R/M 7FGU35-80 7FDU35-80 7FGCU35-70 OPSdealerapplications.tmhna.com/TechInfo/TechnicalDocs/service/manuals... · 9 SIB EN04-001 EPA Compliant Three Way Catalyst System Identification

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 7FGU/7FDU35~80 series and 7FGCU35~70 series. Please use this manual for providingquick, correct servicing of the corresponding forklift models.

For the portion not covered herein, please refer to the repair manuals shown below.

This manual deals with the above models as of September 2005. Pleaseunderstand that disagreement can take place between the descriptions in themanual and actual vehicles due to change in design and specifications. Anychange or modifications thereafter will be informed by Toyota Industrial EquipmentParts & Service News.

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

TOYOTA INDUSTRIAL EQUIPMENT 7FGU/7FDU35~80, 7FGCU35~70REPAIR MANUAL (No. CU030-1)

TOYOTA INDUSTRIAL EQUIPMENT GM6-262 ENGINEREPAIR MANUAL (No. C4630)

TOYOTA INDUSTRIAL EQUIPMENT 11Z, 12Z, 13Z, 14Z ENGINEREPAIR MANUAL (No. C4615-2)

Service Information Bulletins Affecting Models 7FG(D)U35-80 and 7FGCU35-70

Service Information Bulletins1 SIB MA02-001 GM 6-262 Timing & Idle Adjustment Procedure Change2 SIB MA04-001 Revision of Repair Manual for 7FG/DU35-80 & 7FGCU35-703 SIB FS06-001 13Z Updated Fuel System Components4 SIB FS06-002 LPG Pre-Filter Service Parts5 SIB CE05-004 Starter Motor Engagement Delay (All I.C. Units)6 SIB BR06-001 Stiffer Inching Pedal Spring7 SIB EN04-004 13Z Injection Pump Changes8 SIB MA05-003 Change to Periodic Replacement Parts (4Y & GM6-262)9 SIB EN04-001 EPA Compliant Three Way Catalyst System Identification & New SST10 SIB EN03-004 Exhaust Y-Pipe Cracking11 SIB CE01-005 Combination Meter Membrane Grease12 SIB FA06-001 Changes to Reamer Bolt Torque Specification13 SIB MA07-001 Caution During Oil Filling14 SIB FS07-001 New Fuel System for GM6-26215 SIB MA07-001R Caution During Oil Filling16 SIB FS07-002 MIL Strategy Change17 SIB FS07-003 ECM calibration revisions and DTC updates18 SIB CE07-002 Wiring Diagrams for Spectrum Fuel System19 SIB ST07-002 Recommended Service Tools for a Field Service Technician20 SIB FS07-004 New Spectrum DTC 652 and 65321 SIB FS07-008 New Spectrum DTC 9999 and 115122 SIB FS07-005 New Spectrum DTC 627, 628, and 62923 SIB CE07-006 Introduction of VSCS Vehicle Speed Control System24 SIB FS07 006 S t F l S t R l Ch24 SIB FS07-006 Spectrum Fuel System Relay Change25 SIB BF08-002 Product Improvement for 7FGU/7FDU35-80, 7FGCU35-7026 SIB ST08-001 Recommended Special Service Tools27 SIB CE08-001 Low Cab Heater Output28 SIB MA08-001 Removal of Tar from the IMPCO LPG Regulator29 SIB EN08-003 PCV Spacer Hose30 SIB CE09-004 A5, A5-1, or 1-1 Error Codes for OPSS31 SIB EN10-001 Engine Block Heaters32 SIB FS11-001 IMPCO Spectrum III Mixer Overhaul Instructions33 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin 34 SIB CE11-003 Clamp Release Interlock (Standard Lever Units)35 SIB FS11-002 7-Series LPG Regulators

Technical News Brief1 TNB-2003-03 7FGU35 – 80, 7FGCU35 – 70 Poor Engine Performance When Cold2 TNB-2005-03 Quick Reference Sheet for 13Z Diesel Pump Timing3 TNB-2005-04R2 Guidelines for Cleaning a Contaminated Hydraulic System


4 TNB-2007-01 Use of Torque Adapter for SSC FL06-0075 TNB-2007-02 Chassis Lubrication Clarification6 TNB-2007-08 Troubleshooting 13Z Diesel Exhaust Smoke7 TNB-2008-11 Servicing HVAC System Installed as a TSDR Option with Cab Enclosure8 TNB-2008-21 Reverse Locking of Seat Belt9 TNB-2009-01 IMPCO Spectrum III Mixer Overhaul Instructions10 TNB-09-05 How to use the Toyota Service Technical Hotline11 TNB-09-08 Reverse Locking of Seat Belt – Update

Hotline Tech Tips1 HTT-2004-11 - V-6 hard start; Hydraulic valve sticking: Excessive brake wear & noise; Axle

plate mounting bolts loose2 HTT-2004-12 - GMV6 Timing; Strobe Light Failures; V6 hard start; Drive Train Noise;

Hydraulic pump failures3 HTT-2005-1 - Rotten Egg Smell, Retrieving TWC Error Codes, Flame Retardant Hydraulic

Oil, GM V-6 Crank Pulley4 HTT-2005-2 - LP Pre-filter Parts, Retrieving TWC Error Codes, Hydraulic Pump Change

5 HTT-2005-3 - “Rotten Egg” Smell; Driveline Vibration; Aisin LPG Regulator Rich/Lean Air/fuel Ratio; Abnormal Brake Noise; Diesel Engine Smoke; Overheating

6 HTT-2005-4 - Lean LPG Main Path, Engine Compression Check; Key Switch Change7 HTT-2005-5 - Seat Switch Testing, Premium GM V-6 Engine; GM V-6 Crankshaft Bolt8 HTT-2005-6 - Injector Harness Test Light; Cascade House Valves9 HTT-2005-7 - TWC Initial Setting for Injector Period Improvements to the new key switches9 HTT-2005-7 - TWC Initial Setting for Injector Period, Improvements to the new key switches,

Operator Prescence System10 HTT-2005-8 - TWC Initial Setting for Injector Period, Improvements To The New Key

Switches, Operator Presence System11 HTT-2005-9 - 13Z Diesel Injection Timing12 HTT-2005-10 - 13Z Diesel Injection Timing13 HTT-2005-11 - TWC Analyzer Tips, GM V6 Hot Soak Engine Shut Down14 HTT-2005-12 - OPSS Component Information15 HTT-2006-1 - TWC Trouble Shooting Tips, Metal Clad Wiper Seals on Rear Lift Cylinders

16 HTT-2006-2 - O.P.S.S. Error Code 1, TWC Light Strobing & Adjustments, Hood Vents, Replacement Radiators, GM V-6 Y Pipe Update

17 HTT-2006-3 - 7Series Starter Delay Circuit18 HTT-2006-4 - LPG Regulator Air Testing, Home Depot Options, LPG Pre-Filter Service Parts

19 HTT-2006-5 -7FDU Oil Filing, Cotton Core Radiator, LPG Oil Contamination20 HTT-2006-6 - V-Mast Rear Cylinders, Wire Harness Repair, SAS Code 63, Axle Mount Bolts

21 HTT-2006-7 - GM6-262 Exhaust Y-Pipe Breaking


22 HTT-2006-8 -Engine Shutdown Option, Extreme Environment Radiator23 HTT-2006-9 - V-Mast Cylinder Spacer, GM6-262 Timing Chain Tensioner, TWC Tamper

Resistant Plug24 HTT-2006-10 - GM6-262 Hard/Impossible to Start, SAS L-Off25 HTT-2006-11 - Ultra-Low Sulfur Diesel, 7FGCU35-45 Brake Noise, TWC Emission Warranty

26 HTT-2006-12 - Travel Speed Measurement, Clogged LP injector, New Fuel System SST

27 HTT-2007-1 - GM6-262 Spectrum Fuel System28 HTT-2007-2 - Spectrum MIL Strategy change, Chassis Lubrication, USB adapter for

Spectrum29 HTT-2007-3 - IC Radiator Offerings30 HTT-2007-4 - Spectrum Adapter hardware change31 HTT-2007-5 - Spectrum Fuel System Terminology32 HTT-2007-6 - New Active Radiator, Troubleshooting Smoke33 HTT-2007-7 - New Hydraulic Oil, Troubleshooting Overheating, Spectrum III LP and/or 34 HTT-2007-9 - Spectrum Fuel System Calibration35 HTT-2007-10 - LP Lockoff Solenoid Orientation36 HTT-2007-11 - Spectrum Calibration changes, Spectrum DTC 115237 HTT-2007-12 - Spectrum hard start, Engine Block Heaters38 HTT-2008-1 - Threshold Voltages39 HTT-2008-2 - Rear Pillar Assist Grip with Horn Button, Proper Wheel Torque40 HTT-2008-03 - Spectrum Fuel System Calibration Files Updated, Harsh Inching 41 HTT-2008-04 - IMPCO Spectrum Fuel System Diagnostics, No Lowering Complaint42 HTT-2008-05 - Root Cause Analysis as Part of a Complete Repair Solution New Datalink42 HTT-2008-05 - Root Cause Analysis as Part of a Complete Repair Solution, New Datalink 43 HTT-2008-06 - No Updates44 HTT-2008-07 - Slow Lowering on 7FGU35-80 and 7FGCU35-70, 11-15Z Block Heater 45

HTT-2008-08 - Tips on Testing Wire Harness, Dot-Lok Shift Interlock Software46 HTT-2008-09 - SAS Matching, Updated LPG Shutoff Valve for Spectrum Fuel System, Basic 47 HTT-2008-10 - Spectrum Fuel System: Engine will "Hit" But not Start48 HTT-2008-11 - Class IV & V LPG Filter Parts49 HTT-2008-12 - Class I-VI Converting Dwell to Duty Cycle, Class I-V Mast Shimming50 HTT-2009-01 - Class I-V SAS Down Valve, Class IV & V Code 73-151 HTT-2009-02 - 7FG(C)U35-50 External Flow Divider Changes52 HTT-2009-03 - No Information on D70053 HTT-2009-04 - Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters54 HTT-2009-05 - Error Codes After Card Replacement55 HTT-2009-06 - Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On56 HTT-2009-07 - Slow Travel Speed57 HTT-2009-08 - Occurrence of Error Code AO-458 HTT-2009-09 - Jerky Travel at Slow Speeds59 HTT-2009-10 - Gear Case Bolt Torque Increase


60 HTT-2009-11 - A5 Error Code On 7FBE and 7FBC Forklifts With OPSS, 5F and 5G Codes for the 7BNCU Model Forklifts

61 HTT-2009-12 - 7FBCU Transistor Test Procedure & Speed Sensor Check62 HTT-2010-01 - Reverse Polarity, 11Z-15Z Block Heater Install, Spectrum VS E-Controls

F.S., Oil Contamination with Water, Clamping Attachment Will Not Hold Pressure63 HTT-2010-02 - OPS Error Code 4-4 on D700 and GM V6 Hard Start Pre-Spectrum FS64 HTT-2010-03 - No Information on the D70065 HTT-2010-04 - 7-Series and 8-Series IC Threshold Voltage66 HTT-2010-05 - Overheat Complaints, Using a Non-Contact Thermometer67 HTT-2010-06 - SAS Manual Lowering Valve, 2010 GM V6 LP Fuel System Pressure Check

Points68 HTT-2010-07 - D700 Engine Shutdown69 HTT-2010-08 - D700 Diagnosic Tools70 HTT-2010-09 - DST Software Operating System Compatibility71 HTT-2010-10 - GM-262 V6 Hard Starting, Battery Cranking Voltage72 HTT-2010-11 - Seat Switch Failures and Battery Reading73 HTT-2010-12 - D700 Tar Removal from LPG Regulator74 HTT-2011-01 - Class IV & V Oxygen Sensor Readings, D700 with PSI Engine DTC 15475 HTT-2011-02 - Cass I-VI Common Electrical Acronyms, Class IV & V EPA Requirements, 7-

Series HNBR First Valve76 HTT-2011-03 - Class IV & V 8-Series Throttle Body Cleaning/Adjustment and Analyzer

Functions, 77 HTT-2011-04 - Class IV & V Analyzer Functions and D700 Hard Start or Long Crank Time78 HTT-2011-05 - Class IV & V 8-Series IC Analyzer Functions, PSI Fuel System DTC 154,

Starter Sub Relay Location on EZ Pedal Equipped D700 ForkliftsStarter Sub Relay Location on EZ Pedal Equipped D700 Forklifts79 HTT-2011-06 - Class IV & V DST Software and Windows 7 Compatibility, Where to Find

Auxiliary Flow Rate Information80 HTT-2011-07 - No Information on the D70081 HTT-2011-08 - Class IV & V Back to Basics Troubleshooting82 HTT-2011-09 - No Information on the D70083 HTT-2011-10 - Class IV & V Diagnosing Intermittent Complaints84 HTT-2011-11 - Class IV & V Engine Light On with No Error Code on PSI Equipped Trucks,

Diagnosing Intermittent Complaints85 HTT-2011-12 - Class I-VI Hyd Oil Maint and Diagnosing Intermittent Complaints86 HTT-2012-01 - Class I-VI Using DVOM to Check Voltage Drop, Class IV & V Error Code 09-

1, LPG Filter Kit, Spectrum Fuel System Operation During Winter Class V & VI Glow Plug Testing

SECTION INDEXNAME SECTION

GENERAL 0OPS 1BODY 2OIL CONTROL VALVE 3SAS 4APPENDIX 5

0-1

0GENERAL

Page

PERIODIC MAINTENANCE.................................0-2OPS SYSTEM.......................................................0-3SAS.......................................................................0-9

0-2

PERIODIC MAINTENANCE

INSPECTION METHOD

I : Inspection. Repair or Replacement if required.M : Measurement. Repair or Adjustment if required.T : Retightening C : Cleaning L : Lubrication* : For new vehicle *1 : Flaw detector

Inspection Period

Item

Every 6 weeks

Every 3 months

Every 6 months

Every 12 months

Every 250 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

SAFETY DEVICES, ETC.

Seat

Loosening and damage of mounting I ← ← ←

Seatbelt damage and function I ← ← ←

Seat switch function I ← ← ←

OPS Functions I ← ← ←

0-3

0

OPS SYSTEM

GeneralThe OPS (Operator Presence Sensing) system is added as standard.The switch mounted underneath the seat detects the operator on the seat. When there is no operator, the OPSsystem cuts off the driving power and restricts material handling operations. (Refer to page 0-6.)

The OPS system operates (to disable traveling and material handling) upon lapse of 2 seconds after the operatorleaves the seat.

When the OPS controller detects the seat switch going off, it sounds the OPS buzzer* (bleeping) for about onesecond and turns the OPS lamp on before OPS activation. Furthermore, the OPS lamp keeps lighting while the seatswitch stays off.

Only export model:If the seat switch is turned on without returning the forward/reverse lever to the neutral position after drive OPSactivation, the newly added return to neutral warning function sounds the buzzer at short intervals (pip-pip) to warnthe operator of the unreleased state of the drive OPS.When the OPS controller detects any system malfunction, the OPS lamp blinks to warn the abnormality.

*: The buzzer sounds only the export model.

Control block diagram

Forward tilt switch

Battery

Key switch

Foward reverseswitch

Bakward tilt switch

* OPS

Controller

* OPS lamp

* OPS lamp relay

* OPS buzzer

* Plug inanalyzer

Tiltcylinder

* SASController

Liftcylinder* Unload

valve

* Tiltcontrolvalve

* Oil control valve

Oil tank

Oilpump

EngineT/C

* Forwardinterrupt relay

Forward drivevalve

* Reverseinterrupt relay

Reverse drivevalve

* Seat switch

F

N

R

Liftlock

valve

*: Parts added or changed for OPS

Note:

• The OPS buzzer is installed only in the export specification model.• When the OPS system is operating, the hydraulic power supply is interrupted by the unload valve to

provide the steering with no power assistance.

0-4

Name of each part　

(11)

(3) (4)

(5) (6)

(14)

(13)

(12)

(1)

(2)

(7) (8) (9)(10)

(1) OPS controller (8) Backward tilt switch

(2) Seat switch (9) Unload valve

(3) Forward switch (10) Tilt control valve

(4) Reverse switch (11) OPS lamp

(5) Forward interrupt relay (12) OPS lamp relay

(6) Reverse interrupt relay (13) OPS buzzer (Export model)

(7) Forward tilt switch (14) Plug-in analyzer

0-5

0

Function of each partInput to controller

Output from controller

Name Function

(2) Seat switch This switch mounted underneath the seat detects the operator sitting on the seat.

(3) Forward switchThis switch detects inputs the voltage branched from the forward drive valve power supply line of the torque converter to the OPS controller for detecting forward drive operation.

(4) Reverse switchThis switch detects inputs the voltage branched from the reverse drive valve power supply line of the torque converter to the OPS controller for detecting reverse drive operation.

(7) Forward tilt switch This limit switch installed at the tilt spool of the oil control valve detects the forward operation of the tilt lever.

(8) Backward tilt switch This limit switch installed at the tilt spool of the oil control valve detects the backward operation of the tilt lever.

Name Function

(5) Forward interrupt relay This relay interrupts the voltage supply to the forward drive valve in the torque converter according to the instruction from the OPS controller.

(6) Reverse interrupt relay This relay interrupts the voltage supply to the reverse drive valve in the torque converter according to the instruction from the OPS controller.

(9) Unload valve Provides a bypath to the tank circuit for the hydraulic oil supplied from the oil pump to the oil control valve.

(10) Tilt control valveThis valve changes the oil path to the tilt cylinder according to the instruction from the OPS controller to disable forward tilting and to slow down the backward tilting speed.

(11) OPS lampThis lamp lights while the seat switch is off to indicate the OPS operation. Furthermore, it blinks when the OPS controller detects any abnormality.

(12) OPS lamp relayThe OPS lamp electric circuit is opened or closed according to the instruction from the OPS controller. The lamp is kept on when there is no instruction from the OPS controller.

(13) OPS buzzerThis buzzer sounds in the predetermined pattern when the seat switch is turned off or when the forward/reverse shift lever needs returning to the neutral position (return to neutral warning).

(14) Plug-in analyzer

This new plug-in analyzer is added with the OPS analyzer functions to the service functions of the conventional SAS analyzer. It is connected to the same service connector.OPS analyzer functions• Diagnostic display (More detailed display than OPS lamp blinking frequency)• I/O monitor display (Shortening the time required for troubleshooting)• Output test (Shortening the troubleshooting time by setting each output on and off according to the instruction from the OPS controller)

0-6

Control specifications1. Drive OPS

When the OPS controller detects seat switch off state for 2 seconds, the forward/reverse interrupt relay isoperated to disconnect the driving power supply to the forward/reverse drive relay in the torque converter.This drive OPS operation is released when the seat switch is turned on and the forward/reverse shift relay isreturned to the neutral position.

2. Material handling OPS

When the OPS controller detects seat switch OFF for 2 seconds, the tilt control valve is controlled to disableforward tilting operation. Backward tilting, fork lifting and attachment operations are disabled by interruptingthe hydraulic oil supply by means of the unload valve. Fork lowering operation is stopped by interrupting thecontrol hydraulic pressure to the lift lock valve. The disabled material handling operations are released uponlapse of 1 second after seat switch ON.

Caution:• Backward tilting: If the material handling lever is operated while the OPS is functioning, the mast

may move because of its own weight when it is in a backward tilted position.• Attachment: If the material handling lever is operated while the OPS is functioning, the attachment

may move because of its own weight.

3. OPS operation noticeWhen the OPS controller detects the seat switch off state, it sounds the OPS buzzer (bleep) for about onesecond, and turns the OPS lamp on to warn the operator of the OPS operation.

The OPS buzzer sounds only on the export specification vehicle.

4. Return-to-neutral warning (Export specification vehicle only)The OPS controller warns the driver of the failure in releasing the drive OPS by sounding the buzzer at shortintervals (pip-pip) when the seat switch is turned on without returning the forward/reverse shift lever to itsneutral position.

5. Malfunction alarmWhen the OPS controller detects any malfunction, it blinks the OPS lamp to warm the malfunction. The lampblinking frequency identifies the defective part.

SeatEvery seat has the seat switch for operator detection. When replacing seat, install a genuine TOYOTA seat designed specifically for this lift truck. (The OPS may fail tooperate unless the correct seat is used.)

Combination MeterOPS lamp

This lamp indicates OPS operation and warns an OPS error.

Note:With addition of OPS lamp, the remaining fuel warning lamp(OPT), which used to be in the combination meter, isrelocated to the instrument panel.

0-7

OIL CONTROL VALVE1. The tilt solenoid became one (SOL1: Normally open type) from two units (SOL1, SOL2).

2. An unload valve (unload SOL) is newly added this time.

3. Key OFF lift lock:This function prevents the fork from lowering upon lowering operation when the key switch is at the OFFposition (engine in stopped state).

4. There are no change in the specifications (such as relief pressures) and the manner of relief pressureadjustment.

Unloading solenoid valve

0-8

EZ PEDALWhile the forward or reverse traveling direction is selected by operating the direction lever at the steering column onthe standard model, the EZ pedal model changes the direction by stepping on either the left or right half of theaccelerator pedal.

OperationOnly when the parking lever is pulled to apply the brake, the T/C is set in the neutral position to enable the engine tobe started. According to the addition of the OPS system as a standard feature, the parking brake OFF warning isabolished. When the operator is off the seat (judged by seat switch OFF for 2 seconds or more), the drive power isinterrupted (by the drive OPS function) and material handling operations are disabled.When the drive OPS is operated, pull the parking lever to cancel the drive OPS function to allow traveling.

0-9

SASHydraulic Circuit DiagramAn unload valve is added a new to the oil control valve on the previous model.

(1)

(1) Flow control valve(2) Tilt select valve(3) Lift select valve(4) Tilt lock check valve

(Leak lock valve)

(5) Lift lock check valve (Leak lock valve)

(6) Unloading valve & solenoid(7) Tilt control valve & solenoid

(4) (2)

(3)

(5)

C1

C3

C2

PS Gage PortT

SOL

(6)

(7)

P

0-10

Hydraulic circuit controlTilt control is achieved by ON/OFF of the tilt control solenoid (SOL) valve installed on the integral control valve. Therelationships between the tilt hydraulic circuit and tilt control SOL valve is as shown in the table below. When theSOL is OFF upon backward tilting operation, the circuit is fully open. When the SOL is OFF upon neutral or tiltforward operation, tilting is stopped.

*Backward tilting operation with the tilt lever knob switch depressed.

Tilt control SOL

OFF ON

Full open circuit Half open circuit Tilting stop circuit

• Low lifting height and backward tilting• Forward tilting

• High lifting height and backward tilting speed restriction

• Low lifting height and backward tilting speed restriction*

• Tilt lever in neutral position• Stop be forward tilting

angle restriction• Forward automatic

leveling stop

1. Tilt stop circuitThe tilt stop circuit refers to the state where the tiltingoperation is disabled as upon tilt lever setting at the neutralposition or upon stopping with forward tilting angle restrictionor fork automatic leveling. The tilt cylinder operation isstopped because the tilt control valve in the control valve isclosed.

2. Tilt semi-open circuitThe tilt semi-open circuit refers to the state where the tiltingoperation speed is restricted (slowed down).The tilting speed is slowed down because the orifice in the tiltcontrol valve is connected to reduce the oil flow to the tiltcylinder.

Pilot Check Valve

TiltLever

Flow ControlValve

Tilt Cylinder

Pilot Circuit

SOL ONOrifice

Pilot Check Valve

TiltLever

Flow ControlValve

Tilt Cylinder

Pilot Circuit

SOL ONOrifice

0-11

3. Tilt full open circuitThe tilt full open circuit refers to the state where the tiltingspeed is not restricted. The forward/backward tilting speed atthe low lifting height becomes the normal tilting speed.The fully opened circuit in the tilting control valve results innormal tilting speed with no restriction.

Pilot Check Valve

TiltLever

Flow ControlValve

Tilt Cylinder

Pilot Circuit

SOL OFFOrifice

1-1

1

OPSPage

GENERAL ............................................................1-2COMPONENTS ....................................................1-4OPS CONTROLLER ............................................1-5

REMOVAL · INSTALLATION..................................1-5OPS PLUG-IN ANALYZER..................................1-6

SCREEN CONFIGURATION...................................1-6BASIC OPERATION..............................................1-7ANALYZER ..........................................................1-9TROUBLESHOOTING .........................................1-12

OPS TROUBLESHOOTING...............................1-14DIAGNOSIS........................................................1-14DIAGNOSIS ERROR CODE LIST..........................1-15TROUBLESHOOTING BY ERROR CODE..............1-17TROUBLESHOOTING BY PHENOMENON ............1-28Note:See Section 4 (SAS) for the connector layout, controller sequence andconnector diagram.

1-2

GENERAL

Forward tilt switch

Battery

Key switch

Foward reverseswitch

Bakward tilt switch

* OPS

Controller

* OPS lamp

* OPS lamp relay

* OPS buzzer

* Plug inanalyzer

Tiltcylinder

* SASController

Liftcylinder* Unload

valve

* Tiltcontrolvalve

* Oil control valve

Oil tank

Oilpump

EngineT/C

* Forwardinterrupt relay

Forward drivevalve

* Reverseinterrupt relay

Reverse drivevalve

* Seat switch

F

N

R

Liftlock

valve

*: Parts added or changed for OPS

Note:

• The OPS buzzer is installed only in the export specification model.• When the OPS system is operating, the hydraulic power supply is interruptedby the unload valve to

provide the steering with no power assistance.

1-3

1(11)

(3) (4)

(5) (6)

(14)

(13)

(12)

(1)

(2)

(7) (8) (9)(10)

(1) OPS controller (8) Backward tilting switch

(2) Seat switch (9) Unload valve

(3) Forward drive switch (10) Tilt control valve

(4) Reverse drive switch (11) OPS lamp

(5) Forward interrupt relay (12) OPS lamp relay

(6) Reverse interrupt relay (13) OPS buzzer

(7) Forward tilting switch (14) Plug-in analyzer

1-4

COMPONENTS1910

5701-471

4 1

32

VZ

PA

WE

WG

PG

LN

LN

LN

WE

GU

PA

QY

MFPG

RQ

1

2

4

RQ

GU

MF QY

GM6-262(UL-LPS)

WT

LYGU

EPVZ

WEEPNX

RQ

3

5701

1-5

1

OPS CONTROLLERREMOVAL · INSTALLATION

Removal Procedure1 Remove the toe board.

2 Remove the lower panel.

3 Remove the instrument panel (RH).

4 Remove the OPS controller set bolts.

5 Disconnect the connector.

6 Remove the OPS controller.

Installation ProcedureThe installation procedure is the reverse of the removal procedure.

5

46

1-6

OPS PLUG-IN ANALYZERFor the maintenance and service of OPS functions, a separate type plug-in analyzer is introduced as an SST(Special Tool for Service).The plug-in analyzer is designed to read the operating state of sensors and actuators used for the OPS functionsand the error information detected by the controller. It serves to check on the operating state of OPS functions andshortens the repair time for a trouble. Moreover, it is installed with save function to file data displayed on the screenin the SST.

SCREEN CONFIGURATION

SST 09240-23323-71

Menu name Content of function Reference page

Com

mun

icatio

n fu

nctio

n wi

th th

e O

PS co

ntro

ller o

n th

e ve

hicle

side

OPS

DIAG MEMORY Indication of ten error codes and sub-codes in past. 1-9

IN/OUT MONITOR Monitoring input voltage value from the sensors and the output signal, etc. to the solenoid, etc. 1-10

ACTIVE TEST Forced operation of solenoids and warning lamps. 1-11

CONTROLLER DATA Indication of OPS controller abbreviation number and version 1-11

See SAS section of 7FGU35 80 Repair Manual (Pub. No. CU030,-1).

See SAS section of 7FGU35 80 Repair Manual (Pub. No. CU030,-1).

1-7

BASIC OPERATIONName of Sections and the Switch Functions

Caution on using:• Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections.• Operate the switch with finger tip.• Donít give it strong impact from dropping or collision.• Donít leave it under the direct rays of the sun for long time.

Name of section Position of indication Mark Function Switch

A

• Move the cursor to the above item.• Move to the preceding page.

Selectorswitch • Move the cursor to right or left.

<Blank> <No function>

B

• Select the item below.• Move to the following page. Selector

switch

<Blank> <No function>

C

Determine an item for selection.Menu switch

<Blank> • Move to MENU screen.

Connection and Operation of SST1. Turn the key switch OFF.2. Open the diagnosis connector cover of the vehicle and properly

connect the connector on the SST side.SST 09240-23323-71

Note:Since the connector has no locking device, securely connectit to prevent contact defect upon closing the engine hoodwith the connector in connected state.

3. Turn the key switch ON or start engine.4. Display of the initialization screen

After about 15 seconds of display, "LANGUAGE SET" or "MAINMENU" screen appears. The screen may be changed duringthis period by pressing the menu switch .

Connector

Main unit

Screen title A Switch

Switch mark indicatorCB

SST

Diagnosis connector

PLUG IN ANALYZER

SYSTEM PROG VER 4.00

1-8

5. "LANGUAGE SET" screenSince this screen appears only when the language isundefined, determine a language to use for display.(1) Select a display language by pressing selector switch

and .• Japanese• English

(2) Press MENU switch to determine the language setting.

Note:Once the display language is defined, "LANGUAGE SET"screen will not be displayed from the next time onward. Tochange language, go to "TESTER SET" of "MAIN MENU".

6. "MAIN MENU" screen(1) Select the menu using selector switch and and

determine by pressing menu switch .• SAS: Moves to SAS MENU screen. • OPS: Moves to OPS ANALYZER MENU Screen.• TESTER SET: Moves to TESTER SET screen.

Removal of SST

1. Check that the screen title is for one of the MENU screens.

2. Turn the key switch OFF.

3. Disconnect the connector.

Note:To disconnect, hold the body of the connector.

4. Close the diagnosis connector cover.

1-9

ANALYZER

ANALYZER MENU Display contents and function Page

1. DIAG MEMORY Indication of error codes for 10 most recent errors 1-9

2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 1-10

3. ACTIVE TEST Forced operation signal output to the selected item 1-11

4. CONTROLLER DATA Indication of the OPS controller part number and version 1-11

Operation Procedure1. Select and enter "2OPS" on the main menu screen to display

the OPS ANALYZER MENU screen.

2. ANALYZER MENU screen

(1) Move the cursor to the desired menu by operating selectorswitch or , and enter by operating MENU switch .

(2) Select and enter "END" to return to the MAIN MENUscreen.

"1 DIAG MEMORY"This screen displays ten error codes from the most recent one.

[Explanation on display contents]

(1) Order of error occurrence

(2) Error codes

[Clear memory]

Press selector switch continuously for 2 seconds.

[End]

Press MENU switch to return to the ANALYZER MENU screen.

Note:• Only "-" appears at the end of the item involving no error

occurrence.• If reception has not been completed, only the number

appears without "-" indication.

(1) (2)

1-10

"2 IN/OUT MONITOR"[Explanation on display contents]

(1) SEAT: Seat switch input signal

(2) DIR: Direction switch input signal

FWD: Forward direction switch input signal

REV: Reverse direction switch input signal

(3) RLY: Output signal to forward/reverse interrupt relay

FWD: Output signal to forward interrupt relay

REV: Output signal to reverse interrupt relay

(4) VOLTAGE: OPS controller power supply voltage

(5) LIFT LOWER: Unused

(6) UNLOAD SOL: Output signal to unload solenoid

(7) TILS SOL: Output signal to tilt solenoid

(8) TILT: Tilt lever switch input signal

FWD: Forward tilt switch input signal

BWD: Backward tilt switch input signal

CONT: SAS tilt control command input signal

(9) LSOPT: Reserved.

[End]


(1)(2)

(3)

(4)

(1)(5)(6)

(7)

(4)

(1)

(4)

(8)

(9)(7)

1-11

"3 ACTIVE TEST"

Note:ON indication on the screen shows the controller outputstate. The operation, therefore, should be checked visually,by operating sound, etc.

1. Select the item by selector switch , and set OFF/ON byselector switch .


(1) RLY FWDSet to ON for forced output of forward interrupt relayactivating signal. (Forward traveling disabled state)

(2) RLY REVSet to ON for forced output of reverse interrupt relayactivating signal. (Reverse traveling disabled state)

(3) UNLOAD SOLSet to ON for forced output of unload solenoid activatingsignal. (Material handling disabled state)

(4) TILT SOLSet to ON for forced output of tilt solenoid activating signal.(Forward tilting enabled state with backward tilting speedrestriction)

(5) LAMPSet to ON for forced output of OPS lamp lighting signal.(OPS lamp lighting state)

(6) BUZZER (Export model)Set to ON for forced output of OPS buzzer sounding signal.(Continuous OPS buzzer sounding)

2. After resetting all items to OFF, press MENU switch to returnto the ANALYZER MENU screen.

"4 CONTROLLER DATA"The OPS controller abbreviation No. and version No. can bedisplayed on this screen.


(1) DATAController abbreviation No.

(2) VERVersion No.

[End]


(1)(2)(3)

(4)(5)(6)

(1)

(2)

1-12

TROUBLESHOOTING

No display on the screen.

Related Portion

Estimated Causes:

Inspection 1:

Measure the voltage between CN44-12 and CN44-3.Key switch ON (engine in stopped state)

Standard:

Inspection 2:

Measure the voltage between analyzer CN-1 and analyzer CN-13.Key switch ON (engine in stopped state)

Standard:

Connector contact defect Analyzer harness (power supply) defect Plug-in analyzer defect

CN44-12 (+) ~ CN44-3 (-) 8 to 16 V

Analyzer CN-1(+) ~ analyzer CN-13 (-) 8 to 16 V

TAB

RE

C

RE

CTA

BR

EC

TAB

TAB

RE

C

TAB

RE

C

To IG SW

OP

S c

ontr

olle

r

CN44-12(IG, Power supply)

(E2, Main GND)Analyzer CN

Analyzer

1

13

6CN44-1CN45-1

ECU-IG

CN46-3

CN6-3

CN44-3

J2

Inspection 2: Measure the voltage between analyzer CN-1 and analyzer CN-13.

Check CN44 and analyzer connector for any disconnection. Screen check after correction.

Inspection 1: Measure the voltage between CN44-12 and CN44-3.

Plug-in analyzer defect

Harness defect on vehicle side

Analyzer harness defect

NG

OK

NG

NG

NG

OK

OK

CN44 (REC)

1

7

12

2

8

13

3

9

14

54

10

1615

6

11

17

18

2019

21 2322

Analyzer CN (REC)

1-13

No data display on data (DIAG MEMORY, voltage value, etc) display screen

Related Portion

Estimated Causes:

Inspection 1:

Check continuity between CN44-1 and CN45-1.Key switch OFF, disconnection between CN44 and CN45.

Standard:

Inspection 2:

Check continuity between analyzer CN-6 and CN44-1.Key switch OFF, disconnection between analyzer CN andCN44.

Standard:

Connector contact defective Plug-in analyzer defect Analyzer harness (communication) defect OPS controller defect

CN44-1 ~ CN45-1 Continuity

Analyzer CN-6 ~ CN44-1 Continuity

TAB

RE

C

RE

CTA

BR

EC

TAB

RE

CTA

B

RE

CTA

B

To IG SW

OP

S c

ontr

olle

r

CN44-12(IG, Power supply)

(E2, Main GND)Analyzer CN

Analyzer

1

13

6CN44-1CN45-1

ECU-IG

CN46-3

CN6-3

CN44-3

J2

Check CN44 and analyzer connector for any disconnection. Data display check after correction.

Inspection 1:Check continuity between CN44-1 and CN45-1.

Inspection 2:Check continuity between analyzer CN-6 and CN44-1.

Check data display by connecting the analyzer to another vehicle.

Harness defect on vehicle side

Analyzer harness defect

NG

OK

NG

NG

NG

OK

OK

Plug-in analyzer defectNG

OPS controller defect

OK

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN44 (REC)

1

7

12

2

8

13

3

9

14

54

10

1615

6

11

17

18

2019

21 2322

Analyzer CN (REC) CN44 (TAB)

1-14

OPS TROUBLESHOOTINGDIAGNOSISThe diagnosis function informs the operator of a trouble occurrence and the trouble position by blinking the OPSlamp on the combination meter when the OPS controller detects an abnormality. The trouble position is indicated bythe lamp blinking count.

Note:• The OPS lamp is lit for 1 second upon key switch ON for broken lamp check.• The OPS lamp comes on when the operator leaves the seat.• If multiple errors occur at a time, only the lowest error code appears. Upon correction of that error, the

next lowest error code appears.

Example:

Display example of error code 3

Break point indication Code indication

ON

OFF

2 sec.

Abnormality detection (Code 3)

0.5 sec.0.5 sec.

0.5 sec.0.5 sec.

0.5 sec.0.5 sec.

0.5 sec.

1-15

DIAGNOSIS ERROR CODE LIST

Lamp Error code Error description Major cause Phenomenon on vehicle

ON — Dead lamp check — —

Blinking (one short ON

pulse)1-1 Seat switch abnormality Sticking

GND fault The OPS does not function.

Blinking (three short ON cycles)

3-1 Forward interrupt relay (RYF) abnormality

Discontinuity Forward traveling is possible while OPS is operating.

GND fault ↑

+B shorting Forward traveling is always disabled.

3-2 Reverse interrupt relay (RYR) abnormality

Discontinuity Reverse traveling is possible while OPS is operating.

GND fault ↑

+B shorting Reverse traveling is always disabled.

Blinking (four short ON cycles)

4-1 Unload solenoid (SOL1) abnormality

DiscontinuityForward tilting is disabled but other material handling operations are possible while OPS is operating.

GND fault ↑

+B shorting All material handling operations are always disabled.

4-3 Tilt solenoid (SOL3) abnormality

Discontinuity Automatic stop is disabled.

GND fault ↑

+B shorting

All material handling operations are disabled while OPS is operating. While OPS is not operating, only forward tilting is disabled but all other material handling operations are possible.

Blinking (five short ON cycles)

5-1 Shift lever abnormality +B shorting Resetting is disabled while OPS is operating (locked state by return to neutral function).

ON

7-1 CPU abnormality

Controller abnormality

Drive/material handling OPS does not function.7-2 CPU abnormality

7-3 CPU abnormality

Blinking (seven short ON cycles)

7-4 CPU abnormality None in particular.

ON7-5 EEPROM abnormality The OPS lamp keeps lighting. The drive/

material handling OPS does not function.7-6 EEPROM abnormality

ON — Low voltage alarm Low battery voltage Ordinary control (or control failure may arise).

ON — OPS operation Departure from seat —

1-16

List of Reference Pages for Error Codes and Sub Error Codes

List of Pages to be Referenced by Phenomenon

Without analyzer (SST) With analyzer (SST)

Error code Error description Page Error code Error description Page

1 Seat switch abnormality 1-17 1-1 Seat switch abnormality 1-18

3

Forward interrupt relay (RYF) abnormalityReverse interrupt relay (RYR) abnormality

1-203-1 Forward interrupt relay (RYF)

abnormality 1-20

3-2 Reverse interrupt relay (RYR) abnormality 1-20

4 Solenoid (SOL) abnormality 1-224-1 Unload solenoid (SOL) abnormality 1-22

4-3 Tilt solenoid (SOL) abnormality 1-22

5 T/C shift lever abnormality 1-24 5-1 T/C shift lever abnormality 1-26

7 OPS controller abnormality —

7-1 CPU abnormality —




7-5 EEPROM abnormality —

7-6 EEPROM abnormality —

DescriptionPages to be referenced

Without analyzer With analyzer

The OPS buzzer does not sound or keeps sounding. (Export model) 1-28 1-28

The OPS lamp does not come on. 1-32 1-32

The OPS lamp keeps lighting. (Including the case where traveling and material handling are both disabled) 1-34 1-37

The material handling OPS does not function. (Including the case where forward tilting is disabled) 1-40 1-40

Material handling fails. (Including the case where only fork lowering is possible) 1-41 1-41

The mast backward tilting speed is always slow or unrestricted. 1-42 1-42

Mast does not tilt forward. 1-46 1-46

The drive OPS does not function. 1-50 1-50

Traveling fails. (Including forward traveling only, reverse traveling only and occasional traveling failure) 1-53 1-53

1-17

TROUBLESHOOTING BY ERROR CODE

Error Code 1 · 1-1 (Seat switch abnormality)

Related Portion

Estimated Causes:

*: After correction, check the OPS lamp indication.After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFFagain.After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display errorcode 1 with blinking.

Connector contact defect Harness defect Seat switch defect Controller defect

RE

CTA

BR

EC

TAB

RE

CTA

B

RE

CTA

B

TAB

RE

C

OP

S c

ontr

olle

r

CN45-23 (DMI, Seat SW)

CN45-17 (E03, Switch GND)J1

CN4CN50 CN60

CN65

6

1

1

2

1

2Seat switch

Check CN45, CN50, CN60, CN4 and CN65 connectors for any disconnection or internal wetting.

After correction, check the OPS lamp indication.*

Error code 1

Inspection 1:Check the seat switch individually for continuity.

Inspection 2:Check continuity between CN45-23 and CN45-17

Controller defect

Seat switch defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

1-18

Inspection 1:

Check the individual seat switch for continuity.Key switch OFF, CN 60 disconnection.

Standard:

Inspection 2:

Check continuity between CN45-23 and CN45-17.Key switch OFF, CN45 disconnection. (CN4, CN50, CN60 and CN65 must beconnected.)

Standard:

*: After correction check the OPS lamp indication.After connecting all connectors, turn the key switch to OFF once, then to ON (for 2 seconds or more), and to OFF again.After waiting without seating for about 15 minutes and turn the key switch to ON. The OPS must not display error code1 with blinking.

Seated Unseated

CN60-1 ~ CN60-2 Continuity No continuity

Seated Unseated


CN60 (TAB)

2 1

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

Check CN45, CN50, CN60, CN4 and CN65 connectors for any disconnection or internal wetting.


Error code 1-1

Inspection 1:With CN60 disconnected, check the input signal to the controller.

Inspection 2:Check continuity between CN45-23 and CN45-17

Controller defect

Seat switch defect

Harness defect

NG

OK

OK

NG

NG

NG

OK

1-19

Inspection 1:

With CN60 disconnected, check the input signal to the controller.CN60 connector disconnection, key switch OFF ⇒ ONAnalyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Inspection 2:

Check continuity between CN45-23 and CN45-17.Key switch OFF, CN45 disconnection. (CN4, CN50, CN60 and CN65 must beconnected.)

Standard:

Seated Unseated

SEAT OFF OFF

Seated Unseated


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-20

Error Code 3Error Code 3-1 (Forward interrupt relay (RYF) abnormality)Error Code 3-2 (Reverse interrupt relay (RYR) abnormality)

Related Portion

Estimated Causes:

*: After correction, check the OPS lamp indication.After key switch ON, place the shift lever in the forward or reverse position and leave the seat to check if the OPSlamp blinks.The OPS lamp must not display error code 3 with blinking.

Note: When the analyzer is provided, check the related portion after checking the error memory for the currenterror code. See page 1-9 "1 DIAG MEMORY" for the error memory check method.

Connector contact defect Harness defect Forward interrupt relay defect Controller defect Reverse interrupt relay defect

TAB

RE

C

TAB

RE

COP

S c

ontr

olle

r

CN45-10 (RYF, Forward interrupt relay)

CN45-11 (RYR, Reverse interrupt relay)

CN45-17, (E03, SW-GND) CN46-6

T/C relay block

Forward interrupt relay

Reverse interrupt relay

2

1

1

2

Check the CN45 and CN46 connectors for disconnection or internal wetting and the relays for insertion.


Error Codes 3, 3-1, 3-2

Inspection 1:Check the forward/reverse interrupt relay individually (on the coil side) for the resistance value.

Inspection 2: Check the wiring between CN45 and the T/C relay block for continuity.

Controller defect

Interrupt relay defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

1-21

Inspection 1:

Check the forward/reverse interrupt relay (on coil side) individually.Measure the resistance between terminals of each of the forward and reverse interrupt relays.Key switch OFF, relay disconnection from T/C relay block.

Standard:

Inspection 2:

Check continuity of the wiring between CN45 and T/C relay block.Key switch OFF, CN45 disconnection, relay removal from the T/C relay block.

Standard:• Discontinuity check

• GND fault check

• +B shorting check

• IG line shorting check

Resistance

Forward interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)

Reverse interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)

CN45-10 ~ Forward interrupt relay terminal 2 Continuity

CN45-11 ~ Reverse interrupt relay terminal 2 Continuity

CN45-17 ~ Forward interrupt relay terminal 1 Continuity

CN45-17 ~ Reverse interrupt relay terminal 1 Continuity

CN45-10 ~ CN45-17 No continuity




CN45-10 ~ CN45-15,-16 No continuity


RLY

2 1

3(5) 4

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

T/C FR RLY

1 2

35

4

T/C RR RLY

1 2

35

4

1-22

Error Code 4Error Code 4-1 (Unload solenoid (SOL1) abnormality)Error Code 4-3 (Tilt solenoid (SOL3) abnormality)

Related Portion

Estimated Causes:

*: After correction, check the OPS lamp indication.After starting the engine, operate lift up/down, forward/backward tilt in each of OPS activation and deactivation tocheck if the OPS lamp blinks.The OPS lamp must not display error code 4 with blinking.

Note: When the analyzer is provided, check the related portion after checking the error memory for the currenterror code. See page 1-9 "1 DIAG MEMORY" for the error memory check method.

Connector contact defect Controller defect Unload solenoid defect Harness defect Tilt solenoid defect

RE

CTA

BR

EC

TAB

RE

CTA

B

TAB

RE

C

OP

S c

ontr

olle

r

CN45-14 (SOL1, Unload SOL)

CN45-30 (E3, SOL-GND)


CN45-12 (SOL3, Tilt SOL)Unload SOL

Tilt SOL

CN47-1W/SPLICE-Z

CN46-9

CN46-8CN12-2

CN12-1

CN47-2

(E3, Body GND)

Check the CN45, CN46, CN47 and CN12 connectors for any disconnection or internal wetting.


Error Codes 4, 4-1, 4-3

Inspection 1:Check the each solenoids (SOL) individually for the resistance value.

Inspection 2: Check the wiring between CN45 and each solenoid (SOL) for continuity.

Controller defect

Solenoid defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

1-23

Inspection 1:

Check the resistance of each solenoid (SOL).Key switch OFF, CN47 and CN12 disconnection.

Standard:

Inspection 2:

Check continuity of the wiring between CN45 and each of solenoids (SOL).Key switch OFF, CN45, CN47, CN48 and CN12 disconnection.


• GND fault check



Resistance

Unload SOL CN47-1 ~ CN47-2 Approx. 9 Ω (20°C)

Tilt SOL CN12-1 ~ CN12-2 Approx. 9 Ω (20°C)




CN47-2 ~ Frame Continuity




CN12-2 ~ Frame Continuity







2 1

CN47 (TAB) CN12 (TAB)

12

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN47 (REC)

21

CN12 (REC)

1 2

1-24

Error Code 5 · 5-1 (T/C shift lever abnormality)

Related Portion

Estimated causes:

*: After correction, check the OPS lamp indication.After key switch ON, operate the shift lever to forward or reverse position and check if the OPS lamp blinks.The OPS lamp must not display error code 5 with blinking.

Connector contact defect Controller defect Shift lever switch defect Fuse defect Harness defect

TAB

RE

C

TAB

RE

C

RE

C

TAB

RE

C

OP

S c

ontr

olle

r

To IG1SFT

CN6-8

CN46-1 CN53-5(CN57-3)CN53-1

CN53-6

(CN57-6)

4 4

CN46-11

CN45-3 (DRF, Forward drive SW)

CN45-4 (DRR, Reverse drive SW)

T/C relay block


Reverse interrupt relay Shift

lever

Check if the fuse (SFT) is blown. After correction, check the OPS lamp indication.*

Error Code 5

Inspection 1:Check the shift lever individually for continuity.

Inspection 2:Check the continuity of wiring between CN45 and IG SW.

Controller defect

Shift lever defect

Harness defect

NG

OK

NG

NG

NG

OK

OK

Check connectors CN45, CN46, CN53 and CN6 for any disconnection or internal wetting.


NG

OK NG

1-25

Inspection 1:

Check the T/C shift lever individually for continuity.Key switch OFF, CN53 disconnection.

Standard:

Inspection 2:

Check the wiring between CN45 and IG SW for continuity.Key switch OFF, CN45 and IG SW connectors disconnection.(CN6, CN46 and CN53 must be connected.)

Standard:• Lever at neutral



Lever at neutral position

Lever at forward traveling position

Lever at reverse traveling position

Between pins 5 and 6 on lever side No continuity Continuity No continuity

Between pins 6 and 1 on lever side No continuity No continuity Continuity

CN45-3 ~ IG SW-4 No continuity






DIRECTION SWITCH

34789

18 1716 14131215

6 5 2 1

1011

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

IG SW

243

1-26

*: After correction, check the OPS lamp indication.After key switch ON, operate the shift lever to the forward or reverse position and check if the OPS lamp blinks.The OPS lamp must not indicate error code 5 with blinking.

Inspection 1:

Disconnect CN53, and check the input signal to the controller.CN53 disconnection, and key switch ON (engine in stopped state)Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Lever at neutral position Lever at forward traveling position

Lever at reverse traveling position

DIR FWD OFF OFF OFF

DIR REV OFF OFF OFF

Check if the fuse (SFT) is blown. After correction, check the OPS lamp indication.*

Error code 5-1

Inspection 1: Disconnect CN53, and check the input signal to the controller.

Inspection 2: (For the NG portion in inspection 1)Check the wiring between CN45 and IG SW for continuity.

Controller defect

Shift lever defect

Harness defect

NG

OK

OK

NG

NG

NG

OK

Check CN45, CN46 and CN53 connectors for any disconnection or internal wetting.


NG

OK NG

1-27

Inspection 2:

Check the wiring between CN45 and IG SW for continuity.Key switch OFF, CN45 and IG SW connectors disconnection.(CN6, CN46 and CN53 must be connected.)

Standard:• Lever at neutral









CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

IG SW

243

1-28

TROUBLESHOOTING BY PHENOMENON

The OPS buzzer does not sound. (Export model)The OPS buzzer keeps sounding. (Export model)

Related Portion

Estimated Causes:

*: After correction, check the OPS buzzer sound.After connecting all connectors, turn the key switch ON, and leave the seat to check if the buzzer sounds.

Connector contact defect Controller defect OPS buzzer defect Fuse defect Harness defect

TAB

RE

C

RE

CTA

B

To IG SW

OP

S c

ontr

olle

r

CN45-9 (BZO, OPS buzzer) OPS buzzer

ECU-IG

CN51-1

CN51-2

Check for blown fuse (ECU-IG). After correction, check the OPS buzzer sound.*

The OPS buzzer does not sound.

Inspection 1:Check the continuity between the IG SW and CN51, and between CN45 and CN51.

Inspection 2: Check the continuity between CN51-2 and the frame.

Controller defect

Harness defect

OPS buzzer defect

NG

OK

NG

OK

NG

OK

NG

Check the CN45 and CN51 for any disconnection or internal wetting. After correction, check the OPS buzzer sound.*

NG

OK NG

1-29

Inspection 1:

Check the continuity between the IG SW and CN51, and between CN45 and CN51.Key switch OFF, CN45, CN51, IG SW connector disconnection.

Standard:

Inspection 2:

Check the continuity between CN51-2 and the frame.

• Without analyzer

Disconnect CN51 and turn the key switch to ON (engine in stopped state).

Standard:

* Normally, the buzzer sounds for 1 second upon lapse of 0.5 seconds after the operator leaves the seat.

• With analyzer

Disconnect CN51 and turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST

Standard:Forcibly turn the OPS buzzer ON and OFF, and check the continuitybetween CN51-1 and CN51-2.

IG SW-4 ~ CN51-1 Continuity


Buzzer ON Buzzer OFF

Between CN51-2 and the frame Continuity No continuity


Between CN51-2 and the frame Continuity No continuity

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN51 (REC)

1 2

IG SW

243

CN51 (REC)

1 2

CN51 (REC)

1 2

1-30

*: After correction, check the OPS buzzer sound.After connecting all connectors, turn the key switch to ON and leave the seat to check if the buzzer sounds.

Inspection 1:

Check the continuity between the IG SW and CN51, and between CN45 and CN51.Key switch OFF, CN45, CN51, IG SW connector disconnection.

Standard:



Between CN45-9 and the frame No continuity

Check CN45 and CN51 for any disconnection or internal wetting. After correction, check the OPS buzzer sound.*

The OPS buzzer keeps sounding.

Inspection 1:Check the continuity between IG SW and CN51, between CN45 and CN51, and between CN45 and the frame.

Inspection 2:Check the continuity between CN51-2 and the frame.

Controller defect

Harness defect

OPS buzzer defect

NG

OK

NG

OK

NG

OK

NG

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN51 (REC)

1 2

IG SW

243

1-31

Inspection 2:

Check the continuity between CN51-2 and the frame.


Disconnect CN51 and turn the key switch to ON (engine in stopped state).

Standard:

* Normally, buzzer sounds for 1 second upon lapse of 0.5 sec after the operator leaves the seat.

• With analyzer

Disconnect CN51 and turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST

Standard:Forcibly turn the OPS buzzer ON and OFF, and check the continuitybetween CN51-1 and CN51-2.


Between CN51-2 and frame Continuity No continuity


Between CN51-2 and frame Continuity No continuity

CN51 (REC)

1 2

CN51 (REC)

1 2

1-32

The OPS lamp does not come on.

Related Portion

Estimated Causes:

*: After correction, check OPS lamp lighting.After connecting all connectors, turn the key switch to ON (engine in stopped state) and leave the seat to see thatthe OPS lamp comes on.

Connector contact defect Harness defect OPS lamp defect Controller defect OPS lamp relay defect Fuse defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

RE

CTA

B

To IG SW

GAUGE

ECU-IG

W/SPLICE-Y

OP

S c

ontr

olle

r

CN45-8 (RYLP, OPS lamp relay)

CN5-12

CN6-3

CN58-3

CN41-12

421

3

4CN8-3

Combination meter

OPS lamp relay

SAS lamp relay

Check if the OPS lamp is burnt out. After bulb replacement, check that the OPS lamp comes on.

Check for blown fuse (GAUGE).

Check CN45, CN41, CN5, CN6, CN8 and CN58 for any disconnection or internal wetting, and check any relay disconnection.

Inspection 1:Check the continuity between fuse (ECU-IG), CN45, CN41, frame, and OPS lamp relay.

After correction, check that the OPS lamp comes on.*

After correction, check that the OPS lamp comes on.*

NG

OK

NG

NG

NG

OK

OK

NG

Controller defect

OK

NG

Harness defectNG

Inspection 2:Check the OPS lamp relay.

OK

OPS lamp relay defectNG

1-33

Inspection 1:

Check the continuity between fuse (ECU-IG), CN45, CN41, frame, and OPS lamp relay.Turn the key switch OFF, disconnect CN45 and CN41, and remove the OPS lamp relay.

Standard:

Inspection 2:

Check the OPS lamp relay.


(1)Turn the key switch OFF, remove the OPS lamp relay from the relay block, and then turn the key switch to ON (enginein stopped state). Check the continuity between OPS lamp relay pin 1 and the frame with no one on the seat.

Standard:

(2)Turn the key switch to OFF, reinstall the OPS lamp relay, and then turn the key switch to ON (engine instopped state). Measure the voltage between OPS lamp relay pins 3 and 4.

Standard:

• With analyzer

(1)Turn the key switch to OFF, remove the OPS lamp relay from the relayblock, and then turn the key switch to ON (engine in stopped state).Check the continuity between OPS lamp relay pin 1 and the frame withno one on the seat.

Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE TEST

Standard:Forcibly turn the OPS lamp ON and OFF, and check the continuity.


Standard:

Between fuse (ECU-IG) and relay pin 2 Continuity

Between CN45-8 and relay pin 1 Continuity

Between frame and replay pin 3 Continuity


Between frame and relay pin 1 No continuity

Lamp ON signal Lamp OFF signal

Between relay pin 1 and frame No continuity Continuity

Lamp ON Lamp OFF

Between relay pins 3 and 4 0 V Approx. 12 V



Lamp ON Lamp OFF


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN41 (REC)

1 2 3 4 7 8 9 10 11 12 135 6

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

1-34

The OPS lamp keeps lighting. (Including the case where traveling and material handlingare both disabled)

Related Portion

Estimated Causes: Contactor contact defect Controller defect OPS lamp defect Fuse defect OPS lamp relay defect Low battery voltage Harness defect Seat switch discontinuity

RE

CTA

B

TAB

RE

C

RE

CTA

B

RE

CTA

B

TAB

RE

C

TAB

RE

CTA

BR

EC

RE

CTA

B

TAB

RE

C

TAB

RE

C

TAB

RE

C

To IG SWGAUGE

ECU-IG CN6-3

CN58-5

CN46-5

W/SPLICE-Y

CN46-4

CN41-12

CN5-12

CN8-3

CN60CN50CN4

CN65

J1CN45-17(E03, Switch GND)

CN45-23 (DMI, Seat switch)

CN45-8 (RYLP, OPS lamp relay)

CN45-16 (IG2, IG line)CN45-15 (IG, IG line)CN45-32 (BATT, +B)

ECU-B

1

2

1

2

6

1

421

3

4

Combination meter

OPS lamp relay

SAS lamp relay

CN58-3

To battery

Seat switch

OP

S c

ontr

olle

r

1-35

*: After correction, check that the OPS lamp goes off.After connecting all connectors, turn the key switch to ON while staying on the seat (engine in stopped state).Check that the OPS lamp goes off in 1 second.

Check for blown fuse (ECU-B). After correction, check that the OPS lamp goes off.*

Without Analyzer

Check CN45, CN46, CN4, CN5, CN6, CN8, CN41, CN50, CN58 and CN60 for any disconnection or internal wetting, and check the OPS lamp relay for connection.

After correction, check that the OPS lamp goes off.*

NG

OK

NG

NG

OK

NG

Inspection 1:Check and measure the continuity and voltage between IG SW and CN45, between battery and CN45, between IG SW and OPS lamp relay, between OPS lamp relay and CN45, and between CN60 and CN45.

Harness defectNG

OK

Inspection 2:Check the input voltage from the IG line to the controller.

Battery defect (low battery voltage)NG

OK

Inspection 3:Check the OPS lamp relay.

OPS lamp relay defectNG

OK

Inspection 4:Check the seat switch.

Seat switch defectNG

OK

Controller defect

1-36

Inspection 1:

Check and measure the continuity and voltage between IG SW and CN45, between the battery and CN45,between IG SW and OPS lamp relay, between OPS lamp relay and CN45, and between CN60 and CN45.Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamprelay.

Standard:

Inspection 2:

Check the input voltage from the IG line to the controller.Disconnect CN45 and turn the key switch to ON. (Connectors other than CN45 must be connected).

Standard:

Inspection 3:


(1)Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch toON (engine in stopped state). Check the continuity between OPS lamp relay pin 1 and frame with no one onthe seat.

Standard:


Standard:



Between IG SW-4 and relay pin 2 Continuity







CN45-32 ~ CN45-31 Approx. 12 V

CN45-15 ~ CN45-31 11 V or more

CN45-16 ~ CN45-31 11 V or more

Lamp ON Lamp OFF


Lamp ON Lamp OFF


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

IG SW

243

OPS LAMP RLY

1 2

35

4

CN60 (REC)

21

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

1-37

Inspection 4:

Check the individual seat switch for continuity.Turn the key switch to OFF, and disconnect CN60.

Standard:

*: After correction, check that the OPS lamp goes off.After connecting all connectors, turn the key switch to ON with no one on the seat (engine in stopped state).Check that the OPS lamp goes off in 1 second.

Seated Unseated


CN60 (TAB)

2 1

Inspection 2:Check the input voltage from the IG line to the controller. Battery defect (low battery voltage)

NG

OK

Inspection 3:Check the OPS lamp relay. OPS lamp relay defect

NG

OK

Inspection 4:Check the seat switch. Seat switch defect

NG

Controller defect

OK

OK

Check for blown fuse (ECU-B). After correction, check that the OPS lamp goes off.*

With Analyzer

Check CN45, CN46, CN4, CN5, CN6, CN8, CN41, CN50, CN58 and CN60 for any disconnection or internal wetting, and the OPS lamp relay for connection.

After correction, check that the OPS lamp goes off.*

NG

OK

NG

NG

OK

NG

Inspection 1:Check and measure the continuity and voltage between the IG SW and CN45, between the battery and CN45, between the IG SW and the OPS lamp relay, and between the OPS lamp relay and CN45, and between CN60 and CN45.

Harness defectNG

OK

1-38

Inspection 1:

Check and measure the continuity and voltage between the IG SW and CN45, between the battery and CN45,between the IG SW and the OPS lamp relay, between the OPS lamp relay and CN45, and between CN60 and CN45.Turn the key switch to OFF, disconnect CN45, CN60 and IG SW connector, and then remove the OPS lamp relay.

Standard:

Inspection 2:

Check the input voltage from the IG line to the controller.After connecting all connectors, turn the key switch to ON (engine in stopped state).Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT MONITOR

Standard:

Inspection 3:


(1)Turn the key switch to OFF, remove the OPS lamp relay from the relay block, and then turn the key switch toON (engine in stopped state). Check the continuity between OPS lamp relay pin 1 and the frame with no oneon the seat.


Standard:Forcibly turn the OPS lamp to on and off, and check the continuity.


Standard:



Between IG SW-4 and relay pin 2 Continuity







CN45-32 ~ CN45-31 Approx. 12 V

Key ON

VOLTAGE 11 V or more



Lamp ON Lamp OFF


CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN60 (REC)

21

IG SW

243

OPS LAMP RLY

1 2

35

4

OPS LAMP RLY

1 2

35

4

1-39

Inspection 4:

Check the seat switch individually.Turn the key switch to OFF and disconnect CN60.

Standard:

Seated Unseated


CN60 (TAB)

2 1

1-40

The material handling OPS does not function. (Including the case where forward tiltingis disabled)

Related Portion

Estimated Causes:

*1: Check if the OPS lamp is blinking.Turn the key switch to OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle as itis for 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.

*2: Check the control valve solenoid operating sound.Turn the key switch to ON (engine in stopped state) and put a hand on the unload solenoid of the control valve tocheck the solenoid open/close sound is heard in 2 seconds after leaving the seat or upon getting on the seat.

Caution:*2:Be careful so as not to get burnt because the solenoid may be hot.

Controller defect Control valve unload valve defect

RE

CTA

B

RE

CTA

B

TAB

RE

C

OP

S c

ontr

olle

r CN45-14 (SOL1, Unload SOL)



CN46-8

CN46-9(E3, Body GND)

CN47-1

CN47-2

W/SPLICE-Z Unload SOL

Is the OPS lamp blinking?*1

Sticking unload valve on control valve

No

Perform troubleshooting according to the error code.

Yes

Check the operating sound of the control valve solenoid.*2

OK

Controller defectNG

1-41

Material handling fails. (Including the case where only fork lowering is possible)

Related Portion

Estimated Causes:

*: Check the control valve solenoid operating sound.Turn the key switch to ON (engine in stopped state) and put a hand on the unload solenoid of the control valve tocheck if the solenoid open/close sound is heard in 2 seconds after leaving the seat or upon getting on the seat.

Caution:*:Be careful so as not to get burnt because the solenoid may be hot.

Sticking unload valve on control valve Controller defect

TAB

RE

C RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r CN45-14 (SOL1, Unload SOL)



CN46-8

CN46-9

W/SPLICE-Z

CN47-1

CN47-2

Unload SOL

(E3, Body GND)

Is the OPS lamp blinking to indicate an error?

Sticking unload valve on control valve

No


Yes

Check the unload solenoid operating sound.*

OK

Controller defectNG

Check if OPS lamp turns OFF while sitting on the seat.

Yes

Perform troubleshooting for "The OPS lamp keeps lighting".

No

1-42

The mast backward tilting speed is always slow or unrestricted.

Related Portion

Estimated Causes: Connector contact defect Sticking tilt control valve Harness defect OPS controller defect Tilt lever switch defect SAS controller defect Tilt lever switch installation defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r

CN45-25 (TFI, Forward tilt switch)

CN45-24 (TRI, Backward tilt switch)

CN45-17 (E03, SW-GND)

CN45-20 (TGND, Forward/Backward tilt GND)

CN45-22 (TFO, Forward tilt output)CN45-21 (TRO, Backward tilt output)CN45-5 (TCON, Tilt control)

6

10

CN46J1

CN3412

34

W/SPLICE-A

CN1-22CN1-23

CN1-10CN1-9

CN1-13 SA

S c

ontr

olle

r

Forward tilt lever switch

Backward tilt lever switch

After correction, check the backward tilting speed while staying on the seat.*2

Perform troubleshooting according to the error code.Is the OPS lamp blinking?*1

No

Yes

Check CN1, CN34, CN45 and CN46 for any disconnection or internal wetting.

NG

Perform SAS troubleshooting (check the auto level switch and lift height switch).

OK

To be continued

NG

1-43

*1: Check if the OPS lamp is blinking.Turn the key switch to OFF → ON (2 seconds or more) → ON with no one on the seat. Leave the vehicle as it isfor 15 minutes or more, and turn the key switch to ON again to confirm that the OPS lamp does not blink.

*2: After correction, check the backward tilting speed while staying on the seat.After turning the key switch to ON while staying on the seat, check the mast backward tilting speed.

*3: Check the tilt solenoid operating sound.Turn the key switch to ON (engine in stopped state) and put a hand on the tilt solenoid of the control valve tocheck the solenoid open/close sound upon forward tilting operation with the unloaded fork at a height of 500 mm(20 inches).

Caution:*3:Be careful so as not to get burnt because the solenoid may be hot.

OK

Inspection 1:Check the tilt lever switch signal to the OPS controller.

Inspection 2:Check the tilt lever switch individually (as installed on the vehicle) for continuity.

NGHarness defect (between CN34 and CN45)

OK

Inspection 3:Check the tilt lever switch individually (as removed from the vehicle) for continuity.

Tilt lever switch defect

NG

NG

Tilt lever switch installation defect

OK

OK

Inspection 4:Check tilt lever switch signal to SAS controller.

NGInspection 5:Check the continuity between CN45 and CN1.

SAS controller defect

Continued

Harness defect (between CN45 and CN1)

NG

OKOK

Check the tilt solenoid operating sound.*3 Sticking tilt control valve

OK

Inspection 6:Check tilting control by the OPS controller.

NG

NG


1-44

Inspection 1:

Check the tilt lever switch signal to the OPS controller.Turn the key switch to OFF and disconnect CN45. (CN34 and CN46 must beconnected.)

Standard

Inspection 2:

Check the tilt lever switch individually (as installed on the vehicle) for continuity.Turn the key switch to OFF and disconnect CN34.

Standard:

Inspection 3:

Check the tilt lever switch individually (as removed from the vehicle) for continuity.Turn the key switch to OFF and disconnect CN34.

Standard:• Forward tilting switch (upper switch as installed on the vehicle)

• Backward tilting switch (lower switch as Installed on the vehicle)

Inspection 4:

Check the tilt lever switch signal to the SAS controller.Disconnect CN1 and turn the key switch to ON (engine in stopped state).

Standard:

Note: As the key switch is turned to ON with the connector disconnected for this inspection, the SAS lamp comeson and the error code (F1) appears.

Lever at neutral position Lever at forward tilt position

Lever at backward tilt position

CN45-25 ~ CN45-17 No continuity Continuity No continuityCN45-24 ~ CN45-17 No continuity No continuity Continuity


Lever at forward tilt position


CN34-1 ~ CN34-2 No continuity Continuity No continuity

CN34-3 ~ CN34-4 No continuity No continuity Continuity

Free Pressed


Free Pressed


Circuit tester Lever at neutral position



Digital typeCN1-10 (+) ~ CN1-23 (-) No continuity Continuity No continuity

CN1-9 (+) ~ CN1-23 (-) No continuity No continuity Continuity

Analog type CN1-10 (-) ~ CN1-23 (+) No continuity Continuity No continuity

CN1-9 (-) ~ CN1-23 (+) No continuity No continuity Continuity

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN34 (TAB)

1

3

2

4

CN34 (TAB)

1

3

2

4

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

1-45

Inspection 5:

Check the continuity between CN45 and CN1.Turn the key switch to OFF, and disconnect CN1 and CN45. (CN46 must be connected.)

Standard:

Inspection 6:

Check the tilt control by the OPS controller.Disconnect CN1 and turn the key switch to ON. (CN34 and CN46 must be connected).Operate the tilt lever to check the mast movement.

Standard:





Between CN45-22 and frame No continuity

Between CN45-21 and frame No continuity

Lever at neutral position Mast does not move.

Lever at forward tilt position Mast tilts forward.

Lever at backward tilt position Mast tilts backward at the normal speed.

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-46

Mast does not tilt forward.

Related Portion

Estimated Causes: Connector contact defect Sticking tilt control valve Harness defect OPS controller defect Forward tilt lever switch defect SAS controller defect Forward tilt lever switch installation defect

TAB

RE

C

RE

CTA

B

RE

CTA

B

RE

CTA

B

OP

S c

ontr

olle

r

CN45-25 (TFI, Forward tilt switch)

CN45-17 (E03, SW-GND)

CN45-20 (TGND, Forward/reverse tilt GND)

CN45-22 (TFO, Forward tilt output)CN45-5 (TCON, Tilt control)

CN466

10

W/SPLICE-A

CN34

J1

1

2

Forward tilt lever switch

SA

S c

ontr

olle

rCN1-22CN1-23

CN1-10CN1-13

Check if the OPS/SAS lamp blinks to indicate an error.

Get on the seat and check if the fork can be lifted.

Check CN1, CN34, CN45 and CN46 for any disconnection or internal wetting.


Perform troubleshooting for Disabled Material Handling error.

Yes

No

No

Yes

After repair, get on the seat and check forward tilting operation.*1

NG

To be continued

NG

1-47

*1: Get on the seat and check forward tilting operation:Stay on the seat and turn the key switch to ON. Operate the tilt lever with the unloaded fork at a height of 500mm (20 inches) to check if the mast can be tilted forward.

*2: Check for tilt solenoid operating sound:Stay on the seat and turn the key switch to ON (with the engine in stopped state). Put a hand on the tilt solenoidof the control valve with the unloaded fork at a height of 500 mm (20 inches) to check for solenoid operatingsound.

Caution:*2: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:

Check the forward tilt lever switch signal to the OPS controller.Key switch OFF, CN45 disconnection. (CN34 and CN46 must be connected.)

Standard:

Lever at neutral position Lever at forward tilt position



Check the tilt solenoid operating sound.*2

Inspection 1:Check the forward tilt lever switch signal to the OPS controller.

Inspection 2:Check the forward tilt lever switch (as installed on the vehicle) for continuity.

OK

Harness defect (between CN34 and CN45)

NG

OKNG

Continued


Inspection 3:Check the forward tilt lever switch (as removed from the vehicle) for continuity.

Forward tilt lever switch defect

OK

NG

Forward tilt lever switch installation defect

Inspection 4:Check the forward tilt lever switch signal to the SAS controller.

Inspection 5:Check continuity between CN45 and CN1.

OK

Harness defect (between CN45 and CN1)OK

NGNG

Sticking tilt control valve

NG

OK

Inspection 6:Check tilt control by the OPS controller. OPS controller defect

OK

NG

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-48

Inspection 2:

Check the forward tilt lever switch (as installed on the vehicle) for continuity.Key switch OFF, CN34 disconnection.

Standard:

Inspection 3:

Check the forward tilt lever switch (as removed from the vehicle) for continuity.Key switch OFF, CN34 disconnection

Standard:Tilt forward switch (upper switch when installed on the vehicle)

Inspection 4:

Check the forward tilt lever switch signal to the SAS controller.CN1 disconnection, key switch ON (with the engine in stopped state)

Standard:


Inspection 5:

Check continuity between CN45 and CN1.Key switch OFF, CN1 and CN45 disconnection. (CN46 must be connected.)

Standard:





Free Pressed





Digital type CN1-10(+) ~ CN1-23(-) No continuity Continuity No continuity

Analog type CN1-10(-) ~ CN1-23(+) No continuity Continuity No continuity



CN34 (TAB)

1

3

2

4

CN34 (TAB)

1

3

2

4

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

CN1 (REC)

1 2 3 4 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 23 24 25 26

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

1-49

Inspection 6:

Check tilt control by the OPS controller.CN1 disconnection, key switch ON. (CN34 and CN46 must be connected.)Operate the tilt lever and check the mast movement.

Standard:


Lever at neutral position Mast does not move.

Lever at forward tilt position Mast tilts forward.

Lever at backward tilt position Mast tilts backward at the normal speed.

1-50

The drive OPS does not function.

Related portion

Estimated Causes: Connector interrupt defect Harness defect Forward interrupt relay defect Controller defect Reverse interrupt relay defect

RE

C

TAB

RE

C

REC

RECTABTA

BR

EC

TAB

RE

CR

EC

TAB

OP

S c

ontr

olle

r

To IG SW


CN45-4 (DRR, Reverse drive switch) CN46-11

CN46-1

CN46-6

CN6-8 CN53-6CN53-5

CN53-1

CN52

CN541 2

5 7

1 3

2 4

2 3

1 4

SFT

CN45-3 (DRF, Forward drive switch)


CN45-17 (E03, SW-GND)

T/C relay block


Shift lever


Shift SOL

1-51

*1: Check if the OPS lamp blinks to indicate an error.Without getting on the seat, turn the key switch to OFF → ON (2 seconds or more) → OFF. Leave the vehicle asit is for at least 15 minutes. Then turn the key switch to ON again and make sure that the OPS lamp does notblink.

*2: After correction, check if the drive OPS functions normally.Turn the key switch ON, set the shift lever to either forward or reverse and leave the seat. Check if the drive OPSis activated.

Inspection 1:

Check continuity of the wiring between CN53 and T/C relay block, and the wiringbetween CN54 and T/C relay block.Turn the key switch OFF, disconnect CN53 and CN54, and remove the relays from theT/C relay block.

Standard:

Between CN53-5 and pin 4 of forward interrupt relay Continuity

Between CN53-1 and pin 4 of reverse interrupt relay Continuity



CN53-6 ~ IG SW-4 Continuity

Check if the OPS lamp blinks to indicate an error.*1

Inspection 1:Check continuity of the wiring between CN53 and T/C relay block, and the wiring between CN54 and T/C relay block.

Harness defectNG


Yes

No

Check CN45, CN46, CN54, CN6, CN52 and CN53 for any disconnection or internal wetting, and any relay disconnection.

After correction, check if the OPS functions normally.*2

NG

NGOK

Inspection 2:Check the forward/reverse interrupt relay. Interrupt relay defect

NG

OK

Controller defect

OK

CN53 (REC)

76321

10 11 12 14 15 1613

4 5 8 9

1817

CN54 (REC)

1 2

IG SW

243

T/C FR RLY

1 2

35

4

T/C RR RLY

1 2

35

4

1-52

Inspection 2:

Check the forward/reverse interrupt relay individually.

(1)Turn the key switch to OFF and disconnect the relays from the T/C relay block. Measure theresistances between the specified pins of the forward/reverse interrupt relay.

Standard:

(2) Install the relay and disconnect CN53 and CN54. Leave the seat unseated, and turn the keyswitch to ON (with the engine in stopped state).


Standard:

• With analyzer

Forcibly set forward and reverse interrupt relays to ON and OFF and check continuity in each state.


Standard:• Forward interrupt relay (RLY FWD)

• Reverse interrupt relay (RLY REV)

Resistance

Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Unseated Seated

CN53-5 ~ CN54-1 No continuity Continuity


Relay ON Relay OFF


Relay ON Relay OFF


RLY

2 1

3(5) 4

CN53 (REC)

76321

10 11 12 14 15 1613

4 5 8 9

1817

CN54 (REC)

1 2

1-53

Traveling fails. (Including forward traveling only, reverse traveling only and occasionaltraveling failure)

Related Portion

Estimated Causes: Connector contact defect Controller defect Forward interrupt relay defect Shift lever switch defect Reverse interrupt relay defect Fuse defect Harness defect

RE

C

TAB

RE

C

REC

RECTAB

TAB

RE

CTA

BR

EC

RE

CTA

B

OP

S c

ontr

olle

r

To IG SW


CN45-4 (DRR, Reverse drive switch) CN46-11

CN46-1

CN46-6

CN6-8 CN53-6CN53-5

CN53-1

CN52

CN541 2

5 7

1 3

2 4

2 3

1 4

SFT

CN45-3 (DRF, Forward drive switch)


CN45-17 (E03, SW-GND)

T/C relay block


Shift lever


Shift SOL

Check if the fuse (SFT) is blown. After correction, check if the OPS functions normally.*

NG

OK

Check if the OPS lamp blinks to indicate an error. Perform troubleshooting according to the error code.

Yes

No

Stay on the seat and check if the OPS lamp goes off. Perform troubleshooting for "OPS lamp keeps lighting".

No

NG

Yes

Check CN6, CN45, CN46, CN52, CN53 and CN54 for any disconnection or internal wetting.

After correction, check if the OPS functions normally.*

NG

OK

To be continued

NG

1-54

* After correction, check if the OPS functions normally. Check that forward traveling is disabled if operator leaves the seat with key switch ON to activate the OPS, setsthe shift lever to forward and then sits on the seat again. Next, check that forward traveling is enabled if the shift lever is set to neutral once and then to forward again.

Inspection 1:

Check the T/C shift lever unit individually for continuity.Key switch OFF, CN53 disconnection.

Standard:

Inspection 2:

Check the wiring between CN53/CN54 and T/C relay block and between CN45 and CN53 for continuity.Turn the key switch to OFF, disconnect CN53, CN54 and CN45, and disconnect relays from the T/C relay block.

Standard:

Lever at neutral Lever at forward Lever at reverse

Between pins 6 and 5 on lever side No continuity Continuity No continuity

Between pins 6 and 1 on lever side No continuity No continuity Continuity





CN53-6 ~ IG SW-4 Continuity



Inspection 3:Check the forward/reverse interrupt relay. Interrupt relay defect

NG

OK

Inspection 1: Check the shift lever unit individually for continuity. Shift lever defect

NG

OK

Inspection 2:Check the wirings between CN53/CN54 and the T/C relay block, and between CN45 and CN53 for continuity.

Harness defectNG

OK

Controller defect

Continued

DIRECTION SWITCH

34789

18 1716 14131215

6 5 2 1

1011

CN53 (REC)

76321

10 11 12 14 15 1613

4 5 8 9

1817

CN54 (REC)

1 2

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

T/C FR RLY

1 2

35

4

T/C RR RLY

1 2

35

4

1-55

Inspection 3:

Check the forward/reverse interrupt relay individually.

(1)Turn the key switch OFF and remove the relays from the T/C relay block. Measure the resistancebetween pins of each of forward and reverse interrupt relays.

Standard:

(2) Install the relays and disconnect CN53 and CN54. Turn the key switch to ON (with the engine in stoppedstate) after leaving the seat.


Standard:

• With analyzer

Forcibly turn each of the forward and reverse interrupt relays ON and OFF, and check the continuity in each state.


Standard:• Forward interrupt relay (RLY FWD)

• Reverse interrupt relay (RLY REV)

Resistance

Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

Unseated Seated



Relay ON Relay OFF


Relay ON Relay OFF


RLY

2 1

3(5) 4

CN53 (REC)

76321

10 11 12 14 15 1613

4 5 8 9

1817

CN54 (REC)

1 2

2-1

2

BODYPage

COMPONENTS ....................................................2-2RELAY BLOCK....................................................2-3

RELAY INSPECTION ............................................2-3PORTIONS PROTECTED BY FUSES......................2-4

SEAT SWITCH .....................................................2-5INSPECTION ........................................................2-5

2-2

COMPONENTS

5701-471

4 1

32

VZ

PA

WE

WG

PG

LN

LN

LN

WE

GU

PA

QY

MFPG

RQ

1

2

4

RQ

GU

MF QY

GM6-262(UL-LPS)

WT

LYGU

EPVZ

WEEPNX

RQ

3

5701

2-3

2

RELAY BLOCK

RELAY INSPECTIONIndividual Relay Continuity Inspection

Measurement state Measurement positions Standard

Head/tail relay

Normal state1-2 Continuity

3-5 No continuity

When the battery voltage is applied to terminals 1 and 2: 3-5 Continuity

ST relay

Normal state1-2 No continuity

3-4 Continuity

When the battery voltage is applied to terminals 3 and 4: 1-2 Continuity

SAS-LAMP relay, OPS lamp relay, T/C FR relay, T/C RR relay

Normal state 1-2, 3-4 Continuity

When the battery voltage is applied to terminals 1 and 2: 3-4 No continuity

LayoutFront

OPSLAMP

OPS lamp relay

T/C relay

T/CFR

T/CRR

Front

Head/tail relay

ST relay

SAS-Lamp relay, OPS lamp relay, T/C FR relay, T/C RR relay

2-4

PORTIONS PROTECTED BY FUSES

Including options

Fusible links

NO Name Capacity Main protected portions

FUEL 7.5A Fuel solenoid

TWC 7.5A TWC (3-way catalytic) system

ST (Starting motor) 7.5A Starting motor relay (IG) and pre-heating timer (IG)

SFT (Shift) 7.5A Electric shift T/C

SAS-ECU 7.5A SAS controller and SAS lamp relay

IGN (Ignition) 7.5A Alternator, pre-heating timer, ignition coil, LPG main solenoid, LPG slow solenoid and fuel cut

TURN (Turn) 7.5A Turn signal lamp and flasher relay

GAUGE (Meter) 10A

Hour meter, water temperature gauge, fuel gauge, warning lamps (charge, engine oil pressure, air cleaner, lock indicator, sedimenter, glow indicator, fuel, brake, cooling water and battery), back-up buzzer, T/C oil thermometer, strobo, back-up lamp and SAS buzzer

– – –

– – –

HORN (Horn) 7.5A Horn

ALT-S (Alternator sending) 5A Alternator sending

HEAD (Headlamp) 15A Headlamp and meter illumination

– – –

TAIL (Tail) 7.5A Tail lamp and clearance lamp

ECU-B 7.5A OPS controller

STOP (Stop lamp) 7.5A Stop lamp

NO. Name Capacity Type

FL – –

FL AM1 40A

FL HEAD 40A

FL GLOW 120A

FL ALT 80A

Cartridge type

Screw-fastened type

2-5

2

SEAT SWITCHINSPECTIONPush on the seat cushion and check continuity of the seat switch.

Measurement position:Between seat switch connectors CN50-1 and CN50-2 in LH side ofengine room

Standards:Not pushed: OFF (∞ Ω)When pushed: ON (0 Ω)

3-1

3

OIL CONTROL VALVEPage

GENERAL ............................................................3-2SPECIFICATIONS................................................3-8COMPONENTS ....................................................3-9OIL CONTROL VALVE ASSY ...........................3-10

REMOVAL · INSTALLATION................................3-10DISASSEMBLY · INSPECTION · REASSEMBLY ....3-11

RELIEF PRESSURE ADJUSTMENT (Pn35 ~ 50, Cu35 ~ 55 MODEL) .....................3-15

RELIEF PRESSURE ADJUSTMENT (Pn60 ~ 80, Cu60 · 70 model).........................3-16

LIFT LOCK RELEASE BOLT ............................3-17

3-2

GENERAL

(b)

P

C1

(a)

(j)

(d)(f)

(e)

(k)

(h)

(l)

(i)

(g)

C3

C5

T

C2

C4

(c)

3-3

3

Oil Control Valve

(a) Tilt control valve & solenoid (b) Unload solenoid

Tilt spool

k: Lift lock check valve

Lift spool

c: Unloading SOL

(a)

(b)

3-4

(c) Filter and Lift Check Valve

(d) Flow Divider Valve

(e) Relife Valve

Filter

3-5

3

(f) Needle Valve (Manual Down Valve)

(g) Flow Control Valve

(h) Lift Select Valve

(i) Tilt Select Valve

3-6

(j) Limit Switch

(l) Tilt Lock Check Valve

Forward tilt switch

Backward tilt switch

3-7

Hydraulic Circuit Diagram

(1)

(1) Flow control valve(2) Tilt select valve(3) Lift select valve(4) Tilt lock check valve (Leak lock valve)

(5) Lift lock check valve (Leak lock valve)(6) Unloading valve & solenoid(7) Tilt control valve & solenoid

(4) (2)

(3)

(5)

C1

C3

C2

PS Gage PortT

SOL

(6)

(7)

P

3-8

Relief Valve (For Forward Tilt) (Pn60 ~ 80, Cu60 · 70 Model)

SPECIFICATIONS

*: The relief set pressure on the forward tilt side is controlled by connecting another relief valve to the C2 port.

ModelItem Pn35 ~ 50 Pn60 ~ 80

Cu60 · 70 Cu35 ~ 55

Oil control valve type Add-on type(1-, 2-spool monoblock)

Relief set pressurekPa (kgf/cm2) [psi]

Lift18140 (185) [2630]

20590 (210) [2990] (Forward tilt:

13240 (135) [1920])* 18140 (185) [2630]

Tilt

Flow divider valve Frow ratel/min (US gal/min) 17.0 (4.49) 22.0 (5.81) ←

Others Built-in flow divider valve

A(C2 por)

A (C2 por)

B

B T

3-9

COMPONENTS6705

3-10

OIL CONTROL VALVE ASSYREMOVAL · INSTALLATIONNote: Before disconnecting the lever rod, operate the control levers to bring the mast to the neutral position andfully lower the fork to release the residual pressure in the material handling system piping.

T=N·m (kgf·cm) [ft·lbf]

Removal Procedure1 Remove the toe board.2 Remove the lower panel.3 Disconnect the lever rod.4 Disconnect the wiring.5 Disconnect the piping.6 Remove the oil control valve ASSY.

Installation ProcedureThe installation procedure is the reverse of the removal procedure.

Note: • Apply grease (chassis grease) on the oil control valve lever links.• Inspect the hydraulic oil level, and add if insufficient.

Oil control valve ASSY set bolt: T=39.2 (400) [28.9]

5

6

34

3-11

DISASSEMBLY · INSPECTION · REASSEMBLY

Note: • Select a clean location for operation.• Since individual parts are finished with high precision, carefully disassemble so as not to damage them.

T=N·m (kgf·cm) [ft·lbf]

Disassembly Procedure1 Remove the limit switch and spring cover. [Point 1]2 Remove the tilt spool.3 Remove the solenoid valve. [Point 2]4 Remove the lift spool. [Point 3]5 Remove relief valve No.1. [Point 4]6 Remove the flow divider valve. [Point 5]7 Remove the filter. [Point 6]8 Remove the lift select valve. [Point 7]9 Remove the tilt select valve. [Point 8]10 Remove the flow control valve. [Point 9]11 Remove the tilt lock check valve.12 Remove the lift lock check valve.13 Remove the additional spool.14 Remove the unloading SOL. [Point 10]15 Remove the outlet housing.

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

Note: Wash each part thoroughly, remove dirt by blowing compressed air and apply hydraulic oil beforereassembly.

T=34.3~44.1(350~450)[25.3~32.6]

14

1

1

2

3

4

7

6

513

6

4

2

118

10

9

T=26.5~32.4(270~330)[19.5~23.9]

12

3-12

Point Operations[Point 1]

Inspection:Check continuity of limit switches.

Forward tilt side: No continuity when the switch is pressed.

Backward tilt side: No continuity when the switch is pressed.

Reassembly:Carefully connect the limit switches on the forward andbackward tilt sides in correct positions. Install the one for theforward tilt on the upper side. (It is regular that the bothswitches must be in pressed state when installed.)

[Point 2]

Inspection:Check continuity of solenoid.

Inspection:Inspect and wash each orifice to eliminate clogging.

[Point 3]

Disassembly · Reassembly: Remove the compression spring from the lift spool.SST 09610-10160-71

[Point 4]

Inspection:Inspect and wash the orifice to eliminate clogging.

Forward tilt (-)

Forward tilt (+)

Backward tilt (-)

Backward tilt (+)

(+)

(-)

SST

Orifice

3-13

Reassembly:When the relief valve is disassembled, always loosen theadjusting screw fully.

[Point 5]

Inspection:Inspect and wash the orifice to eliminate clogging.

[Point 6]

Inspection:Inspect and wash the filter to eliminate clogging.

[Point 7]

Disassembly Use the service bolt and nut to remove the sleeve.Service bolt size: M10 x 1.25

[Point 8]Inspection:

Inspect and wash the filter to eliminate clogging.

Service nut

Service bolt

3-14

Disassembly:Use the service bolt and nut to remove the sleeve.Service bolt size: M10 x 1.25


[Point 9]


[Point 10]

Inspection:Check the unload SOL for continuity.

Service nut

Service bolt

3-15

RELIEF PRESSURE ADJUSTMENT (Pn35 ~ 50, Cu35 ~ 55 MODEL)Note: • Always make adjustment according to the procedure described below. Careless adjustment may

generate a high pressure to cause damage to the oil pump or other hydraulic devices.• Always check that the no-load maximum speed is as specified.

1. Install an oil pressure gauge.

(1) Remove the oil pressure detection port plug (illustrated)installed on the front side of the oil control valve, andinstall the oil pressure gauge. Plug size: 9/16-18UNF

2. See that the adjusting screw is loosened.

(1) Remove the cap nut and packing, loosen the lock nut, andloosen the adjusting screw until it is about to come offfrom the body.

3. Start the engine, and check no oil leakage and abnormalnoise generation.

4. Adjust the relief pressure.

(1) Set the seat switch to ON. (Operate by two workers withone sitting on the seat.)

(2) Operate the tilt lever for backward tilting, and graduallytighten the adjusting screw until the mast starts to be tiltedbackward. Tilt the mast fully backward.

(3) With the engine running at the maximum speed, operatethe tilt lever for backward tilting. Gradually tighten theadjusting screw for adjustment of the pressure upon reliefto the standard below, and lock the screw by means of thelock nut.

5. After the adjustment, place the packing, tighten the cap nutand check the relief pressure again.

6. Remove the oil pressure gauge, and tighten the plug.

StandardskPa (kgf/cm2) [psi]

For both tilt and lift 18140 (185 )[2630 ]+4900

+50

+700

3-16

RELIEF PRESSURE ADJUSTMENT (Pn60 ~ 80, Cu60 · 70 MODEL)Note: • Always make adjustment according to the procedure described below. Careless adjustment may

generate a high pressure to cause damage to the oil pump or other hydraulic devices.• Always check that the no-load maximum speed is as specified.

1. Install an oil pressure gauge.(1) Remove the oil pressure detection port plug (illustrated)

installed on the front side of the oil control valve, andinstall the oil pressure gauge.Plug size: 9/16-18UNF

2. See that the adjusting screw (A) is loosened.(1) Remove the cap nut and packing, loosen the lock nut, and

loosen the adjusting screw (A) until it is about to come offfrom the body.

3. Start the engine, and check no oil leakage and abnormalnoise generation.

4. Adjust the lift and tilt (backward) relief pressure.(1) Set the seat switch to ON. (Operate by two workers with

one sitting on the seat.)(2) Operate the tilt lever for backward tilting, and gradually

tighten the adjusting screw (A) until the mast starts to betilted backward.Tilt the mast fully backward.

(3) With the engine running at the maximum speed, operatethe tilt lever for backward tilting. Gradually tighten theadjusting screw (A) for adjustment of the pressure uponrelief to the standard below, and lock the screw by meansof the lock nut.

5. See that the adjusting screw (B) is loosened.(1) Remove the cap nut and packing, and loosen the

adjusting screw (B) until it is about to come off from thebody.

6. Adjust the tilt (forward) relief pressure.(1) Set the seat switch to ON. (Operate by two workers with

one sitting on the seat.)(2) Operate the tilt lever for forward tilting, and gradually

tighten the adjusting screw (B) until the mast starts to betilted forward.Tilt the mast fully forward.

(3) With the engine running at the maximum speed, operate the tilt lever for forward tilting. Gradually tightenthe adjusting screw (B) for adjustment of the pressureupon relief to the standard below.

7. After the adjustment, place the packing, tighten the cap nutand check the relief pressure again.

8. Remove the oil pressure gauge, and tighten the plug.


For both tilt (backward) and lift 20590 (210 )[2990 ]+4900

+50

+700


Tilt (forward) 13240 (135 )[1920 ]+4900

+50

+700

A

B

3-17

LIFT LOCK RELEASE BOLTT=N·m (kgf·cm) [ft·lbf]

When the forks do not descend, due to a malfunction or other cause, loosen the lift lock unlocking bolt to lower theforks in emergencies.

After making repairs, tighten it appropriately.

Lift lockunlocking boltT = 26.5 ~ 32.4 (270 ~ 330) [19.5 ~ 23.9]

4-1

4

SASPage

TROUBLESHOOTING .........................................4-2TROUBLESHOOTING BY ERROR CODE................4-3TROUBLESHOOTING BY PHENOMENON ..............4-7

CONNECTOR LAYOUT (SAS, OPS).................4-12CONTROLLER SEQUENCE (SAS, OPS) .........4-13CONNECTOR DIAGRAMS (SAS, OPS)............4-14

4-2

TROUBLESHOOTINGTroubleshooting is described only for the portion changed by adoption of the OPS.

List of Reference Pages for Error Codes and Sub Error Codes

List of Pages to be Referenced by Phenomenon

Without analyzer (SST) With analyzer (SST)

Error code Error description Page Error code Error description Page

63 Tilt lever switch abnormality 4-3

63-1 Tilt lever switch simultaneous ON 4-3

63-2 Forward tilt switch short circuit for 2 minutes 4-3

63-3 Backward tilt switch short circuit for 2 minutes 4-3

64 Tilt solenoid abnormality 4-5 64-1 Tilt solenoid abnormality 4-5

DescriptionPage to be referenced

Without analyzer With analyzer

Act

ive

mas

t fu

nctio

n co

ntro

ller The active mast rear tilt speed control is not regulated, or the

backward tilting speed is always slow. 4-7 4-10

The mast does not perform front tilt. See "Mast dose not tilt forward." section in OPS Troubleshooting.

4-3

4

TROUBLESHOOTING BY ERROR CODEError code 63 (Tilt lever switch abnormality)Error code 63-1 (Both tilt lever switches ON at the same time)Error code 63-2 (Forward tilt switch 2-minute short circuit)Error code 63-3 (Backward tilt switch 2-minute short circuit)

Related Portion

Estimated Causes:

* After the key switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward. Makesure that the 2-minute waiting OPS lamp blinks when the tilt lever is on the neutral position.

Connector contact defect Backward tilt switch defect Harness defect Tilt switch installation defect Forward tilt switch defect Controller defect

TAB

RE

C

TAB

RE

C

RE

CTA

B

RE

CTA

B

SA

S c

ontr

olle

r

CN1-10 (MF, Forward tilt switch)

CN1-9 (MR, Backward tilt switch)

CN1-23 (E02, SW-GND)

CN46-10

J1

CN45-22CN45-21

CN45-20

CN45-17

CN45-24

CN45-25

CN34-1CN34-2

CN34-3

CN34-4

OP

S c

ontr

olle

r

Forward tilt switch

Backward tilt switch

Check CN1, CN45 and CN46 for any disconnection or internal wetting.

After correction, check the indication by the SAS lamp. *

Error code 63

Inspection 2:Check continuity between CN1 and CN45.

Perform troubleshooting for error code 2 for the OPS controller. For this defect, the SAS lamp blinks instead of the OPS lamp.

Harness defect

NG

OK

NG

OK

Inspection 1:Check the wiring between the tilt lever switch and the OPS controller for continuity.

SAS controller defectOK

NG

NG

4-4

Inspection 1:

Check continuity through the tilt lever switch wiring.Turn the key switch OFF and disconnect CN1.

Standard:

Inspection 2:

Check continuity between CN1 and CN45.Turn the key switch OFF and disconnect CN1 and CN45.

Standard:CN1-10 ~ CN1-9 : No continuityCN1-10 ~ CN1-23 : No continuityCN1-9 ~ CN1-23 : No continuityBetween CN1-10 and frame : No continuityBetween CN1-9 and frame : No continuity




Digital typeCN1-10 (+) ~ CN1-23 (-) No continuity Continuity No continuity

CN1-9 (+) ~ CN1-23 (-) No continuity No continuity Continuity

Analog type CN1-10 (-) ~ CN1-23 (+) No continuity Continuity No continuity

CN1-9 (-) ~ CN1-23 (+) No continuity No continuity Continuity

CN1 (REC)

CN1 (REC)

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

4-5

4

Error Code 64 · 64-1 (Tilt solenoid abnormality)

Related Portion

Estimated Causes:

* After correction, check the indication by the SAS lamp.

Start the engine and operate for forward tilting to check if the SAS lamp blinks. The SAS lamp must not blink.

Connector contact defect SAS controller defect Harness defect OPS controller defect

RE

CTA

B

RE

CTA

B

RE

CTA

B

TAB

RE

C

SA

S c

ontr

olle

r

CN1-13 (TILT, Tilt solenoid)

CN1-24 (E1, Main GND) CN46-8

CN46-9

(E3, Body ground)

CN12-2

CN12-1

CN45-5

CN45-29CN45-30

CN45-12

OP

S c

ontr

olle

r

Tilt solenoid

Check CN1, CN45 and CN46 for any disconnection or internal wetting, and disconnected the body ground.

After correction, check the indication by the SAS lamp.*

Inspection 2:Measure the resistance between input pins of OPS controller.



NG

OK

NG

NG

OK

Inspection 1:Check continuity between CN1 and CN45. Harness defectNG

OK

4-6

Inspection 1:

Check continuity between CN1 and CN45.Key switch OFF, CN1 and CN45 disconnection.(Keep CN46 connected and also keep the body ground connected to the frame.)


CN1-13 ~ CN45-5: ContinuityCN1-24 ~ CN45-29: ContinuityCN1-24 ~ CN45-30: Continuity

• GND fault checkCN1-13 ~ CN1-24: No continuity

• +B shorting checkCN45-5 ~ CN45-32: No continuity

• Ignition line shorting checkCN1-13 ~ CN1-11: No continuity

Inspection 2:

Measure the resistance between input pins of the OPS controller.Key switch OFF, CN45 disconnection.

Standard:CN45-4 ~ CN45-31: Approx. 800Ω (at 20°C)

CN1 (REC)

13 12111098765432114 15 16 17 18 2625242322212019

CN45 (REC)

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

CN45 (TAB)

32 31 26 23 17

16 11 10 8 1345912131415

30 29 25 24 22 21 20

267

28 27 19 18

4-7

TROUBLESHOOTING BY PHENOMENON

The active mast rear tilt speed control is not regulated, or the backward tilting speed isalways slow.

Related Portion

Active fork leveling switchC

ontr

olle

r

(MN Tilt knob SW)

Act

ive

fork

leve

ling

switc

h

(E02 SW-GND)

Lifting height switch

Con

trol

ler (MH1, Lifting

height sensor 1)

(MH21, Liftingheight sensor 21)

Lifti

ng h

eigh

t sw

itch(E02, SW-GND)

4-8

OK

Stopping with automatic leveling occurs upon automatic leveling switch operation when the fork is raised to approx. 500 mm (19.6 in) without a load.

Without analyzer

Check connectors CN1 and CN33 for disconnection or internal wetting.

Inspection1Check the automatic leveling switch wiring for continuity.

Inspection 2Check continuity of the automatic leveling switch alone.

Inspection 3Check continuity between CN1 and CN33.

CN33 connector defect.

Fork height switch abnormality.

Check if the backward tilting speed is normal after the repair.

Controller defect.

Automatic leveling switch defect.

Harness defect.

OK

OK

OK

OK

NG

NG

NG

NGNG

NG

NO YES

NG

OKPerform troubleshooting for "The mast backward tilting speed is always slow or unrestricted". (P. 1-42).

Stopping with automatic leveling occurs when tilted forward (without pressing the automatic leveling switch) when the fork is raised to approx. 500 mm (19.6 in) without a load.

Inspection 4Check continuity of the fork height switch alone.

4-9

Inspection 1:

Check continuity of the active fork leveling switch wiring.Key switch OFF, CN1 disconnection.

Standard:

Inspection 2:

Check continuity of the active fork leveling switch only.Switch OFF, CN33 disconnection.

Standard:

Inspection 3:

Check continuity between CN1 and CN33.Turn the key switch OFF and disconnect CN1 and CN33.

Standard:CN1-8 ~ CN33-1: ContinuityCN1-23 ~ CN33-2: Continuity

Inspection 4:

Check continuity of the lifting height switch only.Key switch OFF, CN31 disconnection.

Standard:

Active fork leveling switch free Active fork leveling switch depressed


Active fork leveling switch free

Active fork leveling switch depressed


Low lifting height High lifting height



CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)

CN31 (REC)

4-10

Inspection 1

Check the output signal of the active fork leveling switch.Turn the key switch ON (with the engine in stopped state).Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA

Standard:



KNOB OFF ON

OK

With analyzer

Inspection 1Check the output signal of the active fork leveling switch.

Check for slip off of the CN1 and CN33 connectors.

Inspection 2Check continuity of the active fork leveling switch wiring.

Inspection 3Check continuity of the individual active fork leveling switch.

Inspection 4Check continuity between CN1 and CN33.

CN33 connector defect.

Inspection 5Check the output signal of the lifting height switch.

Inspection 6Check continuity of the individual lifting height switch.

After correction, check the backward tilting speed.

CN1 connector or controller defect

Active fork leveling switch defect

Harness defect

OK

OK

OK

OK

NG

NG

NG

NG

NG

NG

NG

Controller defect.

OK

Lifting height switch defectNG

Perform troubleshooting for "The mast backward tilting speed is always slow or unrestricted". (P. 1-42).

OK

4-11

Inspection 2:

Check continuity of the active fork leveling switch wiring.Key switch OFF, CN1 disconnection.

Standard:

Inspection 3:

Check continuity of the active fork leveling switch only.Key switch OFF, CN33 disconnection.

Standard:

Inspection 4:

Check continuity between CN1 and CN33.Key switch OFF, CN1 and CN33 disconnection.

Standard:CN1-8 ~ CN33-1: Continuity

CN1-23 ~ CN33-2: Continuity

Inspection 5:

Check the output signal of the lifting height switch.Turn the key switch ON (start the engine).Analyzer: MAIN MENU → SAS MENU → ANALYZER MENU → IN OUT MENU → MAST DATA

Standard:When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SW1: ONSW21:OFFSW22:OFF

Inspection 6:

Check continuity of the lifting height switch only.Key switch OFF, CN31 disconnection.

Standard:







Low lifting height High lifting height



CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)

CN31 (REC)

4-12

CONNECTOR LAYOUT (SAS, OPS)

TABREC

TABREC

RECTAB

TABREC

TABREC

TAB

RE

C

TABREC

RECTAB

RECTAB

RECTAB

TABREC

TABREC

TABREC

TABREC

PRES SSR

CN26TABREC

RECTABCN3

CN22CN41 CN42 CN43

SPD SSR

TABREC CN47

UNLORDSOL

TABREC CN51

OPS BZR(Export model)

TABREC CN54

SFT SOL

TABREC CN55

DIODE A

FPC

SAS BZR

COMB METHOUR METSAS LPSWN LOCP LP

SASCONTROLLER

CN1 CN2

TABREC

OPSCONTROLLER

CN45

CN12 CN34

NTRLTILT SW

CN33

OPS-LAMPRLY

(OPS R/B)

CN27

CN31

MAST SW1

TILTSOL

TILT SW1TILT SW2

CN37

HOURMET CNN

TABREC

CN46

CN35

SAS RE-SETTINGCN

CN44

CN4 RECTAB

CN65

CN5

DIAG SW(CHKR)

FR W/H

E/G W/H

TILT AGLSSR

CN6

SAS-LAMP RLY(R/B)

SIDEW/H

RE

CTA

B

RR LWRW/H

CN7 SWN SOL

CN11

FR

W/H

SID

E W

/H

TABREC CN8 TAB

REC CN9

BODY EARTH03

RE

CTA

B

SIDEW/H

TAB

RE

C

HOODW/H

CN50

EZ R/SFT RLY

EZ F/SFT RLY

TAB

RE

C

CN52

T/C FR RLYT/C RR RLY(T/C R/B)

TAB

RE

C

CN57

SEAT SW

CN60RECTAB

TABREC

CN53

SHIFT SW

4-13

CONTROLLER SEQUENCE (SAS, OPS)

5

43

10

7CN525

29

8

63

7

8

5

2

4

111

CN63

+-

OPS CONTROLLER

EZ MAINRELAY

STARTERRELAY

PARKINGSWITCH

DIRECTIONSWITCH RR

DIRECTIONSWITCH FR

EZ RR SFTRELAY

EZ FR SFTRELAY

DR

R

RY

R

DR

F

RY

F

SH

IFT

SO

LEN

OID

RB

T/C RRRELAY

SH

IFT

SO

LEN

OID

FB

T/C FRRELAY

TO E03

DIODE A

JOINT4 JOINT3

CN

68

6C

N6

CN

610

5C

N6

JOIN

T2

JOINT1

DIODE A

JOINT3JOINT4

W/SPLICE-A

W/S

PLI

CE

-Y

W/SPLICE-Z

W/S

PLI

CE

-C

SFT (7.5A)

BU

S B

AR

BZ

O

OPS BUZZER(EXPORT MODEL)

SO

L3

DM

I

DG

ND

DM

O

RY

F

E03

E2

DR

F

RY

R

DR

R

E3

SIL

IG

RY

LP

E3

IG

SO

L1

TF

I

TR

I

TC

ON

TF

O

TR

O

TG

ND

SP

I1

BATTBCON

BCIN

SP

I2

OPS CONTROLLER

SILP

LUG

-IN

AN

ALY

ZE

R

IG

E0

TRG

CHKR

SAS-LAMPRELAY

OPS-LAMPRELAY

EZ PEDAL

ECU-B (7.5A)

SAS SYSTEM

UN

LOA

DS

OLE

NO

ID

E1

RLY

HR

M2

SIL

IG

HR

M3

HR

M1

E02

YAW RATESENSOR

+-

SW

2D

IAG

CO

NN

EC

TO

R

MN

NE

UT

RA

LT

ILT

SW

ITC

H

T/C FRRELAY

T/C RRRELAY

SO

LEN

OID

RB

OU

T1

SO

LEN

OID

FB

SHIFT LEVER

SAS CONTROLLER

MH

22

MH

21

MH

1

SA

S R

E-S

ET

TIN

GC

ON

NE

CT

OR

SW

1

MF

MR

TIL

T S

WIT

CH

FB

SE

AT

SW

ITC

H

TIL

T

ST

RG

SW

N

TIL

TS

OLE

NO

ID

SWINGSOLENOID

SPEEDSENSOR

SPEEDCONTROLLER

YB

1

TR

G

TIL

T A

NG

LES

EN

SO

R

COMBINATION METER

L

OPS LAMP

L

LOCKINDICATOR

SASWARNINGLAMP

L

SP

D

SP

DF

SP

D+

SP

D-

ECU-IG (7.5A)

GAUGE (10A)

FL AM1(40A)

IG1

E01

MA

ST

SW

ITC

H

TIL

T S

WIT

CH

RB

5TT

5MA

MA

5SA

SA

5PR

S

PR

ES

SS

2

SS

C

SS

1

- +

PRESSSENSOR

5CN4

1CN3

2CN3

4CN37

CN3

10C

N5

11C

N5

1

CN4661

14 2

118

3

CN52

CN

65

CN

50

CN50

CN46

CN52

CN46CN46W/SPLICE-F

CN

46

CN

46C

N46

CN46

CN46 CN46 CN

46

CN52

CN52

CN52 CN52

CN52

CN57CN57

W/SPLICE-F

CN46 CN46

CN

58

4-14

CONNECTOR DIAGRAMS (SAS, OPS)

CN2

8 7 6 5 4 3 2 113 12 11 10 9141516

TABNo. JC1 RLY2 -3 HRM14 SPD+5 SPD-6 SS17 SS28 5SA9 OUT110 SPDF11 HRM312 HRM213 SPD14 SSC15 YB116 TRG

13 121110987654321

14 15 16

RECNo. JC1 CN5-11L-W2 --3 CN41-4V-G4 CN22-1G-B5 CN22-2G-R6 --7 --8 --9 CN42-9L-O10 CN6-5P-B11 CN42-12P-L12 CN41-3V-R13 G-B14 --15 --16 CN44-14L-B

CN1

13 12 11 10 9 8 7 6 5 4 3 2 1

141516171826 25 24 23 22 21 2019

TABNo. JC1 5PRS2 SIL3 MH14 MH215 MH226 SW27 SW18 MN9 MR10 MF11 IG12 TLT213 TLT114 5MA15 5T16 YR17 MA18 PRES19 -20 T21 SA22 E0123 E0224 E125 SWN26 STRG

13 12111098765432114 15 16 17 18 2625242322212019

RECNo. C1 G-2 V3 L-4 L-B56 LG-B7 LG8 P-G9 Y-B10 Y11 B-R12 -13 L-14 G-R15 -16 -

Y-GG-Y

---

BR-BR-W-BL-B

-

17181920212223242526

JCN3-1

CN46-3CN3-7CN3-4

CN44-23CN35-1CN33-1

CN45-21CN45-22

W/SPLICE-Y(IG)-

CN45-5CN27-1

--

CN27-2CN3-2

---

W/SPLICE-AW/SPLICE-A

BODY EARTH05CN4-7

-

L-W CN3-5

*

4-15

Note:*: Terminal not related to SAS and OPS.

CN5

TABNo. JC1 *R-L2 *R-B3 *R-W4 *G-Y5 *R-G6 *W7 *LG-B8 BODY EARTH 05G9 CN45-32G-W10 CN41-1P-G11 CN2-1L-W

12BODY EARTH 02 or

W-B or B

5678

1234

9101112

RECNo. JC1 *R-L2 *R-B3 *R-W4 *G-Y5 *R-Y6 *W7 *LG8 *-9 *-10 SAS-LAMP RLY(B)P-G11 SAS-LAMP RLY(+S)L-W12 ST RYL(-S) or SAS-LAMP RLY(L)W-B

8765

4321

1211109

8

4

7 6 5

3 2 1

CN3

RECNo. JC1 CN26-3G2 CN26-2G-Y3 CN31-1BR-W4 CN31-3L-B

5 CN26-1BR

6 --7 CN31-2L8 --

1 2 3

5 6 7

4

8

TABNo. JC1 CN1-1G2 CN1-18G-Y3 W/SPLICE-A(E)BR4 CN1-4L-B

5 W/SPLICE-A(E)BR

6 --7 CN1-3L8 --

CN4

RECNo. JC1 *Y-B2 *Y3 *Y-G4 *B-L5 *L-B6 CN45-23G-W

1 2

TABNo. JC1 --2 *Y3 *Y-G4 *B-L5 CN7-1L-B6 CN50-1G-W

5

2 1

L-W CN1-5 L-W *

6

3

544

3

6

DIODE STBODY EARTH 04 or

4-16

CN7

2 1

TABNo. JC1 CN4-5L-B2 BODY EARTH 03W-B

21

RECNo. JC1 CN11-1L-B2 CN11-2W-B

TABNo. JC1 *B-2 *B-W3 W/SPLICE-Y (IG)B-R4 *B-W5 *R6 *B-Y7 *LG-R8 *L9 --10 *W-L11 --

123

4

7

910

65

8

11

RECNo. JC1 *B-2 *B-W3 F=ECU-IG (L) B-R4 *B-W5 --6 *B-Y7 --8 *L9 --

10 *W-L11 --

1 2 3

4

7

9 10

65

8

11

CN6

TABNo. JC1 Phorting: (+)-2 Phorting: (-)-

12

RECNo. JC1 CN7-1L-B2 CN7-2W-B

1 2

CN11

TABNo. JC1 Phorting: (+)R2 Phorting: (-)B

12

RECNo. JC1 CN45-12GR-R2 W/ SPLICE-Z (E)W-B

1 2

CN12

TABNo. JC1 +S2 -S

12

RECNo. JC1 CN2-4G-B2 CN2-5G-R

1 2

CN22

CN8

RECNo. JC1 *P2 --3 SAS LAMP RLY(L)W-B4 *Y-B5 *L6 --

1 2

TABNo. JC1 *P-B2 *R-W3 OPS LAMP RLY(L)W-B4 *Y-B5 *G-B6 --

5

2 1

6

3

544

3

6

4-17

CN26

123

TABNo. JC123

---

GND (Ground) Vout (output)

Vcc power supply

321

RECNo. C1 BR2 G-Y3 G

JCN3-5CN3-2CN3-1

CN27

123

TABNo. JC123

---

Power supplySensor output

GND

321

RECNo. C1 G2 Y-G3 BR

JCN1-14CN1-17

W/SPLICE-A

CN31

123

TABNo. JC123

BR-WL

L-B

CN3-3CN3-7CN3-4

321

RECNo. C1 BR2 W3 R

JCOMNCNO

CN34

1

3

2

4

TABNo. JC123

RBRR

4 B

Forward tilt side (+)Forward tilt side (-)

Backward tilt side (+)Backward tilt side (-)

2

4

1

3

RECNo. C1 P-G2 BR-W3 P-L

JCN45-25JOINT 1CN45-24

4 BR-W JOINT 1

CN33

12

TABNo. JC12

BRBR

5V or GNDGND or 5V

21

RECNo. C1 P-G2 BR

JCN1-8

W/SPLICE-A

CN35

1

TABNo. JC1 BR-

1

RECNo. C1 LG-

JCN1-7

4-18

CN42

1 2 3 4 7 8 9 10 11 12 135 6

RECNo. JC1 *V-G2 *LG-B3 BODY EARTH02W-B4 *R-W5 --6 *R-G7 *Y-B8 *R-9 CN2-9L-O10 --11 *R-L12 CN2-11P-L13 BODY EARTH02W-B

CN41

1 2 3 4 7 8 9 10 11 12 135 6

RECNo. JC1 CN5-10P-G2 *Y-R3 CN12-2V-R4 CN2-3V-G5 *-6 CN37-2Y-B7 BODY EARTH02W-B8 *V-9 --10 *LG-R11 *Y-G12 OPS-LAMP RLY (B)G13 *Y-

CN37

2 1

TABNo. JC1 CN5-10P-G2 BODY EARTH02W-B

1 2

RECNo. JC1 CN43-1L-W2 CN41-6Y-B

CN44

1

7

12

2

8

13

3

9

14

54

10

1615

6

11

17

18

2019

21 2322

RECNo. J1 JOINT 22 *3 W/SPLICE-B(E):::::

12 W/ SPLICE-Y (IG) 13 *14 CN2-16::

22 W/ SPLICE-A (E)23 CN1-6

CV-

BR-W

B-R

L-B

BRLG-B

SAS Lamp relay (Base side)

3(B)

5

1 4 2(+S) (L) (-S)

No. JC1 CN5-11L-W2 F=ECU-IGB-R3 CN5-10P-G4 CN5-12,CN8-3W-B5 --

CN43

2 1

TABNo. JC1 GNDB2 Power supplyR

21

RECNo. JC1 SAS relayL-W2 FuseR-G

4-19

CN45

32 31 26 23 17

16 11 10 8 1345912131415

30 29 25 24 22 21 20

267

28 27 19 18

TABNo.1234567891011121314151617181920212223242526

JCSIL

-DRFDRR

TCON--

RYLPBZORYFRYRSOL3

SOL1IG

IG2E03

-

-

-TGNDTROTFODMITRITFI

27 --

28 -29 E330 E331 E232 BATT

3231262317

16111081 3 4 5 9 12 13 14 15

20 21 22 24 25 29 30

2 6 7

18 19 27 28

RECNo.1234567891011121314151617181920212223242526

JCN46-3

-CN46-1CN46-11CN1-13

--

OPS-LAMP RLY (-S)CN51-2

T/C FR RLY (+S)T/C RR RLY (+S)

CN12-1-

CN47-1CN46-5CN46-4CN46-6

--

CN46-10CN1-9

CN1-10CN4-6

CN34-3CN34-1

-

CV-

G-RRL--O

W-GG

Y-RGR-R

-GR-GB-RB-R

BR-W--

BRY-BY

G-WP-LP-G

-27 --28 --29 CN46-9W-B30 CN46-8W-B31 CN46-2W-B32 CN58-9W-R

CN46

1 2 4

11106

3

8 9

5

7

RECNo.1234567891011

JT/C FR RLY (B)

BODY EARTH10CN1-2 or CN44-1W/SPLICE-Y (IG)W/SPLICE-Y (IG)T/C RR RLY (-S)

-W/SPLICE-Z (E)W/SPLICE-Z (E)W/SPLICE-A (E)T/C RR RLY (B)

CG-RW-B

VB-RB-R

BR-W-

W-BW-BBRR

11 10 6

4 2 135

89 7

TABNo.1234567891011

JCG-RW-B

VB-RB-R

BR-W-

W-BW-BBRR

CN45-3CN45-31CN45-1

CN45-16CN45-15CN45-17

-CN45-30CN45-29CN45-20CN45-4

4-20

CN54

21

REC

No. C1 L-W2 L-R

JCN52-5CN52-7

2 1

TAB

No.12

JC--

No. C12

JFBRB

CN52

1 2 3

5 6 7

4

8

REC

*

No. C1 Y-R2 G3 R-Y4 G-W5 L-W6 -7 L-R8 W-B

J**

BODY EARTH02T/C RR RLY (L)

-T/C FR RLY (L)

*

8

4

7 6 5

3 2 1

TAB

*

No. C1 Y-R2 G3 L-B4 L5 L-W6 -7 L-R8 W-B

J**

W/SPLICE-F (E)CN54-2

-CN54-1

*

CN53

76321

10 11 12 14 15 1613

4 5 8 9

1817

1718

9 8 5 4

1316 15 14 12 11 10

12367

(RH SHIFT LEVER)

(LH SHIFT LEVER)

RECNo.12345678910111213141516

CR

R-YB/B-Y

-G-R

LB-WR-G

----------

1718

JT/C RR RLY (B)

**-

T/C FR RLY (B)CN6-8

**----------

CN50

1 2

RECNo. C1 G-W2 BR

JCN60-1CN60-2

12

TABNo.12

JCG-WBR

No. C12

JCN4-6

CN65-14

CN47

21

RECNo. C1 GR-G2 W-B

JCN45-14

W/ SPLICE-Z (E)

2 1

TABNo.12

JCWW

No. C12

J--

CN51

1 2

RECNo. C1 B-R2 W-G

JW/SPLICE-Y (IG)

CN45-9

12

TABNo.12

JC--

No. C12

J--

CN55

1 2 3

REC

3 L-R JOINT3

No. C1 L-W2 W-B

JJOINT4

W/SPLICE-F (E)

123

TABJ

--

No. C12

J+-

3 - +

4-21

CN57

123

456

TABNo. C1 R-W2 B3 G-R4 R-G5 B-W

J**

SFT SOL RLY (FR) (NO)**

6 R SFT SOL RLY (RR) (NO)

654

321

RECNo. C1 R-W2 B3 G-R4 R-G5 B-W

J**

T/C FR RLY (B)**

6 R T/C RR RLY (B)

CN60

2 1

TABNo.12

G-WBR

JCN50-1CN50-2

C

21

RECNo. C

12

--

J+-

CN58

TAB

*

No. C1 B-L2 B-O3 V-G4 B5 W-R6 B-Y7 G8 W-B

J**

***

CN45-32*

1234

5678

REC

*

No. C1 B-L2 B-O3 V-G4 B5 W-R6 B-Y7 G8 W-B

J**

***

F=ECU-B*

4321

8765

CN65

RECNo. JC1 *B-O2 *G3 *G-R4 *G-W5 *G-O6 *G-Y7 *G-B8 *B-Y9 *R-Y10 *V11 *V-W12 *B13 R-G14 JOINT 1BR

*

1314

1 2 3 4 5 6

8 9 10 11127

TABNo. JC1 *2 *3 *4 *5 *6 *7 *8 *9 *10 *11 *12 *13 *14 CN50-2

8 7

6 5 4 3 2 1

13 12 1110 914

B-OG

G-RG-WG-OG-YG-BB-YR-YV

V-WB

R-GBR

OPS-LAMP RLY (Base side)

RECNo. C1 O2 B-R3 W-B4 G5 -

JCN45-8

W/SPLICE-Y (IG)CN8-3

CN41-12-

1 2

3

5

4

T/C FR RLY (Base side)

RECNo. C1 BR-W2 G3 L-W

4 G-R

JT/C RR RLY (-S)

CN45-10CN52-5CN46-1,

CN53-5 or CN57-35 - -

1 2

3

5

4

T/C RR RLY (Base side)

No. C1 BR-W2 Y-R3 L-R

4 R

JT/C FR RLY (-S),CN46-6

CN45-11CN52-7

CN46-11,CN53-1 or CN57-6

5 - -

REC

1 2

3

5

4

1

4

2 3

5

EZ FR SFT RLY

RECNo. C1 W-L2 L-B3 G-R4 W-B5 G-W

J**

CN57-3**

1

4

2 3

5

EZ RR SFT RLY

RECNo. C1 W-G2 L-B3 R4 W-B5 G-W

J**

CN57-6**

5-1

5

APPENDIXPage

SST LIST ..............................................................5-2SERVICE STANDARDS LIST..............................5-3WIRING DIAGRAM ..............................................5-4

5-2

SST LIST : Newly adopted SST

Illust. Part number Part nameSection

1 3

09240-23323-71 Plug-in analyzer

09610-10160-71 Oil control valve spring remover and replacer

5-3

5

SERVICE STANDARDS LISTOIL CONTROL VALVE

Oil control valveRelief set pressure (common to lift and tilt)

kPa (kgf/cm2) [psi]Pn35 ~ 50, Cu35 ~ 55 model Standard 18140 (185 ) [2630 ]

Relief set pressure (common to lift and tilt (backward)) kPa (kgf/cm2) [psi]

Pn60 ~ 80, Cu60 · 70 model Standard 20590 (210 ) [2990 ]

Relief set pressure (tilt (forward)) kPa (kgf/cm2) [psi]

Pn60 ~ 80, Cu60 · 70 model Standard 13240 (135 ) [1920 ]

Tightening torque Unit: N·m (kgf·cm) [ft·bf]

Outlet housing set bolt 34.3 ~ 44.1 (350 ~ 450)[25.3 ~ 32.6]

+4900

+50

+700

+4900

+50

+700

+4900

+50

+700

5-4

WIRING DIAGRAM

*1: 7FGU35 ~ 45, 7FGCU35 ~ 60

*2: 7FGAU50, 7FGU60 ~ 80, 7FGCU70, 7FGU35 ~ 45 (W/ VSCS), 7FGCU35 ~ 60 (W/ VSCS)

Note: This manual shows only the wiring diagrams revised in September 2005. As for wiring diagrams not shown herein, refer to 7FGU/7FDU35-80 and 7FGCU35-70 Repair Manuals (Pub.Nos. CU030 and CU030-1) and Parts & Service News, Ref. No. CB-4008 (issued in February 2004).

NAME G D LP G/LP LPS Page

BATTERY, RELAY BOX 5-5

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: 3-WAY CATALYTIC SYSTEM)

— 5-6

ELECTRIC SHIFT T/C, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: LESS 3-WAY CATALYTIC SYSTEM)

— 5-7

ELECTRIC SHIFT T/C, STARTING, GLOW, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (DIESEL ENGINE)

— — — — 5-8

SAS AND OPS CONTROLLER 4-13

COMBINATION METER 5-9

COMBINATION METER (EZ PEDAL) — 5-10

FUEL SYSTEM (GASOLINE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G)

— — — — 5-11

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS)

— — *1 — *1 5-12

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS), VSCS

— — *2 — *2 5-13

FUEL SYSTEM (LPG CONVERTIBLE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G/LP)

— — — — 5-14

5-5

5

BATTERY, RELAY BOX

SA

S W

AR

NIN

GLA

MP

RE

LAY

B-Y

B-Y

BATTERY

W

DISCONNECT SW

W

BUS BAR

FL

HE

AD

40A

FL

AM

140

A

FL

ALT

80A

W-L

BUS BAR

W-L

W-L

HE

AD

15A

TAIL

7.5A

STO

P7.

5A

R W

HE

AD

LP

RLY

TAIL

LP

RLY

R-L

GR-B

R-W

W B W-L

G-Y

R-G

R-Y

G-W

L-W

B-R

W-L

AM

1

IG1

ST

1

IG S

W

FU

SE

ALT

-S

FU

SE

IGN

ALT

BS

IGL

B-Y

B-Y

B-Y

STA

RT

ER

RE

LAY DO

UB

LE

DO

UB

LE

DO

UB

LE

HO

RN

7.5

A

ALT

-S 5

A

GA

UG

E 1

0A

TU

RN

7.5

A

IGN

7.5

A

EC

U-I

G 7

.5A

SF

T 7

.5A

ST

7.5

A

B-Y

B-W

L B-W

B-R

HE

AD

LA

MP,

ME

TE

R IL

LUM

INAT

ION

TAIL

LA

MP

(O

PT

), C

LEA

RA

NC

E L

AM

P (

OP

T)

STO

P L

AM

P (

OP

T)

STA

RT

ER

ALT

ER

NAT

OR

SE

NS

ING

HO

RN

HO

UR

ME

TE

R, W

ATE

R T

EM

P IN

D, F

UE

L IN

DB

AC

K B

UZ

ZE

R (

OP

T),

BA

CK

UP

LA

MP

(O

PT

)LP

G W

AR

NIN

G IN

D (

OP

T),

ST

RO

BE

LIG

HT

(O

PT

)T

/C O

IL T

EM

PE

RAT

UR

E IN

DIC

ATO

R (

OP

T)

TU

RN

SIG

NA

L LA

MP

(O

PT

)

ALT

ER

NAT

OR

, IG

NIT

ION

CO

IL (

OP

T)

SA

S C

ON

TR

OLL

ER

ELE

CT

RIC

SH

IFT

T/C

STA

RT

ER

RE

LAY

(C

OIL

)

FL W

UL-

GU

L-D

UL-

LPU

L-G

/LP

UL-

LPS

EC

U-B

7.5

AW

-RO

PS

CO

NT

RO

LLE

RF

L G

LOW

120A

UL-

D

B-R

INTA

KE

HE

ATE

RU

L-D

W-L

W

B-Y

B-W

B-L

(U

L-G

, LP,

G/L

P, L

PS

)B

-O (

UL-

DS

)

FU

EL

7.5A

B-Y

LPG

SO

LE

NG

INE

SH

UT

DO

WN

DE

VIC

E (

OP

T)

UL-

G, L

P, G

/LP,

LP

S

L-B

UL-

G, L

P, G

/LP,

LP

S

RE

LAY

BO

X

W (UL-G, LP, G/LP)B-R (UL-D)

L-B

TW

C 7

.5A

L-O

TH

RE

E W

AY C

ATA

LYT

IC S

YS

TE

M

5-6

ELECTRIC SHIFT T/C, STARTING, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: 3-WAY CATALYTIC SYSTEM)

VF

2S

TV

RR

aV

F

F1

IG2

IG1

F2 N

Rr

R Ra

N

B-R

SOLENOID

BODY EARTH

W-B

Y

W-B

L-R

W-B

R BODY EARTH

SOLENOID

W-B

R-Y

R-W

BZR W-B

MOTION ALARM (OPT)

W-BR-Y

R-G

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W

B-W

B-W

ST7.5A

GAUGE10A

B

B-Y

STARTER RELAY

STA

RT

ER

B

W-B

B-Y

B-LB-RB

B

B

W-B

B-Y

B-L

RLY2

LFC

STA

BO

DY

EA

RT

H

B-R

B

STARTER KEEPRELAY

SLOW SOLENOIDKEEP RELAY

T/C RRRELAY

T/C FRRELAY

W-B

PARKING BRAKE LAMP (OPT)

LOCK

RELEASE

L-R

L-W

R

G-R L-W

SH

IFT (LP,

LP

S)

CO

NT

RO

L S

W

RE

LAY

BO

X

RE

LAY

BO

X

B-Y

LL

R-G

W

W-L

B-Y

TW

C C

ON

TR

OLL

ER

W-L

B-Y

FL

HE

AD

40A

IG S

W

FL

ALT

80A

SFT7.5A

AM

1S

T1

IG1

FL

AM

140

A

B-R

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W B-W

ST7.5A

B-W B-R

B

B-W

L

RE

LAY

BO

X EZ

MA

IN R

ELA

Y

STA

RT

ER

RE

LAY

(+S

)

PK

B S

WIT

CH

EZ

PE

DA

L

B-Y

B-W

B-Y

IG S

W

SFT7.5A

AM

1S

T1

IG1

STARTER SUBRELAY

B-R

B

A

B

See pages 5-12 ,13 ,14.

5-7

ELECTRIC SHIFT T/C, STARTING, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (GASOLINE ENGINE: LESS 3-WAY CATALYTIC SYSTEM)

B-R

SOLENOID

BODY EARTH

W-B

Y

W-B

W-B

R BODY EARTH

SOLENOID

W-B

R-WW-B

BZR

R L-R

MOTION ALARM (OPT)

W-BW-BR-Y

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W

B-W

ST7.5A

B

W-L

STARTER RELAY

STA

RT

ER

B

W-BW-B

BO

DY

EA

RT

H

B-R

B

R-G


R-Y

B

RE

LAY

BO

X

RE

LAY

BO

X

B-Y

L-W

L-W

L-R

LL

W

W-L

B-Y

B-W

B-W

B-W

W-L

B-Y

FL

HE

AD

40A

IG S

W

FL

ALT

80A

SFT7.5A

GAUGE10A

AM

1S

T1

IG1

FL

AM

140

A

LOCK

RELEASE

R-G

VF

2V

F

F1

ST

VR

Ra

IG2

IG1

F2 N

R Ra

Rr

N

G-R

SH

IFT

CO

NT

RO

L S

W

T/C RR RELAY

T/C FR RELAY

5-8

ELECTRIC SHIFT T/C, STARTING, GLOW, PARKING BRAKE LAMP, SAFETY START SWITCH, MOTION ALARM (DIESEL ENGINE)

VF

2S

TV

RR

aV

F

F1

IG2

IG1

F2 N

Rr

R Ra

N

B-R

SOLENOID

BODY EARTH

W-B

Y

W-B

L-R

W-B

R

W-B

B

W-B

BODY EARTH

SOLENOID

W-B

R-Y

R-W

BZR W-B

MOTION ALARM (OPT)

W-BR-Y

R-G

SA

FE

TY

STA

RT

SW

(O

PT

)

B-W

B-W

B-W

B-W

ST7.5A

GAUGE10A

B

W-L

STARTER RELAY

STA

RT

ER

B

BG

-R

W-BW-B

W-BW-B

BO

DY

EA

RT

H

B-R

B

T/C RRRELAY

T/C FRRELAY

GLOW RELAYMAIN

GLOW PLUG

W-B

R-G

B-O

R

GLOW

R

Y


LOCK

RELEASE

L-R

L-W

R

G-R L-W

SH

IFT

CO

NT

RO

L S

W

RE

LAY

BO

X

RE

LAY

BO

X

B-Y

LL

R-G

W

W-L

B-Y

GLO

W P

LUG

TIM

ER

RE

LAY

BO

X

ALT

(L)

IG S

W(I

G1)

W-L

B-Y

FL

HE

AD

40A

FL

GLO

W60

A

GAUGE10A

IGN7.5A

IG S

W

FL

ALT

80A

FL

(P)

SFT7.5A

AM

1S

T1

IG1

FL

AM

140

A

LG-B

WATER TEMPSENSOR

R-G

G

5-9

COMBINATION METER

GOVERNOR ECU (OPT)

FL

AM

140

AW

-L

GA

UG

E10

A

RE

LAY

BO

X

W-B

AM

1

IG1

ST

1

IG S

W

FU

EL

SE

ND

ER

B-Y

OUT1

HRM1

HRM2

HRM3 E1

SA

S E

CU

RE

LAY

BO

X

CO

MB

INA

TIO

N M

ET

ER

SAS WARNING

LOCK IND

HOUR METER

FUEL

WATER TEMP

CHARGE

AIR CLEANER

RADIATOR(OPT)

OIL

BRAKE (OPT)

OVER HEAT(OPT)

SAS WARNINGLAMP RELAY

P-G

L-O

V-G

V-R

P-L

Y-B

W-B

W-B

V-W Y-L

V V Y-G W-B

W-B

WATER TEMPSENDER

LGLG-B

W-B

BODYEARTH

YYBODYEARTH

ALTERNATOR

VACCUM SW(AIR CLEANER)

LEVEL SW (OPT)(RADIATOR RESERVOIR TANK)

OIL PRESSURE SW

PARKING BRAKE SW (OPT)

WATER TEMP SW (OPT)

Y-RY-R

Y-G Y-G B

W-BW-B

W-BB

LG-R LG-R BODY EARTH

W-BBRR-W

BODY EARTHV-GV-G

R-G

L

B-Y

B-Y

BATTERY

W

DISCONNECT SW

W FL W

UL

-GU

L-D

UL

-LP

UL

-G/L

P

UL

-LP

S


W-L

B-Y

P-G W-B

UL

-G, D

, G/L

P

LEVEL SW(SEDIMENTER)

SEDIMENTER

Y-B Y-B W-BWW-B

UL-D

UL-D

UL-G, LP, G/LP, LPS

GLOW PRE-HEATING TIMER

W-BW-BR R

CHECK ECU(OPT)

W-BVR

TWC TWC ECU

W-BW-BYR

UL-G, LP, G/LP

UL-D

OPS

W-B

OPS-LAMPRELAY

G W-B

5-10

COMBINATION METER (EZ PEDAL)

UL-D

UL-G, LP, G/LP

B-Y

FL

AM

140

AW

-L

GA

UG

E10

A

RE

LAY

BO

X

W-B

AM

1

IG1

ST

1

IG S

W

FU

EL

SE

ND

ER

B-Y

OUT1

HRM1

HRM2

HRM3 E1

SA

S E

CU

RE

LAY

BO

X

CO

MB

INA

TIO

N M

ET

ER

SAS WARNING

LOCK IND

HOUR METER

FUEL WARNING(OPT)

FUEL

WATER TEMP

CHARGE

AIR CLEANER

RADIATOR(OPT)

OIL

BRAKE (OPT)

OVER HEAT(OPT)

SAS WARNINGLAMP RELAY

P-G

L-O

V-G

V-R

P-L

Y-B

W-B

W-B

V-W Y-L

V V Y-G W-B W-B

W-BWATER TEMPSENDER

LGLG-B

W-B

BODYEARTH

YYBODYEARTH

ALTERNATOR

VACCUM SW(AIR CLEANER)

LEVEL SW (OPT)(RADIATOR RESERVOIR TANK)

OIL PRESSURE SW

WATER TEMP SW(OPT)

Y-RY-R

Y-G Y-G B

W-BW-B

W-BB

LG-R LG-R BODY EARTH

BODY EARTHV-GV-G

R-G

BATTERY

B-Y

P-G W-B

L

TWC TWC ECU

W-BW-BYY-B

GLOW PRE-HEATING TIMER

W-BW-BR R

UL

-G, D

, G/L

P

PARKING BRAKE SW

R-W

W-BBSTARTERRELAYEZ PEDALRELAY

B-R

LOCK

RELEASE

G-R

R

L

UL

-G, D

, LP,

G/L

P


W-L

LEVEL SW (SEDIMENTER)SEDIMENTER

Y-B Y-B W-BWW-B

UL-D

B-R

UL-LP

UL-G, LP, G/LPCHECK ECU(OPT)

GOVERNOR ECU (OPT)

W-BRR

R-G

OPS

W-B

OPS-LAMPRELAY

G W-B

5-11

FUEL SYSTEM (GASOLINE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G)

ALT

Y

B

R

W

SH-LD

B

R

W

G

SH-LD

WATER TEMPSENSOR

SEL3

E3W-R

IG- VCC

FL

HE

AD

40A

IG1

ST

1A

M1

IG S

W

FL

AM

140

AB

-Y

W B-Y

RE

LAY

BO

X

RE

LAY

BO

X

BRG-R

G-B BR

BR

W

G

W-B

B

R

W

G

R

B-L

B-L

FUEL PUMP RELAY

B-O

B-O

W-B

B-L

B-L

B-L

B-L

B

CO

MB

INAT

ION

ME

TE

R

G-O

R

Y

V

Y

B-Y

R-G

R-G

B-O

B-O

B-O

CERAMIC CHOKE

FUEL CUT SOLENOID

CLOSE SW

OPEN SW

DIS

TR

IBU

TOR

ST

EP

PIN

G M

OTO

R

MEMORYCLEAR

IGNITIONCOIL

TACH

GO

VE

RN

OR

EC

U

BODY EARTH

BODY EARTH

FUEL PUMP

AC

CE

LS

EN

SO

RM

AP

S

EN

SO

RIGNITION RELAY

B-L

V-G

V-WB-L

W-B

CHECKER

G-W

B-W

SHIFT CONTROL SW

B-W B B

L-B

CHARGE

CHECK ECU

B-Y

B-W

W-B

B

SH

-LD

W-B

W-B

W-B

B-OB-OB-W

B-W

IDL

ACCL

5V

MAP

AE

RLY

E0

CHK

DGN

ST

IG2

IG1

CH

G

WR

N

OPN

CLS

DE

E1

REF

EST

B/P

E

MEM

NIB

IB

NIA

IAS

OL

FU

L

W-L

B-Y

B-W

SH

-LD

AIR

BLE

ED

CO

NT

RO

L V

ALV

E

VA

CU

UM

S

EN

SO

R

CH

EC

KC

ON

NE

CTO

R

W-G

OXYGENSENSOR

TWC

W-B

TWC7.5A

BU

S B

AR

FUEL7.5A

ST7.5A

IGN7.5A

GAUGE10A

B-L

B-L

B

TW

C E

CU

B-L

L-O

W-G

W-G W-G

L-O

L-O

L-B

L-B

L-O

L-O

L-B

L-B

V-G

G-Y

G

G-B

G-W

W-B

W-B

O

W-B

BR

BR

L-W

W

G-R

BR

W-B

W

O

R-G

R

R-W

R-B

L-B

L-B

L-B

L-B

W-B

L-O

L-O

B-L

BB

Y-BY-B

B-W

B

E02

E01

THW

OXM

VF

TE1

TE2

OX

E1

SEL2

E2

PIM

BATT1

BATT2

IGB

IGB2

FCM4

FCM3

FCM2

FCM1

STA

W

SH-LD

SH-LD

BR

W-GTWC RELAY

B

STARTER SUB RELAY

BB-W

5-12

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS)

WATER TEMPSENSOR

ALT

Y

E0W-B

B-O(LP)

B-O(LP)

B-O(LP)

B-O(LP)

FL

HE

AD

40A

ST7.5A

FUEL7.5A

ING7.5A

TWC7.5A

GAUGE10A

IG1

ST

1A

M1

IG S

W

FL

AM

140

AB

-Y

W (LP) B-Y

RE

LAY

BO

X

RE

LAY

BO

X

W

G

W-B

R

FUEL PUMP RELAY

B-L

B-L

B-L

B

CO

MB

INAT

ION

ME

TE

R

Y Y

B-Y

R-G

R-G

DIS

TR

IBU

TOR

IGNITIONCOIL

TACH

GO

VE

RN

OR

EC

U

B

B

LPG MAINSOLENOID

LPG SLOWSOLENOID B-O (LPS)

B-L (LP)

W-B

B

MA

P S

EN

SO

RB-L

SHIFT CONTROL SW

BL-

B

CHARGE

B-Y

B-L

B

W-B

W-B

B-O (LP)B-O (LP)B-L (LP)

5V

MAP

AE

IG2

IG1

CH

G

E1

REF

EST

B/P

E

W-L

B-Y

B-W

SH

-LD

LPG INJECTOR

RESISTOR

VA

CU

UM

SE

NS

OR

CH

EC

KC

ON

NE

CTO

R

W-G

OXYGENSENSOR

TWC

W-B

BU

S B

AR

TW

C E

CU

B-L

L-O

W-G

W-G W-G

L-O

L-O

L-B

L-B

L-O

L-O

L-B

L-B

V-G

G-Y

G

G-B

G-W

W-B

W-B

O

W-B

L-W

W

BR

W-B

W

O

L-R

L

LL-

B

L-B

W-B

L-O

L-O

B-L

BB

Y-BY-B

B-W

B

E02

E01

THW

OXM

VF

TE1

TE2

OX

E1

E2

PIM

VCC

BATT1

BATT2

IGB

IGB2

INJ

RES

STA

W

IG-

FU

L

LFC

B-L

(LP

)B

-O (

LPS

)B

-L(L

P)

B-O

(LP

S)

SH-LD

SH-LD

W-GTWC RELAY

B

W-R

SEL3

E3

SH-LD

W

R

B

DISCONNECT SWFL W

W (LPS) W

B-L

G-R

B-L

B (LPS)B (LPS)B (LPS)

B-W B-W

B-L(LPS)

STARTER SUB RELAY

BB-W

See

page

5-6

A

5-13

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (LP, LPS), VSCS

Y

ALT

B-L

SPDF

SPD

SH

-LD

G-B

P-B

L

P

SA

S E

CU

(VS

CS

ON

LY)

BS

H-L

D

B

SH-LD

NMR

SH-LD

B

R

WVO

LUM

E(V

SC

S O

NLY

)

B-L

IG1

ST

1A

M1

IG S

W

B-Y

W (LP) B-Y

RE

LAY

BO

X

RE

LAY

BO

X

BRG-R

G-B BR

BR

W

G

W-B

B

R

W

G

R

B-L

B-L

G-R

LPG RELAY

B-O(LP)

B-O(LP)

B-O(LP)

B-O(LP)

B-L

B-L

B-L

B-L

B

CO

MB

INAT

ION

ME

TE

R

G-O

R

Y

V

Y

B-Y

R-G

R-G

CLOSE SW

OPEN SW

DIS

TR

IBU

TOR

ST

EP

PIN

G M

OTO

R

MEMORYCLEAR

IGNITIONCOIL

TACH

GO

VE

RN

OR

EC

U

B

B

LPG MAIN SOLENOID

LPG SLOW SOLENOID

B-O (LPS)B-L (LP)

W-B

B(LP)

W

AC

CE

L S

EN

SO

R

W

G

MA

P S

EN

SO

R

B

R

WIGNITION

RELAY

B-L

V-G

V-WB-L

W-B

CHECKER

G-W

B-W

SHIFT CONTROL SW

B-W B

L-B

CHARGE

CHECK ECU

B-Y

B-W

B

SH

-LD

W-B

W-B

W-B

R

B-O (LP)B-O (LP)B-W (LP)

B-W

IDL

ACCL

5V

MAP

AE

RLY

E0

CHK

DGN

ST

IG2

IG1

CH

G

WR

N

OPN

CLS

DE

E1

REF

EST

B/P

E

MEM

NIB

IB

NIA

IA

W-L

B-Y

B-W

SH

-LD

LPG INJECTOR

RESISTOR

VA

CU

UM

SE

NS

OR

CH

EC

KC

ON

NE

CTO

R

W-G

OXYGENSENSOR

TWC

W-B

BU

S B

AR

B-L

B-L

B

TW

C E

CU

B-L

L-O

W-G

W-G W-GL-O

L-O

L-B

L-B

L-O

L-O

L-B

L-B

V-G

G-Y

G

G-B

G-W

W-B

W-B

O

W-B

W-B

L-W

W

BR

W-B W-B

W

OL-R

L

LL-

B

L-B

W-B

L-O

L-O

B-L

BB

Y-BY-B

B-W

B

E02

E01

THW

OXM

VF

TE1

TE2

OX

E1

SEL1

E2

PIM

VCC

BATT1

BATT2

IGB

IGB2

INJ

RES

STA

W

IG-

FU

L

LFC

B-L

(LP

)B

-O (

LPS

)B

-L (

LP)

B-O

(LP

S)

SH-LD

SH-LD

W-B

W-G

TWC RELAY

B

W-R

SEL3

E3

WATER TEMPSENSOR

B (LPS) B (LPS)B (LPS)

B

B-W(LPS)

DISCONNECT SWFL W

W (LPS) W

STARTERSUB RELAY

BB-W

FL

HE

AD

40A

FL

AM

140

A

TWC7.5A

FUEL7.5A

ST7.5A

IGN7.5A

GAUGE10A

See

page

5-6

A

5-14

FUEL SYSTEM (LPG CONVERTIBLE), IGNITION SYSTEM, ELECTRONIC GOVERNOR CONTROL SYSTEM, 3-WAY CATALYTIC SYSTEM (G/LP), VSCS

AIR

BLE

ED

CO

NT

RO

LV

ALV

E

TWC7.5A

FUEL7.5A

ST7.5A

IGN7.5A

GAUGE10A

FUEL CUT SOLENOID

B-Y

B-O

B-Y

B-L

ALT

Y

R

B

B

R

W

SH-LD

SH-LD

WATER TEMPSENSOR

E3

SEL3

W-R

B

TWC RELAYW-G

BR

W-B

B

B-Y

B-L

B-R

SH-LD

SH-LDB

-LB

B-Y

LFC

LPG

GA

SF

UL

IG-

W

STA

FCM1

FCM2

FCM3

FCM4

RES

INJ

IGB2

IGB

BATT2

BATT1

VCC

PIM

E2

SEL2

SEL1

E1

OX

TE2

TE1

VF

OXM

THW

E01

E02

BB

-W

Y-B Y-B

B B

B-L

L-O

L-O

W-B

L-B

L-B

L

L-B

L-B

L-B

L

R-B

R-W

R

R-G

L-R

O

W

W-BW-B

BR

W

L-W

BR

BR

W-B

W-B

O

W-B

W-B

G-W

G-B

G

G-Y

V-G

L-B

L-B

L-O

L-O

L-B

L-B

L-O

L-O

W-GW-G

W-G

L-O

B-L

TW

C E

CU

B

B-L

B-L

BU

S B

AR

W-B

TWC

OXYGENSENSOR

W-G

CH

EC

KC

ON

NE

CTO

R

VA

CU

UM

SE

NS

OR

RESISTOR

LPG INJECTOR

SH

-LD

W-L

LPG SW

LPG

SO

L

IA

NIA

IB

NIB

MEM

E

B/P

EST

REF

E1

DE

CLS

OPN

WR

N

CH

G

IG1

IG2

ST

DGN

CHK

E0

RLY

AE

MAP

5V

ACCL

IDL

B-W

B-W B-O B-O

W-B

W-B

W-B

SH

-LD

B

W-B

B-W

CHECK ECU

CHARGE

L-B

BBB-W

SHIFT CONTROL SW

B-W

G-W

CHECKER

W-B

B-L V-W

V-G

B-L

IGNITIONRELAY

STARTERSUB RELAY

MA

P S

EN

SO

R

G

W

AC

CE

L S

EN

SO

R

FUEL PUMP

GASOLINE

B

W-B

B-L

LPG SLOW SOLENOID

LPG MAIN SOLENOID

B

B

B-Y

BODY EARTH

BODY EARTH

GO

VE

RN

OR

EC

U

TACHIGNITIONCOIL

MEMORYCLEAR

ST

EP

PIN

G M

OTO

R

DIS

TR

IBU

TOR

OPEN SW

CLOSE SW

CERAMIC CHOKE

B-Y

B-O

R-G

R-G

Y

V

Y

R

G-O

CO

MB

INAT

ION

ME

TE

R

B

B-L

B-L

B-L

B-L

W-B

B-Y

B-O B-O B-O B-O

B-Y

LPG RELAY

B-L

G-R

B-L

R

G

W

R

B

W-B

G

W

BR

BRG-B

G-R BR

RE

LAY

BO

X

B-YW

IG S

W

AM

1S

T1

IG1

BB-W

B-Y

RE

LAY

BO

X

B-Y

B-Y

B-Y

B-W

FL

HE

AD

40A

FL

AM

140

A

See

pag

e 5-

6A

C

Published by

1st Printing: Oct. 2005

Pub. No. CU041

Printed in Japan

Documents

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