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

Transcription

1 FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 7FGU/ 7FDU5~3 series and 7FGCU0~3 series. Please use this manual for providing quick, 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 August 005. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 7FGU/7FDU5~3, 7FGCU0~3 REPAIR MANUAL (No. CU07) TOYOTA INDUSTRIAL EQUIPMENT 4Y EINE REPAIR MANUAL (No. CE60) TOYOTA INDUSTRIAL EQUIPMENT DZII EINE REPAIR MANUAL (No. CE68)

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3 SECTION INDEX NAME SECTION GENERAL 0 OPS BODY MATERIAL HANDLI SYSTEM 3 OIL CONTROL VALVE 4 SAS 5 APPENDIX 6

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5 0 GENERAL Page PERIODIC MAINTENANCE...0 OPS SYSTEM...03 SAS

6 0 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 : Flaw detector Item SAFETY DEVICES, ETC. Inspection Period Every 6 weeks Every 50 hours Every 3 months Every 500 hours Every 6 months Every 000 hours Every months Every 000 hours Loosening and damage of mounting I Seat Seatbelt damage and function I Seat switch function I OPS Functions I

7 03 OPS SYSTEM General The OPS (Operator Presence Sensing) system is added as standard. The switch mounted underneath the seat detects the operator on the seat. When there is no operator, the OPS system cuts off the driving power and restricts material handling operations. (Refer to page 06.) The OPS system operates (to disable traveling and material handling) upon lapse of seconds after the operator leaves the seat. When the OPS controller detects the seat switch going off, it sounds the OPS buzzer (bleeping) for about one second and turns the OPS lamp on before OPS activation. Furthermore, the OPS lamp keeps lighting while the seat switch stays off. : The buzzer sounds only export model. Only export model: If the seat switch is turned on without returning the forward/reverse lever to the neutral position after drive OPS activation, the newly added return to neutral warning function sounds the buzzer at short intervals (pippip) to warn the operator of the unreleased state of the drive OPS. When the OPS controller detects any system malfunction, the OPS lamp blinks to warn the abnormality. 0 Control block diagram : Parts added or changed for OPS Battery F Key switch Foward reverse switch Forward tilt switch Bakward tilt switch Lower limit switch OPS Controller Seat switch OPS lamp relay OPS lamp OPS buzzer (Export model) Plug in analyzer SAS Controller Tilt cylinder N R Unload valve Tilt control valve Lift lock valve Lift cylinder Forward interrupt relay Forward drive valve Reverse interrupt relay Reverse drive valve Oil control valve T/C Engine Oil pump Oil tank

8 04 Name of each part () (4) (3) () (3) (4) (7) (8) (9) (0) () () (5) (5) (6) (6) () OPS controller (9) Backward tilt switch () Seat switch (0) Unload valve (3) Forward switch () Lift lock valve (4) Reverse switch () Tilt control valve (5) Forward interrupt relay (3) OPS lamp (6) Reverse interrupt relay (4) OPS lamp relay (7) Lower switch (5) OPS buzzer (Export model) (8) Forward tilt switch (6) Plugin analyzer

9 05 Function of each part Input to controller Name () Seat switch (3) Forward switch (4) Reverse switch (7) Lower switch (8) Forward tilt switch (9) Backward tilt switch Output from controller Name (5) Forward interrupt relay (6) Reverse interrupt relay (0) Unload valve () Lift lock valve () Tilt control valve (3) OPS lamp (4) OPS lamp relay (5) OPS buzzer (Export model) (6) Plugin analyzer Function This switch mounted underneath the seat detects the operator sitting on the seat. This switch inputs the voltage branched from the forward drive valve power supply line to the OPS controller that detects the forward drive operation. This switch inputs the voltage branched from the reverse drive valve power supply line to the OPS controller that detects the reverse drive operation. This limit switch installed at the lift spool of the oil control valve detects the lowering operation by the lift lever. This limit switch installed at the tilt spool of the oil control valve detects the forward operation of the tilt lever. This limit switch installed at the tilt spool of the oil control valve detects the backward operation of the tilt lever. Function This relay cuts off the voltage supply to the forward drive valve in the torque converter according to the instruction from the OPS controller. This relay cuts off the voltage supply to the reverse drive valve in the torque converter according to the instruction from the OPS controller. Provides a bypath to the tank circuit for the hydraulic oil supplied from the oil pump to the oil control valve. This valve cuts off the oil flow from the lift cylinder to the oil tank according to the instruction from the OPS controller to disable fork lowering. This valve changes the oil path to the tilt cylinder according to the instruction from the OPS controller to disable forward tilting and to slow down the backward tilting speed. This lamp lights while the seat switch is off to indicate the OPS operation. Furthermore, it blinks when the OPS controller detects any abnormality. The 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. This 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). This new plugin 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

10 06 Control specifications. Drive OPS When the OPS controller detects seat switch off state for seconds, the forward/reverse interrupt relay is operated 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 is returned to the neutral position.. Material handling OPS When the OPS controller detects seat switch OFF for seconds, the lift lock valve and tilt control valve are controlled to stop fork lowering and forward tilting. Other material handling operations such as backward tilting, fork lifting and attachment operations are stopped by interrupting the hydraulic oil supply by means of the unload valve. The disabled material handling operations are released upon lapse of second after seat switch ON. Caution: Backward tilting: If the material handling lever is operated while the OPS is functioning, the mast may be tilted backward because of the weight of the tilted mast or the back pressure at the unload valve. Attachment: If the material handling lever is operated while the OPS is functioning, the attachment may move because of the own weight of the attachment or the back pressure at the unload valve.. OPS operation notice When the OPS controller detects the seat switch off state, it sounds the OPS buzzer (bleep) for about one second, and turns the OPS lamp on to warn the operator of the OPS operation. : The buzzer sounds only export model.. Returntoneutral warning (Only export model) The OPS controller warns the driver of the failure in releasing the drive OPS by sounding the buzzer at short intervals (pippip) when the seat switch is turned on without returning the forward/reverse shift lever to its neutral position. 3. Malfunction alarm When the OPS controller detects any malfunction, it blinks the OPS lamp to warm the malfunction. The lamp blinking frequency identifies the defective part. Seat Every seat has the seat switch for operator detection. When replacing seat, install a genuine TOYOTA seat designed specifically for this lift truck. (The OPS may fail to operate unless the correct seat is used.) Combination Meter OPS 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, is relocated to the instrument panel.

11 07 Oil Control Valve. A new oil control valve is adopted for use with the added OPS system.. An electronic hydraulic control mechanism is incorporated in the tilt control circuit for controlling the mast tilting operation. 3. The additional check valve in each of the lift and tilt circuit greatly reduces natural drop and natural forward tilt. 4. The unload valve provided in the supply circuit. Unloading solenoid valve Manual downlifting valve Open this valve to forcibly lower the fork with the engine key turned OFF. Lift lock solenoid valve Tilt control solenoid valve Specifications Pnton series Pn Cuton series Pn3 Cu3ton series Relief pressure setting MPa (kgf/cm ) [psi] Lift 8.7 (9) [70] Tilt 5.7 (60) [80] Flow divider flow rate L/min 3.0 (3.43) Pn: 5. (4.0) Cu: 3.0 (3.43)

12 08 SAS Hydraulic circuit diagram The integral control valve has integrated the unload valve (unload SOL), lift lock valve (lift lock SOL) and the tilt control valve (tilt control SOL) with the oil control valve in the previous model. Each solenoid valve (SOL) is normally closed. () T R P (4) OUT () () Unloading valve (Unloading SOL) () Lift lock valve (Lift lock SOL) (3) Tilt control valve (Tilt control SOL) (4) Gage port C (3) C C3 C4 C5 T

13 Hydraulic circuit control Tilt control is achieved by ON/OFF of the tilt control solenoid (SOL) valve installed on the integral control valve. The relationships between the tilt hydraulic circuit and tilt control SOL valve is as shown in the table below. When the SOL is OFF upon backward tilting operation, the circuit is fully open. When the SOL is OFF upon neutral or tilt forward operation, tilting is stopped. 09 Tilt control SOL ON OFF Semiopen circuit Forward tilt circuit Full open circuit for backward tilting Tilt stop circuit High lifting height, backward tilting speed restriction Low liftingheight, backward tilting speed restriction Forward tilting Low lifting height, backward tilting Tilt lever at neutral Stop with forward tilting angle restriction Automatic leveling stop with forward tilting Backward tilting operation with the tilt lever knob switch depressed. Tilt Control Valve Tilt Cylinder Pilot Line. Tilt stop circuit The tilt stop circuit refers to the state where the tilting operation is disabled as upon tilt lever setting at the neutral position or upon stopping with forward tilting angle restriction or fork automatic leveling. The tilt cylinder operation is stopped because the tilt control valve in the control valve is closed. Tilt Lever Tilt Control Valve (Orifice) SOL OFF Tilt Cylinder Pilot Line. Tilt semiopen circuit The tilt semiopen circuit refers to the state where the tilting operation speed is restricted (slowed down). The tilting speed is slowed down because the orifice in the tilt control valve is connected to reduce the oil flow to the tilt cylinder. Tilt Lever SOL ON

14 00 Tilt Control Valve Tilt Cylinder Pilot Line 3. Tilt full open circuit The tilt full open circuit refers to the state where the tilting speed is not restricted. The forward/backward tilting speed at the low lifting height becomes the normal tilting speed. The fully opened circuit in the tilting control valve results in normal tilting speed with no restriction. Tilt Lever RR Tilt : SOL OFF FR Tilt : SOL ON Keyoff lift lock. The integral control valve is designed for addition of the OPS system and the lift hydraulic circuit is modified accordingly.. When the engine key is turned off, the fork cannot be lowered when the lift lever is set to the down position. 3. Since the check valve was closed during no hydraulic pressure generation in the past, lowering operation was disabled. After the change, the lift lock solenoid valve is adopted to enable lowering when the engine is stopped so loan as the key switch is at the ON position.

15 OPS Page GENERAL... COMPONENTS...4 OPS CONTROLLER...5 REMAVAL INSTALLATION...5 OPS PLUGIN ANALYZER...6 SCREEN CONFIGURATION...6 BASIC OPERATION...7 ANALYZER...9 TROUBLESHOOTI... OPS TROUBLESHOOTI...4 DIAGNOSIS...4 DIAGNOSIS ERROR CODE LIST...5 TROUBLESHOOTI BY ERROR CODE...8 TROUBLESHOOTI BY PHENOMENON...33 Note: See Section 5 (SAS) for the connector layout, controller sequence and connector diagram.

16 GENERAL : Parts added or changed for OPS Battery F Key switch Foward reverse switch Forward tilt switch Bakward tilt switch Lower limit switch OPS Controller Seat switch OPS lamp relay OPS lamp OPS buzzer (Export model) Plug in analyzer SAS Controller Tilt cylinder N R Unload valve Tilt control valve Lift lock valve Lift cylinder Forward interrupt relay Forward drive valve Reverse interrupt relay Reverse drive valve Oil control valve T/C Engine Oil pump Oil tank

17 3 () (4) (3) () (3) (4) (7) (8) (9) (0) () () (5) (5) (6) (6) () OPS controller (9) Backward tilting switch () Seat switch (0) Unload valve (3) Forward drive switch () Lift lock valve (4) Reverse drive switch () Tilt control valve (5) Forward interrupt relay (3) OPS lamp (6) Reverse interrupt relay (4) OPS lamp relay (7) Lift lowering switch (5) OPS buzzer (Export model) (8) Forward tilting switch (6) Plugin analyzer

18 4 COMPONENTS PA QY VZ MF 36A 4 3 PA 36A PG MF WG QY WE PG 3 WS LN GU LN RQ RQ RQ WS EP LY WE LN GH GU GH WA VZ

19 5 OPS CONTROLLER REMAVAL INSTALLATION Removal Procedure Remove the toe board. 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 Procedure The installation procedure is the reverse of the removal procedure.

20 6 OPS PLUGIN ANALYZER For the maintenance and service of OPS functions, a separate type plugin analyzer is introduced as an SST (Special Tool for Service). The plugin analyzer is designed to read the operating state of sensors and actuators used for the OPS functions and the error information detected by the controller. It serves to check on the operating state of OPS functions and shortens the repair time for a problem. Moreover, it is installed with save function to file data displayed on the screen in the SST. SST Menu name Content of function Reference page Communication function with the OPS controller on the vehicle side OPS DIAG MEMORY Indication of ten error codes and subcodes in past. 9 IN/OUT MONITOR Monitoring input voltage value from the sensors and the output signal, etc. to the solenoid, etc. ACTIVE TEST Forced operation of solenoids and warning lamps. CONTROLLER DATA Indication of OPS controller abbreviation number and version 0 SCREEN CONFIGURATION See the SAS section. Page 9 0 See the SAS section.

21 7 BASIC OPERATION Name of Sections and the Switch Functions Name of section Main unit Position of indication Mark Function Switch Move the cursor to the above item. Move to the preceding page. A Move the cursor to right or left. Selector switch <Blank> <No function> Connector Screen title A Switch B Select the item below. Move to the following page. Selector switch <Blank> <No function> B C Switch mark indicator C <Blank> Determine an item for selection. Move to MENU screen. Menu switch Caution on using: Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections. Operate the switch with finger tip. Donít give it strong impact from dropping or collision. Donít leave it under the direct rays of the sun for long time. Connection and Operation of SST. Turn the key switch OFF.. Open the diagnosis connector cover of the vehicle and properly connect the connector on the SST side. SST SST Diagnosis connector PLUG IN ANALYZER Note: Since the connector has no locking device, securely connect it to prevent contact defect upon closing the engine hood with the connector in connected state. 3. Turn the key switch ON or start engine. 4. Display of the initialization screen After about 5 seconds of display, "LAUAGE SET" or "MAIN MENU" screen appears. The screen may be changed during this period by pressing the menu switch. SYSTEM PROG VER 4.00

22 8 5. "LAUAGE SET" screen Since this screen appears only when the language is undefined, determine a language to use for display. () Select a display language by pressing selector switch and. apanese English () Press MENU switch to determine the language setting. Note: Once the display language is defined, "LAUAGE SET" screen will not be displayed from the next time onward. To change language, go to "TESTER SET" of "MAIN MENU". 6. "MAIN MENU" screen () Select the menu using selector switch and and determine by pressing menu switch. SAS: Moves to SAS MENU screen. (See the SAS section) OPS: Moves to OPS ANALYZER MENU Screen. TESTER SET: Moves to TESTER SET screen. (See the SAS section) Removal of SST. Check that the screen title is for one of the MENU screens.. Turn the key switch OFF. 3. Disconnect the connector. Note: To disconnect, hold the body of the connector. 4. Close the diagnosis connector cover.

23 9 ANALYZER ANALYZER MENU Display contents and function Page. DIAG MEMORY Indication of error codes for 0 most recent errors 9. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 0 3. ACTIVE TEST Forced operation signal output to the selected item 4. CONTROLLER DATA Indication of the OPS controller part number and version Operation Procedure. Select and enter "OPS" on the main menu screen to display the OPS ANALYZER MENU screen.. ANALYZER MENU screen () Move the cursor to the desired menu by operating selector switch or, and enter by operating MENU switch. () Select and enter "END" to return to the MAIN MENU screen. () () " DIAG MEMORY" This screen displays ten error codes from the most recent one. [Explanation on display contents] () Order of error occurrence () Error codes [Clear memory] Press selector switch continuously for 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.

24 0 () () (3) (4) () (5) (6) (7) (8) (4) () (9) (8) (0) (4) : "CONT " appears on the SASless spec. model. " IN/OUT MONITOR" [Explanation on display contents] () SEAT: Seat switch input signal () 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: Lift lowering switch input signal (6) UNLOAD SOL: Output signal to unload solenoid (7) LWR SOL: Output signal to lowering lock solenoid (8) TILT SOL: Output signal to tilt solenoid (9) TILT: Tilt lever switch input signal FWD: Forward tilt switch input signal BWD: Backward tilt switch input signal CONT: SAS tilt control command input signal (0) LSOPT: Reserved. [End] Press MENU switch to return to the ANALYZER MENU screen.

25 "3 ACTIVE TEST" () () (3) (4) (5) (6) (7) Note: ON indication on the screen shows the controller output state. The operation, therefore, should be checked visually, by operating sound, etc.. Select the item by selector switch, and set OFF/ON by selector switch. [Explanation on display contents] () RLY FWD Set to ON for forced output of forward interrupt relay activating signal. (Forward traveling disabled state) () RLY REV Set to ON for forced output of reverse interrupt relay activating signal. (Reverse traveling disabled state) (3) UNLOAD SOL Set to ON for forced output of unload solenoid activating signal. (Material handling disabled state) (4) LWR SOL Set to ON for forced output of lowering lock solenoid activating signal. (Lowering enabled state) (5) TILT SOL Set to ON for forced output of tilt solenoid activating signal. (Forward tilting enabled state with backward tilting speed restriction) (6) LAMP Set to ON for forced output of OPS lamp lighting signal. (OPS lamp lighting state) (7) BUZZER (Export model) Set to ON for forced output of OPS buzzer sounding signal. (Continuous OPS buzzer sounding). After resetting all items to OFF, press MENU switch to return to the ANALYZER MENU screen. "4 CONTROLLER DATA" The OPC controller abbreviation No. and version No. can be displayed on this screen. () () [Explanation on display contents] () DATA Controller abbreviation No. () VER Version No. [End] Press MENU switch to return to the ANALYZER MENU screen.

26 TROUBLESHOOTI No display on the screen. Related Portion ECUIG CN63 To IG SW OPS controller CN45 CN463 CN44 (IG, Power supply) CN44 CN Analyzer (E, Main GND) Analyzer CN Estimated Causes: Connector contact defect Analyzer harness (power supply) defect Plugin analyzer defect Check CN44 and analyzer connector for any disconnection. Screen check after correction. Inspection : Measure the voltage between CN44 and CN443. Harness defect on vehicle side Inspection : Measure the voltage between analyzer CN and analyzer CN3. Analyzer harness defect Plugin analyzer defect Inspection : Measure the voltage between CN44 and CN443. Key switch ON (engine in stopped state) CN44 (+) ~ CN443 () 8 to 6 V CN44 () Inspection : Measure the voltage between analyzer CN and analyzer CN3. Key switch ON (engine in stopped state) Analyzer CN () Analyzer CN(+) ~ analyzer CN3 () 8 to 6 V

27 3 No data display on data (DIAG MEMORY, voltage value, etc) display screen Related Portion ECUIG CN63 To IG SW OPS controller CN45 CN463 CN44 (IG, Power supply) CN44 CN Analyzer (E, Main GND) Analyzer CN Estimated Causes: Connector contact defective Analyzer harness (communication) defect Plugin analyzer defect OPS controller defect Check CN44 and analyzer connector for any disconnection. Data display check after correction. Inspection : Check continuity between CN44 and CN45. Inspection : Check continuity between analyzer CN6 and CN44. Check data display by connecting the analyzer to another vehicle. Harness defect on vehicle side Analyzer harness defect Plugin analyzer defect OPS controller defect Inspection : Check continuity between CN44 and CN45. Key switch OFF, disconnection between CN44 and CN45. CN44 ~ CN45 Continuity CN45 () CN44 () Inspection : Check continuity between analyzer CN6 and CN44. Key switch OFF, disconnection between analyzer CN and CN44. Analyzer CN () CN44 () Analyzer CN6 ~ CN44 Continuity

28 4 OPS TROUBLESHOOTI DIAGNOSIS The diagnosis function informs the operator of a trouble occurrence and the trouble position by blinking the OPS lamp on the combination meter when the OPS controller detects an abnormality. The trouble position is indicated by the lamp blinking count. Note: The OPS lamp is lit for 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 ON OFF Break point indication Code indication sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. Abnormality detection (Code 3)

29 5 DIAGNOSIS ERROR CODE LIST Phenomenon on vehicle Vehicle spec. Error description Major cause Error code Lamp SAS spec. model SASless spec. model ON Dead lamp check No OPS functioning No OPS functioning Sticking GND fault All specifications Seat switch abnormality Blinking (one short ON pulse) No special change from normal state (Excessive leak during lowering) No special change from normal state (Excessive leak during lowering) Sticking GND fault Lift lowering switch abnormality Other than mini lever model Blinking (two short ON cycles) No special change from normal state (Excessive leak during lowering) Sticking GND fault SASless Tilting switch abnormality 3 4 Forward traveling is possible while OPS is operating. Forward traveling is possible while OPS is operating. Discontinuity GND fault Forward interrupt relay (RYF) abnormality 3 Forward traveling is always disabled. Forward traveling is always disabled. +B shorting All specifications Reverse traveling is possible while OPS is operating. Reverse traveling is possible while OPS is operating. Discontinuity Blinking (three short ON cycles) GND fault Reverse interrupt relay (RYR) abnormality 3 Reverse traveling is always disabled. Reverse traveling is always disabled. +B shorting Lift lowering and backward tilting are disabled but other material handling operations are possible while OPS is operating Lift lowering and backward tilting are disabled but other material handling operations are possible while OPS is operating Discontinuity GND fault All material handling operations are disabled while OPS is operating. While OPS is not operating, only lift lowering is possible but other material handling operations are disabled. All material handling operations are disabled while OPS is operating. While OPS is not operating, only lift lowering is possible but other material handling operations are disabled. Unload solenoid (SOL) abnormality 4 All specifications Blinking (four short ON cycles) +B shorting

30 6 Lamp Error code Vehicle spec. Error description Major cause Phenomenon on vehicle SAS spec. model SASless spec. model 4 All specifications Lowering lock solenoid (SOL) abnormality Discontinuity While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible. While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible. GND fault Blinking (four short ON cycles) 43 All specifications Tilt solenoid (SOL3) abnormality +B shorting Discontinuity While OPS is operating, only lift lowering is possible and all other material handling operations are disabled. While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible. While OPS is operating, only lift lowering is possible and all other material handling operations are disabled. While OPS is operating, all material handling operations are disabled. While OPS is not operating, only forward tilting is disabled and all other material handling operations are possible. GND fault +B shorting Automatic leveling stop is disabled. Blinking (five short ON cycles) 5 All specifications Shift lever abnormality +B shorting When OPS is operating, releasing is disabled (locked state by return to neutral function). When OPS is operating, releasing is disabled (locked state by return to neutral function). ON 7 CPU abnormality 7 CPU abnormality 73 CPU abnormality Drive OPS does not function, lowering is always disabled, and material handling OPS does not function. Drive OPS does not function, lowering is always disabled, and material handling OPS does not function. Blinking (seven short ON cycles) Controller 74 All specifications CPU abnormality None in particular None in particular abnormality ON 75 EEPROM abnormality Drive OPS does not function, lowering is always disabled, and 76 EEPROM abnormality material handling OPS does not function. Drive OPS does not function, lowering is always disabled, and material handling OPS does not function. ON All specifications Low voltage alarm Low battery voltage Alarm before OPS operation, but drive/ material handling OPS does not function, lowering is always disabled. Alarm before OPS operation, but drive/ material handling OPS does not function, lowering is always disabled. ON OPS operation Departure from seat : SASless spec. model only because of detection by the SAS controller here on the SAS spec. models.

31 7 List of Reference Pages for Error Codes and Sub Error Codes Without analyzer (SST) With analyzer (SST) Error code Error description Page Error code Error description Page Seat switch abnormality 8 Seat switch abnormality 8 3 Lowering switch abnormality Tilt switch abnormality (L/SAS spec.) Forward interrupt relay (RYF) abnormality Reverse interrupt relay (RYR) abnormality 6 List of Pages to be Referenced by Phenomenon Lowering switch abnormality Tilt lever switch simultaneous ON abnormality Forward tilt switch minute shorting abnormality Backward tilt switch minute shorting abnormality Forward interrupt relay (RYF) abnormality Reverse interrupt relay (RYR) abnormality Unload solenoid (SOL) abnormality 8 4 Solenoid (SOL) abnormality 8 4 Lowering lock solenoid (SOL) abnormality 8 43 Tilt solenoid (SOL3) abnormality 8 5 T/C shift lever abnormality 30 5 T/C shift lever abnormality 3 7 OPS controller abnormality 7 CPU abnormality 7 ROM abnormality 73 RAM abnormality 74 A/D conversion abnormality 75 EEPROM data abnormality 76 EEPROM access abnormality Description Pages to be referenced Without analyzer With analyzer The OPS buzzer does not sound, or keeps sounding. (Export model) The OPS lamp does not come on The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled) 39 4 Cannot lower the fork The material handling OPS does not function (Including when lowering and forward tilting are disabled) Material handling fails (Including when fork lowering is disabled). 5 5 The mast backward tilting speed is always slow or unrestricted. 5 5 Slow mast backward tilting speed (SASless spec. vehicle) Mast does not tilt forward Mast does not tilt forward. (SASless spec. vehicle). 6 6 The drive OPS does not function Traveling fails (Including forward traveling only, reverse traveling only, and occasional abnormalities)

32 8 TROUBLESHOOTI BY ERROR CODE Error Code (Seat switch abnormality) Related Portion OPS controller CN453 (DMI, Seat SW) CN457 (E03, Switch GND) CN4 CN65 6 CN50 CN60 Seat switch Estimated Causes: Connector contact defect Seat switch defect Harness defect Controller defect Error code Check CN45, CN50, CN60, CN4 and CN65 connectors for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : Check the seat switch individually for continuity. Inspection : Check continuity between CN453 and CN457 Seat switch defect Harness defect Controller defect : After correction, check the OPS lamp indication. After connecting all connectors, turn the key switch to OFF once, then to ON (for seconds or more), and to OFF again. After waiting without seating for about 5 minutes and turn the key switch to ON. The OPS must not display error code with blinking.

33 9 Inspection : Check the individual seat switch for continuity. Key switch OFF, CN 60 disconnection. CN60 () Seated Unseated CN60 ~ CN60 Continuity No continuity Inspection : Check continuity between CN453 and CN457. Key switch OFF, CN45 disconnection. (CN4, CN50 and CN60 must be connected.) CN45 () Seated Unseated CN453 ~ CN457 Continuity No continuity Error code Check CN45, CN50, CN60, CN4 and CN65 connectors for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : With CN60 disconnected, check the input signal to the controller. Inspection : Check continuity between CN453 and CN457 Seat switch defect Harness defect Controller defect : After correction check the OPS lamp indication. After connecting all connectors, turn the key switch to OFF once, then to ON (for seconds or more), and to OFF again. After waiting without seating for about 5 minutes and turn the key switch to ON. The OPS must not display error code with blinking.

34 0 Inspection : With CN60 disconnected, check the input signal to the controller. CN60 connector disconnection, key switch OFF ON Analyzer: MAIN MENU OPS ANALYZER MENU IN/OUT MONITOR Seated Unseated SEAT OFF OFF Inspection : Check continuity between CN453 and CN457. Key switch OFF, CN45 disconnection. (CN4, CN50, CN60 and CN65 must be connected.) CN45 () Seated Unseated CN453 ~ CN457 Continuity No continuity

35 Error Code Error Code (Lowering switch abnormality) Error Code (Tilt lever switch simultaneous ON abnormality) (L/SAS Spec.) Error Code 3 (Forward tilt switch minute shorting abnormality) (L/SAS Spec.) Error Code 4 (Backward tilt switch minite shorting abnormality) (L/SAS Spec.) Related Portion OPS controller CN455 (TFI, Forward tilt switch) CN454 (TRI, Backward tilt switch) CN456 (DOWN, Lowering switch) CN457 (E03, SWGND) CN34 CN34 CN343 CN344 CN49 CN49 Forward tilt switch Backward tilt switch Lowering switch Estimated Causes: Connector contact defect Lowering switch defect Harness defect Controller defect Forward tilt switch defect Backward tilt switch defect Tilt switch installation defect Lowering switch installation defect Error code Check the CN45, CN34, and CN49 connectors for any disconnection or internal wetting. After correction check the OPS lamp indication. Inspection : Check the lift lowering switch wiring and tilt lever switch wiring for continuity. Inspection : Check the lift lowering switch and tilt lever switch individually (as installed on the vehicle) for continuity. Inspection 3: Check the lift lowering lever switch and tilt lever switch individually (as removed from the vehicle) for continuity. Controller defect Harness defect Switch defect Lever switch installation defect : After correction check the OPS lamp indication. After key switch ON, operate the tilt lever forward and backward to check if the OPS lamp blinks. Or keep the tilt lever in the neutral position for minutes and check if the OPS lamp blinks. Or keep the lift lever in the neutral position for minutes and check if the OPS lamp blinks. The OPS lamp must not indicate error code with blinking.

36 Inspection : Check the lift lower lever switch wiring and tilt lever switch wiring for continuity. Key switch OFF, CN45 disconnection. Lift lower switch CN45 () Lever at neutral position Lever at up position Lever at down position CN456 ~ CN457 No continuity No continuity Continuity Tilt switch Inspection : Check the lift lower lever switch and tilt lever switch individually (as installed on the vehicle) for continuity. Key switch OFF, CN34 and CN49 disconnection. Lift lower switch Tilt switch Inspection 3: Lever at neutral position Lever at forward tilt position Lever at backward tilt position CN455 ~ CN457 No continuity Continuity No continuity CN454 ~ CN457 No continuity No continuity Continuity Lever at neutral position Lever at up position Lever at down position CN49 ~ CN49 No continuity No continuity Continuity Lever at neutral position Lever at forward tilt position CN34 () Lever at backward tilt position CN34 ~ CN34 No continuity Continuity No continuity CN343 ~ CN344 No continuity No continuity Continuity 4 3 CN49 () Check the lift lower lever switch and tilt lever switch individually (as removed from the vehicle) for continuity. Key switch OFF, CN34 and CN49 disconnection. Lift lower switch (switch on the upper side when installed on the vehicle) CN34 () Switch free Switch pressed CN49 ~ CN49 Continuity No continuity 4 3 CN49 () Forward tilt switch (switch on the upper side when installed on the vehicle) Switch free Switch pressed CN34 ~ CN34 Continuity No continuity Backward tilt switch (switch on the lower side when installed on the vehicle) Switch free Switch pressed CN343 ~ CN344 Continuity No continuity

37 3 Error code Check CN45 and CN49 connectors for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : Disconnect CN49, and check the switch output upon lowering operation. Inspection 4: Check continuity between CN45 and CN49. Inspection : Check lift lower lever switch individually (as installed on the vehicle) for continuity. Harness defect Controller defect (Error occurrence upon continuing lowering operation for minutes or more, however, is normal.) Inspection 3: Check the lift lower lever switch individually (as removed from the vehicle) for continuity. Lower switch defect Lever switch installation defect : After correction, check the OPS lamp indication. After key switch ON, keep the lift lever in the neutral position for minutes and check if the OPS lamp blinks. The OPS lamp must not indicate error code with blinking. Inspection : Disconnect CN49 and check the switch output upon lowering operation. Key switch ON (engine in stopped state) Analyzer: MAIN MENU OPS ANALYZER MENU IN/OUT MONITOR Lift lower switch Lever at neutral position Lever at up position Lever at down position LIFT LOWER OFF OFF OFF Inspection : Check the lift lower lever switch individually (as installed on the vehicle) for continuity. Key switch OFF, CN49 disconnection. Lift lower switch Lever at neutral position Lever at up position Lever at down position CN49 ~ CN49 No continuity No continuity Continuity CN49 ()

38 4 Inspection 3: Check the lift lower lever switch individually (as removed from the vehicle) for continuity. Key switch OFF, CN49 disconnection. Lift lower switch (switch on the upper side when installed on the vehicle) CN49 () Switch free Switch pressed CN49 ~ CN49 Continuity No continuity Inspection 4: Check continuity between CN45 and CN49. Key switch OFF, CN45 and CN49 disconnection CN45 () CN49 () CN456 ~ CN457 No continuity Error codes:, 3, and 4 Check CN45 and CN34 connectors for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : Disconnect CN34, and check the switch output upon tilting operation. Inspection 4: Check continuity between CN45 and CN34. Inspection : Check the tilt lever switch individually (as installed on the vehicle) for continuity. Harness defect Controller defect (Error occurrence upon continuing lever operation for minutes or more or upon simultaneous ON during installation adjustment, however, is normal.) Inspection 3: Check the tilt lever switch individually (as removed from the vehicle) for continuity. Tilt switch defect Lever switch installation defect : After correction, check the OPS lamp indication. After key switch ON, keep the lift lever in the neutral position for minutes and check if the OPS lamp blinks.

39 5 Inspection : Check the switch output upon tilting operation after disconnecting CN34. Key switch ON (engine in stopped state) Analyzer: MAIN MENU OPS ANALYZER MENU IN/OUT MONITOR Tilt switch Lever at neutral position Lever at forward tilt position Lever at backward tilt position TILT FWD OFF OFF OFF TILT BWD OFF OFF OFF Inspection : Check the tilt lever switch individually (as installed on the vehicle) for continuity. Key switch OFF, CN34 disconnection. Tilt switch Lever at neutral position Lever at forward tilt position CN34 () Lever at backward tilt position CN34 ~ CN34 No continuity Continuity No continuity CN343 ~ CN344 No continuity No continuity Continuity 4 3 Inspection 3: Check the tilt lever switch individually (as removed from the vehicle) for continuity. Key switch OFF, CN34 disconnection. Tilt forward switch (switch on the upper side when installed on the vehicle) Switch free Switch pressed CN34 ~ CN34 Continuity No continuity 4 3 CN34 () Tilt backward switch (switch on the lower side when installed on the vehicle) Switch free Switch pressed CN343 ~ CN344 Continuity No continuity Inspection 4: Check continuity between CN45 and CN34. Key switch OFF, CN45 and CN34 disconnection. CN455 ~ CN457 CN454 ~ CN457 No continuity No continuity CN45 () 3 4 CN34 ()

40 6 Error Code 3 Error Code 3 (Forward interrupt relay (RYF) abnormality) Error Code 3 (Reverse interrupt relay (RYR) abnormality) Related Portion OPS controller CN450 (RYF, Forward interrupt relay) CN45 (RYR, Reverse interrupt relay) CN457, (E03, SWGND) CN466 T/C relay block Forward interrupt relay Reverse interrupt relay Estimated Causes: Connector contact defect Forward interrupt relay defect Reverse interrupt relay defect Harness defect Controller defect Error Codes 3, 3, 3 Check the CN45 and CN46 connectors for disconnection or internal wetting and the relays for insertion. After correction, check the OPS lamp indication. Inspection : Check the forward/reverse interrupt relay individually (on the coil side) for the resistance value. Inspection : Check the wiring between CN45 and the T/C relay block for continuity. Interrupt relay defect Harness defect Controller defect : 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 OPS lamp blinks. The OPS lamp must not display error code 3 with blinking. Note: When the analyzer is provided, check the related portion after checking the error memory for the current error code. See p9 " DIAG MEMORY" for the error memory check method.

41 7 Inspection : 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. Forward interrupt relay, between terminals and Reverse interrupt relay, between terminals and Resistance Approx. 90 Ω (0 C) Approx. 90 Ω (0 C) 4 (5) 3 RLY Inspection : 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 Discontinuity check CN450 ~ Forward interrupt relay terminal CN45 ~ Reverse interrupt relay terminal CN457 ~ Forward interrupt relay terminal CN457 ~ Reverse interrupt relay terminal GND fault check +B shorting check IG line shorting check CN450 ~ CN457 CN45 ~ CN457 CN450 ~ CN453 CN45 ~ CN453 CN450 ~ CN455,6 CN45 ~ CN455,6 Continuity Continuity Continuity Continuity No continuity No continuity No continuity No continuity No continuity No continuity T/C FR RLY CN45 () T/C RR RLY

42 8 Error Code 4 Error Code 4 (Unload solenoid (SOL) abnormality) Error Code 4 (Lowering lock solenoid (SOL) abnormality) Error Code 43 (Tilt solenoid (SOL3) abnormality) Related Portion OPS controller CN454 (SOL, Unload SOL) CN453 (SOL, Lowering lock SOL) CN45 (SOL3, Tilt SOL) CN4530 (E3, SOLGND) CN459 (E3, SOLGND) W/SPLICEZ CN468 CN469 CN47 CN47 CN48 CN48 CN CN (E3, Body GND) Unload SOL Lowering lock SOL Tilt SOL Estimated Causes: Connector contact defect Unload solenoid defect Lowering lock solenoid defect Tilt solenoid defect Controller defect Harness defect Error Codes 4, 4, 4, 43 Check the CN45, CN46, CN47, CN48 and CN connectors for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : Check the solenoids (SOL SOL3) individually for the resistance value. Inspection : Check the wiring between CN45 and each solenoid (SOL SOL3) for continuity. Solenoid defect Harness defect Controller defect : 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 to check 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 current error code. See p9 " DIAG MEMORY" for the error memory check method.

43 9 Inspection : Check the resistance of each solenoid (SOL to SOL 3). Key switch OFF, CN47, CN48 and CN disconnection. CN47 () CN48 () CN () Resistance SOL CN47 ~ CN47 SOL CN48 ~ CN48 SOL3 CN ~ CN Approx. 9 Ω (0 C) Approx. 9 Ω (0 C) Approx. 9 Ω (0 C) Inspection : Check continuity of the wiring between CN45 and each of solenoids SOL to SOL3. Key switch OFF, CN45, CN47, CN48 and CN disconnection. Discontinuity check CN454 ~ CN47 CN459 ~ CN47 CN4530 ~ CN47 CN47 ~ Frame Continuity Continuity Continuity Continuity CN45 () CN453 ~ CN48 CN459 ~ CN48 CN4530 ~ CN48 Continuity Continuity Continuity CN47 () CN48 () CN () CN48 ~ Frame Continuity CN45 ~ CN Continuity CN459 ~ CN Continuity CN4530 ~ CN Continuity CN ~ Frame Continuity GND fault check CN454 ~ CN459,30 No continuity CN453 ~ CN459,30 No continuity CN45 ~ CN459,30 No continuity +B shorting check CN454 ~ CN453 No continuity CN453 ~ CN453 No continuity CN45 ~ CN453 No continuity IG line shorting check CN454 ~ CN455,6 No continuity CN453 ~ CN455,6 No continuity CN45 ~ CN455,6 No continuity

44 30 Error Code 5 5 (T/C shift lever abnormality) Related Portion To IG SFT CN68 CN536 T/C relay block OPS controller CN453 (DRF, Forward drive SW) CN454 (DRR, Reverse drive SW) CN46 CN46 Forward interrupt relay Reverse interrupt relay 4 4 CN535 (CN573) CN53 (CN576) Shift lever Estimated causes: Connector contact defect Shift lever switch defect Harness defect Controller defect Fuse defect Error Code 5 Check if the fuse (SFT) is blown. After correction, check the OPS lamp indication. Check connectors CN45, CN46, CN53 and CN6 for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : Check the shift lever individually for continuity. Inspection : Check the continuity of wiring between CN45 and IG SW. Shift lever defect Harness defect Controller defect : 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.

45 3 Inspection : Check the T/C shift lever individually for continuity. Key switch OFF, CN53 disconnection DITION SWITCH 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 on lever side No continuity No continuity Continuity Inspection : 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.) Lever at neutral CN453 ~ IG SW4 CN454 ~ IG SW4 No continuity No continuity CN45 () 3 4 IG SW +B shorting check CN453 ~ CN453 CN454 ~ CN453 No continuity No continuity IG line shorting check CN453 ~ CN455,6 CN454 ~ CN455,6 No continuity No continuity Error code 5 Check if the fuse (SFT) is blown. After correction, check the OPS lamp indication. Check CN45, CN46 and CN53 connectors for any disconnection or internal wetting. After correction, check the OPS lamp indication. Inspection : Disconnect CN53, and check the input signal to the controller. Inspection : Check the wiring between CN45 and IG SW for continuity. Shift lever defect Harness defect Controller defect

46 3 : 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 : 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 Lever at neutral position Lever at forward traveling position Lever at reverse traveling position DIR FWD OFF OFF OFF DIR REV OFF OFF OFF Inspection : 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.) Lever at neutral CN453 ~ IG SW4 CN454 ~ IG SW4 No continuity No continuity CN45 () 3 4 IG SW +B shorting check CN453 ~ CN453 CN454 ~ CN453 No continuity No continuity IG line shorting check CN453 ~ CN455,6 CN454 ~ CN455,6 No continuity No continuity

47 33 TROUBLESHOOTI BY PHENOMENON The OPS buzzer does not sound. (Export model) The OPS buzzer keeps sounding. (Export model) Related Portion To IG SW ECUIG OPS controller CN459 (BZO, OPS buzzer) CN5 CN5 OPS buzzer Estimated Causes: Connector contact defect OPS buzzer defect Harness defect Controller defect Fuse defect The OPS buzzer does not sound. Check for blown fuse (ECUIG). After correction, check the OPS buzzer sound. Check the CN45 and CN5 for any disconnection or internal wetting. After correction, check the OPS buzzer sound. Inspection : Check the continuity between the IG SW and CN5, and between CN45 and CN5. Inspection : Check the continuity between CN5 and the frame. Harness defect OPS buzzer defect Controller defect : After correction, check the OPS buzzer sound. After connecting all connectors, turn the key switch ON, and leave the seat to check if the buzzer sounds.

48 34 Inspection : Check the continuity between the IG SW and CN5, and between CN45 and CN5. Key switch OFF, CN45, CN5, IG SW connector disconnection CN45 () IG SW4 ~ CN5 CN459 ~ CN5 Continuity Continuity CN5 () Inspection : Check the continuity between CN5 and the frame. Without analyzer Disconnect CN5 and turn the key switch to ON (engine in stopped state). 3 4 IG SW Buzzer ON Buzzer OFF Between CN5 and the frame Continuity No continuity CN5 () Normally, the buzzer sounds for second upon lapse of 0.5 seconds after the operator leaves the seat. With analyzer Disconnect CN5 and turn the key switch to ON (engine in stopped state). Analyzer: MAIN MENU OPS ANALYZER MENU ACTIVE TEST Forcibly turn the OPS buzzer ON and OFF, and check the continuity between CN5 and CN5. Buzzer ON Buzzer OFF Between CN5 and the frame Continuity No continuity CN5 ()