ring. [Point 7]Step 9. Remove the dust seal. [Point 8]

2-132 STEERING

Reassembly ProcedureThe reassembly procedure is the reverse of the disassembly procedure.

Point Operations

a

Point 1 Disassembly:Make a match mark across the end cover, outer gear,and valve body.Reassembly:Follow the steps below for reassembly.

a: Match mark1. Align the match marks made at the time of disas-

sembly.2. Two types of set bolts are used.

• Set bolt with '10' mark on the head• Set bolt without any mark on the headUse a rod-tip bolt with no mark on its head at pos-ition A in the illustration at left.

A

a

b

c

Point 2 Reassembly:Install the drive shaft and inner gear in the illustratedrelative positions.The spool pin shall pass the slit in the drive shaft.

a: Drive shaft match markb: Pinc: Inner gear match mark

a

Reassembly:Install the outer gear with its side having the ∇ markfacing the end cover side.a: Mark

2

2-14 2 STEERING

a A

Point 3 Disassembly:A steel ball is placed in portion A of the valve body.Keep it so as not to be lost.Reassembly:Make sure to put the steel ball in portion A.

a: Steel ball

Point 4 Reassembly:Install the retaining bearing as illustrated at left.Install one plate, the thrust bearing, and two plates inthis order from the depth.

Reassembly:When inserting the sleeve W/ spool into the valvebody, apply MP grease to the packing, ring inner sur-face (portion in sliding contact with the spool), anddust seal lip.

a

Point 5 Disassembly:Measure the screwed-in depth of the adjust plug(depth to the plug end face), and record it on amemo.Reassembly:Refer to the memo for the adjust plug screwed-indepth.Reassembly:Caulk two places on the circumference of the adjustplug after hydraulic pressure adjustment.

a: Caulk

2-152 STEERING

a

b

Point 6 Reassembly:Install the center spring as illustrated at left.Reassembly:After spool insertion into the sleeve, the notched por-tion of the spring shall securely set in the groove onthe sleeve.

a: Center springb: Notch

a c

b

Point 7 Reassembly:The packing and ring shall be installed in the illus-trated directions.Reassembly:Apply MP grease to the ring before assembling withthe packing. Apply MP grease to the outer peripheryof the packing.Reassembly:Guide the packing W/ ring to the assembling portionin the valve body with a finger, and set them for inser-tion.

a: Bearing sideb: Apply greasec: Dust seal side

a c

b c

Reassembly:a: SST 09950-76018-71(Plate with punch mark 37)b: SST 09950-76018-71(Plate with punch mark 34)c: SST 09950-76020-71

a

b

Point 8 Reassembly:a: SST 09950-76018-71b: SST 09950-76020-71

2

2-16 2 STEERING

2.4.2 RELIEF PRESSURE INSPECTION (1ZS and 4YE)

P port

SST

Step 1. Install an oil pressure gauge.1. Disconnect the hose from the P port of the steer-

ing valve, and connect the SST (adapter).SST 09450-23320-71

2. Install the oil pressure gauge.Plug size: PT1/8

Step 2. Start the engine, rotate the steering wheel slowlyclockwise and counterclockwise, and inspect the re-lief pressure at each stroke end.Standard: MPa (kgf/cm2) [psi]Pn1 ton series7.2 to 7.7 (73.4 to 78.5) [1044 to 1117]Pn2/3 ton series7.8 to 8.3 (79.5 to 84.6) [1131 to 1204]

3-173 MATERIAL HANDLING SYSTEM

3 MATERIAL HANDLING SYSTEM3.1 HYDRAULIC CIRCUIT DIAGRAM........................................................... 173.2 COMPONENTS....................................................................................... 21

3.1 HYDRAULIC CIRCUIT DIAGRAM4YE and 1ZS engineWithout oil cooler

(3)(7)

(1)

(8)

(2)

(4)(5)

(6)

(1) Oil pump(2) Priority valve(3) Oil control valve(4) Steering valve(5) Solenoid valve (OPT)(6) Power steering cylinder(7) Lift, tilt and ATT cylinder(8) Oil tank

3

3-18 3 MATERIAL HANDLING SYSTEM

With oil cooler

(3)(7)

(1)

(8)

(2)

(4)(5)

(6)

(10)

(9)

(1) Oil pump(2) Priority valve(3) Oil control valve(4) Steering valve(5) Solenoid valve (OPT)(6) Power steering cylinder(7) Lift, tilt and ATT cylinder(8) Oil tank(9) Oil cooler

(10) Relief valve


4YM and 1DZ-II engineWithout oil cooler

(3)(7)

(1)

(8)

(2)

(4)(5)

(6)

(1) Oil pump(2) Flow divider(3) Oil control valve(4) Steering valve(5) Solenoid valve (OPT)(6) Power steering cylinder(7) Lift, tilt and ATT cylinder(8) Oil tank

3

3-20 3 MATERIAL HANDLING SYSTEM

With oil cooler

(3)(7)

(1)

(8)

(2)

(4)(5)

(6)

(10)

(9)

(1) Oil pump(2) Flow divider(3) Oil control valve(4) Steering valve(5) Solenoid valve (OPT)(6) Power steering cylinder(7) Lift, tilt and ATT cylinder(8) Oil tank(9) Oil cooler

(10) Relief valve


3.2 COMPONENTS[6801]

3

4-22 4 OIL PUMP

4 OIL PUMP4.1 GENERAL................................................................................................ 224.2 SPECIFICATIONS................................................................................... 234.3 PERFORMANCE TEST........................................................................... 24

4.1 GENERAL4Y(STD),1ZS,1DZ-II

4-234 OIL PUMP

4.2 SPECIFICATIONSVehicle model Engine Specifica-

tion Maker (Model) Pump type Theoretical dischargecm3 (in3)/rev

Pn1 ton series

4YESTD KYB (KFS2422) Gear pump/

single gear 22.0 (1.342)

Steel cabin KYB (DGP2321) Gear pump/double gear 21.5 (1.312)

4YM KYB (KFS2425) Gear pump/single gear 25.7 (1.568)

1ZS KYB (KFS2422) Gear pump/single gear 22.0 (1.342)

1DZ-II KYB (KFS2425) Gear pump/single gear 25.7 (1.568)

Pn2 ton series







Pn3 ton series







Cu2/Cu3 ton series 4YESTD KYB (KFS2422) Gear pump/



4

4-24 4 OIL PUMP

4.3 PERFORMANCE TESTLifting Speed

Vehicle model Engine

Lifting speed (loaded/no-load) mm/sec (fpm)mm/sec (fpm)V mast FSV mast FV mastWhenloaded

When notloaded

Whenloaded

When notloaded

Whenloaded

When notloaded

Pn1 ton series

4YE 665 (131) 680 (134) 620 (122) 635 (125) 615 (121) 630 (124)4YM 665 (131) 680 (134) 620 (122) 635 (125) 615 (121) 630 (124)1ZS 650 (128) 675 (133) 620 (122) 650 (128) 600 (118) 640 (126)

1DZ-II 650 (128) 675 (133) 620 (122) 650 (128) 600 (118) 640 (126)

Pn2 ton series

4YE 600 (118) 640 (126) 565 (111) 600 (118) 575 (113) 600 (118)4YM 600 (118) 640 (126) 565 (111) 600 (118) 575 (113) 600 (118)1ZS 615 (121) 655 (129) 590 (116) 630 (124) 600 (118) 640 (126)

1DZ-II 615 (121) 655 (129) 590 (116) 630 (124) 600 (118) 640 (126)

Pn3 ton series

4YE 510 (100) 550 (108) 480 (94) 520 (102) 460 (91) 490 (96)4YM 510 (100) 550 (108) 480 (94) 520 (102) 460 (91) 490 (96)1ZS 500 (98) 530 (104) 470 (93) 500 (98) 445 (88) 480 (94)

1DZ-II 500 (98) 530 (104) 470 (93) 500 (98) 445 (88) 480 (94)Cu2 ton series 4YE 610 (120) 640 (126) 590 (116) 615 (121) 595 (117) 625 (123)Cu3 ton series 4YE 500 (98) 530 (104) 475 (93) 495 (97) 460 (91) 480 (94)

Vehicle model EngineQFV mastWhen loaded When not loaded

Cu2 ton series 4YE 570 (112) 580 (114)Cu3 ton series 4YE 570 (112) 580 (114)

5-255 OIL CONTROL VALVE

5 OIL CONTROL VALVE5.1 OIL CONTROL VALVE ASSY ................................................................. 265.2 OIL CONTROL VALVE ASSY(MINI LEVER AND JOYSTICK LEVER) .. 395.3 RELIEF PRESSURE ADJUSTMENT ...................................................... 50

5

5-26 5 OIL CONTROL VALVE

5.1 OIL CONTROL VALVE ASSY

5.1.1 GENERAL

1ZS and 4YE engine

T2

CF

S2

P

R

C1

LS

S1

C3

C5

T1

C2 C4

X1X2 X3

X4

X1

X2 X3

X4


X1-X1 INLET

Priority valve

Relief valve

Electromagnetic proportional reducing valve

5


Hydraulic Circuit Diagram (1ZS engine)

T2 LS R

P

CF

S1

S2C1

C2C3

C4C5

T1


Load check valve

Priority valve

Gauge port

Flow regulator valve

Load check valve

Tilt backward lock valve

(Tilt backward lock SOL)

Load check valve

Tilt control valve

(Tilt control SOL)

Manual

downlifting valve

Relief valve

Lift lock valve

(Lift lock SOL)


Hydraulic Circuit Diagram (4YE engine)

T2 LS R

P

CF

S1

S2C1

C2C3

C4C5

T1


Load check valve

Priority valve

Gauge port


Load check valve

Tilt backward lock valve

(Tilt backward lock SOL)

Load check valve

Tilt control valve

(Tilt control SOL)

ATT spool with

drain circuit

Manual

downlifting valve

Relief valve

Lift lock valve

(Lift lock SOL)

5


5.1.2 SPECIFICATIONS

ItemVehicle model1 ton series 2 ton series 3 ton series

Type Add-on typeRelief pressure

MPa (kgf/cm2) [psi]Lift 18.7 (191) [2720]Tilt 15.7 (160) [2277]

Flow divider flow rate (Except 1ZS and 4YE engine)L/min (US gal/min)

13.6 (3.59) 13.6 (3.59) Pn: 15.8 (4.17)Cu: 13.6 (3.59)

Flow regulator flow volumeL/min (US gal/min)

50 (13.2) 60 (15.8) 75 (19.8)

Lowering speed specificationmm/sec (fpm)

V (Pn)No-load 550 (108) 500 (98) 500 (98)Loaded 500 (98) 500 (98) 500 (98)

V (Cu)No-load - 500 (98) 500 (98)Loaded - 500 (98) 500 (98)

FSV (Pn)No-load 450 (89) 450 (89) 420 (83)Loaded 480 (94) 480 (94) 460 (91)

FSV (Cu)No-load - 450 (89) 420 (83)Loaded - 480 (94) 460 (91)

FV (Pn)No-load 420 (83) 420 (83) 390 (77)Loaded 480 (94) 480 (94) 460 (91)

FV (Cu)No-load - 420 (83) 390 (77)Loaded - 480 (94) 460 (91)

QFV (Cu)No-load - 450 (89) 450 (89)Loaded - 510 (100) 510 (100)


5.1.3 COMPONENTS1ZS and 4YE engine [ASSY&FITTING] [6705]

1DZ-II and 4YM engine [ASSY&FITTING] [6705]

5


1DZ-II and 4YM engine [INLET,OUTLET,LIFT,TILT] [6705]

1DZ-II and 4YM engine [ATT] [6705]


5.1.4 DISASSEMBLY, INSPECTION AND REASSEMBLY(1ZS and4YE engine)

NOTICE• Work in a clean location.• Since individual parts are finished with high precision, carefully operate so as not to damage them.

1

2

3

2

2

3

4

5

6

6

6

7

7

7

8

9

9

10

10

11

11

12

12

T

T=39.2 N m (400 kgf-cm) [28.94 ft-lbf]

Disassembly ProcedureStep 1. Remove the lift lock SOL and flow regulator valve. [Point 2]Step 2. Remove the lift limit switch and spring cover. [Point 3]Step 3. Remove the lift spool. [Point 4]Step 4. Remove the tilt control SOL. [Point 5]Step 5. Remove the backward tilt lock SOL. [Point 6]Step 6. Remove the tilt limit switch and spring cover. [Point 7]Step 7. Remove the tilt spool. [Point 8]Step 8. Remove the electromagnetic relief valve. [Point 9]Step 9. Remove the priority valve.Step 10. Remove the relief valve. [Point 10]Step 11. Remove the attachment valve.Step 12. Remove the rod bolt, and then remove the housing.


5


NOTICEClean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.

5.1.4.1 Point OperationsPoint 2 Disassembly:

Put match marks to prevent solenoid installation in anincorrect position.Reassembly:Align match marks for reassembly.

Inspection:Check the lift lock solenoid for continuity.(Reference)Resistance: 9.4 to 10.4 Ω (at 20 °C)

Inspection:Check and clean any clogged filter.Reassembly:Carefully reassemble to prevent incorrect installationof each solenoid spool, etc.


2 1

4 3

Point 3 Inspection:Check the lift limit switch for continuity.Lowering side (measurement terminal 1 ⇔ 2):No continuity when the switch is pressed.

Lifting side (measurement terminal 3 ⇔ 4):No continuity when the switch is pressed.Reassembly:Be careful not to mistake the lowering side and liftingside.

SST

Washer

Point 4 Disassembly and Reassembly:Remove the compression spring from the lift spool.SST 09610-10161-71Use the SST after attaching a washer.

Point 5 Inspection:Check the tilt solenoid for continuity.(Reference)Resistance: 9.4 to 10.4 Ω (at 20 °C)

Inspection:Check and clean any clogged filter.

5


Inspection:Check and clean any clogged orifice.Reassembly:Carefully reassemble to prevent incorrect installationof each solenoid spool.

Point 6 Inspection:Check the backward tilt lock SOL for continuity.(Reference)Resistance: 9.4 to 10.4 Ω (at 20 °C)

Inspection:Check and clean any clogged filter.Reassembly:Carefully reassemble to prevent incorrect installationof each solenoid spool.

1 2

3 4

Point 7 Inspection:Check the tilt limit switch for continuity.Forward tilting side (measurement terminals 1 ⇔ 2):No continuity when the switch is pressed.

Backward tilting side (measurement terminals 3 ⇔ 4):No continuity when the switch is pressed.

Be careful not to mistake the forward and backwardtilt limit switches.


SST

Washer

Point 8 Disassembly and Reassembly:Remove the compression spring from the tilt spool.SST 09610-10161-71Use the SST after attaching a washer.

Point 9 Inspection:Check the proportional reducing valve for continuity.Measurement terminal: Continuity exists.(Reference)Resistance: 6.5 to 7.2 Ω (at 20 °C)

Point 10 Inspection:Check and clean any clogged filter.

a

Adjusting screw A Lock nut 1

Adjustingsleeve B

Lock nut 2

Reassembly:When the relief valve is disassembled, temporarily in-stall it after fitting the nuts as illustrated.

a = 27.0 mm (1.06 in)

NOTICE: Do not loosen the adjusting screw A and the

lock nut 1 for tilt relief pressure adjustmentbecause the adjustment is not necessary.

When replacing the relief valve, change thesetting value (H and L rank) it is necessary.(Refer to chapter of the display for MATCHINGEMRV "EMRV")

5


Level of current to plate

Reference: Level of current to plate

4 unit of short No. 5 unit serial No. and whose 5 unit start from 00001

Stamp 3 unit aim pressure

Mention I-P current rank(H-L each 1unit)

Stamp the current value that calculated than an approximate expression(example: 3.5 MPa → 035)(example: 590 mA → 590)


5.2 OIL CONTROL VALVE ASSY(MINI LEVER ANDJOYSTICK LEVER)

5.2.1 GENERAL

1ZS and 4YE engine

T2

CF

S2

P

R

C1

LS

S1

C3

C5

T1

C2

C4

X1 X2 X3

X4

X1

X2 X3

X4

5


X1-X1 INLET

Priority valve

Relief valve



Hydraulic Circuit Diagram (1ZS engine)

T2 LS R1

P

CF

S1

S2C1

C2C3

C4C5

R2T1


Load check valve

Priority valve

Gauge port


Load check valve

a2

a1b1

b2

b3 a3

Load check valve

Decompression

valve

Tilt control valve

(Tilt control SOL)

Manual

downlifting valve

Relief valve

Lift lock valve

(Lift lock SOL)

Gauge port

5


Hydraulic Circuit Diagram (4YE engine)

T2 LS R1

P

CF

S1

S2C1

C2C3

C4C5

R2T1


Load check valve

Priority valve

Gauge port


Load check valve

a2

a1b1

b2

b3 a3

Load check valve

Tilt control valve

(Tilt control SOL)

ATT spool with

drain circuit

Manual

downlifting valve

Relief valve

Lift lock valve

(Lift lock SOL)

Gauge port


5.2.2 SPECIFICATIONS

ItemVehicle model1 ton series 2 ton series 3 ton series

Type Add-on typeRelief pressure

MPa (kgf/cm2) [psi]Lift 18.7 (191) [2720]Tilt 15.7 (160) [2277]

Flow divider flow rate (Except 1ZS and 4YE engine)L/min (US gal/min)

13.6 (3.59) 13.6 (3.59) Pn: 15.8 (4.17)Cu: 13.6 (3.59)

Flow regulator flow volumeL/min (US gal/min)

50 (13.2) 60 (15.8) 75 (19.8)

Lowering speed specificationmm/sec (fpm)

V (Pn)No-load 550 (108) 500 (98) 500 (98)Loaded 500 (98) 500 (98) 500 (98)

V (Cu)No-load - 500 (98) 500 (98)Loaded - 500 (98) 500 (98)

FSV (Pn)No-load 450 (89) 450 (89) 420 (83)Loaded 480 (94) 480 (94) 460 (91)

FSV (Cu)No-load - 450 (89) 420 (83)Loaded - 480 (94) 460 (91)

FV (Pn)No-load 420 (83) 420 (83) 390 (77)Loaded 480 (94) 480 (94) 460 (91)

FV (Cu)No-load - 420 (83) 390 (77)Loaded - 480 (94) 460 (91)

QFV (Cu)No-load - 450 (89) 450 (89)Loaded - 510 (100) 510 (100)

5


5.2.3 COMPONENTS1ZS and 4YE engine [ASSY&FITTING] [6705]


5.2.4 DISASSEMBLY, INSPECTION AND REASSEMBLY(1ZS and4YE engine)

NOTICE• Work in a clean location.• Since individual parts are finished with high precision, carefully operate so as not to damage them.

7

7

8

2

1

9

T

4

4

4

3

3

3

5

5

5

6

8

T=39.2 N m (400 kgf-cm) [28.94 ft-lbf]

Disassembly ProcedureStep 1. Remove the lift lock SOL and flow regulator valve. [Point 2]Step 2. Remove the tilt control SOL. [Point 3]Step 3. Remove the proportional solenoid (a). [Point 4]Step 4. Remove the proportional solenoid (b). [Point 5]Step 5. Remove the lift spool, tilt spool and attachment spool.Step 6. Remove the electromagnetic relief valve. [Point 6]Step 7. Remove the priority valve.Step 8. Remove the relief valve. [Point 7]Step 9. Remove the rod bolt, and then remove the housing.


5


NOTICEClean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.

5.2.4.1 Point OperationsPoint 2 Disassembly:

Put match marks to prevent solenoid installation in anincorrect position.Reassembly:Align match marks for reassembly.

Inspection:Check the lift lock solenoid for continuity.(Reference)Resistance: 9.4 to 10.4 Ω (at 20 °C)

Inspection:Check and clean any clogged filter.Reassembly:Carefully reassemble to prevent incorrect installationof each solenoid spool, etc.


Point 3 Inspection:Check the tilt solenoid for continuity.(Reference)Resistance: 9.4 to 10.4 Ω (at 20 °C)

Inspection:Check and clean any clogged filter.

Inspection:Check and clean any clogged orifice.Reassembly:Carefully reassemble to prevent incorrect installationof each solenoid spool.

1 2

5 6

3

7

Point 4 Inspection:Check the proportional solenoid (a) for continuity.

Measurement terminal 1 ⇔ 5: Continuity exists.Measurement terminal 2 ⇔ 6: Continuity exists.Measurement terminal 3 ⇔ 7: Continuity exists.

5


(A)Adjusting screw (A)Disassembly:Before disassembly, measure the installation position(dimension (A)) of the material handling start timingadjusting screw.Reassembly:Reassemble according to the dimension (A) meas-ured before disassembly.Adjustment:After installing the control valve to the vehicle, checkwhether there are any abnormalities in material hand-ling start timing by slowly operating the lever. If youfeel any abnormalities, perform tuning with the dis-play. (See section 18)

1 2

5 6

3

7

Point 5 Inspection:Check the proportional solenoid (b) for continuity.

Measurement terminal 1 ⇔ 5: Continuity exists.Measurement terminal 2 ⇔ 6: Continuity exists.Measurement terminal 3 ⇔ 7: Continuity exists.

(A)Adjusting screw (A)Disassembly:Before disassembly, measure the installation position(dimension (A)) for the material handling start timingadjusting screw.Reassembly:Reassemble according to the dimension (A) meas-ured before disassembly.Adjustment:After installing the control valve to the vehicle, checkwhether there are any abnormalities in material hand-ling start timing by slowly operating the lever. If youfeel any abnormalities, perform tuning with the dis-play. (See section 18)

Point 6 Inspection:Check the proportional reducing valve for continuity.Measurement terminal: Continuity exists.(Reference)Resistance: 6.5 to 7.2 Ω (at 20 °C)


Point 7 Inspection:Check and clean any clogged filter.

a


Adjustingsleeve B

Lock nut 2

Reassembly:When the relief valve is disassembled, temporarily in-stall it after fitting the nuts as illustrated.

a = 27.0 mm (1.06 in)



When replacing the relief valve, change thesetting value (H and L rank) it is necessary.(Refer to chapter of the display for MATCHINGEMRV "EMRV")

Level of current to plate

Reference: level of current to plate





5


5.3 RELIEF PRESSURE ADJUSTMENT

NOTICE• Relief pressure adjustment for tilt side is "Not" necessary by adopting Electromagnetic relief valve while

relief valve is dual structure type as before.• Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause high-

pressure generation that may result in damage to the oil pump and other hydraulic devices.• Before starting adjustment, check if the no-load maximum rpm is as specified.

9/16-18UNF

Fitting

1. Open the engine hood.2. Remove the lower panel and toe board.3. Install an oil pressure gauge.

Remove the oil-pressure detecting plug installed onthe left side of the oil control valve, and install the oilpressure gauge there.Plug size: 9/16-18UNFFitting size: 9/16-18UNF × PF1/4Fitting: 90407-13469-71

a


Adjustingsleeve B

Lock nut 2

4. Set the adjusting sleeve B of the lift relief valve as de-scribed below.Loosen lock nut 2, and position adjusting sleeve B tothe following dimension.a = 27.0 mm (1.06 in)



b

Adjusting screw A

Adjustingsleeve B

If loosening, perform the position adjustmentfor the adjusting screw A as the following loc-ation and lock by the lock nut 1.

Reference: b = 11.4 mm (0.449 in)


5. Start the engine, and check for oil leaks and abnor-mal noise.

6. Install the toe board.7. Close the engine hood.8. Adjust the lift side relief pressure.

(1) Set the seat switch to ON. (Operate by two workerswith one sitting on the seat.)

(2) Operate the lift lever to lift the fork fully.(3) While running the engine at the maximum speed, op-

erate the lift lever to the lifting side. Gradually tightenadjusting sleeve B to make the oil pressure in the re-lief state satisfy the standard, and fix the sleeve posi-tion by tightening lock nut 2.StandardsLift relief set pressure:19.2 to 18.7 Mpa (196 to 191 kg/cm2)[2784 to 2712 psi]

9. Turn the key switch OFF10. Remove the oil pressure gauge, and install and

tighten the removed plug.

5

6-52 6 SAS/OPS

6 SAS/OPS

6.1 SAS FUNCTION

6.1.1 COMPONENTSLoad Sensor (4Y engine) [5803]

Load Sensor (1ZS engine) [5803]

6-536 SAS/OPS

6

6-54 6 SAS/OPS

Load Sensor (1DZ-II engine) [5803]

7-557 DISPLAY

7 DISPLAY7.1 MULTI-FUNCTION DISPLAY DX............................................................ 557.2 SERVICE FUNCTIONS "MASK MENU".................................................. 71

7.1 MULTI-FUNCTION DISPLAY DX

7.1.1 GeneralThe multi-function display DX has various functions that indicate / notify the vehicle’s information such asvehicle speed. And the operator or administrator can set the vehicle performance with this display. Further-more, it has functions to perform maintenance, feeling adjustments and specification setting as a servicefunction.On this model, a graphic LCD (Liquid Crystal Display) has been adopted and this provides various informa-tion to be easy-to-understand with expressive capability.

Multi-function display DX

No. Switch Name Description(1) Switch (1) Low speed setting switch / Down switch(2) Switch (2) Mode select switch / Left switch(3) Switch (3) Right switch(4) Switch (4) Meter mode select switch / Enter switch(5) - Multiple screen display area

NOTICEAlways operate switches on the display with a fingertip. If a sharp pointed tool is used, the switchmay be damaged.

7

7-56 7 DISPLAY

7.1.2 FUNCTION LIST

Multi-function Display DX Function List： Operator availableA： Operator available when menu lock setting is "NO" ,

Administrator available (protected by the administrator password)B： Administrator only (protected by the administrator password)

Functions Novelty -Auto speed

control(OPT)

Status display

Digital speedometer - Torque converter oil temperature indicator - Low speed setting indicator - Auto speed control indicator - - Eco-mode indicator NEW Planned maintenance hour warning indicator - Menu lock indicator NEW

MeterOdometer - Trip meter - Planned maintenance hour meter -

Warningfunction

Parking brake ON warning - Parking brake OFF warning - Torque converter oil temperature overheat warning - Over speed alarm - Diagnostic code display -

Settingfunction

Low speed setting - A ATravel speed limiter level setting - B BOver speed alarm setting - A APlanned maintenance hour setting - B BEngine auto stop time setting NEW B BSecond password registration for administrator NEW B BMenu lock setting - B B

7-577 DISPLAY

7.1.3 SCREEN

7.1.3.1 Initial screen after Key-OnThe initial screen is displayed for about 1 second after the key switch is turned ON.

7.1.3.2 Status screenThe status screen is displayed after the initial screen.

Function activation indicatorSpeedometerFunction activation indicator

Low speed setting indicator

Eco-mode indicator

Menu lock indicator

Torque converter oil temperature indicator

7

7-58 7 DISPLAY

7.1.4 DETAIL DESCRIPTION

7.1.4.1 Speedometer The speedometer indicates the vehicle speed digitally by 1

mph or 1 km/h.In factory setting, default models are preset in "mph". Andexport SPEC.[OPT], E.E.C. SPEC.[OPT],mm-kg indicator spec[OPT] are preset in "km/h".

7.1.4.2 Torque converter oil temperature indicator This indicator indicates the torque converter oil temperature

in 10 levels.

7.1.4.3 Function activation indicator1. Low speed setting indicator

This indicator lights and goes off alternately when the oper-ator presses the low speed setting switch.This indicator lights when the low speed setting is effectiveand the vehicle speed is limited at a preset level.In case this setting is "level 8", the indicator does not light. The low speed setting level is set up on the operator menuscreen or the administrator menu screen. But this level can be set up only on the administrator menuscreen when the menu lock is effective.

2. Auto speed control indicator (with auto speed control only) This indicator lights the auto speed control when auto

speed control activates.This indicator is also lighted for a while after the ignitionswitch is turned on to inform that this feature is in availableconfiguration.

7-597 DISPLAY

3. Eco-mode indicator This indicator lights and goes off alternately when the oper-

ator presses the mode select switch. The Eco-mode func-tion is effective when this indicator lights.But this indicator cannot be switched by pressing the modeselect switch when the menu lock is effective.

4. Maintenance indicator When the elapsed time of the maintenance hour meter ex-

ceeds the preset hours, this indicator is displayed to inform.The buzzer also sounds for 5 seconds whenever the keyswitch is turned on under the above condition.However, the buzzer doesn't sound at that time when theelapsed time has just exceeded the preset hour while thevehicle is in operation. (The indicator is displayed duringoperation).The preset hour is set on the administrator menu screen.

5. Menu lock indicator When Menu Lock setting is “YES”, the Menu lock indicator

is displayed.When the Menu lock indicator is displayed, if the operationfor opening “operator menu” is executed (Pressing switch(1) for more than 2 seconds on the status screen), the dis-play informs the operator that the operation is invalid withblinking of the indicator.Eco-mode is not switched when the Menu lock indicator isdisplayed.

7

7-60 7 DISPLAY

7.1.4.4 MeterEvery pressing switch (4) on the status screen, change the screen to Odometer/Trip, maintenance hourmeter screen.1. Odometer

The Odometer displays the total travel distance.In factory setting, default models are preset in "mile". And export SPEC.[OPT], E.E.C. SPEC.[OPT], mm-kg indicator SPEC [OPT] are preset in "km/h".

2. Trip meter The trip meter displays the travel distance after reset.The trip meter can be reset by pressing switch (1) for 2 seconds or more. In factory setting, default models are preset in "mile".And export SPEC.[OPT], E.E.C. SPEC. [OPT], mm-kg indicator SPEC [OPT] are preset in "km/h".

3. Planned maintenance hour meter The planned maintenance hour meter displays preset service interval time and the current elapsed time.The maintenance hour meter integrates the elapsed time while the key switch is turned on.It also continues to integrate the elapsed time even if it exceeds the preset service interval time.

NOTICEThe odometer, trip meter, and planned maintenance hour meter are not started in the factory setting.When the truck is delivered, please start the meter according to the repair manual.(The indicator below appears when the meter doesn’t start.)

7-617 DISPLAY

7.1.4.5 Warning1. Parking brake ON warning

This indicator blinks and buzzer sounds when the operatorattempts to travel the vehicle without releasing the parkingbrake.

2. Parking brake OFF warning The buzzer sounds when the operator leaves the seat with the parking brake released.

The buzzer sounds when the operator turns off the key switch with the parking brake released.The buzzer sounds as well when the operator releases the parking brake within 1 minute after turn-ing off the key switch.After the buzzer is sounding for 30 seconds for the warning, it stops sounding.（No warning is displayed on the multi-function display DX.）

3. Torque Converter oil temperature overheat warning The indicator blinks when the oil temperature level be-

comes more than or equal to level 9 (approx. 120 degreesC).The entire gauge blinks at level 10 (approx. 135 degreesC).

4. Over speed alarm When the vehicle speed exceeds the preset speed, the

speedometer blinks and the buzzer sounds to inform theoperator of over speed.Unlike low speed setting, there is no speed limitation ap-plied even if the speed exceeds the preset speed.The over speed alarm value is set up on the operator menuscreen or the administrator menu screen. But this value can be set up only on the administrator menuscreen when the menu lock is effective. (Operator menu screen is disable.)

5. Diagnostic code display

This indicator displays an error code and buzzer soundswhen the diagnosis process in the multi-function display DXacts.

7

7-62 7 DISPLAY

7.1.5 SETTING FUNCTIONS

Setting menu for operatorPressing switch (1) on the status screen for more than 2 seconds displays the setting menu for operator.But the setting menu screen is not displayed when the menu lock is effective.“Menu lock” is set “YES” automatically when the key is turned off on US domestic model or CANADA SPEC[OPT] model.Use switch (1) to select the desired item and press switch (4); each setting screen will appear.Select [END] on the menu and press switch (4); the status screen returns.

1) Low speed level setting screen

switch (2) switch (3) switch (4)

The low speed level setting function is set up on this screen.Switch (2): Select the lower level.Switch (3): Select the higher level.Switch (4): Display the menu screen.The function is disabled when setting it to level 8. In this case,the low speed setting switch is disabled on the normal screenin that case.

2) Over speed alarm setting screen


The traveling speed level for the over speed alarm is set onthis screen.Switch (2): Decrease the traveling speed setting.Switch (3): Increase the traveling speed setting.Switch (4): Display the menu screen.It is adjustable from 3 mph (or 5 km/h) to 30 mph (or 50 km/h)by 1 mph (or 1 km/h).

7-637 DISPLAY

7.1.6 ADMINISTRATOR FUNCTIONSThe multi-function display DX provide administrators to adjust performance and set up some functions.These functions are password-protected not to be changed by general operators.Entering the password displays the setting menu for administrator.

7.1.6.1 Administrator functions listGroup Setting Screen

Travel FunctionsSpeed Setting of Low Speed *Speed Setting of Speed LimiterSpeed Setting of Over Speed Alarm *

Vehicle Management Functions

Setting of Maintenance Hour MeterSetting of Engine Auto StopSetting of Administrator's Second PasswordSwitching of Menu Lock

*: When menu lock setting is released, the operator can set it.

7.1.6.2 Administrator password

Password Entry Procedure

NOTICEIf an operation error occurs during entry operation, turn the key switch OFF and start over again.

Step Display Operation Vehicle response

1Press switch (2) and switch (4)at the same time for more than2 seconds.

When pressing theswitches, a short beepsounds, and after 2seconds another shortbeep sounds.

2 Press switch (3) within 10seconds. A short beep sounds.

3 Press switch (3) within 10seconds. A short beep sounds.

4

Within 10 seconds, pressswitch (2) and switch (4) at thesame time for more than 2seconds.

When pressing theswitches, a short beepsounds, and after 2seconds repeated shortbeeps sound.

7

7-64 7 DISPLAY


5

When the second password has been set:password screen is displayed. Enter the password.Other:Skip this screen.

6 Administrator menu screen is displayed automatically.

7-657 DISPLAY

7.1.6.3 Setting menu for administratorUse switch (1) to select the desired item and press switch (4) ; each setting screen will appear.Select [END] on the menu and press switch (4) ; the status screen returns.

7

7-66 7 DISPLAY

7.1.6.3.1 Administrator functions1) Low speed level setting screen


This screen has the same functions as for general operat-ors.

2) Travel speed limiter setting screen


The travel speed limiter level is set on this screen. Switch (2): Select the lower level.

Switch (3): Select the higher level.Switch (4): Display the menu screen.The function is disabled when setting it to level 8.

3) Over speed alarm setting screen


This screen has the same functions as for general operat-ors.

7-677 DISPLAY

4) Planned maintenance hour setting screen

switch (2) switch (3) switch (4)switch (1)

Planned time of maintenance hour meter is set up on thisscreen.Time for maintenance hour meter can be set from　10 hoursup to 2400 hours, by 10 hours for 10 hours to 200 hours and by50 hours for 200 hours to 2400 hours.

Press switch (2) to decrease the setting time.Switch (3): Increase the setting time.Switch (4): Display the menu screen.

Pressing switch (1) for more than 2 seconds will reset thecurrent hour meter value to 0.(This operation keeps the set-ting value same.)

The function is turned off when 10h is set for maintenance hourmeter and the switch (2) is pressed to decrease the settingtime. The current value is kept but the maintenance indicatorand the buzzer are deactivated with this “OFF” setting.

5) Engine auto stop time setting screen

Time of engine auto stop is set up on this screen. Switch (2): Decrease the setting time.

Switch (3): Increase the setting time.Switch (4): Display the menu screen.

Time for auto engine stop can be set from 10 seconds up to30minutes, by 10 seconds for 10 seconds to 1 minute and by 1minute for 1minute to 30 minutes.The function is turned off when 30 minutes is set for the engineauto stop and the switch (3) is pressed to increase the set time.In that case “OFF” is displayed.

7

7-68 7 DISPLAY

7.1.6.3.2 Administrator’s second password setting screenAdministrator’s second password can be registered or deleted on this screen.Registration of password

The administrator can register the second password. The second password can be registered by continuing topress switch (1) for 2 seconds after entering the passwordby using switch (1) to (4). If the switch (4) is pressed for 2 seconds or more before re-gistration, the screen returns to the menu screen and thepassword is NOT registered. Administrator should manage the second password so asnot to forget it. Even if it has been forgotten, the service technician canclear it on the service menu.

7-697 DISPLAY

Deletion of password

The password can be cleared by pressing switch (1) formore than 2 seconds on the administrator’s second pass-word setting screen. If the switch (4) is pressed for 2 seconds or more beforedeletion, the screen returns to the menu screen and thepassword is NOT deleted.

Menu Lock setting screen

This function can limit the change of the vehicle setting bythe operator. When menu lock setting is "YES”, the following items arelimited.･Setting menu for operator is NOT displayed.･Eco-mode is NOT changed.

Menu lock indicator is displayed on the status screen whenmenu lock setting is “YES”.

Switch (2): Selecting "Yes" Switch (3): Selecting "No"Switch (4): Returning to menu screen

Conditions to release Menu lock vary by optionset items, "MENULOCK SPEC". In factory setting, "MENU-LOCK SPEC" is preset in "A" on US domestic models and CANADA SPEC [OPT] models, and is preset in"B" on export models [OPT] (except for CANADA SPEC [OPT]) and E.E.C. spec [OPT].MENULOCK SPEC : A The lock release setting (“NO”) is effective till key-OFF. (It means set “YES” automatically when the keyswitch is turned off.)MENULOCK SPEC : B The lock release setting (”NO”) is effective till setting "YES" with a setting screen again.

7

7-70 7 DISPLAY

7.1.6.3.3 Menu Lock setting screen This function can limit the change of the vehicle setting by

the operator. When menu lock setting is "YES”, the following items arelimited.･Setting menu for operator is NOT displayed.･Eco-mode is NOT changed.

Menu lock indicator is displayed on the status screen whenmenu lock setting is “YES”.

Switch (2): Selecting "Yes" Switch (3): Selecting "No"Switch (4): Returning to menu screen

Conditions to release Menu lock vary by optionset items, "MENULOCK SPEC". In factory setting, "MENU-LOCK SPEC" is preset in "A" on US domestic models and CANADA SPEC [OPT] models, and is preset in"B" on export models [OPT] (except for CANADA SPEC [OPT]) and E.E.C. spec [OPT].MENULOCK SPEC : A The lock release setting (“NO”) is effective till key-OFF. (It means set “YES” automatically when the keyswitch is turned off.)MENULOCK SPEC : B The lock release setting (”NO”) is effective till setting "YES" with a setting screen again.

7-717 DISPLAY

7.2 SERVICE FUNCTIONS "MASK MENU"

7.2.1 GENERALIn the multi-function display DX, aside from the general functions that an operator or an administrator nor-mally use, the following mask functions for use by the service staff for vehicle maintenance and specificationsetting are also provided.The service functions are protected by the password so that the important internal data will not be damagedby wrong use of service functions by users by mistake.

NOTICEBe sure to operate while not only keeping the vehicles on a state in accordance with instructions, but alsosecuring a safe station around the vehicles.

Mask Function List

Function DescriptionWhen usedVehicle de-livery

Board re-placement Others

Analyzer[ANALYZER]

Displays the electrical systemstatus and reads the error in-formation detected by control-lers.

- -Upon

vehicle ab-normality

Tuning[TUNING]

Makes fine adjustment of trav-eling and material handlingfunctions.

- *2

As reques-ted by cus-tomer

Option Setting[OPTIONSET]

Specification set-ting

Sets each vehicle option andother specifications. *1 -

*2 and *3 -

Each controlfunction enable/disable

Enables or disables each con-trol function. -

*2 and *3 -

Matching[MATCHING]

SASUpdates voltage values ofsensor signals under thestandard vehicle condition.

- *2

*4

Material handlinglever *1

Updates voltage values ofsensor signals under thestandard vehicle condition.(Mini lever/ Joy-stick lever)

- *2

*4

Electromagneticrelief valve *1

Sets electric current level ofthe electromagnetic relief valvesolenoid.

- *2

*6

Wheel radius[WHEEL RADIUS]

Makes the speedometer read-ing appropriate. -

*2*5

Speed Setting of Speed Limiter[SPEED LIMIT SET]

Changes the limit value of themaximum vehicle speed con-trol function.

- *2


Engine idle adjustment[IDLE ADJUSTMENT]

Adjusts engine idle speed. - *2


Mask second password setting[MASK PASSWORD]

Sets the service second pass-word. -

*3As neces-sary

7

7-72 7 DISPLAY

Function DescriptionWhen usedVehicle de-livery

Board re-placement Others

Administrator's second passwordclear[MANAGER PASS CLR]

Deletes the administrator'ssecond password. - -


Contrast[CONTRAST]

Adjusts the contrast of the dis-play screen. -

*3


Meter start[METER START]

Starts counting the odometer,trip meter and maintenancehour meter.

*3 -

*1: This is to match the controller and display control according to the installed option and control func-tions equipped in the vehicle. Note that this function does not enable or disable the option or controlfunction itself.

*2: Board: SAS/OPS controller control board*3: Board: Control board for the multi-function display*4: During the condition that is listed in matching*5: When tire size is changed or tire is replaced*6: When removing/installing or replacing oil control valve

7.2.2 PASSWORD

NOTICE• Always operate switches displayed on the display with a finger tip. If a sharp pointed tool is used,the switch may be damaged.• If an operation error occurs during entry operation, turn the ignition key switch OFF and reenterfrom the beginning. If the service function "MASK MENU" cannot be displayed after several attempts,the system may be faulty.

7.2.2.1 Password entry procedureStep Display Operation Vehicle response

1

Switch (2) Switch (3) Switch (4)

Press switch (2), switch (3)and switch (4) at the sametime for more than 2 seconds.

When pressing theswitches, a short beepsounds, and after 2seconds another shortbeep sounds.

2

Switch (4)

Press switch (4) within 10seconds. A short beep sounds.

7-737 DISPLAY


3

Switch (1)

Press switch (1) within 10seconds. A short beep sounds.

4

Switch (2) Switch (3)

Within 10 seconds, pressswitch (2) and switch (3) at thesame time for more than 2seconds.

When pressing theswitches, a short beepsounds, and after 2seconds repeated shortbeeps sound.

5

When the service second password "MASK PASS-WORD" has been set: Password screen is displayed.Enter the password.This screen will not be displayed if a service secondpassword "MASK PASSWORD" has not been set.

6 Service function initial screen is displayed for 5 seconds.

7 Service function "MASK MENU" screen is automaticallydisplayed.

7

7-74 7 DISPLAY

7.2.2.2 SERVICE FUNCTION "MASK MENU" Screen

NOTICEDuring all the test screen display, the vehicle can be operated normally.

Operating ProcedureService function "MASK MENU" initial screen is dis-played for 5 seconds.

Step 1 Enter the password on the general screen to displaythe service function "MASK MENU" screen.


Step 2 Select a desired function using switch (1). Then,press switch (4) (set) to display the function screen orsetting screen of the selected function.

Step 3 Press (enter) switch (4) while selecting "9. END"menu to return to the general screen. Also, in each screen, once the ignition key switch isturned OFF, you can move to the general screen.

7-757 DISPLAY

"1. ANALYZER"This function indicates the electrical system status andreads the error information detected by the controller.Switch (1): Switching selection to next item Switch (4): To "ANALYZER MENU" screen

7

7-76 7 DISPLAY

"2. TUNING"Use this function for fine adjustment of control of the travel-ing and material handling.Switch (1): Switching selection to next itemSwitch (4): To "TUNING MENU" screen

"3. OPTIONSET"Use this function to match control of the controller or dis-play according to the set options or control.Switch (1): Switching selection to next itemSwitch (4): To "OPTIONSET" setting screen

7-777 DISPLAY

"4. MATCHING"This function updates the signal voltage values stored inthe controller (signal voltage values from the SAS or MiniLever functions sensors under the standard vehicle condi-tion).Switch (1): Switching selection to next item Switch (4): To "MATCHING MENU" screen

"5. WHEEL RADIUS"This function rewrites the tire information in the controllerfor correcting the speed indication, odometer and tripmeter.Switch (1): Switching selection to next itemSwitch (4): To "WHEEL RADIUS" screen

"6. SPEED LIMIT SET"Use this function to change the limit value of the maximumvehicle speed control function.Switch (1): Switching selection to next itemSwitch (4): To "SPEED LIMIT SET" screen

7

7-78 7 DISPLAY

"7. IDLE ADJUSTMENT"Adjusts engine idle speed.Switch (1): Switching selection to next item Switch (4): To "IDLE ADJUSTMENT" screen

"8. MASK PASSWORD"Sets the mask second password.Switch (1): Switching selection to next item Switch (4): To "MASK PASSWORD" screen

"9. MANAGER PASS CLR"Deletes the manager second password.Switch (1): Switching selection to next item Switch (4): To "MANAGER PASS CLR" screen

"10. CONTRAST"Adjusts the contrast of the display LCD screen.Switch (1): Switching selection to next itemSwitch (4): To "CONTRAST" screen

7-797 DISPLAY

"11. METER START"Starts counting the odometer, trip meter and maintenancehour meter.Switch (1): Switching selection to next itemSwitch (4): To "METER START" screen

NOTICE: After start counting the meters, "METER START" will

not be displayed on the service function "MASKMENU" screen.

"12. END"Switch (1): Switching selection to next item Switch (4): To general screen

7

7-80 7 DISPLAY

7.2.3 ANALYZER

7.2.3.1 GENERALAnalyzer function supports operations for inspecting/investigating faulty section by displaying the condition ofthe control system, using communication between each controller and the multi-function display DX.By switching the multi-function display DX to analyzer mode, operative conditions of the sensor actuator thatis used for traveling, material handling, FHPS and SAS/OPS functions, or the error information detected bythe controller can be read. This is very useful for checking operative condition of each function and savingtime for repairing when there is a defect.Full utilization of the analyzer functions helps quick, easy servicing.The analyzer has the following functions:1. Diagnosis memory function "DIAG MEMORY"

The controller stores up to 10 error codes (diagnosis codes) detected in the electrical system in the past.The diagnosis function reads these error codes and indicates them on the display.Each error code is displayed with its detection time as the key ON hour meter reading.

2. In/Out monitor function "I/O MONITOR"This function displays the analog input values from individual sensors in the traveling, material handling,FHPS, SAS and OPS systems. Monitoring the displayed values enables the quality of each circuit/sensorto be judged.(1) "I/O ENGINE CTRL"Displays ON/OFF states of the engine controller switch, various input values including analog inputvoltage from the sensor and correction value of the control.(2) "I/O TRAVELING"Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing con-trol.(3) "I/O M.HANDLING"Displays the material handling and mast switch ON/OFF states and analog input voltages from materialhandling and mast sensors.(4) "I/O STEERING"Displays the ON/OFF states of knob position correction control and the analog input voltages from re-spective sensors.(5) "I/O OTHERS"Displays the ON/OFF states of hour meter time and other switches and the analog input voltages fromrespective sensors.

3. Active test "ACTIVE TEST"In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the se-lected item in order to permit operation check of that function.

4. Program version display "VERSION"Displays program version of each controller.

7-817 DISPLAY

7.2.3.2 ANALYZER SCREEN MENU LISTAnalyzer menu screen

Display item DescriptionMenu screen Screen No.1. DIAG MEMORY 1. to 10. Indications of errors occurred

2. I/O ENGINE CTRL(Engine control)(4Y)

1/10

IGSW Key switch (IG)STA Key switch (ST)BATT Battery voltageG/LP Fuel changeover switchSEL Fuel specification discrimination signalADJ Engine specification discrimination signal

2/10

MREL EFI main relay drive signalFC Circuit opening relay drive signalLPR LP gas main relay drive signalLFC LP gas slow solenoid drive signalOXHT O2 sensor heater drive signal

3/10

THA Intake temperature sensor voltageTHA( ) Intake air temperatureTHW Coolant temperature sensor voltageTHW( ) Coolant temperaturePIM Intake pipe negative pressure sensor voltagePIM( ) Intake manifold pressure

4/10

VPA1 Accelerator pedal position sensor (1) voltageVPA1( ) (standard)VPA2 Accelerator pedal position sensor (2) voltageVPA2( ) (standard)PA Throttle position

5/10

VTA1 Throttle position sensor (1) voltageVTA1( ) (standard)VTA2 Throttle position sensor (2) voltageVTA2( ) (standard)TA Throttle opening angleIM Electronic throttle motor current

6/10

PA Accelerator pedal positionNE Engine speedNE( ) (Traveling speed)TA Throttle position

7/10

NE Engine speedNE( ) (Traveling speed)PIM Intake manifold pressureIGT Ignition timing (spark advance amount)

8/10

NE Engine speedNE( ) (Traveling speed)PIM Intake manifold pressureINJ Injector correction value (gasoline)OX O2 sensor voltage

7

7-82 7 DISPLAY

Analyzer menu screenDisplay item Description

Menu screen Screen No.

2. I/O ENGINE CTRL(Engine control)(4Y)

9/10

NE Engine speedNE( ) (Traveling speed)PIM Intake manifold pressureVF VF voltage (LPG/CNG)OX O2 sensor voltageOX( ) (O2 sensor monitor)

10/10

NE Engine speedNE( ) (Traveling speed)PIM Intake manifold pressureLINJ Injector correction value (LPG/CNG)FCM Fuel control module correction value (LPG/CNG)

2. I/O ENGINE CTRL(Engine control)(1ZS)

1/5

NE Engine speedNE( ) (Traveling speed)BATT Battery voltagePA Accelerator pedal positionTHW Coolant temperature

2/5

ATM Atmospheric pressurePIM Intake manifold pressure past turbochargerMAF Intake air massTHA Intake air temperature before turbochargerTHW Coolant temperature

3/5

NE Engine speedNE( ) (Traveling speed)FILT Fuel filter cloggingSEDI Water sedimenter levelTHF Fuel TemperatureQF Fuel injection quantity

4/5

NE Engine speedNE( ) (Traveling speed)VPA1 Accelerator sensor (1) voltageVPA2 Accelerator sensor (2) voltagePA Accelerator pedal position

5/5

ATM Atmospheric pressureTHA Intake air temperature before turbochargerMAF Intake air mass flowTHIA Intake air temperature past turbocharger

7-837 DISPLAY



3. I/O TRAVELING（Traveling/swing system）

1/3

SPD Traveling speed sensor voltageSPD( ) (Traveling speed)ACCSW Accelerator switchBRKSW Brake switchPKBSW Parking brake switchSPARE Spare

2/3

SEAT Seat switchDRF Forward traveling switchDRR Reverse traveling switchRYF Forward/reverse traveling interrupt relay

3/3

YRS Yaw rate sensor voltageMH Lifting height switchSA (Unused)SWN Swing lock solenoidPRES Load sensor voltagePRES( ) (MPa　display)SPEED Traveling speed

7

7-84 7 DISPLAY



4. I/O M.HANDLING(Material handling/mastcontrol system)

1/7

MD/MU Lift lowering switch/Lift raising switchMF/MR Forward tilt switch/Backward tilt switchUSOL (Unused)LSOL Lift lowering lock solenoidTSOL Tilt solenoidBTSL Backward tilt lock solenoidSEAT Seat switch

2/7

MA Tilt angle sensor voltageMH Lifting height switchPRES Load sensor voltage (MPa　display)SWLK (Unused)SWTK Automatic fork leveling stop switchSWATS T/C interlock relay

3/7POTL Lift lever angle sensor (1) voltage/Lift lever angle

sensor (2) voltageLPSOL Lift proportional valve solenoid currentLSOL Lift lowering lock solenoid

4/7POTT Tilt lever angle sensor (1) voltage/Tilt lever angle

sensor (2) voltageTPSOL Tilt proportional valve solenoid currentTSOL Tilt solenoid

5/7POTA1 Attachment (1) lever angle sensor (1) voltage/At-

tachment (1) lever angle sensor (2) voltageA1SOL Attachment (1) proportional valve solenoid current

6/7POTA2 Attachment (2) lever angle sensor (1) voltage/At-

tachment (2) lever angle sensor (2) voltageA2SOL Attachment (2) proportional valve solenoid current

7/7

RPRES P port pressure sensor voltageRPRES() (MPa display)RSOL Electromagnetic relief valve solenoid currentMU Lift raising switchMALL Material handling operations switchNE Engine speed

5. I/O STEERING(Steering control system)

1/1

TIRE Tire angle sensor voltageSPEED Traveling speed

K-POS Steering angle knob position actual value (targetvalue)

STS Steering angle sensor

6. I/O OTHERS(Others)

1/2HR Hour meterBATT Battery voltageTHO Torque converter oil temperature sensor voltage

2/2IGSW Key switch (IG)MAT Matching connectorMTC (Unused)

7-857 DISPLAY



7.ACTIVE TEST(Operation test)

1/3

SWING SOL Swing lock solenoid forced operationSTEERINGSOL

Knob position compensation solenoid forced oper-ation

T/C RLY Forward/reverse traveling cut-off relay forced op-eration

ASC RLY (Unused)

2/3

LIFT LWRSOL Lift lowering lock solenoid forced operation

TILT SOL Tilt solenoid forced operationTILT BWDSOL Backward tilt lock solenoid forced operation

UNLOAD SOL (Unused)

3/3

OPTION RLY T/C interlock relay forced operationBUZZER Warning buzzer forced operationSWG TESTLMP Swing lock operation check

RELIEF SOL Electromagnetic relief valve forced operation

8.VERSION(Program version)

1/1

DISPLAY Display program versionSAS/OPSECU SAS/OPS controller program version

ENGINE ECU Engine controller program versionCAN BRIDGE (Unused)

7.2.3.3 ANALYZER MENU Screen

Operating ProcedureStep 1 Enter the password on the general screen to display

the service function "MASK MENU" screen.


Step 2 Check that "1. ANALYZER" is selected (highlighted)on the screen and press switch (4) (enter) to call the"ANALYZER MENU" screen.

Step 3 Select the menu with switch (1), and press (enter)switch (4) to move to the screen of the selected item.

7

7-86 7 DISPLAY

Step 4 If you select "9. END" on the "ANALYZER MENU"screen and press switch (4) (enter), the service func-tion "MASK MENU" screen appears again.

"1. DIAG MEMORY"Switch (1): Switching selection to next itemSwitch (4): To "DIAG MEMORY" screen

"2. I/O ENGINE CTRL"Switch (1): Switching selection to next itemSwitch (4): To "I/O ENGINE CTRL" screen

"3. I/O TRAVELING"Switch (1): Switching selection to next itemSwitch (4): To "I/O TRAVELING" screen

"4. I/O M.HANDLING"Switch (1): Switching selection to next item switch(4): To "I/O M.HANDLING" screen

"5. I/O STEERING"Switch (1): Switching selection to next itemSwitch (4): To "I/O STEERING" screen

"6. I/O OTHERS"Switch (1): Switching selection to next itemSwitch (4): To "I/O OTHERS" screen

"7. ACTIVE TEST"Switch (1): Switching selection to next itemSwitch (4): To "ACTIVE TEST" screen

"8. VERSION"Switch (1): Switching selection to next itemSwitch (4): To "VERSION" screen

"9. END"Switch (1): Switching selection to next itemSwitch (4): Returning to service function "MASK MENU"screen

7-877 DISPLAY

7.2.3.4 Diagnosis Memory Function "1.DIAG MEMORY"The controller stores up to 10 most recent errors. The "DIAG MEMORY" screen displays these diagnosiscodes with their detection time information (in ignition key ON hour meter reading).The most recent diagnosis code is displayed as 1, followed by 2, 3 and so on to 10.

Operating ProcedureStep 1 Display the "ANALYZER MENU" screen.

Switch(4)

Step 2 Check that "1. DIAG MEMORY" is selected on thescreen, and press (enter) switch (4) to display "DIAGMEMORY 1/2" screen.

Step 3 Press switch (4) on "DIAG MEMORY 2/2" screen toreturn to the "ANALYZER MENU" screen.

NOTICE: When no error codes are displayed on the

screen and the hour meter time is 0.0h, it in-dicates that no errors occurred in the pastafter that row.

It is impossible to directly jump from the"DIAG MEMORY" screen to other functionscreen. Return to the "ANALYZER MENU"screen once and then go to the desired func-tion screen.

For details of diagnosis code, refer to section18, Diagnosis Code List.

"DIAG MEMORY 1/2"Displays diagnosis 1 to 5.Switch (4): To "DIAGMEMORY 2/2" screen

7

7-88 7 DISPLAY

"DIAG MEMORY 2/2"Displays diagnosis 6 to 10.Switch (4): Returning to the "ANALYZER MENU" screen

7-897 DISPLAY

7.2.3.5 In/Out Monitor Function "I/O MONITOR"This function displays the input voltage from each of traveling, material handling, FHPS, SAS and OPSsensors. The circuit or sensor quality can be judged by monitoring the displayed value.

7.2.3.5.1 In/Out Monitor (1) "2.I/O ENGINE CTRL"4Y Engine VehicleDisplays ON/OFF states of the 4Y engine controller switch, various input values including input voltage fromthe sensor, correction value of the control and output condition to the relay.


(1) (2) (3) (4)

Step 2 Press switch (1) once to check that "2. I/O ENGINECTRL" is selected, and press (enter) switch (4) to dis-play "I/O ENGINE CTRL 1/10" screen.

NOTICE: You cannot move directly from I/O ENGINE

CTRL screen to the screen of the other items.Return to "ANALYZER MENU" screen once,then move to screen of each item.

7

7-90 7 DISPLAY

"I/O ENGINE CTRL 1/10"IGSW: Key switch (IG)Displays key switch(IG) ON/OFF.IGSW: 0 = OFFIGSW: 1 = ONSTA: Key switch (ST)Displays key switch(ST) ON/OFF.STA: 0 = OFFSTA: 1 = ONBATT: Battery voltage (V)Displays battery voltage.Standard: 8.0 to16.0 VG/LP: Fuel changeover switchDisplays states of the fuel changeover switch selection.G/LP: 10 When gasoline is selectedG/LP: 01 When LP gas is selectedSEL: Fuel specification discrimination signalDisplays states of fuel specification discrimination signal.SEL: 1100 Exclusive for gasolineSEL: 1010 Exclusive for LP gasSEL: 0110 Gasoline/LP gas convertible typeSEL: 0101 Gasoline/CNG convertible typeADJ: Engine specification discrimination signalDisplays states of engine specification discrimination sig-nal.Switch (4): To "I/O ENGINE CTRL 2/10" screen

"I/O ENGINE CTRL 2/10"MREL: EFI main relay drive signalDisplays states of drive signal output to EFI main relay.MREL: 1 DriveMREL: 0 HaltedFC: Circuit opening relay drive signalDisplays states of drive signal output to the circuit openingrelay.FC: 1 DriveFC: 0 HaltedLPR: LP gas main relay drive signalDisplays states of drive signal output to LP gas main relay.LPR: 1 DriveLPR: 0 HaltedLFC: LP gas slow solenoid drive signalDisplays states of drive signal output to LP gas slow solen-oid.LFC: 1 DriveLFC: 0 HaltedOXHT: O2 sensor heater drive signalDisplays states of drive signal output to the O2 sensorheater.OXHT: 1 DriveOXHT: 0 HaltedSwitch (4): To "I/O ENGINE CTRL 3/10" screen

7-917 DISPLAY

"I/O ENGINE CTRL 3/10"THA: Intake temperature sensor voltage(V), Intake air tem-perature(°C) Display intake temperature sensor voltage(V), Intake airtemperature(°C).THW: Coolant temperature sensor voltage(V), Coolanttemperature(°C)Display coolant temperature sensor voltage(V), Coolanttemperature(°C).PIM: Intake pipe negative pressure sensor voltage(V), In-take manifold pressure(°C)Display Intake pipe negative pressure sensor voltage(V),Intake manifold pressure(°C).Standard:3.6 ± 0.3 V (100 ± 10 kPa) (when engine is halted)Switch (4): To "I/O ENGINE CTRL 4/10" screen

"I/O ENGINE CTRL 4/10"VPA1: Accelerator pedal position sensor (1) voltage(standard)Display Accelerator pedal position sensor (1) voltage(standard).Accelerator sensor (1) voltage standard:0.2 to1.3 V (when accelerator is not operated)1.4 to 4.1 V (during maximum pressing of accelerator)

Accelerator fully closed position stored value stand-ard: 0.2 to 1.3 VVPA2: Accelerator pedal position sensor (2) voltage(standard)Display Accelerator pedal position sensor (2) voltage(standard).Accelerator sensor (2) voltage standard:0.7 to 2.0 V (when accelerator is not operated)2.1 to 4.7 V (during maximum pressing of accelerator)

Accelerator fully closed position stored value stand-ard: 0.7 to 2.0 VPA: Accelerator pedal positionDisplays operation amount of the accelerator pedal.Accelerator opening angle standard:0% (when accelerator is not operated) 100% (during maximum pressing of accelerator)Switch (4): To "I/O ENGINE CTRL 5/10" screen

7

7-92 7 DISPLAY

"I/O ENGINE CTRL 5/10"VTA1: Throttle position sensor (1) voltage (standard)Display throttle position sensor (1) voltage (standard).Throttle position sensor (1) voltage standard:0.3 to 1.5 V (during engine idle (after warm-up))

Throttle fully closed position stored value standard:0.3 to 1.5 VVTA2: Throttle position sensor (2) voltage (standard)Display throttle position sensor (2) voltage (standard).Throttle position sensor (1) voltage standard:1.7 to 3.3V (during engine idle (after warm-up))

Throttle fully closed position stored value standard:1.7 to 3.3VTA: Throttle positionDisplays throttle position (° ).

Standard:1.0 to 8.0° (during engine idle (after warm-up))IM: Electronic throttle motor currentDisplays current flowing to the electronic throttle motor.

Standard: 0.2 to 10.0 ASwitch (4): To "I/O ENGINE CTRL 6/10" screen

"I/O ENGINE CTRL 6/10"PA: Accelerator pedal position (refer to "I/O ENGINE CTRL4/10")NE: Engine speed(rpm), (Traveling speed(km/h or mph))Display engine speed (Traveling speed).

Engine speed standard: 0 to 3500 rpmTA: Throttle position (refer to page "I/O ENGINE CTRL5/10")Switch (4): To "I/O ENGINE CTRL 7/10" screen

"I/O ENGINE CTRL 7/10"NE: Engine speed (refer to "I/O ENGINE CTRL 6/10")PIM: Intake pipe negative pressure sensor voltage, Intakemanifold pressure (refer to "I/O ENGINE CTRL 3/10")IGT: Ignition timing (spark advance amount)Displays ignition timing (spark advance amount: ° ).Standard:5.0 to 25.0 ° (during engine idle (after warm-up))Switch (4): To "I/O ENGINE CTRL 8/10" screen

7-937 DISPLAY

"I/O ENGINE CTRL 8/10"NE: Engine speed (refer to "I/O ENGINE CTRL 6/10")PIM: Intake pipe negative pressure sensor voltage, Intakemanifold pressure (refer to "I/O ENGINE CTRL 3/10")INJ: Injector correction value (gasoline)Displays correction value of the fuel injection amount.OX: O2 sensor voltage (O2 sensor monitor)Displays voltage of O2 sensor (O2 sensor monitor).O2sensor voltage standard: 0 to 1.0 VO2 sensor monitor1: rich0: leanSwitch (4): To "I/O ENGINE CTRL 9/10" screen

"I/O ENGINE CTRL 9/10"NE: Engine speed (refer to "I/O ENGINE CTRL 6/10")PIM: Intake pipe negative pressure sensor voltage, Intakemanifold pressure (refer to "I/O ENGINE CTRL 3/10")VF: VF voltage (LPG/CNG)Displays the voltage (V) output from VF terminal.Standard: 2.0 to 3.0 VOX: O2 sensor voltage (O2 sensor monitor) (refer to "I/OENGINE CTRL 8/10")Switch (4): To "I/O ENGINE CTRL 10/10" screen

"I/O ENGINE CTRL 10/10"NE: Engine speed (refer to "I/O ENGINE CTRL 6/10")PIM: Intake pipe negative pressure sensor voltage, Intakemanifold pressure (refer to "I/O ENGINE CTRL 3/10")LINJ: Injector correction value (LPG/CNG)Displays correction value of the fuel injection amount.FCM: Fuel control module correction value (LPG/CNG)Displays correction value of the air-fuel ratio motor openingangle.Switch (4): To "ANALYZER MENU" screen

7

7-94 7 DISPLAY

1ZS Engine VehicleDisplays ON/OFF states of the 1ZS engine controller switch, various input values including analog inputvoltage from the sensor and correction value of the control.



Step 2 Press switch (1) once to check that "2. I/O ENGINECTRL" is selected, and press (enter) switch (4) to dis-play "I/O ENGINE CTRL 1/5" screen.

NOTICE: You cannot move directly from "I/O ENGINE

CTRL" screen to the screen of the other items.Return to "ANALYZER MENU" screen once,then move to screen of each item.

"I/O ENGINE CTRL 1/5"NE: Engine speed(rpm), (Traveling speed(km/h or mph))Displays engine speed and traveling speed.BATT: Battery voltage (V)Displays battery voltage.

Standard: 8.0 to 16.0 VPA: Accelerator pedal position (%)Displays operation amount of the accelerator pedal.0% (when accelerator is not operated)100% (during maximum pressing of accelerator)THW: Coolant temperature (°C)Displays coolant temperature.Switch (4): To "I/O ENGINE CTRL 2/5" screen

7-957 DISPLAY

"I/O ENGINE CTRL 2/5"ATM: Atmospheric pressure (kPa)Display atmospheric pressure.PIM: Intake manifold pressure past turbocharger (kPa )Displays the engine intake manifold pressure after beingsupplied by the turbocharger.Standard: Within ATM + 155(kPa)MAF: Intake air massDisplay Intake air mass.THA: Intake air temperature (°C)Displays intake air temperature.THW: Coolant temperature (°C)Displays coolant temperature.Switch (4): To "I/O ENGINE CTRL 3/5" screen

"I/O ENGINE CTRL 3/5"NE: Engine speed(rpm), (Traveling speed(km/h or mph))Refer to "I/O ENGINE CTRL 1/5"FILT: Fuel filter clogging Display fuel filter clogging.SEDI: Water sedimenter level Display water sedimenter level.THF: Fuel Temperature (°C)Display fuel Temperature.QF: Fuel injection quantityDisplay fuel injection quantity.Switch (4): To "I/O ENGINE CTRL 4/5" screen

"I/O ENGINE CTRL 4/5"NE: Engine speed(rpm), (Traveling speed(km/h or mph))Refer to "I/O ENGINE CTRL 1/5".VPA1: Accelerator sensor (1) voltage (V) Display accelerator sensor (1) voltage.VPA2: Accelerator sensor (2) voltage (V)Display accelerator sensor (2) voltage.PA: Fuel Temperature (%)Refer to "I/O ENGINE CTRL 1/5".Switch (4): To "I/O ENGINE CTRL 5/5" screen

"I/O ENGINE CTRL 5/5"ATM: Atmospheric pressure (kPa)Refer to "I/O ENGINE CTRL 2/5".THA: Intake air temperature before turbocharger (°C) Refer to "I/O ENGINE CTRL 2/5".MAF: Intake air mass flowRefer to "I/O ENGINE CTRL 2/5".THIA: Intake air temperature past turbocharger (°C)Displays the engine intake air temperature after being sup-plied by the turbocharger.Switch (4): To "ANALYZER MENU" screen

7

7-96 7 DISPLAY

7.2.3.5.2 In/Out Monitor (2) "3.I/O TRAVELING"This function displays the ON/OFF status of traveling and swing switches, and analog input voltages ofsensors.



Step 2 Press switch (1) twice to check that "3. I/O TRAVEL-ING" is selected, and press (enter) switch (4) to dis-play "I/O TRAVELING 1/3" screen.

NOTICE: You cannot move directly from "I/O TRAVELING"

screen to the screen of the other items. Return to"ANALYZER MENU" screen once, then move toscreen of each item.

7-977 DISPLAY

"I/O TRAVELING 1/3"SPD: Traveling speed sensor voltage (V), and travelingspeed (km/h or mph)Display traveling speed sensor voltage and travelingspeed.Standard when vehicle is stationary: approx. 2.5V (0.0 (km/h or mph))ACCSW: Accelerator switchDisplays states of accelerator switch.ACCSW: 0 = Standard accelerator pedal typeACCSW: 1 = EZ pedal typeBRKSW: Brake switch Display states of brake switch.Vehicle without brake switchBRKSW: 0 = AlwaysVehicle with brake switchBRKSW: 1 = ON when brake pedal is depressedBRKSW: 0 = OFF when brake pedal is not operatedPKBSW: Parking brake switch Displays states of parking brake switch.Vehicle without parking brake switchPKBSW: 0 = AlwaysVehicle with parking brake switchPKBSW: 1 = ON in a state of parking brake being operatedPKBSW: 0 = OFF in a state of parking brake being re-leasedSPARE: Spare (Unused)Switch (4): To "I/O TRAVELING 2/3" screen

7

7-98 7 DISPLAY

"I/O TRAVELING 2/3"SEAT: Seat switchDisplays states of seat switch.SEAT: 1 = ON when taking the seatSEAT: 0 = OFF when leaving the seatDRF: Forward direction switchDRR: Reverse direction switchDisplays states of forward/reverse traveling switch.Direction lever: Forward traveling positionDisplayed code:DRF: 1 (= ON)DRR: 0 (= OFF)Direction lever: Neutral positionDisplayed code:DRF: 0 (= OFF)DRR: 0 (= OFF)Direction lever: Reverse travel positionDisplayed code:DRF: 0 (= OFF)DRR: 1 (= ON)RYF: Forward/reverse traveling interrupt relayDisplays output signal to forward/reverse traveling interruptrelay.RYF: 1 = ON Relay energized (forward/reverse travelingnot possible) stateRYF: 0 = OFF Relay non-energized (forward/reverse trav-eling possible) stateSwitch (4): To "I/O TRAVELING 3/3" screen

7-997 DISPLAY

"I/O TRAVELING 3/3"YRS: Yaw rate sensor voltage (V)Display voltage of the yaw rate sensor.

Vehicle without rear stabilizer: Normally 0.00 VVehicle with rear stabilizer:Standard when vehicle is stationary: Approx. 2.5 VMH: Lifting height switch1 = ON0 = OFF

MH1 MH2-1

MH2-2

SA: (Unused)SWN: Swing lock solenoidDisplays output signal from the controller to the swing locksolenoid.

Vehicle without rear stabilizer:SWN: - = AlwaysVehicle with rear stabilizer:SWN: 1 = ON Energized (swing lock released) stateSWN: 0 = OFF Non-energized (swing lock) statePRES: Load sensor voltage, and MPa displayDisplays input voltage from the load sensor to the control-ler, and detected pressure.Standard at no load: 0.5 to 4.5 VVoltage increases as load increases.SPEED: Traveling speed (km/h or mph)Displays traveling speed.Switch (4): To "ANALYZER MENU" screen

Lifting Height Switch (MH) ON/OFF Combination Table

Lifting height switch circuit diagram

(MH1)E3

(MH2-1)

(MH2-2)

At a low lift (less than 2200 mm (87 in)*)MH1 1 (= ON)MH2-1 0 (= OFF)MH2-2 0 (= OFF)

At a medium lift (2200 mm (87 in) or more)MH1 0 (= OFF)MH2-1 1 (= ON)MH2-2 0 (= OFF)

*: The height at which the lifting height switch changes will vary according to the lifting height set for themast.

7

7-100 7 DISPLAY

7.2.3.5.3 In/Out Monitor (3) "4.I/O M.HANDLING"This function displays the ON/OFF status of material handling and mast control switches and analog inputvoltages from sensors.



Step 2 Press switch (1) 3 times to check that "4. I/OM.HANDLING" is selected, and press (enter) switch(4) to display "I/O M.HANDLING 1/7" screen.

NOTICE: You cannot move directly from "I/O M.HAND-

LING" screen to the screen of the other items.Return to "ANALYZER MENU" screen once,then move to screen of each item.

7-1017 DISPLAY

"I/O M.HANDLING 1/7"MD/MU: Lift lowering switch/Lift raising switchDisplays states of Lift lowering switch/Lift raising switch.

STD lever vehicle:Lift lever: Lowering positionDisplayed code:MD: 1 (= ON)MU: 0 (= OFF)Lift lever: Neutral positionDisplayed code:MD: 0 (= OFF)MU: 0 (= OFF)Lift lever: Raising positionDisplayed code:MD: 0 (= OFF)MU: 1 (= ON)Mini lever/Joystick vehicle:MD/MU: - = AlwaysMF/MR: Forward tilt switch/Backward tilt switchDisplays states of Forward tilt switch/Backward tilt switch.STD lever vehicle:Tilt lever: Forward tilt positionDisplayed code:MF: 1 (= ON)MR: 0 (= OFF)Tilt lever: Neutral positionDisplayed code:MF: 0 (= OFF)MR: 0 (= OFF)Tilt lever: Backward tilt positionDisplayed code:MF: 0 (= OFF)MR: 1 (= ON)Mini lever/Joystick vehicle:MF/MR: - = AlwaysUSOL: (Unused)MF/MR: - = AlwaysLSOL: Lift lowering lock solenoidDisplays output signal from the controller to the lift loweringlock solenoid.TSOL: Tilt solenoidDisplays output signal from the controller to the tilt locksolenoid.BTSL: Backward tilt lock solenoid. Displays output signal from the controller to the backwardtilt lock solenoid.SEAT: Seat switchRefer to "I/O TRAVELING 2/3"Switch (4): To "I/O M.HANDLING 2/7" screen

7

7-102 7 DISPLAY

Condition of the Seat/lever and Detected Values (USOL/LSOL/TSOL/BTSL/SEAT)

Seat condition Sitting on seat Leavingseat

Lever condition Not oper-ated

Lift lever Tilt lever

-Raising Lowering Forward tilt

Backward tiltLow liftingheight

High liftingheight

STD levervehicle

USOL - - - - - - -LSOL 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF)TSOL 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 1 (= ON) 0 (= OFF)BTSL 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON) 1 (= ON) 0 (= OFF)SEAT 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 0 (= OFF)

Mini lever/Joystickvehicle

USOL - - - - - - -LSOL 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF)TSOL 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 1 (= ON) 0 (= OFF)BTSL - - - - - - -SEAT 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 0 (= OFF)

"I/O M.HANDLING 2/7"MA: Tilt angle sensor voltage (V)Displays the input voltage from the tilt angle sensor to thecontroller.Standard with mast in the vertical position: 1.1 to 4.2 VMast vertical → forward tilt: Input voltage decreasesMast vertical → backward tilt: Input voltage increasesMH: Lifting height switchPRES: Load sensor voltage (V), and MPa displaySWLK: (Unused)SWTK: Automatic fork leveling stop switchDisplays states of automatic fork leveling stop switch.SWTK: 0 = OFFSWTK: 1 = ONSWATS: T/C interlock relayDisplay states of T/C interlock relay.SWATS: 0 = Traveling not possibleSWATS: 1 = Traveling possibleSwitch (4): To "I/O M.HANDLING 3/7" screen

7-1037 DISPLAY

"I/O M.HANDLING 3/7"POTL: Lift lever angle sensor (1) voltage (V)/lift lever anglesensor (2) voltage (V)Displays input voltage from the lift lever angle sensor (1)/liftlever angle sensor (2) to the controller.STD lever vehicle:POTL: - = AlwaysMini lever/Joystick vehicle:Standard:Lift lever: RasingLift lever angle sensor (1) voltage: 1.8 to 4.1 VLift lever angle sensor (2) voltage: 0.3 to 2.9 VLift lever: LoweringLift lever angle sensor (1) voltage: 0.4 to 2.8 VLift lever angle sensor (2) voltage: 1.6 to 4.3 VLPSOL: Lift proportional valve solenoid current (A)Displays output current from the controller to the lift propor-tional valve solenoid.STD lever vehicle:LPSOL: - = AlwaysMini lever/Joystick vehicle:Standard when lever is operated: 0.3 to 0.85 ALSOL: Lift lowering lock solenoidRefer to "I/O M.HANDLING 1/7"Switch (4): To "I/O M.HANDLING 4/7" screen

"I/O M.HANDLING 4/7"POTT: Tilt lever angle sensor (1) voltage (V)/tilt lever anglesensor (2) voltage (V)Displays input voltage from the tilt lever angle sensor (1)/tiltlever angle sensor (2) to the controller.STD lever vehicle:POTT: - = AlwaysMini lever/Joystick vehicle:Standard:Tilt lever: Forward tiltTilt lever angle sensor (1) voltage: 1.8 to 4.1 VTilt lever angle sensor (2) voltage: 0.3 to 2.9 VTilt lever: Backward tiltTilt lever angle sensor (1) voltage: 0.4 to 2.8 VTilt lever angle sensor (2) voltage: 1.6 to 4.3 VTPSOL: Tilt proportional valve solenoid current (A)Displays output current from the controller to the tilt propor-tional valve solenoid.STD lever vehicle:TPSOL: - = AlwaysMini lever/Joystick vehicle:Standard when lever is operated: 0.3 to 0.85 ATSOL: Tilt solenoidRefer to "I/O M.HANDLING 1/7"Switch (4): To "I/O M.HANDLING 5/7" screen

7

7-104 7 DISPLAY

"I/O M.HANDLING 5/7"POTA1: Attachment (1) lever angle sensor (1) voltage (V) /attachment (1) lever angle sensor (2) voltage (V)Displays input voltage from the attachment (1) lever anglesensor (1)/attachment (1) lever angle sensor (2) to the con-troller.STD lever vehicle:POTA1: - = AlwaysMini lever/Joystick lever vehicle:Standard:Attachment (1) lever: Backward tilt sideAttachment (1) lever angle sensor (1) voltage: 1.8 to 4.1 VAttachment (1) lever angle sensor (2) voltage: 0.3 to 2.9 VAttachment (1) lever: Forward tilt sideAttachment (1) lever angle sensor (1) voltage: 0.4 to 2.8 VAttachment (1) lever angle sensor (2) voltage: 1.6 to 4.3 VA1SOL: Attachment (1) proportional valve solenoid current(A)Displays output current from the controller to the attach-ment (1) proportional valve solenoid.STD lever vehicle:A1SOL: - = Always

Mini lever/Joystick vehicle:Standard when lever is operated: 0.3 to 0.85 ASwitch (4): To "I/O M.HANDLING 6/7" screen

7-1057 DISPLAY

"I/O M.HANDLING 6/7"POTA2: Attachment (2) lever angle sensor (1) voltage (V) /attachment (2) lever angle sensor (2) voltage (V)Displays input voltage from the attachment (2) lever anglesensor (1)/attachment (2) lever angle sensor (2) to the con-troller.STD lever vehicle:POTA2: - = AlwaysMini lever/Joystick lever vehicle:Standard:Attachment (2) lever: Backward tilt sideAttachment (2) lever angle sensor (1) voltage: 1.8 to 4.1 VAttachment (2) lever angle sensor (2) voltage: 0.3 to 2.9 VAttachment (2) lever: Forward tilt sideAttachment (2) lever angle sensor (1) voltage: 0.4 to 2.8 VAttachment (2) lever angle sensor (2) voltage: 1.6 to 4.3 VA2SOL: Attachment (2) proportional valve solenoid current(A)Displays output current from the controller to the attach-ment (2) proportional valve solenoid.STD lever vehicle:A2SOL: - = AlwaysMini lever/Joystick vehicle:Standard when lever is operated: 0.3 to 0.85 ASwitch (4): To "I/O M.HANDLING 7/7" screen

7

7-106 7 DISPLAY

"I/O M.HANDLING 7/7"RPRES:P port pressure sensor voltage (V), (MPa display)Displays voltage value and pressure corresponding valueof P port pressure sensor.4YE engine model:Standard (No load): 0.5V to 4.5VIncreases the voltage value as a hydraulic load increases.Except 4YE engine model:RPRES: ---- = AlwaysRSOL:Electromagnetic relief valve solenoid current (A)Displays electromagnetic relief valve solenoid current.Standard solenoid current (When operating material hand-ling): 　0.3A to 0.75AMU:Lift raising switchDisplays status of lift raising switch.Refer to "I/O M.HANDLING 1/7"Mini lever/Joystick vehicle:MALL:Material handling operations switchDisplays status of any material handling operations switch.Vehicle without material handling switches are OFF: 0Vehicle with material handling swiches are ON: 1NE:Engine speed (rpm)Refer to "I/O ENGINE CTRL 1/5"Switch (4): Returning to ANALYZER MENU screen

7.2.3.5.4 In/Out monitor (4) "5.I/O STEERING"This function displays ON/OFF status of the knob position correction and other switches, and analog inputvoltages from sensors.

Operation ProcedureStep 1 Display the "ANALYZER MENU" screen.

7-1077 DISPLAY


Step 2 Press switch (1) 4 times to check that "5. I/O STEER-ING" is selected, and press (enter) switch (4) to dis-play "I/O STEERING 1/1" screen.

NOTICE: You cannot move directly from "I/O STEER-

ING" screen to the screen of the other items.Return to "ANALYZER MENU" screen once,then move to screen of each item. 7

7-108 7 DISPLAY

"I/O STEERING 1/1"TIRE: Tire angle sensor voltage (V)Displays input voltage from tire angle sensor to the control-ler.

Vehicle without synchronized steering:TIRE: ---- = AlwaysVehicle with synchronized steering:Standard when tires are in straight ahead position: 1.9 to 2.4 VSPEED: Traveling speed (km/h or mph)K-POS: Steering knob position actual value (target value)and steering synchronizer solenoidActual value:The knob position calculated and recognized by the con-troller from the steering angle sensor signalTarget value:The knob position calculated and recognized by the con-troller from the tire angle sensor signalOne rotation (360°) of the steering wheel is divided by 160,and the value is set to "80" when the knob is in the positionas indicated in the illustration.Vehicle without synchronized steering:K-POS:---- = AlwaysVehicle with synchronized steering:Clockwise turn of the steering wheel: Increase in valueCounterclockwise turn of the steering wheel: Decrease invalueSteering synchronizer solenoid:Vehicle without synchronized steering:K-POS:---- = AlwaysVehicle with synchronized steering:0 = OFF (non-energized) state1 = ON (energized) stateSTS: Steering angle sensor

STS1 STS2

STSC

Vehicle without synchronized steering:STS: ---- = AlwaysVehicle with synchronized steering:1 = ON0 = OFFWhen the steering wheel is rotated once, STS1 and STS2repeat ON and OFF.STSC only turns on when the knob is in the standard posi-tion.Switch (4): To "ANALYZER MENU" screen

Standard position

80

0159

1

7-1097 DISPLAY

7.2.3.5.5 In/Out Monitor (5) "6.I/O OTHERS"



Step 2 Press switch (1) 5 times to check that "6. I/O OTH-ERS" is selected, and press (enter) switch (4) to dis-play "I/O OTHERS 1/2" screen.

NOTICE: You cannot move directly from "I/O OTHERS"

screen to the screen of the other items. Re-turn to "ANALYZER MENU" screen once, thenmove to screen of each item.

"I/O OTHERS 1/2"HR: Hour meterDisplays hour meter value.BATT: Battery voltage (V)Displays battery voltage.Standard: 8.0 to 16.0VTHO: Torque converter oil temperature sensor voltage (V),and oil temperature (°C)Displays input voltage from the torque converter oil temper-ature sensor to the controller, and oil temperature.Switch (4): To "I/O OTHERS 2/2" screen

"I/O OTHERS 2/2"IGSW: Key switchDisplays key switch ON/OFF.IGSW: 1 = ONIGSW: 0 = OFFMAT: Matching connectorDisplays states of matching connector.

STD lever vehicle:MAT: 0 = OFF (State of matching connector separation)MAT: 1 = ON (State of matching connector connection)Mini lever/Joystick vehicle:MAT: - = AlwaysMTC: (Unused)Switch (4): Returning to "ANALYZER MENU" screen

7

7-110 7 DISPLAY

7.2.3.6 Active Test "ACTIVE TEST"This function outputs ON/OFF signals to switches in the electrical system and compare controller input sig-nals with those signals.

Active Test Menu List

Item DescriptionSelection itemSignal Content of operation Signal Content of operation

SWING SOL*1 Swing lock solenoidforced operation ON Unlock OFF Lock

STEERING SOL*2 Steering synchronizersolenoid forced operation ON By-pass open OFF By-pass close

T/C RLYForward/reverse travel-ing interrupt relay forcedoperation

ON Traveling not possible OFF Traveling possible

ASC RLY Unused - - - -

LIFT LWR SOL Lift lowering lock solen-oid forced operation ON Lowering possible OFF Lowering not possible

TILT SOL Tilt solenoid forced oper-ation ON

Forward tilt possibleBackward tilting speedlimited

OFFForward tilt not pos-sibleBackward tilt possible

TILT BWD SOL Backward tilt lock solen-oid forced operation ON Backward tilt possible OFF Backward tilt not pos-

sibleUNLOAD SOL Unused - - - -

OPTION RLY T/C interlock relay forcedoperation *4 ON Traveling is possible OFF Traveling is not pos-

sible

BUZZER*3 Warning buzzer forcedoperation ON Buzzer ON OFF Buzzer OFF

SWG TESTLMP*1

Swing lock solenoid op-eration display ON Indication OFF No indication

RELEIF SOL Electromagnetic reliefvalve forced operation ON Material handling is

possible OFFExcept loweringMaterial handling notpossible *6

*1: Vehicle with rear stabilizer only*2: Vehicle with synchronized steering only*3: Vehicle with OPS buzzer only*4: T/C interlock specification vehicle only*5: Depending on the attachment, 3rd to 5th way operation may be possible. Depending on the load, the

forward tilt operation may occur.*6: It may slowly lower according to load condition, but this is not a fault.

The OFF/ON for each item on the "ACTIVE TEST" screen normally shows the status. By operating switch (2) or switch (3), the OFF/ON for the selected item will be activated forcibly, and by

operating switch (1) to exchange the item, the forced operation will be released (turn to normal opera-tion).

A guidance corresponding to switch (2) and switch (3) will show if there is a forced operation. (see tablebelow)

7-1117 DISPLAY

Operation guidance Status

No forced operation of the selected item.

The selected item is on forced ON status.

The selected item is on forced OFF status.

No function for corresponding item, or no signal shows status.


Switch (1) Switch (2) Switch (4)Switch (3)

Step 2 Press switch (1) 6 times to check that "7. ACTIVETEST" is selected, and press (enter) switch (4) to dis-play "ACTIVE TEST 1/3" screen.Switch (1): Move to next itemSwitch (2): Forced OFFSwitch (3): Forced ONSwitch (4): Returning to the "ANALYZER MENU"screenNOTICE:

You cannot move directly from "ACTIVETEST" screen to the screen of the other items.Return to "ANALYZER MENU" screen once,then move to screen of each item.

7

7-112 7 DISPLAY

"ACTIVE TEST 1/3"SWING SOL: Swing lock solenoid forced operationJack up the rear axle, and check that the rear axle swings.Vehicle without swing lock: (Unused)Vehicle with swing lock:ON (solenoid ON): UnlockOFF (solenoid OFF): LockSTEERING SOL: Steering synchronizer solenoid forcedoperationSlowly turn the steering wheel, and check the difference ofthe rear tire movement.Vehicle without steering synchronizer: (Unused)Vehicle with steering synchronizer:ON (solenoid ON): By-pass open (tires move slowly)OFF (solenoid OFF): By-pass close (tires move (normal op-eration))T/C RLY: Forward/reverse interrupt relay forced operationCheck the operation of the torque converter forward/ re-verse interrupt relay.ON (relay ON): Traveling not possibleOFF (relay OFF): Traveling possible (normal operation)ASC RLY: (Unused)Switch (4): Returning to "ANALYZER MENU" screen

"ACTIVE TEST 2/3"NOTICE:When performing "ACTIVE TEST 2/3" item, make sureto sit on the seat correctly. If not, OPS is activated andmaterial handling operation may be limited.LIFT LWR SOL: Lift lowering lock solenoid forced opera-tionCheck the quality of lowering action by lift lowering opera-tion.ON (solenoid ON): Lowering possible (normal operation)OFF (solenoid OFF): Lowering not possibleTILT SOL: Tilt solenoid forced operationCheck the quality of mast forward tilt operation by forwardtilt operation.ON (solenoid ON): Forward tilt possible (normal operation),backward tilting speed limitedOFF (solenoid OFF): Forward tilt not possible, backward tiltoperated normally (normal operation)TILT BWD SOL: Backward tilt lock solenoid forced opera-tionCheck the quality of mast backward tilt operation by back-ward tilt operation.STD lever vehicle:ON (solenoid ON): Backward tilt possibleOFF (solenoid OFF): Backward tilt not possibleMini lever/Joy stick vehicle: (Unused)UNLOAD SOL: Unused

7-1137 DISPLAY

"ACTIVE TEST 3/3"NOTICE! When performing "RELIEF SOL" item, makesure to sit on the seat correctly. If not, OPS is activatedand material handling operation may be limited.OPTION RLY:T/C interlock relay forced operation (T/C interlock specifica-tion vehicle only)Check that T/C interlock can be enabled and disabled.ON (relay ON): Travel is possibleOFF (relay OFF): Travel is not possibleBUZZER: Warning buzzer forced operationCheck the warning buzzer operation.ON: Buzzer soundsOFF: Buzzer stopsSWG TEST LAMP: Swing lock solenoid operation displayCheck the swing lock operation states according to travel-ing and material handling states by OPS light.Vehicle without swing lock: (Unused)Vehicle with swing lock:ON (Indicated):Operation situation is indicated with OPS light.OPS light ON: Swing lock operatedOPS light OFF: Swing lock releasedOFF (not indicated):OPS light operates as OPS light (normal operation).Switch (4): Returning to "ANALYZER MENU" screenRELIEF SOL:Electromagnetic relief valve forced operationCheck the quality of ERV by any material handling opera-tion.ON (SOL ON): Material handling possibleOFF(SOL OFF): Material handling not possible(Depending on the attachment type, 3 to 5way may be op-erated.)(It may be forward tilting due to a load)

7

7-114 7 DISPLAY

7.2.3.7 Program Version "VERSION"Displays program version of each controller.



Step 2 Press switch (1) 7 times to check that "8. VERSION"is selected, and press (enter) switch (4) to display"VERSION" screen.Switch (4): Returning to "ANALYZER MENU" screen

NOTICE: You cannot move directly from "VERSION"

screen to the screen of the other items. Re-turn to "ANALYZER MENU" screen once, thenmove to screen of each item.

"VERSION"DISPLAY: Displaying program version Program version ofthe multifunction display DXSAS/OPS ECU: SAS/OPS program versionProgram version of SAS/OPS controllerENGINE ECU: Engine program versionEngine controller program versionCAN BRIDGE: UnusedSwitch (4): Returning to "ANALYZER MENU" screen

7-1157 DISPLAY

7.2.4 TUNING

7.2.4.1 GENERALPerforms fine adjustment of traveling and material handling control.When receiving a request from a user such as "I want to adjust the lift idle up", a setting level can be alteredfrom the tuning screen.55 tuning items are provided including spares.

7.2.4.2 Tuning Item List

Menu No. ItemLevel (: initial setting value)1 2 3 4 5 6 7 8

TUNEGEN.

No.1 *1 Lift Idle Up Slow FastNo.2 *2 T/C interlock threshold Slow ← ← → → → FastNo.3 Spare 1

No.4 Traveling or load handling accelerationperformance of Eco-mode Weak ← ← ← → → Strong

No.5 Spare 2

*1: For auto speed control [OPT] vehicle only*2: For T/C interlock specification vehicle only

Tuning Item List (for mini lever specification vehicle only)


LIFTDOWN

START Lift lowering adjustment (1):Play at the beginning of lift down operation Wide ← ← ← → → Small

INCH Lift lowering adjustment (2):Inching speed during lift down operation Slow ← ← ← → → Fast

MAX Lift lowering adjustment (3):Maximum speed during lift down operation Slow ← ← ← → → Fast

ACCLift lowering adjustment (4):Acceleration speed during lift down opera-tion

Weak ← ← ← → → Strong

DECLift lowering adjustment (5):Deceleration speed during lift down opera-tion


LIFT UP

START Lift raising adjustment (1):Play at the beginning of lift up operation Wide ← ← ← → → Small

INCH Lift raising adjustment (2):Inching speed during lift up operation Slow ← ← ← → → Fast

MAX Lift raising adjustment (3):Maximum speed during lift up operation Slow ← ← ← → → Fast

ACC Lift raising adjustment (4):Acceleration speed during lift up operation Weak ← ← ← → → Strong

DEC Lift raising adjustment (5):Deceleration speed during lift up operation Weak ← ← ← → → Strong

7

7-116 7 DISPLAY


TILTFWD

STARTForward tilt adjustment (1):Play at the beginning of tilt forward opera-tion

Wide ← ← ← → → Small

INCH Forward tilt adjustment (2):Inching speed during tilt forward operation Slow ← ← ← → → Fast

MAXForward tilt adjustment (3):Maximum speed during tilt forward opera-tion

Slow ← ← ← → → Fast

ACCForward tilt adjustment (4):Acceleration speed during tilt forward op-eration


DECForward tilt adjustment (5):Deceleration speed during tilt forward op-eration


TILTBWD

STARTBackward tilt adjustment (1):Play at the beginning of tilt backward oper-ation


INCHBackward tilt adjustment (2):Inching speed during tilt backward opera-tion


MAXBackward tilt adjustment (3):Maximum speed during tilt backward oper-ation


ACCBackward tilt adjustment (4):Acceleration speed during tilt backwardoperation


DECBackward tilt adjustment (5):Deceleration speed during tilt backwardoperation


ATT1PUSH

START

Attachment (1) lever forward tilt side ad-justment (1):Play at the beginning of the attachment (1)lever push operation


INCH

Attachment (1) lever forward tilt side ad-justment (2):Inching speed during the attachment (1)lever push operation


MAX

Attachment (1) lever forward tilt side ad-justment (3):Maximum speed during the attachment (1)lever push operation


ACC

Attachment (1) lever forward tilt side ad-justment (4):Acceleration speed during the attachment(1) lever push operation


DEC

Attachment (1) lever forward tilt side ad-justment (5):Deceleration speed during the attachment(1) lever push operation


7-1177 DISPLAY


ATT1PULL

START

Attachment (1) lever backward tilt side ad-justment (1):Play at the beginning of the attachment (1)lever pull operation


INCH

Attachment (1) lever backward tilt side ad-justment (2):Inching speed during the attachment (1)lever pull operation


MAX

Attachment (1) lever backward tilt side ad-justment (3):Maximum speed during the attachment (1)lever pull operation


ACC

Attachment (1) lever backward tilt side ad-justment (4):Acceleration speed during the attachment(1) lever pull operation


DEC

Attachment (1) lever backward tilt side ad-justment (5):Deceleration speed during the attachment(1) lever pull operation


ATT2PUSH

START



INCH



MAX



ACC



DEC



7

7-118 7 DISPLAY


ATT2PULL

START



INCH



MAX



ACC



DEC



ATT3PUSH

START



INCH



MAX



ACC



DEC



7-1197 DISPLAY


ATT3PULL

START



INCH



MAX



ACC



DEC



7.2.4.3 TUNING MENU Screen




Step 2 Press switch (1) to check that "2. TUNING" is selec-ted, and press (enter) switch (4) to display "TUNINGMENU" screen.

Step 3 Select the menu with switch (1), and press (enter)switch (4) to move to the tuning screen of the selec-ted item.

Step 4 Press (enter) switch (4) while selecting "7. END"menu to return to service function "MASK MENU"screen.

7

7-120 7 DISPLAY

"1. GENERAL"Switch (1): Switching selection to next itemSwitch (4): To tuning level setting screen

"2. LIFT LEVER" (Mini lever/Joy stick vehicles only)Switch (1): Switching selection to next itemSwitch (4): To tuning level setting screen

"3. TILT LEVER" (Mini lever/Joy stick vehicles only)Switch (1): Switching selection to next itemSwitch (4): To tuning level setting screen

"4. ATT1 LEVER" (Mini lever/Joy stick vehicles only)Switch (1): Switching selection to next itemSwitch (4): To tuning level setting screen




7-1217 DISPLAY

7.2.4.4 TUNING GENERAL "TUNE GEN."Perform fine adjustment for traveling and load handling. (excluding load handling lever tuning)

Step 1 Display the "TUNING MENU" screen.


Step 2 Check that "1. GENERAL" is selected, and press(enter) switch (4) to display "TUNE GEN." screen.

NOTICE: You cannot move directly from level setting

screen of "GENERAL" to the screen of theother items. Return to "TUNING MENU"screen once, then move to level settingscreen of each item.

"TUNE GEN."General tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

7

7-122 7 DISPLAY

7.2.4.5 TUNING LIFT LEVER "LIFT DOWN/LIFT UP"Sets tuning levels for the lift lever of mini lever and joy stick vehicles.

Step 1 Display the "TUNING MENU" screen.


Step 2 Press switch (1) once to check that "2. LIFT LEVER"is selected, and press (enter) switch (4) to display the"LIFT DOWN" screen.


screen of "LIFT LEVER" to the screen of theother items. Return to "TUNING MENU"screen once, then move to level settingscreen of each item.

"LIFT DOWN"Lift down operation tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

"LIFT UP"Lift up operation tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

7-1237 DISPLAY

7.2.4.6 TUNING TILT LEVER "TILT FWD/TILT BWD"Sets tuning levels for the tilt lever of mini lever and joy stick vehicles.

Operating ProcedureStep 1 Display the "TUNING MENU" screen.


Step 2 Press switch (1) twice to check that "3. TILT LEVER"is selected, and press (enter) switch (4) to display the"TILT FWD" screen.


screen of "TILT LEVER" to the screen of theother items. Return to "TUNING MENU"screen once, then move to level settingscreen of each item.

"TILT FWD"Tilt forward operation tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

"TILT BWD"Tilt backward operation tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

7

7-124 7 DISPLAY

7.2.4.7 TUNING ATT1 LEVER "ATT1 PUSH/ATT1 PULL"Sets tuning levels for the attachment (1) lever of mini lever and joy stick vehicles.



Step 2 Press switch (1) 3 times to check that "4. ATT1LEVER" is selected, and press (enter) switch (4) todisplay the "ATT1 PUSH" screen.


screen of "ATT1 LEVER" to the screen of theother items. Return to "TUNING MENU"screen once, then move to level settingscreen of each item.

"ATT1 PUSH"Attachment (1) lever push operation tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

"ATT1 PULL"Attachment (1) lever pull operation tuning screenSwitch (1): Switching selection to next itemSwitch (2): Tuning level downSwitch (3): Tuning level upSwitch (4): Returning to "TUNING MENU" screen

7-1257 DISPLAY

7.2.4.8 TUNING ATT2 LEVER "ATT2 PUSH/ATT2 PULL"Sets tuning levels for the attachment (2) lever of mini lever and joy stick vehicles.



Step 2 Press switch (1) 4 times to check that "5. ATT2LEVER" is selected, and press (enter) switch (4) todisplay the "ATT2 PUSH screen.





7

7-126 7 DISPLAY

7.2.4.9 TUNING ATT3 LEVER "ATT3 PUSH/ATT3 PULL"Sets tuning levels for attachment (3) lever of mini lever and joy stick vehicles.



Step 2 Press switch (1) 5 times to check that "6. ATT3LEVER" is selected, and press (enter) switch (4) todisplay the "ATT3 PUSH screen.





7-1277 DISPLAY

7.2.5 OPTION SETTING

NOTICE• The option set function is used to set control of the controller and display control according to theoptions equipped on the vehicle. It does not enable or disable the function itself.• If SAS/OPS controller or multi-function display DX is replaced, it is necessary to reset it accordingto the vehicle specification.

7.2.5.1 Option Set Menu List

Indication DescriptionSwitching settingsIndica-tion Setting content Indica-

tion Setting content

DISP. MODE Setting display specification J Japan spec. I Other than Japanspec. (Default)

MPH *1 Setting traveling speed displayunit YES mph NO km/h

USA *1 Setting buzzer specification YES USA NO Other than USA

MENULOCKSPEC *1

Setting the mode of menu lockrelease A

Unlock ("NO") ef-fective till key-OFF

BUnlock ("NO") ef-fective till set"YES"

SEAT BUZZERSetting to enable/disablebuzzer sound when seatswitch is off

YESEnabled(Default)

NO Disabled

PKB BUZZER *1 Setting to enable/disable park-ing brake off warning YES Enabled NO Disabled

CONV. BUZZER Unused - - - -

TEMPGAUGE Setting to enable/disable oiltemperature indication YES

Enabled(Default)

NO Disabled

CONV. TEMP Unused (fixed to YES) YES-(Default)

NO -

ENGINE STOP Setting to enable/disable en-gine auto stop YES

Enabled(Default)

NO Disabled

ASC W/LOAD *1Setting to enable/disabletravel and load handling con-trol

YES Enabled NO Disabled

MODE *1Setting to enable/disable trav-eling speed limit of travel andload handling control

S Enabled A Disabled

T/C INTLOCK *1 Setting to enable/disable T/Cinterlock control YES Enabled NO Disabled

H.TEMP P-LIM*2

Setting to enable/disable en-gine output down when detect-ing coolant overheat

YESEnabled(Default)

NO Disabled

LIFT IDLEUP *1 Setting to enable/disable liftidle up YES

Enabled(Default)

NO Disabled

T FWD LIMIT Setting to enable/disable for-ward tilt regulating control YES

Enabled(Default)

NO Disabled

7

7-128 7 DISPLAY

Indication DescriptionSwitching settingsIndica-tion Setting content Indica-

tion Setting content

T BWD LEVEL *3Setting to enable/disablebackward tilt automatic level-ing control

YESEnabled(Default)

NO Disabled

SWG W-LOCK Unused (fixed to YES) YES-(Default)

NO -

KNOB CONT *1 Setting to enable/ disable thesteering knob synchronizer YES Enabled NO Disabled

OCV WAY *1, *3,*4

Setting the number of ways foroil control valve 2 / 3 / 4 / 5

WAY SELECT *3Switching output destinationduring C/V 5th way specifica-tion

2->3 / 3->4 (Default)

FLS Unused (fixed to YES) YES-(Default)

NO -

*1: These are set according to the vehicle specification at the time of shipment.*2: 4Y-engine-equipped model only*3: Mini lever/Joystick specification vehicle only*4: Please set this setting to the number of ways for oil control valve that is installed on the vehicle.

7.2.5.2 OPTION SET Screen "OPTIONSET"




Step 2 Press switch (1) twice to check that "3. OPTION SET"is selected, and press (enter) switch (4) to display theoption set setting screen.


screen of POTION SET to the screen of theother items. Return to MASK MENU screenonce, then move to level setting screen ofeach item.

7-1297 DISPLAY

Option set screen 1Switch (1): Switching selection to next itemSwitch (2): Setting from I to J, from NO to YES, or from B toASwitch (3): Setting from J to I, from YES to NO, or from A toBSwitch (4): Returning to service function "MASK MENU"screen

Option set screen 2Switch (1): Switching selection to next itemSwitch (2): Setting from NO to YESSwitch (3): Setting from YES to NOSwitch (4): Returning to service function "MASK MENU"screen



7

7-130 7 DISPLAY

Option set screen 5Switch (1): Switching selection to next itemSwitch (2): Setting 5→4→3→2, 3->4→2->3, NO to YESSwitch (3): Setting 2→3→4→5, 2->3→3->4, YES to NOSwitch (4): Returning to service function "MASK MENU"screen

7-1317 DISPLAY

7.2.6 MATCHING

7.2.6.1 GENERAL For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage

values under the mast vertical, no load and tire straight conditions are stored, respectively, in the control-ler for the control based on these values. When servicing or replacing these sensors, matching (updatingthe sensor signal voltage value in the standard vehicle condition) is necessary. Also, matching is neededfor the tilt angle sensor when the vehicle posture has changed excessively, and for the load sensor whenthe load under no load condition (no load on fork) is changed because of addition or removal of any at-tachment.

Each lever angle sensor for mini lever is controlled based on the memory of signal voltage values in theneutral position stored in the controller at the time of shipment. When servicing these sensors or repla-cing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condi-tion) is necessary.

Solenoid current level for the electromagnetic relief valve (EMRV) is set for each electromagnetic reliefvalve, before shipping, and it is registered to SAS/OPS controller.So "MATCHING" is necessary when maintaining or replacing parts for electromagnetic relief valve(EMRV).

7.2.6.2 Matching items and prerequisite for implementation1. SAS

No. Indication Description Prerequisite for im-plementation

1 TILT LEVEL Stores the tilt angle sensor output value with fork in thehorizontal position to the controller. *1, *2, *3, *6, *7, *8

2 TILT FWD LIMITStores the tilt angle sensor output value at the forwardtilt limit position and the load sensor output value with noload to the controller.

*1, *2, *3, *4, *6, *7,*8

3 TIRE POSITION Stores the tire angle sensor output value while thevehicle is traveling straight to the controller. *1, *5

4 SWING LEVEL Unused -

Prerequisite content for implementation*1: SAS/OPS controller replacement*2: Tilt angle sensor removing/installing or replacement*3: Length change or replacement of tilt angle sensor rod*4: When removing/installing or replacing load sensor*5: When removing/installing or replacing tire angle sensor or sensor cover*6: When installing or changing attachment or fork*7: When removing/installing or replacing mast*8: When removing/installing or replacing tilt cylinder

7

7-132 7 DISPLAY

2. MINI LEVER


1 LEVER1 Lift lever angle sensor output value in the lift lever neut-ral position is stored in the controller. *1, *9

2 LEVER2 Tilt lever angle sensor output value in the tilt lever neut-ral condition is stored in the controller. *1, *10

3 LEVER3Attachment (1) lever angle sensor output value in the at-tachment (1) lever neutral position is stored in the con-troller.

*1, *11

4 LEVER4Attachment (2) lever angle sensor output value in the at-tachment (2) lever neutral position is stored in the con-troller.

*1, *12

3. EMRV


1 C01 Electromagnetic relief valve solenoid current L level *1, *132 C02 Electromagnetic relief valve solenoid current H level *1, *13

Prerequisite content for implementation*1: SAS/OPS controller replacement*9: When replacing lift lever angle sensor*10: When replacing tilt lever angle sensor*11: When replacing attachment (1) lever angle sensor*12: When replacing attachment (2) lever angle sensor*13: When removing/installing or replacing oil control valve

7.2.6.3 BEFORE STARTING MATCHINGSet the vehicle to "Standard vehicle condition" before starting matching."Standard vehicle condition" means that the vehicle satisfies the conditions described below.

Standard vehicle conditionNOTICE:

Items 1 to 4 below show the standard vehicle condition for SAS matching. Before carrying out matching for mini lever/joystick vehicles, move the armrest to the driving po-

sition and check the neutral state of the levers. In case of a detachable attachment, keep the attachment installed on the vehicle.

Level surface

1. Tire pressure checkAdjust the tire pressure to the specified level. Match-ing will be inaccurate if the pressure is low, or if thereare air pressure fluctuations between front and rearas well as left and right.

2. Surface levelness checkIf matching is conducted on an inclined or rough floorsurface, errors in standard vehicle condition will oc-cur, so perform matching on a flat, level surface (in-clination: within 0.5°).

7-1337 DISPLAY

500 mm(19.7 in)

V mast FV·FSV mast

a

3. No-load vertical condition checkStore the output voltage of the load sensor in no-loadstate in the controller. At this time, the following con-ditions must be satisfied:

For the V mast, set the lifting height to about 500mm (19.7 in) and use a goniometer to check thatthe mast is vertical.

For the FV/FSV mast, set the rear cylinder rodprojection to about 100 mm (3.93 in) and use agoniometer to check that the mast is vertical.

On a vehicle with attachment , set the mast ver-tical with the attachment at a height of 500 mm(19.7 in) and perform relief at the topmost posi-tion.

Set the mast in the vertical position from thebackward tilted position by operating the tilt leverin the forward tilting direction.

50 mm(2.0 in)50 mm(2.0 in)

5 m (16 ft)

4. Tire straight traveling position checkStore the tire angle sensor output voltage in the con-troller in the condition of the vehicle traveling straightahead. Condition of the vehicle traveling straight aheadmeans that the deviance to left or right is within 50mm (2.0 in) when the vehicle travels for 5 meters (16ft) with the steering being fixed.

5. Loadmeter 0 set (0 set of the load gauge) checkFor all the V/FV/FSV mast, the mast is to be verticaland the fork height is to be 500 mm (19.7 in).

7

7-134 7 DISPLAY

7.2.6.4 MATCHING MENU Screen

MATCHING MENU Screen




Step 2 Press switch (1) 3 times to check that "4. MATCH-ING" is selected, and press (enter) switch (4) to dis-play the service function "MASK MENU" screen.

Step 3 Select the menu with switch (1), and press (enter)switch (4) to move to the service function "MASKMENU" setting screen of the selected item.

Step 4 Press (enter) switch (4) while selecting "4. END"menu to return to service function "MASK MENU"screen.

"1. SAS"Switch (1): Switching selection to next itemSwitch (4): To SAS matching screen

"2. MINI LEVER"Switch (1): Switching selection to next itemSwitch (4): To mini lever matching screen

"3. EMRV"Switch (1): Switching selection to next itemSwitch (4): To EMRV matching screen


7-1357 DISPLAY

NOTICE: "2. MINI LEVER" will not be displayed other than on

mini lever and joystick specification vehicle.

7

7-136 7 DISPLAY

7.2.6.5 MATCHING SAS "SAS"Matching is performed for SAS functions.

Operating ProcedureStep 1 Display the "MATCHING MENU" screen.


Step 2 Check that "1. SAS" is selected, and press (enter)switch (4) to display "TILT LEVEL" screen.On SAS matching screen:Values in bracket ( ) are currently stored value.Values outside bracket ( ) are current vehicle condi-tion value.

NOTICE: You cannot move directly from each matching

set screen of "SAS" to the matching setscreen of the other items. Return to "MATCH-ING MENU" screen once, then move to match-ing set screen of each item.

"TILTL LEVEL" ScreenIf matching is performed (press switch (1)), "OK" is indic-ated on the display.Switch (1): Pressing this for more than 2 seconds will per-form matching.Switch (4): To "TILT FWD LIMIT" screen

"TILT FWD LIMIT" ScreenIf matching is performed (press switch (1)), "OK" is indic-ated on the display.Switch (1): Pressing this for more than 2 seconds will per-form matching.Switch (4): To "TIRE POSITION" screen

7-1377 DISPLAY

"TIRE POSITION" ScreenIf matching is performed (press switch (1)), "OK" is indic-ated on the display.Switch (1): Pressing this for more than 2 seconds will per-form matching.Switch (4): To "SWING LEVEL" screen

"SWING LEVEL" ScreenUnused.Switch (4): Returning to "MATCHING MENU" screen

7

7-138 7 DISPLAY

7.2.6.6 MATCHING MINI LEVER "MINI LEVER"Matching is performed for mini lever functions.



Step 2 Press switch (1) to check that "2. MINI LEVER" is se-lected, and press (enter) switch (4) to display the"LEVER1" screen.On mini lever matching screen: Values in bracket ( )are currently stored value.Values outside bracket ( ) are current vehicle condi-tion value.

NOTICE: You cannot move directly from each matching

set screen of "MINI LEVER" to the matchingset screen of the other items. Return to"MATCHING MENU" screen once, then moveto matching set screen of each item.

"LEVER1" ScreenIf matching is performed (press switch (1)), "OK" is indic-ated on the display.Switch (1): Pressing this for more than 2 seconds will per-form matching.Switch (4): To "LEVER2" screen


7-1397 DISPLAY


NOTICE: "LEVER3" screen will be displayed according to the

number of ways being set.

"LEVER4" ScreenIf matching is performed (press switch (1)), "OK" is indic-ated on the display.Switch (1): Pressing this for more than 2 seconds will per-form matching.Switch (4): Returning to "MATCHING MENU" screen

NOTICE: "LEVER4" screen will be displayed according to the

number of ways being set.

7.2.6.7 MATCHING EMRV "EMRV"Perform the setting for current level of electromagnetic relief valve.It is set appropriately for each electromagnetic relief valve before shipping. So if replacing OCV or SAS/OPScontroller, perform the resetting by the value written or attached at OCV.

CAUTIONIn case of "without" multi-function display spec, perform the matching by using diagnostic program(SST).


7

7-140 7 DISPLAY


Step 2 Press switch (1) to check that "3. EMRV" is selected,and press (enter) switch (4) to display the "MAT.EMRV" screen.


screen of MATCHING to the screen of theother items. Return to "MATCHING MENU"screen once, then move to level settingscreen of each item.

Reference: Name plate





EMRV C01: Electromagnetic relief valve current LlevelEMRV C02: Electromagnetic relief valve current Hlevel

"EMRV C01 to EMRV C02" ScreenEMRV current level setting screenSwitch (1): Switching selection to next itemSwitch (2): Decreasing current levelSwitch (3): Increasing current levelSwitch (4): Returning to "MATCHING MENU" screen

7-1417 DISPLAY

7.2.7 Other service function

7.2.7.1 WHEEL RADIUS

GENERALIt is necessary to input the wheel radius to the controller according to the tire radius, for optimizing thespeedometer reading. Although the wheel radius is set to the value of new tires at the time of shipment, ad-just it whenever the tire size or type is changed according to "Wheel Radius List".




Step 2 Press switch (1) 4 times to check that "5. WHEELRADIUS" is selected, and press (enter) switch (4) todisplay the "WHEEL RADIUS" screen.

Step 3 Change the wheel radius to desired value with switch(2) and switch (3), and press (enter) switch (4) to setthe value and return to service function "MASKMENU" screen.

"WHEEL RADIUS" ScreenSwitch (2): Reducing wheel radiusSwitch (3): Increasing wheel radiusSwitch (4): Entering wheel radius and returning to servicefunction "MASK MENU" screen.

7

7-142 7 DISPLAY

Vehicle type Vehicle model Tire size Tire type Wheel radius

Pneumatic

1.0 ton model6.5-10-10PR

STD 313WIDE TREAD 313

6.5-10 / 5.00SOLID 298WIDE TREAD SOLID 298

2.0 ton model

7.00-12-12PRSTD 354WIDE TREAD 354

7.00-12 / 5.00SOLID 344WIDE TREAD SOLID 344

7.00-12 12PRDUAL 362DUAL SOLID 348

3.0 ton model

28X9-15 12PRSTD 361WIDE TREAD 361

28X9-15 / 7.00SOLID 365WIDE TREAD SOLID 365

29X8-15 12PRDUAL 390DUAL SOLID 387

Cushion

1.0 ton model

18X6X12 1/8

STD 240NON-MARKING 240SMOOTH 238SMOOTH NON-MARKING 238

18X8X12 1/8

WIDE TREAD 240WIDE TREAD NON-MARKING 240WIDE TREAD SMOOTH 238WIDE TREAD SMOOTH NON-MARKING 238

2.0 ton model 21X7X15


3.0 ton model 21X8X15


7-1437 DISPLAY

7.2.7.2 SPEED SETTING OF SPEED LIMITER "SPEED LIMIT SET"

GENERALThe speed limit of the Maximum speed limiter can be changed.




Step 2 Press switch (1) 5 times to check that "6. SPEEDLIMIT SET" is selected, and press (enter) switch (4)to display the "SPEED LIMIT SET" screen.

Step 3 Change the speed limit to desired value with switch(2) and switch (3), and press (enter) switch (4) to setthe value and return to service function "MASKMENU" screen.

"SPEED LIMIT SET"Switch (2): Setting speed limit downSwitch (3): Setting speed limit upSwitch (4): Entering speed limit and returning to servicefunction "MASK MENU" screen.

NOTICE: This function is same as speed setting of speed limiter

of administrator function. Travel speed level limiter setting function is disabled

with setting level 8.

7

7-144 7 DISPLAY

7.2.7.3 IDLE ADJUSTMENT(IDLE ADJUSTMENT)

GENERALAdjusts engine idle speed.




Step 2 Press switch (1) 6 times to check that "6. IDLE AD-JUSTMENT" is selected, and press (enter) switch (4)to display the "IDLE ADJUSTMENT" screen.

"IDLE ADJUSTMENT" ScreenSwitch (2): Reducing the speedSwitch (3): Increasing the speedSwitch (4): Entering idle speed and returning to servicefunction "MASK MENU" screen.

NOTICE: It is adjustable from ±0 to +150 by 10 rpm.

7-1457 DISPLAY

7.2.7.4 SERVICE SECOND PASSWORD SETTING "MASK PASSWORD"

GENERALSets and deletes the mask second password.You can use the four switches on the multi-function display DX to set arbitrary four digits as the mask secondpassword.When the password is set, the mask second password is prompted after the normal service password input.You can move to the service functions screen only when the password matches your input operation.The mask second password is not set at the time of shipment.




Step 2 Press switch (1) 7 times to check that "8. MASKPASSWORD" is selected, and press (enter) switch(4) to display the "MASK PASSWORD" screen.

NOTICE: Set the mask second password only if it is ne-

cessary. When the mask second password is missing,

it is necessary to replace the multifunctiondisplay.

Distributor or dealer must manage the masksecond password organizationally to avoidmissing the mask second password and mak-ing the service functions unusable.

Clear the mask second password when thetruck is out of your service such as truck re-sale.

7

7-146 7 DISPLAY

"MASK PASSWORD" ScreenOperation to delete mask second passwordIn the mask second password setting screen, press switch(1) for two seconds or more without any digits entered. Thepassword is deleted and "OK" is displayed after the opera-tion.

NOTICE: The delete mask second password operation is pos-

sible only when no digits are entered for the password( is displayed for all digits).

7-1477 DISPLAY

Set mask second password operationWhen all four digits are entered, SET is displayed on thebottom left of the screen, indicating that you are ready forthe set password operation.Press switch (1) for two seconds or more to perform Pass-word Set. When the setting is completed, "OK" is dis-played.

NOTICE: Password Set is not possible until you enter all four di-

gits. Press switch (4) for two seconds or more to discard

the ongoing input and return to service function"MASK MENU" screen.

7

7-148 7 DISPLAY

7.2.7.5 ADMINISTRATOR'S SECOND PASSWORD CLEAR "MANAGER PASSCLR"

GENERALDeletes the administrator's second password.You can delete the administrator's second password with a service function in case of user request.




Step 2 Press switch (1) 8 times to check that "9. MANAGERPASS CLR" is selected, and press (enter) switch (4)to display the "MANAGER PASS CLR" screen.

Step 3 Press switch (1) for two seconds or more to performpassword deletion. When the setting is completed,"OK" is displayed.

"MANAGER PASS CLR"Switch (1): Press for two seconds or more to perform pass-word deletion.Switch (4): Returning to service function "MASK MENU"screen.

7-1497 DISPLAY

7.2.7.6 CONTRAST ADJUSTMENT "CONTRAST"

GENERALAdjusts LCD contrast.



Step 2 Press switch (1) 9 times to check that "10. CON-TRAST" is selected, and press (enter) switch (4) todisplay the "CONTRAST" screen.

NOTICE: After completing the meter start setting,

"11.METER START" will not be displayed onthe service function "MASK MENU" screen.


Step 3 Change the contrast level with switch (2) and switch(3), and press (enter) switch (4) to set the value andreturn to service function "MASK MENU" screen.

"CONTRAST" ScreenSwitch (2): Reducing contrastSwitch (3): Increasing contrastSwitch (4): Entering contrast and returning to service func-tion "MASK MENU" screen.

7

7-150 7 DISPLAY

7.2.7.7 METER START "METER START"

GENERALStarts counting the odometer, trip meter and maintenance hour meter.




Step 2 Press switch (1) 10 times to check that "11. METERSTART" is selected, and press (enter) switch (4) todisplay the "METER START" screen.

NOTICE: The speed limit of the Low speed level setting

function is "8OFF" when meter start settingbecomes "YES".Set the speed limit of the Low speed level set-ting function on the low speed setting screenwhen using the Low speed level setting func-tion.

Step 3 "METER START" ScreenPress switch (2) for more than 2 seconds to displaythe right arrow on the screen.

7-1517 DISPLAY

Step 4 While pressing switch (2), if you press switch (3), in-verted "NO" on the screen turns to inverted "YES",and the setting is completed.

Step 5 Press switch (4) to return to service function "MASKMENU" screen.

NOTICE: After completing the meter start setting, "METER

START" will not be displayed on the service function"MASK MENU" screen.

NOTICE: If the meter start is not set yet, the symbol indicating

that the hour meter is not started will be displayed onthe "GENERAL" screen.

7

8-152 8 TROUBLESHOOTING

8 TROUBLESHOOTING8.1 DIAGNOSIS CODE LIST....................................................................... 1538.2 WARNING LIST..................................................................................... 1548.3 WHEN NO ERROR CODE IS DISPLAYED .......................................... 1558.4 WHEN ERROR CODE IS DISPLAYED................................................. 189

8-1538 TROUBLESHOOTING

8.1 DIAGNOSIS CODE LISTDetection ECUSAS/OPS: SAS/OPS/Mini lever (OPT) Controller

Indica-tion Memory Spanner Detection

ECU Error mode

61-3 61-3 Blinking SAS/OPS Pressure sensor open abnormality ( P-port)61-4 61-4 Blinking SAS/OPS Pressure sensor VCC short abnormality ( P-port)EC-1 EC-1 Blinking SAS/OPS Unload solenoid open circuit or load short abnormalityEC-2 EC-2 Blinking SAS/OPS Electromagnetic relief solenoid open abnormalityEC-3 EC-3 Blinking SAS/OPS Electromagnetic relief solenoid short abnormalityEC-4 EC-4 Blinking SAS/OPS Electromagnetic relief solenoid drive circuit abnormality

8


8.2 WARNING LIST

CAUTIONIf the wrench lamp illuminates and the following phenomena occur on the vehicle without an error being dis-played, it is not a fault. Take the appropriate corrective action.

Indication Memory Wrenchlamp

DetectionECU Phenomenon on vehicle Content of warn-

ing

Appropriatecorrectiveaction

Water tem-peraturegaugeflashing

OB-1 - E/GTop speed and load liftingspeed are limited. (Only whenOPT equipped)

Overheat

Leave thevehicle atidle for awhile

- - On SAS/OPS

Swing lock control is alwayslockedKnob offset occurrenceMaterial handling disabled(mini lever)Material handling except liftingdisabled

High batteryvoltage

Use a bat-tery of thespecifiedvoltage

- - On SAS/OPS Swing lock control is alwayslocked

Low batteryvoltage

Charge orreplace thebattery

- - On SAS/OPS Tilt operates to forward mosttilt position

Forward tilt re-striction angle notmatching

Carry outmatchingfor eachitem

- - On SAS/OPS Tilt disabled with the knobswitch in the ON position

Auto levelingangle not match-ing

- - On SAS/OPS

Tilt operates to forward mosttilt positionTilt disabled with the knobswitch in the ON position

SAS/OPS NL loadnot matching(NL: No-load)

- - On SAS/OPS Knob offset occurrence Tire angle notmatching

- - On SAS/OPS Lift stop Lift lever notmatching

- - On SAS/OPS Tilt stop Tilt lever notmatching

- - On SAS/OPS Attachment 1 stop Attachment 1 notmatching

- - On SAS/OPS Attachment 2 stop Attachment 2 notmatching


8.3 WHEN NO ERROR CODE IS DISPLAYEDDefect causes related to SAS/OPS

8


Control type Phenomenon onvehicle

Malfunction areaand mode Checking method Corrective action

Travel and loadhandling control

For vehicles withtravel and loadhandling control:Engine is alwaysslow to rev up.(Even with the direc-tion lever left in F orR position and thebrake applied, theengine is still slow torev up)

Brake switchunit:Open fault(Stuck in de-pressed state, orinternal damage)

Brake switchline:Disconnectionfault (Harness,connector, fuse)

ON/OFF check withanalyzer

Harness check or re-place switch

Acceleratorsensor unit:Internal damage

Acceleratorsensor installa-tion:Link, installationpart destroyed,damaged

Accelerator pedalposition check:Check the openingdegree of the accel-erator pedal whennot operated.

If not close to 0%,installation check orreplace sensor.

SAS/OPS con-troller:Controller defect

- Replace

For vehicles withtravel and loadhandling control:Even if the lift israised, the idlespeed does not rise.

Lift raise switchunit:Open fault(Switch mountedincorrectly, in-ternal damage,stuck)

Lift raise switchline:Disconnectionfault (Harness,connector)

Switch groundline:Disconnectionfault (Harness,connector)



Display setting:Lift idle up dis-abled, Idle upspeed tuningvalue low

Check settings withoption set and tuning Change


- Replace





For vehicles withtravel and loadhandling control:Speed limit appliesat high lifting heightdespite not beingloaded

Load sensorunit:Sensor defect

Load sensor line(Power supply,signal, ground):Disconnectionfault (Harness,connector)Short or link fault(Harness, con-nector)



Display setting:Maximum speedlimiter, Speedlimit setting en-abled

Check the settingcontent of the max-imum speed limiter,check the settingcontent of the speedlimit setting.

Change


- Replace


For vehicles withtravel and loadhandling control:Despite beingloaded at high liftingheight the speedlimit does not oper-ate.


Load sensor line(Power supply,signal, ground):Disconnectionfault (Harness,connector)Short or link fault(Harness, con-nector)

Load sensor voltagecheck:Mount a load,ground the forks andcheck the change involtage.

If there is nochange, perform aharness check or re-place the sensor.

Lifting heightswitch unit:Disconnectionfault (internaldamage, stuck)


Harness check or re-place sensor

Display setting:Traveling limitsetting disabledLoad sensingspeed limit dis-abled

Check setting valueswith option set Change


- Replace

8





For vehicles withtravel and loadhandling control:Speed limit applieswhen loaded despitebeing at a low liftingheight

Lifting heightswitch unit:Disconnectionfault (Internaldamage, stuck)



Display setting:Maximum speedlimiter, speedlimiter settingenabled


Change


- Replace

For vehicles withtravel and loadhandling control:Speed limit appliesat all times regard-less of lifting heightor load



Change


- Replace





4YE/1ZS enginemodel(STD lever)When lifting a heavyload, it is unable tolift upward or liftspeed is slow, evenif rising enginespeed.

Lift raise switchunit:Open fault(Switch mountedincorrectly, in-ternal damage,stuck)

Lift raise switchline:Disconnectionfault (Harness,connector)




4YE/1ZS enginemodel(Mini lever or Joystick)When lifting a heavyload, it is unable tolift upward or liftspeed is slow, evenif rising enginespeed.

Material hand-ling lever poten-tiometer unit:Lever defect

Material hand-ling lever line(Power supply,signal, ground):Disconnectionfault (Harness,connector)Short or link fault(Harness, con-nector)

Material handlinglever potentiometervoltage check: Move the lever intoforward and reversepositions and checkthe voltage change.

If there is nochange, perform aharness check or re-place the poten-tiometer

8





4YE engine model(Mini lever or Joystick)Starting is slowwhen tilting back-ward.


Load sensor line(Power supply,signal, ground):Disconnectionfault (Harness,connector)Short or leakfault (Harness,connector)

Load sensor voltagecheck:Mount a load,ground the forks andcheck the change involtage.


4YE engine modelEasy to stall.

P port pressuresensor:: Internal dam-age

P port pressuresensor line(Power supply,signal, ground): Disconnectionfault (Harness,connector)Short or leakfault (Harness,connector)

P port pressuresensor voltagecheck:Mount a load,ground the forks andcheck the change involtage.





Buzzer related (Onlyexport model except“WITHOUT OPSBUZZER” specifica-tion)

Buzzer sounds con-stantly

Buzzer unit:Buzzer defect

Buzzer harnessline (Lead-inside):Ground short orlink fault (Har-ness, connector)

- Harness check or re-place buzzer


- Replace

OPS leaving seatwarning does notsound.


Buzzer harnessline (Power sup-ply side, lead-inside):Disconnectionfault (Harness,connector)


Display setting:OPS leavingseat notificationbuzzer settingdisabled

Check setting valueswith option set. Change


- Replace

Traveling OPS re-turn to neutral alarmdoes not sound.




Direction leverunit:Lever defect

Direction leversignal:Disconnectionfault (Harness,connector)

Refer to "TravelingOPS does not oper-ate, cannot travel".

Refer to "TravelingOPS does not oper-ate, cannot travel".

Display setting:USA specifica-tion enabled



- Replace

8





For cowl levervehicles:Material handlingOPS return to neut-ral alarm does notsound.




Lowering leverswitch:Lever defect

Lowering leversignal line:Disconnectionfault (Harness,connector)

Refer to “Cowl levervehicles: cannotlower lift”.*: The materialhandling OPS returnto neutral is only afunction for thelowering lever oncowl lever vehicles.

Refer to “Cowl levervehicles: cannotlower lift”.

Display setting:Controller defect



- Replace





For mini lever, joy-stick lever vehicles:Material handlingOPS return to neut-ral alarm does notsound.




Material hand-ling lever poten-tiometer unit:Lever defect

Material hand-ling lever line(Power supply,signal, ground):Disconnectionfault (Harness,connector)Short or link fault(Harness, con-nector)

Material handlinglever potentiometervoltage check: Move the lever intoforward and reversepositions and checkthe voltage change.

If there is nochange, perform aharness check or re-place the poten-tiometerIf none of the mater-ial handling leversmove, refer to “Cowllever, mini lever, joy-stick lever vehicles:cannot perform anymaterial handling”.

Display setting:USA specifica-tion enabled

Check setting valueswith option set Change


- Replace

8




Buzzer related (Onlymodels with "MULTI-FUNCTION DIS-PLAY DX" or "E.E.C.SPEC."option)

Vehicles withMULTI-FUNCTIONDISPLAY DX orE.E.C. SPEC.:Parking brake re-minder alarm doesnot sound.


Buzzer harnessline (Power sup-ply side, lead-inside):Fault (Harness,connector)


Parking brakeswitch unit:Open fault (stuckin releasedstate, internaldamage)

Parking brakedetection mech-anism:Always released

Parking brakeline:Disconnectionfault (Harness,connector)

ON/OFF check withanalyzer.

If there is nochange, perform aninstallation check,harness check, orreplace the switch.

Display setting:Parking brakereminder alarmsetting disabled


SAS/OPS con-troller setting:Not matched

- Follow matching pro-cedure to match.


- Replace





Vehicles withMULTI-FUNCTIONDISPLAY DX orE.E.C. SPEC.:Parking brake re-minder alarm contin-ues to sound evenafter the parkingbrake has been de-pressed (or pulled).


Buzzer harnessline (Lead-inside):Fault (Harness,connector)


Parking brakeswitch unit:Ground shortfault (Stuck in re-leased state, in-ternal damage)

Parking brakedetection mech-anism:Always released

Parking brakeline:Ground shortfault (Harness,connector)


If there is nochange, perform aninstallation check,harness check, orreplace the switch.


- Replace


Vehicles withMULTI-FUNCTIONDISPLAY DX orE.E.C. SPEC.:Parking brake returnreminder alarm doesnot sound. * Firstperform a “Parkingbrake reminderalarm does notsound” check.

Vehicle speedsensor unit:Cannot detectlow speed (In-ternal damage)

Vehicle speedsensor line (SPD+ side, SPD-side):Link fault (Har-ness, connector)

Check sensorvoltage and vehiclespeed with the ana-lyzer * With the parkingbrake not returned,even when the ac-celerator pedal isdepressed, thealarm only sounds atspeeds above 2 km/h.

If there is nochange, perform aninstallation check orreplace the sensor.

Vehicles withMULTI-FUNCTIONDISPLAY DX orE.E.C. SPEC.:Parking brake returnreminder alarmsounds on traveling.* First perform a“Parking brake re-minder alarm doesnot sound” check.

Meter unit (withOK monitor):Meter defect

- Replace

8




Display function

Vehicles withMULTI-FUNCTIONDISPLAY DX:Torque converter oiltemperature indic-ator stays at level 1.

Torque con-verter oil temper-ature sensorunit:Open fault (In-ternal damage)

Torque con-verter oil temper-ature sensor line(Signal, ground):Disconnectionfault (Harness,connector)+B short fault(Harness, con-nector)

Start the engine andafter leaving thevehicle running for awhile, check the in-dicator.

Harness check or re-place sensor, or re-place SAS/OPS con-troller


- Replace

Vehicles withMULTI-FUNCTIONDISPLAY DX:Torque converter oiltemperature indic-ator continually dis-plays overheat warn-ing indication.

Torque con-verter oil temper-ature sensorunit:Short fault (In-ternal damage)

Torque con-verter oil temper-ature sensor line(Signal):Ground shortfault (Harness,connector)

Stop the engine andafter leaving thevehicle stopped for awhile, check the in-dicator.

Harness check or re-place sensor, or re-place SAS/OPS con-troller


- Replace

Vehicles withMULTI-FUNCTIONDISPLAY DX:Torque converter oiltemperature indic-ator does not dis-play.

Display setting:Torque con-verter oil temper-ature emergencysetting enabled

Check that the TEM-PGAUGE on the op-tion set screen is setto YES.

If the TEMPGAUGEis set to NO on theoption set screen,change it to YES.




Active control rearstabilizer

Feels unstable whentraveling. (Travelinglock has become dif-ficult or no longerpossible)

Tire unit:Burst, tire pres-sure adjustmentdefect

- Adjust or replace

Lock cylinderunit:Leak, cannotlock (Internaldamage)

Lock cylinderlocked status:Installation partdamaged or des-troyed

Check the lockedstatus with an activetest.

Replace



Load sensor voltagecheck:Peform lift relief andcheck the change involtage.


Lifting heightswitch unit:Disconnectionfault (Internaldamage, stuck)



Yaw rate sensorunit:Reduced sensit-ivity, voltagestuck (Internaldamage)

Yaw rate sensorline (Signal):Leak (Harness,connector)

Yaw rate sensorvoltage check:Check that thevoltage is approxim-ately 2.5 V when thevehicle is stopped.

Installation check orreplace sensor

Vehicle speedsensor unit:Cannot detectlow speeds (In-ternal damage)

Vehicle speedsensor line (SPD+ side, SPD-side):Leak fault (Har-ness, connector)

Check sensorvoltage and vehiclespeed with the ana-lyzer



- Replace

8




Active control rearstabilizer

Swing lock continu-ally activates whiletraveling and mater-ial handling opera-tions, or swing lockactivates frequently.

Lock cylinderunit:Lock stuck (in-ternal damage)


Replace

Swing locksolenoid line(SWN+, SWN-):Disconnectionfault (Harness,connector)

Solenoid groundline (E01, E02):Disconnectionfault (Harness,connector)


Harness check or re-place solenoid



Load sensor voltagecheck:Peform lift relief andcheck that thevoltage rises.


Lifting heightswitch unit(2200H):Disconnectionfault (internaldamage, stuck)



Yaw rate sensorunit:Reduced sensit-ivity, voltagestuck (Internaldamage)

Yaw rate sensorvoltage check:Check that thevoltage is approxim-ately 2.5 V when thevehicle is stopped.

Installation check orreplace sensor


- Replace




Active mast functioncontrol

Forward tilt auto-matic fork levelingdoes not stop. (Con-tinues to tilt to theforward most tilt pos-ition without stop-ping at the level pos-ition)

Tilt angle sensorunit:Sensor defect

Tilt angle sensorinstallation:Link, installationpart destroyed,damaged

Tilt angle sensorvoltage check:Tilt to forward andbackward tilt posi-tions and check thevoltage change.


Horizontalmatching valuefor tilt anglesensor:Does not matchactual status (re-match)

- Follow matching pro-cedure to rematch.

Automatic forkleveling switchunit:Open fault (in-ternal damage)

Automatic forkleveling switchdetection mech-anism (minilever, joysticklever):Detection partgap adjustmentdefect

Automatic forkleveling switchline (Power sup-ply, signal,ground):Disconnectionfault (Harness,connector)



C/V tilt controlvalve:Stuck (internaldamage)

Turn the tilt solenoidOFF and operate toforward tilt using anactive test.

If forward tilt can beperformed, replacethe C/V tilt controlvalve.


- Replace

8





Forward tilt auto-matic fork levelingdoes not stop.(Stops at a positionslightly off the levelposition)



Load sensor voltagecheck:Peform lift relief andcheck that thevoltage rises.


Load sensor no-load matchingvalue:Does not matchactual status (re-match)









- Replace





Forward tilt auto-matic fork levelingdoes not stop.(Stops at the posi-tion where the auto-matic fork levelingswitch is pressed)



Load sensor voltagecheck:Check that thevoltage rises on liftrelief.


Load sensor no-load matchingvalue:Does not matchactual status (re-match)












- Replace

8





Mast backward tilt-ing speed is not lim-ited.Or, backward tiltingspeed is alwaysslow.


Automatic forkleveling switchdetection mech-anism (minilever, joysticklever):Detection partgap adjustmentdefect





Turn the tilt solenoidON/OFF and oper-ate to backward tiltusing an active test.

If there is no changein the backward tilt-ing speed when ON/OFF operated, re-place the C/V tiltcontrol valve.





- Replace




Mini lever function

Mini lever, joysticklever vehicles:Backward tilt auto-matic fork levelingdoes not stop. (Con-tinues to tilt to back-ward most tilt posi-tion without stoppingat the level position)








Automatic forkleveling switchdetection mech-anism (minilever, joysticklever)Detection partgap adjustmentdefect




Display setting:Backward tiltautomatic forkleveling is deac-tivated

Check the option setcontent Change


- Replace

Mini lever, joysticklever vehiclesBackward tilt auto-matic fork levelingdoes not stop.(Stops at a positionslightly off the levelposition)

Refer to forward tiltautomatic fork level-ing does not stop(stops at the positionwhere the automaticleveling switch ispressed).

- -

8




Mini lever function

Mini lever, joysticklever vehicles:Backward tilt auto-matic fork levelingdoes not stop.(Stops at the posi-tion where the auto-matic fork levelingswitch is pressed)








- Replace




Active steering con-trol

Knob moves out ofalignment into a cer-tain position.(More than 10° offthe straight aheadposition)

Tire anglesensor unit:Sensor defect

Tire anglesensor installa-tion:Looseness ofthe attachmentpart, damage,bearing housingdamage

Tire angle sensorvoltage check: Oper-ate the steering andcheck the change involtage.


Tire anglesensor matchingvalue:Does not matchactual status (re-match)


Steering anglesensor unit:Sensor defect

Steering anglesensor installa-tion:Cam or steeringwheel defect



Knob compensa-tion valve unit:Leak, stuck, (in-ternal damage)

Using an active test,turn the knob com-pensation SOL ONand OFF and oper-ate the steering atthe tire end.SOL ON: check thatthe steering wheelcan be turned freely.SOL OFF: Checkthat the steeringwheel cannot beturned freely (steer-ing is heavy).

Replace


- Replace

8





Knob position is outof alignment.(Knob position is notconstant when trav-eling straight ahead)

Tire anglesensor unit:Sensor defect

Tire anglesensor installa-tion:Looseness ofthe attachmentpart, damage,bearing housingdamage

Tire angle sensorvoltage check:Operate the steeringand check thechange in voltage.


Tire anglesensor matchingvalue:Does not matchactual status (re-match)


Steering anglesensor unit:Sensor defect

Steering anglesensor installa-tion:Cam or steeringwheel defect

Check sensorvoltage with the ana-lyzer.



Knob compensa-tion valve unit:Leak, stuck, (in-ternal damage)

Using an active test,turn the knob com-pensation SOL ONand OFF and oper-ate the steering atthe tire end.SOL ON: Check thatthe steering wheelcan be turned freely.SOL OFF: Checkthat the steeringwheel cannot beturned freely (steer-ing is heavy).

Replace

PS cylinder sys-tem link defect:Eccentric pin,kingpin defect

- Replace






Vehicle speedsensor unit:Cannot detectlow speed (in-ternal damage)

Vehicle speedsensor installa-tion:High speed notdetected cor-rectly (sensor tiphas metallicparticle adhered)

Vehicle speedsensor line (SPD+ side, SPD-side):Leak fault (Har-ness, connector)

Check sensorvoltage and vehiclespeed with the ana-lyzer.



- Replace

Knob position is outof alignment(Knob position is notconstant when trav-eling straight ahead)(Except C31B opt. or1DZ Engine models)

Display setting:Knob compensa-tion spec. is dis-abled.

Check the option setcontent. Change

8




Meter

Wrench lamp is litcontinually.

Fuse:ECU+B fuseblownECU-IG fuseblown

- Check for blownfuse

Meter commu-nication line:Ground short(Harness, con-nector)Disconnectionfault (Harness,connector)

SAS/OPS IGline, +B line,ground system:Disconnectionfault (Harness,connector)

- Harness check

Battery unit:Low voltage, in-take heater,large currentauxiliary equip-ment operation

Check batteryvoltage with the ana-lyzer.

Keep the engine athigh speed for awhile.

SAS/OPS con-troller setting:Not matched


Meter unit:Meter defect

- Replace


- Replace

The wrench lampdoes not light evenwhen the ignitionkey switch is turnedON.

Meter powersupply line:Disconnectionfault (Harness,connector, Fuse)

- Harness check


- Replace

Hour meter is notdisplayed.

Hour meter startconnector:Not connected

Hour meter startsignal line:Disconnectionfault (Harness,connector)

- Harness check or re-place connector


- Replace




OPSFor cowl levervehicles:Cannot lower the lift.

Lift lower switchunit:Open fault(Switch mountedincorrectly, in-ternal damage,stuck)

Lift lower switchline:Disconnectionfault (Harness,connector)




C/V lift lowerlock valve:Stuck (internaldamage)

Using an active test,turn the lift lowerlock solenoid ONand perform loweroperation.

If the lift cannotlower by lower oper-ation, replace the C/V.

Seat switch unit:Open fault (in-ternal damage)

Seat switch line(Signal, ground):Disconnectionfault (Harness,connector)



8




OPS

For cowl levervehicles:Cannot perform for-ward tilt.

Forward tiltswitch unit:Open fault(Switch mountedincorrectly, in-ternal damage,stuck)

Forward tiltswitch line:Disconnectionfault (Harness,connector)





Turn the tilt solenoidON and operate toforward tilt using anactive test.

If forward tilt cannotbe performed, re-place the C/V tiltcontrol valve.








OPS

For cowl levervehicles:Cannot performbackward tilt.

Backward tiltswitch unit:Open fault(Switch mountedincorrectly, in-ternal damage,stuck)

Backward tiltswitch line:Disconnectionfault (Harness,connector)




C/V backward tiltlock valve:Stuck (internaldamage)

Turn the backwardtilt lock solenoid ONand operate to back-ward tilt using anactive test.

If backward tilt can-not be performed,replace the C/Vbackward tilt lockvalve.


Seat switch line(Signal, ground):Disconnectionfault(Harness, con-nector)



Cannot perform ma-terial handling ex-cept for lift lower.

C/V unloadvalve:Stuck (internaldamage)

For cowl levervehicles:Turn the unloadvalve solenoid OFFand perform raisingoperation using anactive test.For mini lever, joy-stick lever vehicles:Turn the unloadvalve solenoid ONand perform raisingoperation using anactive test.

If raising cannot beperformed, replacethe C/V unloadvalve.

8




OPSMaterial handlingOPS does not oper-ate.


Turn the tilt solenoidOFF and operate toforward tilt using anactive test.

If forward tilt can beperformed, replacethe C/V tilt controlvalve.

C/V backward tiltlock valve:Stuck (internaldamage)

Turn the backwardtilt lock solenoidOFF and operate tobackward tilt usingan active test.

If backward tilt canbe performed, re-place the C/V tiltcontrol valve.

C/V lift lowerlock valve:Stuck (internaldamage)

Using an active test,turn the lift lowerlock solenoid OFFand perform loweroperation.

If lowering can beperformed, replacethe C/V lift lowerlock valve.


For cowl levervehicles:Turn the unloadvalve solenoid ONand perform lift rais-ing operation usingan active test.For mini lever, joy-stick lever vehicles:Turn the unloadvalve solenoid OFFand perform lift rais-ing operation usingan active test.

If raising can be per-formed, replace theC/V unload valve.

Seat switch unit:Short fault (in-ternal damage)




SAS/OPS con-troller, OPS con-troller:Controller defect

- Replace




OPS

Cowl lever, minilever, joystick levervehicles:No material handlingcan be performed.






For cowl levervehicles:Turn the unloadvalve solenoid OFFand perform lift rais-ing operation usingan active test.For mini lever, joy-stick lever vehicles:Turn the unloadvalve solenoid ONand perform lift rais-ing operation usingan active test.

If raising cannot beperformed, replacethe C/V unloadvalve.


- Replace

8




OPS Traveling OPS doesnot operate.

Forward travelinterrupt relayunit:Stuck (internaldamage, wel-ded)

Reverse travelinterrupt relayunit:Stuck (internaldamage, wel-ded)

Relay secondaryside line:Short fault (Har-ness, connector)

Turn the forward andreverse travel inter-rupt relays ON andoperate forward andreverse travel usingan active test.

If forward travel canbe performed, re-place the forwardtravel interrupt relay.If reverse travel canbe performed, re-place the reversetravel interrupt relay.Or perform a har-ness check.

Short switchunit:Open fault (in-ternal damage)





- Replace




OPS

Cannot travel.

Fuse:Shift fuse blown

- Check for blownfuse

Forward travelinterrupt relayunit:Open fault (in-ternal damage,welded)

Reverse travelinterrupt relayunit:Open fault (in-ternal damage,welded)

Relay secondaryside line:Open fault (Har-ness, connector)

Turn the forward andreverse travel inter-rupt relays OFF andoperate forward andreverse travel usingan active test.

If forward travel can-not be performed,replace the forwardtravel interrupt relay.If reverse travel can-not be performed,replace the reversetravel interrupt relay.Or perform a har-ness check.





Direction leverunit:Open systemfault (internaldamage)

Direction leversignal line:Disconnectionfault (Harness,connector)




- Replace

For cowl levervehicles:Cannot perform ma-terial handling ex-cept for lift up andattachments

Power harness:Wire breakage,short circuit orleakage (Har-ness, connector,fuse)

Check the har-nesses, connectorsand fuses on thepower line betweenthe battery and thecontroller while re-ferring to the systemcircuits diagram.

Check the har-nesses, and repairor replace them. Re-place the fuses.

SAS/OPS con-troller:Internal damage

- Replace the control-ler.

8




Torque converter in-terlock

Cannot travel.

Torque con-verter interlockrelay main unitfor forwardmovement:An open circuit(internal dam-age)

Torque con-verter interlockrelay main unitfor backwardmovement:An open circuit(internal dam-age)

Relay secondaryline:An open circuit(harnesses, con-nectors)

-

Check the har-nesses.If the vehicle cannottravel forward, re-place the torqueconverter interlockrelay for forwardmovement.If the vehicle cannottravel backward, re-place the torqueconverter interlockrelay for backwardmovement.



The torque converterinterlock does notoperate.

SAS/OPS con-troller is set:Option set is notset

-

Set the controlleragain according tothe option set pro-cedure.

Torque con-verter interlockrelay main unitfor forwardmovement:An open circuit(internal dam-age)

Torque con-verter interlockrelay main unitfor backwardmovement:An open circuit(internal dam-age)

Relay secondaryline:Frame short(harnesses)

-

Check the har-nesses.If the vehicle cannottravel forward, re-place the torqueconverter interlockrelay for forwardmovement.If the vehicle cannottravel backward, re-place the torqueconverter interlockrelay for backwardmovement.






Power supply

The power does notturn on even whenoperating the ignitionswitch. (The meteror display does notlight up, and the en-gine does not run.)

Battery:Low voltage

Battery voltagecheck:Ignition switch OFF:Check the batteryvoltage.

Charge or replacethe battery.

Power harness:Wire breakage,short circuit orleakage(Harness, con-nector, fuse)

Check the har-nesses, connectorsand fuses on thepower line betweenthe battery and thecontroller while re-ferring to the systemcircuits diagram.

Check the har-nesses, and repaireor replace them.Replace the fuses.

Ignition switchmain body:Open failure

Ignition switchharness:Wire breakage,short circuit orleakage(Harness, con-nector, fuse)

Check the har-nesses, connectorand fuse betweenthe ignition switchand the controllerwhile referring to thesystem circuits dia-gram.

Check and replacethe switch.Check the har-nesses, and repaireor replace them.Replace the fuses.

Power shut-offrelay main body(only for modelswith "MULTI-FUNCTION DIS-PLAY DX"):Open failure

Power shut-offrelay harness(only for modelswith "MULTI-FUNCTION DIS-PLAY DX"):Wire breakage,short circuit orleakage(Harness, con-nector)

-

Check and replacethe relay.Check the har-nesses, and repairor replace them.



8




Power supply

The power does notturn off even whenoperating the autoengine stop function.(The meter or dis-play does not turnoff even when theengine stops.

Power shut-offrelay main body(only for modelswith "MULTI-FUNCTION DIS-PLAY DX")Short circuit

Power shut-offrelay harness(only for modelswith "MULTI-FUNCTION DIS-PLAY DX"):Short circuit orleakage(Harness, con-nector)

-

Check and replacethe relay.Check the har-nesses, and repairor replace them.


8.4 WHEN ERROR CODE IS DISPLAYED

8


Error Code: 61-3

Failure mode: Pressure sensor open abnormality (P-port)

Probable cause Connector contact defect Pressure sensor defect Harness defect SAS/OPS ECU defect

Related portion

5 (E2)

SAS/OPS

ECUPressure sensor

A21

20 (5PBR)

31 (PBRK)

1 (B)

A103

2 (P)

3 (E) (P-port)

STEP11. Disconnect the battery negative terminal, after inspecting

and correcting disconnection and water entry of A103 andA21.

2. Reconnect all connectors and the battery negative terminal.3. Turn the ignition key switch ON (engine stopped) and check

whether or not there is an error.

JudgmentResult Procedure

Error Go to STEP2 [page 191].No error Connector contact defect


STEP2Individual inspection for pressure sensor

A103

3

1

2

1. Turn the ignition key switch OFF.2. Disconnect A103, and use SST 09230-13700-71 to short

circuit A103-1 and A103-2 (main harness side).3. Turn the ignition key switch ON (engine stopped).


61-3 is displayed Go to STEP3 [page 191].61-4 is displayed Pressure sensor defect

STEP3Inspection for harness continuity and short circuit

A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16

1. Turn the ignition key switch OFF, and disconnect A21 (withthe SST used in step 2 still connected).

Portion to be checked StandardA21-20 to A21-31 Continuity


OK Go to STEP4 [page 192].NG Harness defect

8



A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16

1. Inspect for continuity and short circuiting of the harness inthe same state as for step 3.

Portion to be checked StandardA21-31 to A21-5 No continuityA21-20 to Frame No continuityA21-31 to Frame No continuity


NG Harness defectOK SAS/OPS ECU defect


Error Code: 61-4

Failure mode: Pressure sensor VCC short abnormality (P-port)

Probable cause Connector contact defect Pressure sensor defect Harness defect SAS/OPS ECU defect

Related portion

5 (E2)

SAS/OPS

ECUPressure sensor

A21

20 (5PBR)

31 (PBRK)

1 (B)

A103

2 (P)

3 (E) (P-port)

STEP11. Disconnect the battery negative terminal, after inspecting

and correcting disconnection and water entry of A103 andA21.

2. Reconnect all connectors and the battery negative terminal.3. Turn the ignition key switch ON (engine stopped) and check

whether or not there is an error.


Error Go to STEP2 [page 193].No error Connector contact defect

STEP21. Turn the ignition key switch OFF.2. Disconnect A103.3. Turn the ignition key switch ON (engine stopped), and

check whether the error changes.


61-4 Go to STEP3 [page 194].61-3 Go to STEP4 [page 194].

8



A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16

1. Turn the ignition key switch OFF, and disconnect A21.

Portion to be checked StandardsA21-20 to A21-31 No continuityA21-20 to Frame No continuityA21-31 to Frame No continuity


NG Harness defectOK SAS/OPS ECU defect

STEP4Individual inspection for pressure sensor

A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16

1. Turn the ignition key switch OFF, and disconnect the batterynegative terminal.

2. Disconnect A103 and A21, and use SST 09230-13700-71 toshort circuit A103-2 to A103-3 (main harness side).

Portion to be checked StandardsA21-31 to A21-5 Continuity


OK Pressure sensor defectNG Harness defect


Error Code: EC-1

Failure mode: Unload solenoid open circuit or load short abnormality

CAUTIONIn case of EMRV model, set "FLS" to "YES" at option set screen of the multifunction display or dia-gnostic program (SST).

Probable cause Connector contact defect Harness defect Unload solenoid defect SAS/OPS ECU defect

Related portion

8 (E01)

Unload

solenoid

A20

5 (USOL)

9 (E02)

A12

1

2SAS/OPS

ECU

STEP11. Disconnect the battery negative terminal.2. After inspecting and correcting disconnection and water

entry of A12 and A20, reconnect all connectors and the bat-tery negative terminal.

3. Turn the ignition key switch ON (start the engine) and checkwhether or not there is an error.Check whether an error occurs after turning the ignition keyswitch ON and moving the life lever upward (for at least 2seconds).


Error Go to STEP2 [page 196]..No error Connector contact defect

8


STEP2Individual inspection of unload solenoid1. Turn the ignition key switch OFF and disconnect A12.

Portion to be checked (Solenoid side) Standard

A12-1 to A12-2 Approx. 10 Ω(20°C)


OK Go to STEP3 [page 196]..NG Unload solenoid defect

STEP3Inspection for harness continuity and short circuit1. Turn the ignition key switch OFF and disconnect A20 (w/

SAS)/A109 (wo/SAS) and A12.

Portion to be checked StandardA20-5 to A12-1 ContinuityA109-14 to A12-1 ContinuityA12-2 to Frame ContinuityA20-8 to Frame ContinuityA109-29 to Frame ContinuityA20-9 to Frame ContinuityA109-30 to Frame ContinuityA20-5 to Frame No continuityA109-14 to Frame No continuity


OK SAS/OPS ECU defectNG Harness defect


Error Code: EC-2

Failure mode: Electromagnetic relief solenoid open abnormality

Probable cause Connector contact defect Harness defect Electromagnetic relief solenoid defect SAS/OPS ECU defect

Related portion

7 (RSO-)SAS/OPS

ECU

Electromagnetic

relief solenoid

A21

6 (RSO+) 1 (B)

A102

2 (E)


entry of A21 and A102, reconnect all connectors and thebattery negative terminal.

3. Turn the ignition key switch ON (start the engine) and checkwhether or not there is an error.Check whether an error occurs after turning the ignition keyswitch ON and moving the lift lever upward (for at least 2seconds).



8


STEP2Individual inspection of electromagnetic relief solenoid

A102

2 1

1. Turn the ignition key switch OFF, disconnect the batterynegative terminal.Disconnect A102, measure the electromagnetic relief valvesolenoid resistancevalue.

Portion to be checked (Solenoid side) StandardA102-1 to A102-2 Approx. 7 Ω


OK Go to STEP3 [page 196]..NG Electromagnetic relief solenoid defect


A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16

A102

2 1

1. Turn the ignition key switch OFF, disconnect the batterynegative terminal.Disconnect A21 and A102.

Portion to be checked StandardA21-6 to A102-1 ContinuityA21-7 to A102-2 ContinuityA21-6 to Frame No continuityA21-7 to Frame No continuity




Error Code: EC-3

Failure mode: Electromagnetic relief solenoid short abnormality


Related portion

7 (RSO-)SAS/OPS

ECU

Electromagnetic

relief solenoid

A21

6 (RSO+) 1 (B)

A102

2 (E)



3. Turn the ignition key switch ON (start the engine) and checkwhether or not there is an error.Check whether an error occurs after turning the ignition keyswitch ON and moving the lift lever upward (for at least 2seconds).



8



A102

2 1






A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16


Portion to be checked StandardA21-6 to A21-7 No continuityA21-1 to A21-6 No continuityA21-1 to A21-7 No continuityA21-6 to A21-8 No continuityA21-7 to A21-8 No continuity




Error Code: EC-4

Failure mode: Electromagnetic relief solenoid drive circuit abnormality


Related portion

7 (RSO-)SAS/OPS

ECU

Electromagnetic

relief solenoid

A21

6 (RSO+) 1 (B)

A102

2 (E)



3. Turn the ignition key switch ON (start the engine) and checkwhether or not there is an error.



8



A102

2 1






A21

4321

23 24

3529

27

343128

22

30 32 33

262521

5 6

20

8

1817 19

7 9 10 11 12 13 14 15 16


Portion to be checked StandardA21-6 to A21-7 No continuityA21-1 to A21-6 No continuityA21-1 to A21-7 No continuityA21-6 to A21-8 No continuityA21-7 to A21-8 No continuity



9-2039 WIRING DIAGRAM

9 WIRING DIAGRAM9.1 ELECTRICAL WIRING ROUTINGS ...................................................... 2049.2 RELAY LOCATIONS ............................................................................. 2079.3 SYSTEM CIRCUITS.............................................................................. 2089.4 CONNECTOR LIST ............................................................................... 216

9

9-204 9 WIRING DIAGRAM

9.1 ELECTRICAL WIRING ROUTINGS

9.1.1 INSTRUMENT PANEL

to E2-14

to E2-12

to E2-18

to E2-14

to E2-14

a1A18

A78

A19

r1

r2

A4

A93

A1A41

A3

A95

A20A23

A21

A52A51

A11

A42

A9

A8

A80

A7

h1

A2

h2

A6

j3

j4 Q2

A88

A88Q2Q1

A49

A11

A12

m1A10

A14 A13

m1

A10

A12

A56

A49

Q1

A15

Ah2

Ah1

jA1

mA1 QA2

Aa1

mA1

QA2 AQ2

AQ2

rA1

AA1

Ab2

mM

mM

A102

A103

A102

[MINI LEVER]

*1: 4Y-M, 1DZ

*2: 4Y-E, 1ZS

h

Ar

a

B

b

RU

Q

m

jd

WIPER SUB WIREh

FR STAY WIRE LHd

MAST SENSOR WIREb

BODY MAIN WIREA

BODY SUB NO.1 WIREB ACCEL SUB WIREa

FR STAY WIRE RHR

HEAD GUARD SW WIREU

INSTRUMENT PANEL SW WIREj

12V PWR SUPPLY WIREmINSTRUMENT PANEL WIREQ

KEY OFF H/LP OFF WIREr

*1

*2

*1

*2

E2-10


PARTS

Code NameA1 HORN SWITCHA2 IGNITION SWITCHA3 STEERING SENSORA4 LIGHT CONTROL SWITCHA6 STOP LAMP SWITCHA7 BRAKE WARNING SWITCHA8 OPS WARNING BUZZERA9 PARKING BRAKE SWITCH

A10 TILT SOLENOIDA11 LIFT SOLENOIDA12 UNLOAD SOLENOIDA13 TILT SWITCHA14 LIFT SWITCHA15 NEUTRAL TILT SWITCHA18 PRESSURE SENSORA19 SPEED SENSORA20 SAS/OPS ECUA21 SAS/OPS ECUA23 MINI LEVER ECUA41 LEFT T/C SHIFT SWITCHA42 TILT ANGLE SENSORA49 HORNA51 CONTROL VALVE PUSH SOLENOIDA52 CONTROL VALVE PULL SOLENOIDA56 BACK TILT SOLENOIDA78 EZ PEDAL DIRECTION SWITCHA80 PARKING WARNING LAMPA88 LPG WARNING SWITCHA93 STEERING SOLENOIDA95 ACCEL SENSOR

A102 ELECTROMAGNETIC RELIEF SOLENOIDA103 RELIEF PRESSURE SENSORQ1 COMBINATION METERQ2 DISPLAYa1 ACCEL SENSORh1 FRONT WIPER RELAYh2 FRONT WIPER MOTORj3 INPANE SWITCH(+)j4 INPANE SWITCH(-)

m1 12V POWER SUPPLYr1 KEY OFF HEAD RELAYr2 KEY OFF TAIL RELAY

E2-11-1

9


:WIRE TO WIRE

Code NameAA1 BODY MAIN WIRE to BODY MAIN WIREAQ2 BODY MAIN WIRE to INSTRUMENT PANEL WIREAa1 BODY MAIN WIRE to ACCEL SUB WIREAb2 BODY MAIN WIRE to MAST SENSOR WIREAh1 BODY MAIN WIRE to WIPER SUB WIREAh2 BODY MAIN WIRE to WIPER SUB WIREQA2 INSTRUMENT PANEL WIRE to BODY MAIN WIREjA1 INSTRUMENT PANEL SW WIRE to BODY MAIN WIRE

mA1 12V PWR SUPPLY WIRE to BODY MAIN WIRErA1 KEY OFF H/LP OFF WIRE to BODY MAIN WIRE

:EARTH

Code NamemM FRONT PILLAR RIGHT UNDER EARTH

E2-11-2


9.2 RELAY LOCATIONS

9.2.1 ENGINE ROOM R/B : ENGINE ROOM LEFT

40A AM1

*7

SPARE

* 1:15A E-THRO (4Y-E)20A EDU (1ZS)7.5A ECU-B2 (4Y-M,1DZ)

* 2:LPG MAIN RELAY (4Y-E)ASC RELAY (4Y-M,1DZ)EZ MAIN RELAY (1ZS)

* 3:15A (4Y-E)7.5A (4Y-M,1DZ,1ZS)

* 4:POWER OFF RELAY (1ZS,4YE)* 5:30A STA (4Y-E,4Y-M,1DZ)

30A AM2 (1ZS)* 6:15A (4Y-E)

20A (1ZS)* 7:40A AM2 (4Y-E,4Y-M,1DZ)

50A STA (1ZS)* 8:10A SAS-IG (1ZS,4YE)* 9:ST RELAY (4Y-E,4Y-M,1DZ)

EFI MAIN RELAY (1ZS)

GLOW PLUG RELAY:SEE PAGE E2-6

SPARE

SPARE

SPARE

EFI

*1

BLR

*5

RR WIP

FR WIP

HORN

ALT-S

STOP

ACC-B

TAIL

ECU-B

HTR

WORK LP

HEAD

ST

GAUGE

BACK LP

SFT

TURN

IGN

ECU-IG

*2

*10,*11

*4

AM2 RELAY

*9

35

2

1

EFI MAIN RELAY

*10:4Y-E

*11:1ZS

C/OPN RELAY

ST RELAY

1

1

3

3

5

5

2

22

53

1

1

2

5 3

35

2

1

1

3 5

2

12

12

12

12

1

2

2

12

12

30A

20

A

SP

AR

E

5A

20A

20A

7.5A

*8

7.5A

7.5A

7.5A

5A

10A

*3

15A

10A

7.5A

*6

7.5A

7.5A

10A

7.5A

7.5A

15A

15A

15A

10A

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

1 2

E3-4

9


9.3 SYSTEM CIRCUITS

9.3.1 BODY

9.3.1.1 SAS/OPS SYSTEM

*1 :w

/ E

NG

INE

AU

TO

ST

OP

*2 :w

/o E

NG

INE

AU

TO

ST

OP

*3 :w

/ M

INI L

EV

ER

*4 :w

/o M

INI L

EV

ER

*5 :w

/ O

PT

ION

(exce

pt S

TA

ND

AR

D)

*6 :E

xce

pt Y

EL

LO

W F

RE

IGH

T S

PE

C.

*7 :w

/ S

YN

CH

RO

NIZ

ED

ST

EE

RIN

G*1

8 :4

Y-E

,1Z

S

*19

:4

Y-M

,1D

Z

G B-L

B-L

(*5)

G-B

G-R

LG-R

R-B

R-W

G

(*7)

R-Y

(*4)

W-B

W-B

W-B

(*3)

W-B

(*3)

W-B

W-B

W-B

W-B

(*4)

W-B

(*7)

W-B

W-B

W-B

W-B

W-B

W-B

W-B

W-B

W-B

W-B

L

(*3

)

L

(*3)

L

(*2)

L

(*2)

L-W

(*6)

B

(*6)

BB

L

(*7)

L

(*7

)L

(*7)

L

(*7

)

L

(*7

)

L

L-W

L-R

R-B

B-R

(*1)

W-B

(*1)

L-R

(*1)

B-R

(*1)

L

(*1)

L

(*1)

21

B

1E

28

1B

22

1B

23

1B

25

1E

14

1B

20

1C

14

1B

6

1E

26

1A

15

1B

71

B1

1A

19

1B

31

B1

91

B8

T/C

FR

RE

LA

Y21

3

4

T/C

RR

RE

LA

Y 21

3

4

A2

0(A

),A

21

(B)

SA

S/O

PS

EC

U

1B IG

3B

E11

4B

E1

2

22

B

SP

1+

23

B

SP

1-

10

B

E4

2

9B

E4

1

8B

BA

TT

11

B

BU

ZZ

17

A

BS

W

9A

E0

2

8A

E0

1

10

A

BT

SL

5A

US

OL

4A

TS

OL

7A

LS

OL

6A

ST

RG

2B

IG2

18

A

DR

F

19

A

DR

R

17

B

RY

F

18

B

RY

R

10

A

SA

S-I

G

(IG

)

2

1

7.5

A

IGN

(IG

)

1

1

POWER OFF RELAY

2

1

5

1

3

1

1

1

10

A

EC

U-I

G

(IG

)

2

1

7.5

A

EC

U-B

(BA

T)

2

1

A8

OPS WARNING BUZZER

2EC

U

1

B

OK

AA

A23

MINI LEVER ECU

9E4

3

10E

44

A56

BACK TILT SOLENOID

1 2

A93

STEERING SOLENOID

1 2

A12

UNLOAD SOLENOID

1 2

A10

TILT SOLENOID

1 2

A11

LIFT SOLENOID

1 2

A19

SPEED SENSOR

1 2

STOP LAMP SWITCH

A6

21

7.5

A

ST

OP

(BA

T)

2

1

(*19)(*19)

V-R

(*18)

6B

RS

O+

A102

ELECTROMAGNETIC

RELIEF SOLENOID

1 2

P-B

(*18)

7B

RS

O-

A B

E4-31


*3 :w

/ M

INI L

EV

ER

*4 :w

/o M

INI L

EV

ER

*6 :E

xce

pt Y

EL

LO

W F

RE

IGH

T S

PE

C.

*7 :w

/ S

YN

CH

RO

NIZ

ED

ST

EE

RIN

G

*8 :Y

EL

LO

W F

RE

IGH

T S

PE

C.

*9 :w

/ E

Z P

ED

AL

*10

:U

ND

ER

MA

ST

HIG

HT

25

00

*11

:M

AS

T H

IGH

T 2

50

0 A

ND

OV

ER

*12

:w

/ M

ULT

I D

ISP

LA

Y

*13

:w

/o M

ULT

I D

ISP

LA

Y

*14

:E

EC

SP

EC

.

*15

:E

xce

pt E

EC

SP

EC

.

*25

:4

Y-E

Y-R

(*7)

V-W

(*7)

LG-B

(*7)

V

(*12)

V

(*12)

BR

(*6)

BR

(*6

)

BR

(*8) BR

(*12)

R-L

(*6)

G-O

(*6)

R

(*6)

Y-G

(*6)

BR

(*6)

BR

(*6)

BR

(*6

)

BR

(*6

)BR

(*6)

BR

(*7)

G-W

(*7)

G-W

(*7)

G-W

(*7)

P-L

(*7)

P-L

(*7)

P-L

(*7)

BR

(*7)

BR

(*7)

BR

(*7

)

R

(*6)

R

(*6)

R

(*6)

W-B

(*6)

W-B

(*6)

W-B

(*6)

Y

(*4)

Y-B

(*4)

BR

(*4)

BR

(*4)

R-L

(*4)

Y-R

(*4)

BR

(*4)

BR

(*4)

BR

Y-B

(*6)

Y-B

(*6)

LG

(*6)

LG

(*6)

Y

(*6)

Y

(*6)

L

(*3

)

L

(*3

)

L

(*3

)

L-Y

(*6)

L

(*6 *11)

BR

(*6

*1

0)

BR

(*6)

BR

(*6)

L-B

(*6)

L-B

(*6 *11)

BR

(*6 *11)

V-GBRBR

L

(*7)

L

(*7

)

BR

(*9)

Y-G

(*15)

BR

(*15)

Y-G

BR

(*1

4 *

3)

BR

(*1

4 *

3)

BR

(*1

4 *

4)

BR

(*1

4 *

4)

Y-G

(*1

4 *

4)

Y-G

(*1

4 *

4)

Y-G

(*1

4 *

3)

Y-G

(*1

4 *

3)

1A

91

E3

01

A1

01

C1

91

C2

01

C2

11

C2

31

B2

41

A11

B

A42

TILT ANGLE SENSOR31

2

1

OX

1

5

OX

1

1

YO

3

2

YO

3

SEAT SWITCH(EEC)

X10

21

SEAT SWITCH(EEC)

Y10

12

1A

A2

1A

D1

2A

A2

2A

D1

A14

LIFT UP SWITCH

LIFT DOWN SWITCH

LIFT SWITCH

1

D

3

U

4

E

2

E

A13

TILT FR SWITCH

TILT RR SWITCH

TILT SWITCH

3

R

1

F

2

E

4

E

Z3

TIRE ANGLE SENSOR

132

b1

MAST SWITCH

2N/C

3N/O

1

E

A20(A

),A

21

(B)

SA

S/O

PS

EC

U

29

A

AC

SW

20

A MF

21

A

MR

22

A

MU

23

A

MD

30

B5T

34

BT

2A

SW

N-

3A

SW

N+

1A E3

26

B

YR

S-

25

B

YR

S

24

B

YR

S+

35

A

DM

S

27

B

PR

ES

19

B

5P

RS

32

B

MA

28

B

5M

A

16

B

SS

C

15

B

SS

2

14

B

SS

1

5BE2

31

A

MH

1

32

A

MH

21

35

B

TH

O

24

A

MA

T

Ab2

1

SEAT SWITCH

O5

21 AO

11

Ab

22

Ab

23

O1

YAW RATE SENSOR

2 YR

S-

3 YR

S

1 YR

S+

5A

O1

6A

O1

4A

O1

Z1

SWING LOCK

SOLENOID

1 2

ZO

22

13

AO

1

ZO

23

12

AO

111

AO

1

ZO

24

ZO

262

AO

1

ZO

258

AO

1

D1

T/C OIL TEMPERATURE

SENSOR

1SD

R

2

+

A18

PRESSURE SENSOR

2

P

1

B

3

E

A3

STEERING SENSOR

5 SS

C

4 SS

2

3 SS

1

2ES

S

1

IG

4A

D1

3A

D1

V-Y

(*25)

B-Y

(*25)

BR

(*25)

31

B

PB

RK

20

B

5P

BR

A103

RELIEF PRESSURE SENSOR

2

P

1

B

3

E

(*1

3)

(*1

2)

(*1

3)

(*1

2)

AA B

E4-32

9


*3 :w

/ M

INI L

EV

ER

*4 :w

/o M

INI LE

VE

R

*5 :w

/ O

PT

ION

(excep

t S

TA

ND

AR

D)

*6 :E

xcep

t Y

ELLO

W F

RE

IGH

T S

PE

C.

*9 :w

/ E

Z P

ED

AL

*16

:H

OM

E D

EP

OT

SP

EC

.

*17

:E

xce

pt H

OM

E D

EP

OT

SP

EC

.

*18

:4Y

-E,1

ZS

*19

:4Y

-M,1

DZ

*20

:w

/ O

K M

ON

ITO

R

*21

:1Z

S

*22

:E

xce

pt 1

ZS

*23

:w

/ O

PT

ION

(exce

pt S

TA

ND

AR

D)

w/o

EZ

PE

DA

L

*24

:T

WIS

TE

D W

IRE

G-B

(*4)

BR

(*4)

G-B

(*3)

G-B

(*3

)

G-B

(*3)

G-B

(*3

)

BR

(*3)

BR

(*3

)

BR

(*3)B

R

(*3

)

L

(*3)

L

(*3

)

L

(*3

)

BR

(*3)

L

(*3)

R

RR

R-G R-G

R-G

W-B W-B W-B

G

G-R

R-W

(*20 *22)

W-BW-B

(*5)

W-B

R-W

(*5 *6)

R-W

(*5 *6)

R-W

(*17

*2

3)

R-W

(*17 *23)

R-W

(*16)

R-W

(*16)

R-B

(*16)

R-B

(*16)

R-W

(*20)

R-W

(*20 *21)

R

(*20 *21)

R-W

(*9)

R-W

(*9)

R-W

(*9)

1E

31

1A

23

1C

8

1E

28

1C

32

1C

27

1C

17

1C

1

1B

4

1C

18

1C

24

B

SY

ST

EM

PO

WE

R

SU

PP

LY C

ON

TR

OL A

RE

A

LC

D

OPS

BRAKE

OPS

Q1

CO

MB

INA

TIO

N M

ET

ER

1

IG+

11

PK

BI

3

SIL

2

8

E1

A96

DIODE(OK MONITOR)

12

13

QA

2(*

22

)

(*21

)A8

5(A

),A

97

(B)

NE

UT

RA

L S

TA

RT

RE

LA

Y

4A-S

1B

A9

PARKING BRAKE SWITCH

3

2

A81

PARKING LAMP DIODE

21

AB

A2

7(A

)

JU

NC

TIO

N C

ON

NE

CT

OR

A2

9(B

)

CA

N J

OIN

T C

ON

NE

CT

OR

1B

5A

2B

1A

6

OX

1

2

OX

1

12

OX

3

A2

0(A

),A

21

(B)

SA

S/O

PS

EC

U

15

A

PK

B

14

ASIL

12

A

CA

NH

13

A

CA

NL

30

A

MN

OK

4Q

A2

8Q

A2

10

QA

2

5A

GA

UG

E

(IG

)

2

1

20

AO

3

2

E

X7

LOAD INDICATOR SWITCH

1

IG

X1(B)

NEUTRAL TILT SWITCH

3B+

2BE

1B IG

NEUTRAL TILT SWITCH

A15(A)

2A

1A

(*1

8)

(*1

9)

(*24)

(*22)

(*21)

A

E4-33


PARTS

Code See Page Code See Page Code See Page Code See PageA3 page 204 A18 page 204 A85 E2-12 X1 E2-16A6 page 204 A19 page 204 A93 page 204 X7 E2-16A8 page 204 A20 page 204 A96 E2-12 X10 E2-16A9 page 204 A21 page 204 A97 E2-12 Y10 E2-16

A10 page 204 A23 page 204 A102 page 204 Z1 E2-16A11 page 204 A27 E2-12, E3-7 A103 page 204 Z3 E2-16A12 page 204 A29 E2-12, E3-6 D1 E2-12 b1 E2-14A13 page 204 A42 page 204 O1 E2-16A14 page 204 A56 page 204 O5 E2-16A15 page 204 A81 E2-12 Q1 page 204

:RELAY BLOCK , JUNCTION BLOCK

Code See Page Name1 E3-4 ENGINE ROOM R/B

1A E2-12, E3-5 BODY MAIN WIRE to J/B1B E2-12, E3-5 BODY MAIN WIRE to J/B1C E2-12, E3-5 BODY MAIN WIRE to J/B1E E2-12, E3-5 SIDE LH WIRE to J/B

:WIRE TO WIRE

Code See Page NameAA2 E2-12 BODY MAIN WIRE to BODY MAIN WIREAD1 E2-12 BODY MAIN WIRE to T/C HEAT GAUGE WIREAO1 E2-12 BODY MAIN WIRE to SIDE LH WIREAO3 E2-12 BODY MAIN WIRE to SIDE LH WIREAb2 E2-10, 14 BODY MAIN WIRE to MAST SENSOR WIREOX1 E2-16 SIDE LH MAIN WIRE to HOOD WIREOX3 E2-16 SIDE LH MAIN WIRE to HOOD WIREQA2 page 204 INSTRUMENT PANEL WIRE to BODY MAIN WIREYO3 E2-16 HOOD SUB NO.1 WIRE to SIDE LH WIREZO2 E2-16 RR LWR WIRE to SIDE LH WIRE

:EARTH

Code See Page NameAA E2-12 FRONT PLATE LEFT OUTSIDE EARTHAB E2-12 FRONT PLATE LEFT OUTSIDE EARTHOK E2-16 REAR PILLAR LEFT UNDER EARTH

E4-34

9


9.3.2 LIGHTING SYSTEM

9.3.2.1 HEAD LAMP

(*6

)

(*5

)

(*6

)

(*5

)

R

(*5)

R

(*5)

R

(*5)

W-B

(*5)

W-B

(*5)

W-B

(*5

)

W-B

R-B

(*5)

R-B

(*4)

R-B

(*3

)

R-L

(*5)

R-L

(*4)

R-L

(*4

)

R-G R-G

(*2)

R-G

R-G

R-G

(*2)

W-B

(*2)

W-B

W-B

(*2)

W-B

W-B

R-G

(*1)

W-B

(*1)

R-G

(*1)

W-B

(*1)

R-G

R-G

R-B

(*6)

32

1C

1A

22

6A

A1

6rA

1

3A

A1

3rA

1

d11

LED HEAD LAMP LEFT

21

R11

LED HEAD LAMP RIGHT

21

HEAD LAMP RIGHT

R6

1 2

r1

KEY OFF HEAD RELAY

35

21

HEAD LAMP LEFT

d6

1 2

1R

A4

1d

A4

RA

43

dA

43

15

A

HE

AD

(BA

T)

2

1

TA

IL

OF

F

+B

HE

AD

TE

L(H

)

HU

HL

HL

HU

ED

A4

LIGHT CONTROL SWITCH

8

BH

11

HL

AA

4rA

1

rA1

1

5A

GA

UG

E

(IG

)

2

1

*1 :L

ED

TY

PE

*2 :B

UL

B T

YP

E

*3 :w

/o O

PT

ION

(STA

ND

AR

D)

*4 :w

/ O

PT

ION

(exce

pt S

TA

ND

AR

D)

*5 :w

/ K

EY

OF

F H

EA

D L

IGH

T O

FF

SY

ST

EM

*6 :w

/o K

EY

OF

F H

EA

D L

IGH

T O

FF

SY

ST

EM

E4-51


PARTS

Code See Page Code See Page Code See Page Code See PageA4 page 204 R11 E2-14 d11 E2-14R6 E2-14 d6 E2-14 r1 page 204



1A E2-12, E3-5 BODY MAIN WIRE to J/B1C E2-12, E3-5 BODY MAIN WIRE to J/B

:WIRE TO WIRE

Code See Page NameAA1 page 204 BODY MAIN WIRE to BODY MAIN WIRERA4 E2-14 FR STAY WIRE RH to BODY MAIN WIREdA4 E2-14 FR STAY WIRE LH to BODY MAIN WIRErA1 page 204 KEY OFF H/LP OFF WIRE to BODY MAIN WIRE

:EARTH

Code See Page NameAA E2-12 FRONT PLATE LEFT OUTSIDE EARTH

E4-52

9


9.3.2.2 CLEARANCE LAMP

(*8

)

(*9

)

(*9

)

(*8

)

G

(*6)

G

(*5)

G (*5

)

G

(*6)

G

(*5)

G (*5

)

W-B

(*5)

W-B

(*5

)

W-B

(*6)

W-B

(*6)

W-B

(*5)

W-B

(*5

)

W-B

(*7)

W-B

(*7)

W-B

G

(*7)

G

(*7)

G

(*7)

G G W-B W-B

W-BW-BGG

G

(*2)

G (*2

)

LG-B

G (*3

)

G (*3

)

R

(*8)

R

(*8)

R

(*8)

W-B

(*8)

W-B

(*8)

W-B

W-B

R

(*8)

G

(*4

*2)

G

(*4 *2)

G-W

(*4)

G

(*4

*1)

G

(*4

*1)

W-B

(*7

)

R-B R-L

G-W

(*9)

G

(*8)

G-W

(*8)

12

1E

1B

13

1A

22

1C

32

1E

7

1B

30

1B

27

5A

A1

5rA

1

TA

IL

OF

F

+B

HE

AD

TE

L(H

)

A4

LIGHT CONTROL SWITCH

9T

7

BT

2A

A1

2rA

1

r2

KEY OFF TAIL RELAY

35

21

r1

KEY OFF HEAD RELAY

21

35

TAIL

S14

LED REAR COMBINATION

LAMP RIGHT

34

TAIL

S13

LED REAR COMBINATION

LAMP LEFT

34

CLEARANCE

FRONT COMBINATION

LAMP LEFT

d1

2 3

CLEARANCE

FRONT COMBINATION

LAMP RIGHT

R1

2 3

TAIL

REAR COMBINATION

LAMP LEFT

S3

1 4

TAIL

REAR COMBINATION

LAMP RIGHT

S4

1 6

4rA

1

rA1

1

5A

GA

UG

E

(IG

)

2

1

7.5

A

TA

IL

(BA

T)

2

1

dA

45 4

dA

44

RA

4

RA

45

SO

23

AA

6S

O2

(*8) (*8)

*1 :H

OM

E D

EP

OT

SP

EC

.

*2 :E

xce

pt H

OM

E D

EP

OT

SP

EC

.

*3 :w

/o O

PT

ION

(STA

ND

AR

D)

*4 :w

/ O

PT

ION

(exce

pt S

TA

ND

AR

D)

*5 :L

ED

TY

PE

*6 :B

UL

B T

YP

E

*7 :w

/ R

EA

R C

OM

BIN

AT

ION

LA

MP

*8 :w

/ K

EY

OF

F H

EA

D L

IGH

T O

FF

SY

ST

EM

*9 :w

/o K

EY

OF

F H

EA

D L

IGH

T O

FF

SY

ST

EM

E4-55


PARTS

Code See Page Code See Page Code See Page Code See PageA6 page 204 S4 E2-16 d1 E2-14R1 E2-14 S13 E2-16 r1 page 204S3 E2-16 S14 E2-16 r2 page 204



1A E2-12, E3-5 BODY MAIN WIRE to J/B1B E2-12, E3-5 BODY MAIN WIRE to J/B1C E2-12, E3-5 BODY MAIN WIRE to J/B1E E2-12, E3-5 SIDE LH WIRE to J/B

:WIRE TO WIRE

Code See Page NameAA1 page 204 BODY MAIN WIRE to BODY MAIN WIRERA4 E2-14 FR STAY WIRE RH to BODY MAIN WIRESO2 E2-16 RR UPR MAIN WIRE to SIDE LH WIREdA4 E2-14 FR STAY WIRE RH to BODY MAIN WIRErA1 page 204 KEY OFF H/LP OFF WIRE to BODY MAIN WIRE

:EARTH

Code See Page NameAA E2-12 FRONT PLATE LEFT OUTSIDE EARTH

E4-56

9


9.4 CONNECTOR LIST

9.4.1 CONNECTOR LISTA82

NATURAL

(S)6020-6161

1 2 3

4 5 6

FRONT SOLENOIDRELAY

A83NATURAL

(S)6020-6161

1 2 3

4 5 6

REAR SOLENOIDRELAY

A84NATURAL

(S)6020-6161

1 2 3

4 5 6

EZ PEDAL MAIN RE-LAY

A85NATURAL

(S)6020-6161

1 2 3

4 5 6

NEUTRAL STARTRELAY

A102BROWN

90980- 11155

2 1

ELECTROMAGNETICRELIEF SOLENOID

A103GRAY

3

1

2

90080- 98200

RELIEF PRESSURESENSOR

r1NATURAL

3

5

1 2

82660- 20340

4

KEY OFF HEADRELAY

r2NATURAL

3

5

1 2

82660- 20340

4

KEY OFF TAILRELAY

E7-17

10-21710 SST LIST AND SERVICE STANDARDS LIST

10 SST LIST AND SERVICE STANDARDS LIST10.1 SST LIST ............................................................................................... 21710.2 SERVICE STANDARDS LIST ............................................................... 218

10.1 SST LISTIllustration Part No. Part Name

Section1 2 3 4 ―

09610-10161-71 Oil control valve spring re-mover and replacer О

10

10-218 10 SST LIST AND SERVICE STANDARDS LIST

10.2 SERVICE STANDARDS LISTSTEERINGHydrostatic steering valve ASSY


Pn1 tonseries 1ZS,4YE Standard 7.2 to 7.7 (73.4 to 78.5)

[1044 to 1117]Pn2 tonseries 1ZS,4YE Standard 7.8 to 8.3 (79.5 to 84.6)

[1131 to 1204]Pn3 tonseries 1ZS,4YE Standard 7.8 to 8.3 (79.5 to 84.6)

[1131 to 1204]

Relief set pressure(L/synchronized steering)

MPa (kgf/cm2) [psi]

Cu2 tonseries 4YE Standard 6.4 to 6.9 (65.3 to 70.4)

[928 to 1001]Cu3 tonseries 4YE Standard 8.2 to 8.7 (83.6 to 88.7)

[1044 to 1117]

Relief set pressure(W/synchronized steering)

MPa (kgf/cm2) [psi]

Pn1 tonseries

4YM Standard 7.5 to 8.0 (76.5 to 81.6)[1088 to 1160]1DZ-II Standard

Pn2 tonseries


Pn3 tonseries


Cu2 tonseries 4YE Standard 7.5 to 8.0 (76.5 to 81.6)

[1088 to 1160]Cu3 tonseries 4YE Standard 8.1 to 8.6 (82.6 to 87.7)

[1175 to 1247]

OIL CONTROL VALVEOil control valveRelief pressure

Mpa (kgf/cm2) [psi]

Lift Standard 19.2 to 18.7 (196 to 191) [2784 to 2712]

Tilt Standard (Reference)16.2 to 15.7 (165 to 160) [2349 to 2277]

Tightening torque Unit: N m (kgf·cm) [ft·lbf]

Oil control valve ASSY set bolt Standard 21.6 to 50.4 (220 to 514)[15.92 to 37.19]

Published by

1st Printing: Mar. 2016

Pub. No. CE118

Printed in USA

imprint.fm 1 ページ２０１４年３月１２日　水曜日　午後１時４０分

PRINTED IN USA Pub. No. CE118

Documents

8FG(D)U15-32, 8FGCU20-32 Repair Manual Supplement …dealerapplications.tmhna.com/TechInfo/TechnicalDocs//service... · FOREWORD This manual covers the service procedures of the TOYOTA