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• Page 1
  8FGU 15, 18, 20, 25, 30, 32 8FDU 15, 18, 20, 25, 30, 32 62-8FDU 15, 18, 20, 25, 30 8FGCU 20, 25, 30, 32 Supplement Pub. No. CE118…
• Page 2
  Any change or modifications thereaf- ter will be informed by Toyota Industrial Equipment Parts & Service News. For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual.

• Page 3: Table Of Contents

  Table of Contents GENERAL……………….. 2 STEERING ……………….. 5 MATERIAL HANDLING SYSTEM ………… 17 OIL PUMP ……………….. 22 OIL CONTROL VALVE……………. 25 SAS/OPS ……………….. 52 DISPLAY……………….. 55 TROUBLESHOOTING……………. 152 WIRING DIAGRAM……………. 203 10 SST LIST AND SERVICE STANDARDS LIST…….. 217…

• Page 4: General

  1 GENERAL 1 GENERAL 1.1 VEHICLE MODEL Pneumatic Tire Models (Pn) Classification Transmis- Load Capacity Vehicle Model Engine sion Type Series Model 8FGU15 Gasoline (4YM) Pn15 3000 lbs 8FDU15 Diesel 62-8FDU15 1DZ-II Pn1 ton series 8FGU18 Gasoline (4YM) Pn18 3500 lbs…

• Page 5
  1 GENERAL 1.2 FRAME NUMBER Frame No. Punching Position Punching position…
• Page 6
  1 GENERAL Pneumatic tire Capacity (L.C.24inch) Series Engine Vehicle model Punching format lbs. 3000 8FGU15 8FGU18-60011 3500 8FGU18 (4YM) 3000 8FDU15 Pn1 ton series 8FDU18-60011 3500 8FDU18 3000 62-8FDU15 1DZ-II 608FDU18-60011 3500 62-8FDU18 4000 8FGU20 8FGU25-60011 5000 8FGU25 (4YM) 4000…

• Page 7: Steering

  2 STEERING 2 STEERING 2.1 GENERAL Hydrostatic Steering Valve 1ZS and 4YE engine A — A B — B D — D C — C…

• Page 8
  2 STEERING 4YM and 1DZ engine (W/synchronized steering)
• Page 9
  2 STEERING 4YM engine (L/synchronized steering) Shock valve (No used) Neutral position spring Housing Check valve Spool Sleeve Cardan shaft Gear rim Gear wheel (rotor) Relief valve…
• Page 10
  2 STEERING 2.2 SPECIFICATIONS Item All models Steering wheel diameter 300 (11.81) mm (in) Steering wheel play (at idling) 20 to 50 (0.79 to 1.97) mm (in) Power steering type Hydrostatic steering Hydrostatic steering valve (L/synchronized steering) Pn1 ton Pn2 ton Pn3 ton Cu2 ton Cu3 ton…
• Page 11
  2 STEERING 2.3 COMPONENTS 1ZS and 4YE engine [4507] 4YM and 1DZ-II engine [4507]…
• Page 12
  2-10 2 STEERING PS Valve 1ZS and 4YE engine [4503] 4YM engine (L/synchronized steering) [4503] 01K=(INCL. ) 4503-036…
• Page 13
  2 STEERING 2-11 4YM and 1DZ-II engine (W/synchronized steering) [4503]…
• Page 14
  2-12 2 STEERING 2.4 HYDROSTATIC STEERING VALVE ASSY 2.4.1 DISASSEMBLY, INSPECTION AND REASSEMBLY (1ZS and 4YE) NOTICE Clean dirt off from ports and joints before disassembly and operate in a clean place. a: T=23 to 27 N m (235 to 275 kgf-cm) [17.0 to 19.9 ft-lbf] b: T=60 to 80 N m (612 to 816 kgf-cm) [44.3 to 59.0 ft-lbf] Disassembly Procedure Step 1.
• Page 15
  2 STEERING 2-13 Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. Point Operations Point 1 Disassembly: Make a match mark across the end cover, outer gear, and valve body. Reassembly: Follow the steps below for reassembly. a: Match mark 1.
• Page 16
  2-14 2 STEERING Point 3 Disassembly: A steel ball is placed in portion A of the valve body. Keep it so as not to be lost. Reassembly: Make sure to put the steel ball in portion A. a: Steel ball Point 4 Reassembly: Install the retaining bearing as illustrated at left.
• Page 17
  2 STEERING 2-15 Point 6 Reassembly: Install the center spring as illustrated at left. Reassembly: After spool insertion into the sleeve, the notched por- tion of the spring shall securely set in the groove on the sleeve. a: Center spring b: Notch Point 7 Reassembly:…
• Page 18
  2-16 2 STEERING 2.4.2 RELIEF PRESSURE INSPECTION (1ZS and 4YE) Step 1. Install an oil pressure gauge. 1. Disconnect the hose from the P port of the steer- ing valve, and connect the SST (adapter). SST 09450-23320-71 2. Install the oil pressure gauge. Plug size: PT1/8 P port Step 2.

• Page 19: Material Handling System

  3 MATERIAL HANDLING SYSTEM 3-17 3 MATERIAL HANDLING SYSTEM 3.1 HYDRAULIC CIRCUIT DIAGRAM………… 17 3.2 COMPONENTS ……………… 21 3.1 HYDRAULIC CIRCUIT DIAGRAM 4YE and 1ZS engine Without oil cooler (1) Oil pump (2) Priority valve (3) Oil control valve (4) Steering valve (5) Solenoid valve (OPT) (6) Power steering cylinder (7) Lift, tilt and ATT cylinder…

• Page 20: Oil Pump

  3-18 3 MATERIAL HANDLING SYSTEM With oil cooler (10) (1) Oil pump (2) Priority valve (3) Oil control valve (4) Steering valve (5) Solenoid valve (OPT) (6) Power steering cylinder (7) Lift, tilt and ATT cylinder (8) Oil tank (9) Oil cooler (10) Relief valve…

• Page 21: Oil Control Valve

  3 MATERIAL HANDLING SYSTEM 3-19 4YM and 1DZ-II engine Without oil cooler (1) Oil pump (2) Flow divider (3) Oil control valve (4) Steering valve (5) Solenoid valve (OPT) (6) Power steering cylinder (7) Lift, tilt and ATT cylinder (8) Oil tank…

• Page 22
  3-20 3 MATERIAL HANDLING SYSTEM With oil cooler (10) (1) Oil pump (2) Flow divider (3) Oil control valve (4) Steering valve (5) Solenoid valve (OPT) (6) Power steering cylinder (7) Lift, tilt and ATT cylinder (8) Oil tank (9) Oil cooler (10) Relief valve…
• Page 23
  3 MATERIAL HANDLING SYSTEM 3-21 3.2 COMPONENTS [6801]…
• Page 24
  4-22 4 OIL PUMP 4 OIL PUMP 4.1 GENERAL……………….. 22 4.2 SPECIFICATIONS……………….  23 4.3 PERFORMANCE TEST……………. 24 4.1 GENERAL 4Y(STD),1ZS,1DZ-II…
• Page 25
  4 OIL PUMP 4-23 4.2 SPECIFICATIONS Specifica- Theoretical discharge Vehicle model Engine Maker (Model) Pump type tion )/rev Gear pump/ KYB (KFS2422) 22.0 (1.342) single gear Gear pump/ Steel cabin KYB (DGP2321) 21.5 (1.312) double gear Gear pump/ Pn1 ton series KYB (KFS2425) 25.7 (1.568) single gear…
• Page 26
  4-24 4 OIL PUMP 4.3 PERFORMANCE TEST Lifting Speed Lifting speed (loaded/no-load) mm/sec (fpm) mm/sec (fpm) Vehicle model Engine V mast FSV mast FV mast When When not When When not When When not loaded loaded loaded loaded loaded loaded 665 (131) 680 (134) 620 (122)
• Page 27
  5 OIL CONTROL VALVE 5-25 5 OIL CONTROL VALVE 5.1 OIL CONTROL VALVE ASSY ………….. 26 5.2 OIL CONTROL VALVE ASSY(MINI LEVER AND JOYSTICK LEVER) ..  39 5.3 RELIEF PRESSURE ADJUSTMENT ………… 50…
• Page 28
  5-26 5 OIL CONTROL VALVE 5.1 OIL CONTROL VALVE ASSY 5.1.1 GENERAL 1ZS and 4YE engine…
• Page 29
  5 OIL CONTROL VALVE 5-27 X1-X1 INLET Priority valve Relief valve Electromagnetic proportional reducing valve…
• Page 30
  5-28 5 OIL CONTROL VALVE Hydraulic Circuit Diagram (1ZS engine) Electromagnetic proportional reducing valve Gauge port Priority valve Relief valve Load check valve Lift lock valve Flow regulator valve (Lift lock SOL) Load check valve Manual downlifting valve Tilt backward lock valve (Tilt backward lock SOL) Tilt control valve (Tilt control SOL)
• Page 31
  5 OIL CONTROL VALVE 5-29 Hydraulic Circuit Diagram (4YE engine) Electromagnetic proportional reducing valve Gauge port Priority valve Relief valve Load check valve Lift lock valve Flow regulator valve (Lift lock SOL) Load check valve Manual downlifting valve Tilt backward lock valve (Tilt backward lock SOL) Tilt control valve (Tilt control SOL)
• Page 32
  5-30 5 OIL CONTROL VALVE 5.1.2 SPECIFICATIONS Vehicle model Item 1 ton series 2 ton series 3 ton series Type Add-on type Relief pressure Lift 18.7 (191) [2720] Tilt 15.7 (160) [2277] MPa (kgf/cm ) [psi] Flow divider flow rate (Except 1ZS and 4YE engine) Pn: 15.8 (4.17) 13.6 (3.59) 13.6 (3.59)
• Page 33
  5 OIL CONTROL VALVE 5-31 5.1.3 COMPONENTS 1ZS and 4YE engine [ASSY&FITTING] [6705] 1DZ-II and 4YM engine [ASSY&FITTING] [6705]…
• Page 34
  5-32 5 OIL CONTROL VALVE 1DZ-II and 4YM engine [INLET,OUTLET,LIFT,TILT] [6705] 1DZ-II and 4YM engine [ATT] [6705]…
• Page 35
  5 OIL CONTROL VALVE 5-33 5.1.4 DISASSEMBLY, INSPECTION AND REASSEMBLY(1ZS and 4YE engine) NOTICE • Work in a clean location. • Since individual parts are finished with high precision, carefully operate so as not to damage them. T=39.2 N m (400 kgf-cm) [28.94 ft-lbf] Disassembly Procedure Step 1.
• Page 36
  5-34 5 OIL CONTROL VALVE NOTICE Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly. 5.1.4.1 Point Operations Point 2 Disassembly: Put match marks to prevent solenoid installation in an incorrect position. Reassembly: Align match marks for reassembly. Inspection: Check the lift lock solenoid for continuity.
• Page 37
  5 OIL CONTROL VALVE 5-35 Point 3 Inspection: Check the lift limit switch for continuity. Lowering side (measurement terminal 1 ⇔ 2): No continuity when the switch is pressed. Lifting side (measurement terminal 3 ⇔ 4): No continuity when the switch is pressed. Reassembly: Be careful not to mistake the lowering side and lifting side.
• Page 38
  5-36 5 OIL CONTROL VALVE Inspection: Check and clean any clogged orifice. Reassembly: Carefully reassemble to prevent incorrect installation of each solenoid spool. Point 6 Inspection: Check the backward tilt lock SOL for continuity. (Reference) Resistance: 9.4 to 10.4 Ω (at 20 °C) Inspection: Check and clean any clogged filter.
• Page 39
  5 OIL CONTROL VALVE 5-37 Point 8 Disassembly and Reassembly: Remove the compression spring from the tilt spool. Washer SST 09610-10161-71 Use the SST after attaching a washer. Point 9 Inspection: Check the proportional reducing valve for continuity. Measurement terminal: Continuity exists. (Reference) Resistance: 6.5 to 7.2 Ω…
• Page 40
  5-38 5 OIL CONTROL VALVE Reference: Level of current to plate 4 unit of short No. 5 unit serial No. and whose 5 unit start from 00001 Mention I-P current rank (H-L each 1unit) Stamp 3 unit aim pressure Stamp the current value that calculated Level of current to plate than an approximate expression (example: 3.5 MPa →…
• Page 41
  5 OIL CONTROL VALVE 5-39 5.2 OIL CONTROL VALVE ASSY(MINI LEVER AND JOYSTICK LEVER) 5.2.1 GENERAL 1ZS and 4YE engine…
• Page 42
  5-40 5 OIL CONTROL VALVE X1-X1 INLET Priority valve Relief valve Electromagnetic proportional reducing valve…
• Page 43
  5 OIL CONTROL VALVE 5-41 Hydraulic Circuit Diagram (1ZS engine) Electromagnetic proportional reducing valve Gauge port Priority valve Relief valve Load check valve Lift lock valve Flow regulator valve (Lift lock SOL) Manual Load check valve downlifting valve Tilt control valve (Tilt control SOL) Load check valve Decompression…
• Page 44
  5-42 5 OIL CONTROL VALVE Hydraulic Circuit Diagram (4YE engine) Electromagnetic proportional reducing valve Gauge port Priority valve Relief valve Load check valve Lift lock valve Flow regulator valve (Lift lock SOL) Manual Load check valve downlifting valve Tilt control valve (Tilt control SOL) Load check valve ATT spool with…
• Page 45
  5 OIL CONTROL VALVE 5-43 5.2.2 SPECIFICATIONS Vehicle model Item 1 ton series 2 ton series 3 ton series Type Add-on type Relief pressure Lift 18.7 (191) [2720] MPa (kgf/cm ) [psi] Tilt 15.7 (160) [2277] Flow divider flow rate (Except 1ZS and 4YE engine) Pn: 15.8 (4.17) 13.6 (3.59) 13.6 (3.59)
• Page 46
  5-44 5 OIL CONTROL VALVE 5.2.3 COMPONENTS 1ZS and 4YE engine [ASSY&FITTING] [6705]…
• Page 47
  5 OIL CONTROL VALVE 5-45 5.2.4 DISASSEMBLY, INSPECTION AND REASSEMBLY(1ZS and 4YE engine) NOTICE • Work in a clean location. • Since individual parts are finished with high precision, carefully operate so as not to damage them. T=39.2 N m (400 kgf-cm) [28.94 ft-lbf] Disassembly Procedure Step 1.
• Page 48
  5-46 5 OIL CONTROL VALVE NOTICE Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly. 5.2.4.1 Point Operations Point 2 Disassembly: Put match marks to prevent solenoid installation in an incorrect position. Reassembly: Align match marks for reassembly. Inspection: Check the lift lock solenoid for continuity.
• Page 49
  5 OIL CONTROL VALVE 5-47 Point 3 Inspection: Check the tilt solenoid for continuity. (Reference) Resistance: 9.4 to 10.4 Ω (at 20 °C) Inspection: Check and clean any clogged filter. Inspection: Check and clean any clogged orifice. Reassembly: Carefully reassemble to prevent incorrect installation of each solenoid spool.
• Page 50
  5-48 5 OIL CONTROL VALVE Disassembly: Before disassembly, measure the installation position Adjusting screw (dimension (A)) of the material handling start timing adjusting screw. Reassembly: Reassemble according to the dimension (A) meas- ured before disassembly. Adjustment: After installing the control valve to the vehicle, check whether there are any abnormalities in material hand- ling start timing by slowly operating the lever.
• Page 51
  5 OIL CONTROL VALVE 5-49 Point 7 Inspection: Check and clean any clogged filter. Reassembly: When the relief valve is disassembled, temporarily in- Adjusting screw A stall it after fitting the nuts as illustrated. Lock nut 1 a = 27.0 mm (1.06 in) Adjusting sleeve B NOTICE:…
• Page 52
  5-50 5 OIL CONTROL VALVE 5.3 RELIEF PRESSURE ADJUSTMENT NOTICE • Relief pressure adjustment for tilt side is «Not» necessary by adopting Electromagnetic relief valve while relief valve is dual structure type as before. • Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause high- pressure generation that may result in damage to the oil pump and other hydraulic devices.
• Page 53
  5 OIL CONTROL VALVE 5-51 Start the engine, and check for oil leaks and abnor- mal noise. Install the toe board. Close the engine hood. Adjust the lift side relief pressure. (1) Set the seat switch to ON. (Operate by two workers with one sitting on the seat.) (2) Operate the lift lever to lift the fork fully.

• Page 54: Sas/Ops

  6-52 6 SAS/OPS 6 SAS/OPS 6.1 SAS FUNCTION 6.1.1 COMPONENTS Load Sensor (4Y engine) [5803] Load Sensor (1ZS engine) [5803]…

• Page 55: Display

  6 SAS/OPS 6-53…

• Page 56
  6-54 6 SAS/OPS Load Sensor (1DZ-II engine) [5803]…
• Page 57
  7 DISPLAY 7-55 7 DISPLAY 7.1 MULTI-FUNCTION DISPLAY DX ………… 55 7.2 SERVICE FUNCTIONS «MASK MENU»………. 71 7.1 MULTI-FUNCTION DISPLAY DX 7.1.1 General The multi-function display DX has various functions that indicate / notify the vehicle’s information such as vehicle speed. And the operator or administrator can set the vehicle performance with this display. Further- more, it has functions to perform maintenance, feeling adjustments and specification setting as a service function.
• Page 58
  7-56 7 DISPLAY 7.1.2 FUNCTION LIST Multi-function Display DX Function List ○： Operator available A： Operator available when menu lock setting is «NO» , Administrator available (protected by the administrator password) B： Administrator only (protected by the administrator password) Auto speed Functions Novelty control…
• Page 59
  7 DISPLAY 7-57 7.1.3 SCREEN 7.1.3.1 Initial screen after Key-On The initial screen is displayed for about 1 second after the key switch is turned ON. 7.1.3.2 Status screen The status screen is displayed after the initial screen. Function activation indicator Speedometer Function activation indicator Low speed setting indicator…
• Page 60
  7-58 7 DISPLAY 7.1.4 DETAIL DESCRIPTION 7.1.4.1 Speedometer ▪ The speedometer indicates the vehicle speed digitally by 1 mph or 1 km/h. In factory setting, default models are preset in «mph». And export SPEC.[OPT], E.E.C. SPEC.[OPT], mm-kg indicator spec[OPT] are preset in «km/h». 7.1.4.2 Torque converter oil temperature indicator ▪…
• Page 61
  7 DISPLAY 7-59 3. Eco-mode indicator ▪ This indicator lights and goes off alternately when the oper- ator presses the mode select switch. The Eco-mode func- tion is effective when this indicator lights. But this indicator cannot be switched by pressing the mode select switch when the menu lock is effective.
• Page 62
  7-60 7 DISPLAY 7.1.4.4 Meter Every pressing switch (4) on the status screen, change the screen to Odometer/Trip, maintenance hour meter screen. 1. Odometer The Odometer displays the total travel distance. In factory setting, default models are preset in «mile». And export SPEC.[OPT], E.E.C.
• Page 63
  7 DISPLAY 7-61 7.1.4.5 Warning 1. Parking brake ON warning ▪ This indicator blinks and buzzer sounds when the operator attempts to travel the vehicle without releasing the parking brake. 2. Parking brake OFF warning ▪ The buzzer sounds when the operator leaves the seat with the parking brake released. The buzzer sounds when the operator turns off the key switch with the parking brake released.
• Page 64
  7-62 7 DISPLAY 7.1.5 SETTING FUNCTIONS Setting menu for operator Pressing switch (1) on the status screen for more than 2 seconds displays the setting menu for operator. But the setting menu screen is not displayed when the menu lock is effective. “Menu lock”…
• Page 65
  7 DISPLAY 7-63 7.1.6 ADMINISTRATOR FUNCTIONS The multi-function display DX provide administrators to adjust performance and set up some functions. These functions are password-protected not to be changed by general operators. Entering the password displays the setting menu for administrator. 7.1.6.1 Administrator functions list Group Setting Screen…
• Page 66
  7-64 7 DISPLAY Step Display Operation Vehicle response When the second password has been set: password screen is displayed. Enter the password. Other: Skip this screen. Administrator menu screen is displayed automatically.
• Page 67
  7 DISPLAY 7-65 7.1.6.3 Setting menu for administrator Use switch (1) to select the desired item and press switch (4) ; each setting screen will appear. Select [END] on the menu and press switch (4) ; the status screen returns.
• Page 68
  7-66 7 DISPLAY 7.1.6.3.1 Administrator functions 1) Low speed level setting screen ▪ This screen has the same functions as for general operat- ors. switch (2) switch (3) switch (4) 2) Travel speed limiter setting screen The travel speed limiter level is set on this screen. ▪…
• Page 69
  7 DISPLAY 7-67 4) Planned maintenance hour setting screen Planned time of maintenance hour meter is set up on this screen. Time for maintenance hour meter can be set from　10 hours up to 2400 hours, by 10 hours for 10 hours to 200 hours and by 50 hours for 200 hours to 2400 hours.
• Page 70
  7-68 7 DISPLAY 7.1.6.3.2 Administrator’s second password setting screen Administrator’s second password can be registered or deleted on this screen. Registration of password ▪ The administrator can register the second password. The second password can be registered by continuing to press switch (1) for 2 seconds after entering the password by using switch (1) to (4).
• Page 71
  7 DISPLAY 7-69 Deletion of password ▪ The password can be cleared by pressing switch (1) for more than 2 seconds on the administrator’s second pass- word setting screen. If the switch (4) is pressed for 2 seconds or more before deletion, the screen returns to the menu screen and the password is NOT deleted.
• Page 72
  7-70 7 DISPLAY 7.1.6.3.3 Menu Lock setting screen ▪ This function can limit the change of the vehicle setting by the operator. When menu lock setting is «YES”, the following items are limited. ･Setting menu for operator is NOT displayed. ･Eco-mode is NOT changed.
• Page 73
  7 DISPLAY 7-71 7.2 SERVICE FUNCTIONS «MASK MENU» 7.2.1 GENERAL In the multi-function display DX, aside from the general functions that an operator or an administrator nor- mally use, the following mask functions for use by the service staff for vehicle maintenance and specification setting are also provided.
• Page 74
  7-72 7 DISPLAY When used Function Description Vehicle de- Board re- Others livery placement Administrator’s second password As reques- Deletes the administrator’s clear ted by cus- second password. tomer [MANAGER PASS CLR] As reques- Contrast Adjusts the contrast of the dis- ○…
• Page 75
  7 DISPLAY 7-73 Step Display Operation Vehicle response Press switch (1) within 10 A short beep sounds. seconds. Switch (1) When pressing the Within 10 seconds, press switches, a short beep switch (2) and switch (3) at the sounds, and after 2 same time for more than 2 seconds repeated short seconds.
• Page 76
  7-74 7 DISPLAY 7.2.2.2 SERVICE FUNCTION «MASK MENU» Screen NOTICE During all the test screen display, the vehicle can be operated normally. Operating Procedure Service function «MASK MENU» initial screen is dis- played for 5 seconds. Step 1 Enter the password on the general screen to display the service function «MASK MENU»…
• Page 77
  7 DISPLAY 7-75 ▪ «1. ANALYZER» This function indicates the electrical system status and reads the error information detected by the controller. Switch (1): Switching selection to next item Switch (4): To «ANALYZER MENU» screen…
• Page 78
  7-76 7 DISPLAY ▪ «2. TUNING» Use this function for fine adjustment of control of the travel- ing and material handling. Switch (1): Switching selection to next item Switch (4): To «TUNING MENU» screen ▪ «3. OPTIONSET» Use this function to match control of the controller or dis- play according to the set options or control.
• Page 79
  7 DISPLAY 7-77 ▪ «4. MATCHING» This function updates the signal voltage values stored in the controller (signal voltage values from the SAS or Mini Lever functions sensors under the standard vehicle condi- tion). Switch (1): Switching selection to next item Switch (4): To «MATCHING MENU»…
• Page 80
  7-78 7 DISPLAY ▪ «7. IDLE ADJUSTMENT» Adjusts engine idle speed. Switch (1): Switching selection to next item Switch (4): To «IDLE ADJUSTMENT» screen ▪ «8. MASK PASSWORD» Sets the mask second password. Switch (1): Switching selection to next item Switch (4): To «MASK PASSWORD»…
• Page 81
  7 DISPLAY 7-79 ▪ «11. METER START» Starts counting the odometer, trip meter and maintenance hour meter. Switch (1): Switching selection to next item Switch (4): To «METER START» screen NOTICE: ▪ After start counting the meters, «METER START» will not be displayed on the service function «MASK MENU»…
• Page 82
  7-80 7 DISPLAY 7.2.3 ANALYZER 7.2.3.1 GENERAL Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of the control system, using communication between each controller and the multi-function display DX. By switching the multi-function display DX to analyzer mode, operative conditions of the sensor actuator that is used for traveling, material handling, FHPS and SAS/OPS functions, or the error information detected by the controller can be read.
• Page 83
  7 DISPLAY 7-81 7.2.3.2 ANALYZER SCREEN MENU LIST Analyzer menu screen Display item Description Menu screen Screen No. 1. DIAG MEMORY 1. to 10. Indications of errors occurred IGSW Key switch (IG) Key switch (ST) BATT Battery voltage 1/10 G/LP Fuel changeover switch Fuel specification discrimination signal Engine specification discrimination signal…
• Page 84
  7-82 7 DISPLAY Analyzer menu screen Display item Description Menu screen Screen No. Engine speed NE( ) (Traveling speed) Intake manifold pressure 9/10 VF voltage (LPG/CNG) O2 sensor voltage 2. I/O ENGINE CTRL OX( ) (O2 sensor monitor) (Engine control) (4Y) Engine speed NE( )
• Page 85
  7 DISPLAY 7-83 Analyzer menu screen Display item Description Menu screen Screen No. Traveling speed sensor voltage SPD( ) (Traveling speed) ACCSW Accelerator switch BRKSW Brake switch PKBSW Parking brake switch SPARE Spare SEAT Seat switch Forward traveling switch 3. I/O TRAVELING Reverse traveling switch （Traveling/swing system）…
• Page 86
  7-84 7 DISPLAY Analyzer menu screen Display item Description Menu screen Screen No. MD/MU Lift lowering switch/Lift raising switch MF/MR Forward tilt switch/Backward tilt switch USOL (Unused) LSOL Lift lowering lock solenoid TSOL Tilt solenoid BTSL Backward tilt lock solenoid SEAT Seat switch Tilt angle sensor voltage…
• Page 87
  7 DISPLAY 7-85 Analyzer menu screen Display item Description Menu screen Screen No. SWING SOL Swing lock solenoid forced operation STEERING Knob position compensation solenoid forced oper- ation Forward/reverse traveling cut-off relay forced op- T/C RLY eration ASC RLY (Unused) LIFT LWR Lift lowering lock solenoid forced operation 7.ACTIVE TEST…
• Page 88
  7-86 7 DISPLAY Step 4 If you select «9. END» on the «ANALYZER MENU» screen and press switch (4) (enter), the service func- tion «MASK MENU» screen appears again. ▪ «1. DIAG MEMORY» Switch (1): Switching selection to next item Switch (4): To «DIAG MEMORY»…
• Page 89
  7 DISPLAY 7-87 7.2.3.4 Diagnosis Memory Function «1.DIAG MEMORY» The controller stores up to 10 most recent errors. The «DIAG MEMORY» screen displays these diagnosis codes with their detection time information (in ignition key ON hour meter reading). The most recent diagnosis code is displayed as 1, followed by 2, 3 and so on to 10. Operating Procedure Step 1 Display the «ANALYZER MENU»…
• Page 90
  7-88 7 DISPLAY ▪ «DIAG MEMORY 2/2» Displays diagnosis 6 to 10. Switch (4): Returning to the «ANALYZER MENU» screen…
• Page 91
  7 DISPLAY 7-89 7.2.3.5 In/Out Monitor Function «I/O MONITOR» This function displays the input voltage from each of traveling, material handling, FHPS, SAS and OPS sensors. The circuit or sensor quality can be judged by monitoring the displayed value. 7.2.3.5.1 In/Out Monitor (1) «2.I/O ENGINE CTRL» 4Y Engine Vehicle Displays ON/OFF states of the 4Y engine controller switch, various input values including input voltage from the sensor, correction value of the control and output condition to the relay.
• Page 92
  7-90 7 DISPLAY ▪ «I/O ENGINE CTRL 1/10» IGSW: Key switch (IG) Displays key switch(IG) ON/OFF. IGSW: 0 = OFF IGSW: 1 = ON STA: Key switch (ST) Displays key switch(ST) ON/OFF. STA: 0 = OFF STA: 1 = ON BATT: Battery voltage (V) Displays battery voltage.
• Page 93
  7 DISPLAY 7-91 ▪ «I/O ENGINE CTRL 3/10» THA: Intake temperature sensor voltage(V), Intake air tem- perature(°C) Display intake temperature sensor voltage(V), Intake air temperature(°C). THW: Coolant temperature sensor voltage(V), Coolant temperature(°C) Display coolant temperature sensor voltage(V), Coolant temperature(°C). PIM: Intake pipe negative pressure sensor voltage(V), In- take manifold pressure(°C) Display Intake pipe negative pressure sensor voltage(V), Intake manifold pressure(°C).
• Page 94
  7-92 7 DISPLAY ▪ «I/O ENGINE CTRL 5/10» VTA1: Throttle position sensor (1) voltage (standard) Display throttle position sensor (1) voltage (standard). Throttle position sensor (1) voltage standard: 0.3 to 1.5 V (during engine idle (after warm-up)) Throttle fully closed position stored value standard: 0.3 to 1.5 V VTA2: Throttle position sensor (2) voltage (standard) Display throttle position sensor (2) voltage (standard).
• Page 95
  7 DISPLAY 7-93 ▪ «I/O ENGINE CTRL 8/10» NE: Engine speed (refer to «I/O ENGINE CTRL 6/10») PIM: Intake pipe negative pressure sensor voltage, Intake manifold pressure (refer to «I/O ENGINE CTRL 3/10») INJ: Injector correction value (gasoline) Displays correction value of the fuel injection amount. OX: O sensor voltage (O sensor monitor)
• Page 96
  7-94 7 DISPLAY 1ZS Engine Vehicle Displays ON/OFF states of the 1ZS engine controller switch, various input values including analog input voltage from the sensor and correction value of the control. Operating Procedure Step 1 Display the «ANALYZER MENU» screen. Step 2 Press switch (1) once to check that «2.
• Page 97
  7 DISPLAY 7-95 ▪ «I/O ENGINE CTRL 2/5» ATM: Atmospheric pressure (kPa) Display atmospheric pressure. PIM: Intake manifold pressure past turbocharger (kPa ) Displays the engine intake manifold pressure after being supplied by the turbocharger. Standard: Within ATM + 155(kPa) MAF: Intake air mass Display Intake air mass.
• Page 98
  7-96 7 DISPLAY 7.2.3.5.2 In/Out Monitor (2) «3.I/O TRAVELING» This function displays the ON/OFF status of traveling and swing switches, and analog input voltages of sensors. Operating Procedure Step 1 Display the «ANALYZER MENU» screen. Step 2 Press switch (1) twice to check that «3. I/O TRAVEL- ING»…
• Page 99
  7 DISPLAY 7-97 ▪ «I/O TRAVELING 1/3» SPD: Traveling speed sensor voltage (V), and traveling speed (km/h or mph) Display traveling speed sensor voltage and traveling speed. Standard when vehicle is stationary: approx. 2.5V (0.0 (km/ h or mph)) ACCSW: Accelerator switch Displays states of accelerator switch.
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  7-98 7 DISPLAY ▪ «I/O TRAVELING 2/3» SEAT: Seat switch Displays states of seat switch. SEAT: 1 = ON when taking the seat SEAT: 0 = OFF when leaving the seat DRF: Forward direction switch DRR: Reverse direction switch Displays states of forward/reverse traveling switch. Direction lever: Forward traveling position Displayed code: DRF: 1 (= ON)
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  7 DISPLAY 7-99 ▪ «I/O TRAVELING 3/3» YRS: Yaw rate sensor voltage (V) Display voltage of the yaw rate sensor. Vehicle without rear stabilizer: Normally 0.00 V Vehicle with rear stabilizer: Standard when vehicle is stationary: Approx. 2.5 V MH: Lifting height switch 1 = ON 0 = OFF MH2-2…
• Page 102
  7-100 7 DISPLAY 7.2.3.5.3 In/Out Monitor (3) «4.I/O M.HANDLING» This function displays the ON/OFF status of material handling and mast control switches and analog input voltages from sensors. Operating Procedure Step 1 Display the «ANALYZER MENU» screen. Step 2 Press switch (1) 3 times to check that «4. I/O M.HANDLING»…
• Page 103
  7 DISPLAY 7-101 ▪ «I/O M.HANDLING 1/7» MD/MU: Lift lowering switch/Lift raising switch Displays states of Lift lowering switch/Lift raising switch. STD lever vehicle: Lift lever: Lowering position Displayed code: MD: 1 (= ON) MU: 0 (= OFF) Lift lever: Neutral position Displayed code: MD: 0 (= OFF) MU: 0 (= OFF)
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  7-102 7 DISPLAY Condition of the Seat/lever and Detected Values (USOL/LSOL/TSOL/BTSL/SEAT) Leaving Seat condition Sitting on seat seat Lift lever Tilt lever Not oper- Backward tilt Lever condition ated Raising Lowering Forward tilt Low lifting High lifting height height USOL LSOL 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF)
• Page 105
  7 DISPLAY 7-103 ▪ «I/O M.HANDLING 3/7» POTL: Lift lever angle sensor (1) voltage (V)/lift lever angle sensor (2) voltage (V) Displays input voltage from the lift lever angle sensor (1)/lift lever angle sensor (2) to the controller. STD lever vehicle: POTL: — = Always Mini lever/Joystick vehicle: Standard:…
• Page 106
  7-104 7 DISPLAY ▪ «I/O M.HANDLING 5/7» POTA1: Attachment (1) lever angle sensor (1) voltage (V) / attachment (1) lever angle sensor (2) voltage (V) Displays input voltage from the attachment (1) lever angle sensor (1)/attachment (1) lever angle sensor (2) to the con- troller.
• Page 107
  7 DISPLAY 7-105 ▪ «I/O M.HANDLING 6/7» POTA2: Attachment (2) lever angle sensor (1) voltage (V) / attachment (2) lever angle sensor (2) voltage (V) Displays input voltage from the attachment (2) lever angle sensor (1)/attachment (2) lever angle sensor (2) to the con- troller.
• Page 108
  7-106 7 DISPLAY ▪ «I/O M.HANDLING 7/7» RPRES:P port pressure sensor voltage (V), (MPa display) Displays voltage value and pressure corresponding value of P port pressure sensor. 4YE engine model: Standard (No load): 0.5V to 4.5V Increases the voltage value as a hydraulic load increases. Except 4YE engine model: RPRES: —- = Always RSOL:…
• Page 109
  7 DISPLAY 7-107 Step 2 Press switch (1) 4 times to check that «5. I/O STEER- ING» is selected, and press (enter) switch (4) to dis- play «I/O STEERING 1/1» screen. NOTICE: ▪ You cannot move directly from «I/O STEER- Switch (1) Switch (4) ING»…
• Page 110
  7-108 7 DISPLAY ▪ «I/O STEERING 1/1» TIRE: Tire angle sensor voltage (V) Displays input voltage from tire angle sensor to the control- ler. Vehicle without synchronized steering: TIRE: —- = Always Vehicle with synchronized steering: Standard when tires are in straight ahead position: 1.9 to 2.4 V SPEED: Traveling speed (km/h or mph) K-POS: Steering knob position actual value (target value)
• Page 111
  7 DISPLAY 7-109 7.2.3.5.5 In/Out Monitor (5) «6.I/O OTHERS» Operating Procedure Step 1 Display the «ANALYZER MENU» screen. Step 2 Press switch (1) 5 times to check that «6. I/O OTH- ERS» is selected, and press (enter) switch (4) to dis- play «I/O OTHERS 1/2″…
• Page 112
  7-110 7 DISPLAY 7.2.3.6 Active Test «ACTIVE TEST» This function outputs ON/OFF signals to switches in the electrical system and compare controller input sig- nals with those signals. Active Test Menu List Selection item Item Description Signal Content of operation Signal Content of operation Swing lock solenoid SWING SOL*1…
• Page 113
  7 DISPLAY 7-111 Operation guidance Status No forced operation of the selected item. The selected item is on forced ON status. The selected item is on forced OFF status. No function for corresponding item, or no signal shows status. Operating Procedure Step 1 Display the «ANALYZER MENU»…
• Page 114
  7-112 7 DISPLAY ▪ «ACTIVE TEST 1/3» SWING SOL: Swing lock solenoid forced operation Jack up the rear axle, and check that the rear axle swings. Vehicle without swing lock: (Unused) Vehicle with swing lock: ON (solenoid ON): Unlock OFF (solenoid OFF): Lock STEERING SOL: Steering synchronizer solenoid forced operation Slowly turn the steering wheel, and check the difference of…
• Page 115
  7 DISPLAY 7-113 ▪ «ACTIVE TEST 3/3» NOTICE! When performing «RELIEF SOL» item, make sure to sit on the seat correctly. If not, OPS is activated and material handling operation may be limited. OPTION RLY: T/C interlock relay forced operation (T/C interlock specifica- tion vehicle only) Check that T/C interlock can be enabled and disabled.
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  7-114 7 DISPLAY 7.2.3.7 Program Version «VERSION» Displays program version of each controller. Operating Procedure Step 1 Display the «ANALYZER MENU» screen. Step 2 Press switch (1) 7 times to check that «8. VERSION» is selected, and press (enter) switch (4) to display «VERSION»…
• Page 117
  7 DISPLAY 7-115 7.2.4 TUNING 7.2.4.1 GENERAL Performs fine adjustment of traveling and material handling control. When receiving a request from a user such as «I want to adjust the lift idle up», a setting level can be altered from the tuning screen. 55 tuning items are provided including spares.
• Page 118
  7-116 7 DISPLAY Level (●: initial setting value) Menu Item Forward tilt adjustment (1): START Play at the beginning of tilt forward opera- Wide ← ← ← ● → → Small tion Forward tilt adjustment (2): INCH Slow ← ← ← ●…
• Page 119
  7 DISPLAY 7-117 Level (●: initial setting value) Menu Item Attachment (1) lever backward tilt side ad- justment (1): START Wide ← ← ← ● → → Small Play at the beginning of the attachment (1) lever pull operation Attachment (1) lever backward tilt side ad- justment (2): INCH Slow…
• Page 120
  7-118 7 DISPLAY Level (●: initial setting value) Menu Item Attachment (2) lever backward tilt side ad- justment (1): START Wide ← ← ← ● → → Small Play at the beginning of the attachment (2) lever pull operation Attachment (2) lever backward tilt side ad- justment (2): INCH Slow…
• Page 121
  7 DISPLAY 7-119 Level (●: initial setting value) Menu Item Attachment (3) lever backward tilt side ad- justment (1): START Wide ← ← ← ● → → Small Play at the beginning of the attachment (3) lever pull operation Attachment (3) lever backward tilt side ad- justment (2): INCH Slow…
• Page 122
  7-120 7 DISPLAY ▪ «1. GENERAL» Switch (1): Switching selection to next item Switch (4): To tuning level setting screen ▪ «2. LIFT LEVER» (Mini lever/Joy stick vehicles only) Switch (1): Switching selection to next item Switch (4): To tuning level setting screen ▪…
• Page 123
  7 DISPLAY 7-121 7.2.4.4 TUNING GENERAL «TUNE GEN.» Perform fine adjustment for traveling and load handling. (excluding load handling lever tuning) Step 1 Display the «TUNING MENU» screen. Step 2 Check that «1. GENERAL» is selected, and press (enter) switch (4) to display «TUNE GEN.» screen. NOTICE: ▪…
• Page 124
  7-122 7 DISPLAY 7.2.4.5 TUNING LIFT LEVER «LIFT DOWN/LIFT UP» Sets tuning levels for the lift lever of mini lever and joy stick vehicles. Step 1 Display the «TUNING MENU» screen. Step 2 Press switch (1) once to check that «2. LIFT LEVER» is selected, and press (enter) switch (4) to display the «LIFT DOWN»…
• Page 125
  7 DISPLAY 7-123 7.2.4.6 TUNING TILT LEVER «TILT FWD/TILT BWD» Sets tuning levels for the tilt lever of mini lever and joy stick vehicles. Operating Procedure Step 1 Display the «TUNING MENU» screen. Step 2 Press switch (1) twice to check that «3. TILT LEVER» is selected, and press (enter) switch (4) to display the «TILT FWD»…
• Page 126
  7-124 7 DISPLAY 7.2.4.7 TUNING ATT1 LEVER «ATT1 PUSH/ATT1 PULL» Sets tuning levels for the attachment (1) lever of mini lever and joy stick vehicles. Operating Procedure Step 1 Display the «TUNING MENU» screen. Step 2 Press switch (1) 3 times to check that «4. ATT1 LEVER»…
• Page 127
  7 DISPLAY 7-125 7.2.4.8 TUNING ATT2 LEVER «ATT2 PUSH/ATT2 PULL» Sets tuning levels for the attachment (2) lever of mini lever and joy stick vehicles. Operating Procedure Step 1 Display the «TUNING MENU» screen. Step 2 Press switch (1) 4 times to check that «5. ATT2 LEVER»…
• Page 128
  7-126 7 DISPLAY 7.2.4.9 TUNING ATT3 LEVER «ATT3 PUSH/ATT3 PULL» Sets tuning levels for attachment (3) lever of mini lever and joy stick vehicles. Operating Procedure Step 1 Display the «TUNING MENU» screen. Step 2 Press switch (1) 5 times to check that «6. ATT3 LEVER»…
• Page 129
  7 DISPLAY 7-127 7.2.5 OPTION SETTING NOTICE • The option set function is used to set control of the controller and display control according to the options equipped on the vehicle. It does not enable or disable the function itself. •…
• Page 130
  7-128 7 DISPLAY Switching settings Indication Description Indica- Indica- Setting content Setting content tion tion Setting to enable/disable Enabled T BWD LEVEL *3 backward tilt automatic level- Disabled (Default) ing control SWG W-LOCK Unused (fixed to YES) (Default) Setting to enable/ disable the KNOB CONT *1 Enabled Disabled…
• Page 131
  7 DISPLAY 7-129 ▪ Option set screen 1 Switch (1): Switching selection to next item Switch (2): Setting from I to J, from NO to YES, or from B to Switch (3): Setting from J to I, from YES to NO, or from A to Switch (4): Returning to service function «MASK MENU»…
• Page 132
  7-130 7 DISPLAY ▪ Option set screen 5 Switch (1): Switching selection to next item Switch (2): Setting 5→4→3→2, 3->4→2->3, NO to YES Switch (3): Setting 2→3→4→5, 2->3→3->4, YES to NO Switch (4): Returning to service function «MASK MENU» screen…
• Page 133
  7 DISPLAY 7-131 7.2.6 MATCHING 7.2.6.1 GENERAL ▪ For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage values under the mast vertical, no load and tire straight conditions are stored, respectively, in the control- ler for the control based on these values.
• Page 134
  7-132 7 DISPLAY 2. MINI LEVER Prerequisite for im- Indication Description plementation Lift lever angle sensor output value in the lift lever neut- LEVER1 *1, *9 ral position is stored in the controller. Tilt lever angle sensor output value in the tilt lever neut- LEVER2 *1, *10 ral condition is stored in the controller.
• Page 135
  7 DISPLAY 7-133 3. No-load vertical condition check V mast FV·FSV mast Store the output voltage of the load sensor in no-load state in the controller. At this time, the following con- ditions must be satisfied: ▪ For the V mast, set the lifting height to about 500 mm (19.7 in) and use a goniometer to check that the mast is vertical.
• Page 136
  7-134 7 DISPLAY 7.2.6.4 MATCHING MENU Screen MATCHING MENU Screen Operating Procedure Step 1 Enter the password on the general screen to display the service function «MASK MENU» screen. Step 2 Press switch (1) 3 times to check that «4. MATCH- ING»…
• Page 137
  7 DISPLAY 7-135 NOTICE: ▪ «2. MINI LEVER» will not be displayed other than on mini lever and joystick specification vehicle.
• Page 138
  7-136 7 DISPLAY 7.2.6.5 MATCHING SAS «SAS» Matching is performed for SAS functions. Operating Procedure Step 1 Display the «MATCHING MENU» screen. Step 2 Check that «1. SAS» is selected, and press (enter) switch (4) to display «TILT LEVEL» screen. On SAS matching screen: Values in bracket ( ) are currently stored value.
• Page 139
  7 DISPLAY 7-137 ▪ «TIRE POSITION» Screen If matching is performed (press switch (1)), «OK» is indic- ated on the display. Switch (1): Pressing this for more than 2 seconds will per- form matching. Switch (4): To «SWING LEVEL» screen ▪…
• Page 140
  7-138 7 DISPLAY 7.2.6.6 MATCHING MINI LEVER «MINI LEVER» Matching is performed for mini lever functions. Operating Procedure Step 1 Display the «MATCHING MENU» screen. Step 2 Press switch (1) to check that «2. MINI LEVER» is se- lected, and press (enter) switch (4) to display the «LEVER1″…
• Page 141
  7 DISPLAY 7-139 ▪ «LEVER3» Screen If matching is performed (press switch (1)), «OK» is indic- ated on the display. Switch (1): Pressing this for more than 2 seconds will per- form matching. Switch (4): To «LEVER4» screen NOTICE: ▪ «LEVER3» screen will be displayed according to the number of ways being set.
• Page 142
  7-140 7 DISPLAY Step 2 Press switch (1) to check that «3. EMRV» is selected, and press (enter) switch (4) to display the «MAT. EMRV» screen. NOTICE: ▪ You cannot move directly from level setting Switch (1) Switch (4) screen of MATCHING to the screen of the other items.
• Page 143
  7 DISPLAY 7-141 7.2.7 Other service function 7.2.7.1 WHEEL RADIUS GENERAL It is necessary to input the wheel radius to the controller according to the tire radius, for optimizing the speedometer reading. Although the wheel radius is set to the value of new tires at the time of shipment, ad- just it whenever the tire size or type is changed according to «Wheel Radius List».
• Page 144
  7-142 7 DISPLAY Vehicle type Vehicle model Tire size Tire type Wheel radius 6.5-10-10PR WIDE TREAD 1.0 ton model SOLID 6.5-10 / 5.00 WIDE TREAD SOLID 7.00-12-12PR WIDE TREAD SOLID 2.0 ton model 7.00-12 / 5.00 WIDE TREAD SOLID Pneumatic DUAL 7.00-12 12PR DUAL SOLID…
• Page 145
  7 DISPLAY 7-143 7.2.7.2 SPEED SETTING OF SPEED LIMITER «SPEED LIMIT SET» GENERAL The speed limit of the Maximum speed limiter can be changed. Operating Procedure Step 1 Enter the password on the general screen to display the service function «MASK MENU» screen. Step 2 Press switch (1) 5 times to check that «6.
• Page 146
  7-144 7 DISPLAY 7.2.7.3 IDLE ADJUSTMENT(IDLE ADJUSTMENT) GENERAL Adjusts engine idle speed. Operating Procedure Step 1 Enter the password on the general screen to display the service function «MASK MENU» screen. Step 2 Press switch (1) 6 times to check that «6. IDLE AD- JUSTMENT»…
• Page 147
  7 DISPLAY 7-145 7.2.7.4 SERVICE SECOND PASSWORD SETTING «MASK PASSWORD» GENERAL Sets and deletes the mask second password. You can use the four switches on the multi-function display DX to set arbitrary four digits as the mask second password. When the password is set, the mask second password is prompted after the normal service password input. You can move to the service functions screen only when the password matches your input operation.
• Page 148
  7-146 7 DISPLAY ▪ «MASK PASSWORD» Screen Operation to delete mask second password In the mask second password setting screen, press switch (1) for two seconds or more without any digits entered. The password is deleted and «OK» is displayed after the opera- tion.
• Page 149
  7 DISPLAY 7-147 ▪ Set mask second password operation When all four digits are entered, SET is displayed on the bottom left of the screen, indicating that you are ready for the set password operation. Press switch (1) for two seconds or more to perform Pass- word Set.
• Page 150
  7-148 7 DISPLAY 7.2.7.5 ADMINISTRATOR’S SECOND PASSWORD CLEAR «MANAGER PASS CLR» GENERAL Deletes the administrator’s second password. You can delete the administrator’s second password with a service function in case of user request. Operating Procedure Step 1 Enter the password on the general screen to display the service function «MASK MENU»…
• Page 151
  7 DISPLAY 7-149 7.2.7.6 CONTRAST ADJUSTMENT «CONTRAST» GENERAL Adjusts LCD contrast. Operating Procedure Step 1 Enter the password on the general screen to display the service function «MASK MENU» screen. Step 2 Press switch (1) 9 times to check that «10. CON- TRAST»…
• Page 152
  7-150 7 DISPLAY 7.2.7.7 METER START «METER START» GENERAL Starts counting the odometer, trip meter and maintenance hour meter. Operating Procedure Step 1 Enter the password on the general screen to display the service function «MASK MENU» screen. Step 2 Press switch (1) 10 times to check that «11.
• Page 153
  7 DISPLAY 7-151 Step 4 While pressing switch (2), if you press switch (3), in- verted «NO» on the screen turns to inverted «YES», and the setting is completed. Step 5 Press switch (4) to return to service function «MASK MENU»…
• Page 154
  8-152 8 TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 DIAGNOSIS CODE LIST……………  153 8.2 WARNING LIST……………… 154 8.3 WHEN NO ERROR CODE IS DISPLAYED ……….  155 8.4 WHEN ERROR CODE IS DISPLAYED………. 189…
• Page 155
  8 TROUBLESHOOTING 8-153 8.1 DIAGNOSIS CODE LIST Detection ECU SAS/OPS: SAS/OPS/Mini lever (OPT) Controller Indica- Detection Memory Spanner Error mode tion 61-3 61-3 Blinking SAS/OPS Pressure sensor open abnormality ( P-port) 61-4 61-4 Blinking SAS/OPS Pressure sensor VCC short abnormality ( P-port) EC-1 EC-1 Blinking…
• Page 156
  8-154 8 TROUBLESHOOTING 8.2 WARNING LIST CAUTION If the wrench lamp illuminates and the following phenomena occur on the vehicle without an error being dis- played, it is not a fault. Take the appropriate corrective action. Appropriate Wrench Detection Content of warn- Indication Memory Phenomenon on vehicle…
• Page 157
  8 TROUBLESHOOTING 8-155 8.3 WHEN NO ERROR CODE IS DISPLAYED Defect causes related to SAS/OPS…
• Page 158
  8-156 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Brake switch unit: Open fault (Stuck in de- pressed state, or ON/OFF check with Harness check or re- internal damage) analyzer place switch ▪…
• Page 159
  8 TROUBLESHOOTING 8-157 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Load sensor unit: Sensor defect ▪ Load sensor line (Power supply, ON/OFF check with Harness check or re- signal, ground): analyzer place switch Disconnection For vehicles with fault (Harness,…
• Page 160
  8-158 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Lifting height switch unit: ON/OFF check with Harness check or re- Disconnection analyzer place switch fault (Internal For vehicles with damage, stuck) travel and load Check the setting handling control: ▪…
• Page 161
  8 TROUBLESHOOTING 8-159 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Lift raise switch unit: Open fault (Switch mounted incorrectly, in- 4YE/1ZS engine ternal damage, model stuck) (STD lever) ▪ Lift raise switch When lifting a heavy ON/OFF check with Harness check or re- line:…
• Page 162
  8-160 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Load sensor unit: Sensor defect 4YE engine model Load sensor voltage ▪ Load sensor line (Mini lever or Joy check: (Power supply, If there is no stick) signal, ground): change, perform a…
• Page 163
  8 TROUBLESHOOTING 8-161 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Buzzer unit: Buzzer defect ▪ Buzzer harness Harness check or re- line (Lead-in place buzzer side): Buzzer sounds con- Ground short or stantly link fault (Har- ness, connector) ▪…
• Page 164
  8-162 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Buzzer unit: Buzzer defect ▪ Buzzer harness line (Power sup- Harness check or re- ply side, lead-in place buzzer side): Disconnection fault (Harness, connector) For cowl lever Refer to “Cowl lever…
• Page 165
  8 TROUBLESHOOTING 8-163 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Buzzer unit: Buzzer defect ▪ Buzzer harness line (Power sup- Harness check or re- ply side, lead-in place buzzer side): Disconnection fault (Harness, connector) ▪…
• Page 166
  8-164 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Buzzer unit: Buzzer defect ▪ Buzzer harness Harness check or re- line (Power sup- place buzzer ply side, lead-in side): Fault (Harness, connector) ▪…
• Page 167
  8 TROUBLESHOOTING 8-165 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Buzzer unit: Buzzer defect ▪ Buzzer harness Harness check or re- line (Lead-in place buzzer side): Fault (Harness, connector) ▪ Parking brake switch unit: Vehicles with MULTI-FUNCTION Ground short…
• Page 168
  8-166 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Torque con- verter oil temper- ature sensor unit: Open fault (In- ternal damage) Start the engine and ▪ Torque con- Harness check or re- after leaving the Vehicles with verter oil temper-…
• Page 169
  8 TROUBLESHOOTING 8-167 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Tire unit: Burst, tire pres- Adjust or replace sure adjustment defect ▪ Lock cylinder unit: Leak, cannot lock (Internal Check the locked damage) status with an active Replace ▪…
• Page 170
  8-168 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Lock cylinder Check the locked unit: status with an active Replace Lock stuck (in- test. ternal damage) ▪ Swing lock solenoid line (SWN+, SWN-): Disconnection fault (Harness, Check the locked…
• Page 171
  8 TROUBLESHOOTING 8-169 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Tilt angle sensor unit: Tilt angle sensor Sensor defect voltage check: If there is no change, perform an ▪ Tilt angle sensor Tilt to forward and installation check or installation: backward tilt posi-…
• Page 172
  8-170 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Load sensor unit: Sensor defect ▪ Load sensor line Load sensor voltage (Power supply, If there is no check: signal, ground): change, perform an Peform lift relief and installation check or Disconnection…
• Page 173
  8 TROUBLESHOOTING 8-171 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Load sensor unit: Sensor defect ▪ Load sensor line Load sensor voltage (Power supply, If there is no check: signal, ground): change, perform an Check that the installation check or Disconnection…
• Page 174
  8-172 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Automatic fork leveling switch unit: Open fault (in- ternal damage) ▪ Automatic fork leveling switch detection mech- anism (mini lever, joystick lever): ON/OFF check with Harness check or re- analyzer place switch…
• Page 175
  8 TROUBLESHOOTING 8-173 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Tilt angle sensor unit: Tilt angle sensor Sensor defect voltage check: If there is no change, perform an ▪ Tilt angle sensor Tilt to forward and installation check or installation: backward tilt posi-…
• Page 176
  8-174 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Tilt angle sensor unit: Tilt angle sensor Sensor defect voltage check: If there is no change, perform an ▪ Tilt angle sensor Tilt to forward and installation check or installation: backward tilt posi-…
• Page 177
  8 TROUBLESHOOTING 8-175 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Tire angle sensor unit: Sensor defect Tire angle sensor ▪ Tire angle If there is no voltage check: Oper- sensor installa- change, perform an ate the steering and tion: installation check or…
• Page 178
  8-176 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Tire angle sensor unit: Sensor defect Tire angle sensor ▪ Tire angle If there is no voltage check: sensor installa- change, perform an tion: Operate the steering installation check or…
• Page 179
  8 TROUBLESHOOTING 8-177 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Vehicle speed sensor unit: Cannot detect low speed (in- ternal damage) ▪ Vehicle speed sensor installa- tion: Check sensor If there is no High speed not voltage and vehicle change, perform an…
• Page 180
  8-178 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Fuse: ECU+B fuse Check for blown blown fuse ECU-IG fuse blown ▪ Meter commu- nication line: Ground short (Harness, con- nector) Disconnection fault (Harness, Harness check connector) ▪…
• Page 181
  8 TROUBLESHOOTING 8-179 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Lift lower switch unit: Open fault (Switch mounted incorrectly, in- ternal damage, stuck) ▪ Lift lower switch ON/OFF check with Harness check or re- line: analyzer place switch…
• Page 182
  8-180 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Forward tilt switch unit: Open fault (Switch mounted incorrectly, in- ternal damage, stuck) ▪ Forward tilt ON/OFF check with Harness check or re- switch line: analyzer place switch…
• Page 183
  8 TROUBLESHOOTING 8-181 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Backward tilt switch unit: Open fault (Switch mounted incorrectly, in- ternal damage, stuck) ▪ Backward tilt ON/OFF check with Harness check or re- switch line: analyzer place switch…
• Page 184
  8-182 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ C/V tilt control Turn the tilt solenoid If forward tilt can be valve: OFF and operate to performed, replace forward tilt using an the C/V tilt control Stuck (internal active test.
• Page 185
  8 TROUBLESHOOTING 8-183 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Seat switch unit: Open fault (in- ternal damage) ON/OFF check with Harness check or re- ▪ Seat switch line analyzer place switch (Signal, ground): Disconnection fault (Harness, connector)
• Page 186
  8-184 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Forward travel interrupt relay unit: Stuck (internal If forward travel can damage, wel- be performed, re- ded) place the forward Turn the forward and travel interrupt relay.
• Page 187
  8 TROUBLESHOOTING 8-185 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Fuse: Check for blown fuse Shift fuse blown ▪ Forward travel interrupt relay unit: Open fault (in- If forward travel can- ternal damage, not be performed, welded) replace the forward…
• Page 188
  8-186 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Torque con- verter interlock relay main unit for forward movement: Check the har- nesses. An open circuit (internal dam- If the vehicle cannot age) travel forward, re- place the torque…
• Page 189
  8 TROUBLESHOOTING 8-187 Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode Battery voltage check: ▪ Battery: Charge or replace Ignition switch OFF: the battery. Low voltage Check the battery voltage. Check the har- ▪ Power harness: nesses, connectors Check the har- Wire breakage,…
• Page 190
  8-188 8 TROUBLESHOOTING Phenomenon on Malfunction area Control type Checking method Corrective action vehicle and mode ▪ Power shut-off relay main body (only for models with «MULTI- FUNCTION DIS- PLAY DX») The power does not turn off even when Short circuit Check and replace operating the auto the relay.
• Page 191
  8 TROUBLESHOOTING 8-189 8.4 WHEN ERROR CODE IS DISPLAYED…
• Page 192
  8-190 8 TROUBLESHOOTING Error Code: 61-3 Failure mode: Pressure sensor open abnormality (P-port) Probable cause ▪ Connector contact defect ▪ Pressure sensor defect ▪ Harness defect ▪ SAS/OPS ECU defect Related portion A103 20 (5PBR) 1 (B) 31 (PBRK) 2 (P) SAS/OPS Pressure sensor 5 (E2)
• Page 193
  8 TROUBLESHOOTING 8-191 STEP2 Individual inspection for pressure sensor 1. Turn the ignition key switch OFF. 2. Disconnect A103, and use SST 09230-13700-71 to short circuit A103-1 and A103-2 (main harness side). 3. Turn the ignition key switch ON (engine stopped). A103 Judgment Result…
• Page 194
  8-192 8 TROUBLESHOOTING STEP4 Inspection for harness continuity and short circuit 1. Inspect for continuity and short circuiting of the harness in the same state as for step 3. Portion to be checked Standard A21-31 to A21-5 No continuity 9 10 11 12 13 14 15 16 A21-20 to Frame No continuity 23 24…
• Page 195
  8 TROUBLESHOOTING 8-193 Error Code: 61-4 Failure mode: Pressure sensor VCC short abnormality (P-port) Probable cause ▪ Connector contact defect ▪ Pressure sensor defect ▪ Harness defect ▪ SAS/OPS ECU defect Related portion A103 20 (5PBR) 1 (B) 31 (PBRK) 2 (P) SAS/OPS Pressure sensor…
• Page 196
  8-194 8 TROUBLESHOOTING STEP3 Inspection for harness continuity and short circuit 1. Turn the ignition key switch OFF, and disconnect A21. Portion to be checked Standards A21-20 to A21-31 No continuity A21-20 to Frame No continuity 9 10 11 12 13 14 15 16 A21-31 to Frame No continuity 23 24…
• Page 197
  8 TROUBLESHOOTING 8-195 Error Code: EC-1 Failure mode: Unload solenoid open circuit or load short abnormality CAUTION In case of EMRV model, set «FLS» to «YES» at option set screen of the multifunction display or dia- gnostic program (SST). Probable cause ▪…
• Page 198
  8-196 8 TROUBLESHOOTING STEP2 Individual inspection of unload solenoid 1. Turn the ignition key switch OFF and disconnect A12. Portion to be checked (Solenoid side) Standard Approx. 10 Ω A12-1 to A12-2 (20°C) Judgment Result Procedure Go to STEP3 [page 196].. Unload solenoid defect STEP3 Inspection for harness continuity and short circuit…
• Page 199
  8 TROUBLESHOOTING 8-197 Error Code: EC-2 Failure mode: Electromagnetic relief solenoid open abnormality Probable cause ▪ Connector contact defect ▪ Harness defect ▪ Electromagnetic relief solenoid defect ▪ SAS/OPS ECU defect Related portion A102 6 (RSO+) 1 (B) SAS/OPS Electromagnetic 7 (RSO-) 2 (E) relief solenoid…
• Page 200
  8-198 8 TROUBLESHOOTING STEP2 Individual inspection of electromagnetic relief solenoid 1. Turn the ignition key switch OFF, disconnect the battery negative terminal. Disconnect A102, measure the electromagnetic relief valve solenoid resistancevalue. Portion to be checked (Solenoid side) Standard A102-1 to A102-2 Approx.
• Page 201
  8 TROUBLESHOOTING 8-199 Error Code: EC-3 Failure mode: Electromagnetic relief solenoid short abnormality Probable cause ▪ Connector contact defect ▪ Harness defect ▪ Electromagnetic relief solenoid defect ▪ SAS/OPS ECU defect Related portion A102 6 (RSO+) 1 (B) SAS/OPS Electromagnetic 7 (RSO-) 2 (E) relief solenoid…
• Page 202
  8-200 8 TROUBLESHOOTING STEP2 Individual inspection of electromagnetic relief solenoid 1. Turn the ignition key switch OFF, disconnect the battery negative terminal. Disconnect A102, measure the electromagnetic relief valve solenoid resistancevalue. Portion to be checked (Solenoid side) Standard A102-1 to A102-2 Approx.
• Page 203
  8 TROUBLESHOOTING 8-201 Error Code: EC-4 Failure mode: Electromagnetic relief solenoid drive circuit abnormality Probable cause ▪ Connector contact defect ▪ Harness defect ▪ Electromagnetic relief solenoid defect ▪ SAS/OPS ECU defect Related portion A102 6 (RSO+) 1 (B) SAS/OPS Electromagnetic 7 (RSO-) 2 (E)
• Page 204
  8-202 8 TROUBLESHOOTING STEP2 Individual inspection of electromagnetic relief solenoid 1. Turn the ignition key switch OFF, disconnect the battery negative terminal. Disconnect A102, measure the electromagnetic relief valve solenoid resistancevalue. Portion to be checked (Solenoid side) Standard A102-1 to A102-2 Approx.
• Page 205
  9 WIRING DIAGRAM 9-203 9 WIRING DIAGRAM 9.1 ELECTRICAL WIRING ROUTINGS ………… 204 9.2 RELAY LOCATIONS ……………. 207 9.3 SYSTEM CIRCUITS ……………. 208 9.4 CONNECTOR LIST ……………. 216…
• Page 206
  9-204 9 WIRING DIAGRAM 9.1 ELECTRICAL WIRING ROUTINGS 9.1.1 INSTRUMENT PANEL BODY MAIN WIRE HEAD GUARD SW WIRE WIPER SUB WIRE BODY SUB NO.1 WIRE ACCEL SUB WIRE INSTRUMENT PANEL SW WIRE INSTRUMENT PANEL WIRE MAST SENSOR WIRE 12V PWR SUPPLY WIRE FR STAY WIRE RH FR STAY WIRE LH KEY OFF H/LP OFF WIRE…
• Page 207
  9 WIRING DIAGRAM 9-205 PARTS Code Name HORN SWITCH IGNITION SWITCH STEERING SENSOR LIGHT CONTROL SWITCH STOP LAMP SWITCH BRAKE WARNING SWITCH OPS WARNING BUZZER PARKING BRAKE SWITCH TILT SOLENOID LIFT SOLENOID UNLOAD SOLENOID TILT SWITCH LIFT SWITCH NEUTRAL TILT SWITCH PRESSURE SENSOR SPEED SENSOR SAS/OPS ECU…
• Page 208
  9-206 9 WIRING DIAGRAM :WIRE TO WIRE Code Name BODY MAIN WIRE to BODY MAIN WIRE BODY MAIN WIRE to INSTRUMENT PANEL WIRE BODY MAIN WIRE to ACCEL SUB WIRE BODY MAIN WIRE to MAST SENSOR WIRE BODY MAIN WIRE to WIPER SUB WIRE BODY MAIN WIRE to WIPER SUB WIRE INSTRUMENT PANEL WIRE to BODY MAIN WIRE INSTRUMENT PANEL SW WIRE to BODY MAIN WIRE…
• Page 209
  9 WIRING DIAGRAM 9-207 9.2 RELAY LOCATIONS 9.2.1 ENGINE ROOM R/B : ENGINE ROOM LEFT * 1:15A E-THRO (4Y-E) 20A EDU (1ZS) 7.5A ECU-B2 (4Y-M,1DZ) * 2:LPG MAIN RELAY (4Y-E) ASC RELAY (4Y-M,1DZ) EZ MAIN RELAY (1ZS) * 3:15A (4Y-E) 7.5A (4Y-M,1DZ,1ZS) * 4:POWER OFF RELAY (1ZS,4YE) SPARE…
• Page 210
  9-208 9 WIRING DIAGRAM 9.3 SYSTEM CIRCUITS 9.3.1 BODY 9.3.1.1 SAS/OPS SYSTEM E4-31…
• Page 211
  9 WIRING DIAGRAM 9-209 E4-32…
• Page 212
  9-210 9 WIRING DIAGRAM E4-33…
• Page 213
  9 WIRING DIAGRAM 9-211 PARTS Code See Page Code See Page Code See Page Code See Page E2-12 E2-16 page 204 page 204 E2-16 page 204 page 204 page 204 E2-12 E2-16 page 204 page 204 E2-12 E2-16 page 204 page 204 A102 E2-16 page 204 page 204 page 204 E2-12, E3-7 A103 E2-16 page 204…
• Page 214
  9-212 9 WIRING DIAGRAM 9.3.2 LIGHTING SYSTEM 9.3.2.1 HEAD LAMP E4-51…
• Page 215
  9 WIRING DIAGRAM 9-213 PARTS Code See Page Code See Page Code See Page Code See Page E2-14 E2-14 page 204 E2-14 E2-14 page 204 :RELAY BLOCK , JUNCTION BLOCK Code See Page Name E3-4 ENGINE ROOM R/B E2-12, E3-5 BODY MAIN WIRE to J/B E2-12, E3-5 BODY MAIN WIRE to J/B :WIRE TO WIRE…
• Page 216
  9-214 9 WIRING DIAGRAM 9.3.2.2 CLEARANCE LAMP E4-55…
• Page 217
  9 WIRING DIAGRAM 9-215 PARTS Code See Page Code See Page Code See Page Code See Page E2-16 E2-14 page 204 E2-14 E2-16 page 204 E2-16 E2-16 page 204 :RELAY BLOCK , JUNCTION BLOCK Code See Page Name E3-4 ENGINE ROOM R/B E2-12, E3-5 BODY MAIN WIRE to J/B E2-12, E3-5 BODY MAIN WIRE to J/B…
• Page 218
  9-216 9 WIRING DIAGRAM 9.4 CONNECTOR LIST 9.4.1 CONNECTOR LIST NATURAL NATURAL NATURAL NATURAL (S)6020-6161 (S)6020-6161 (S)6020-6161 (S)6020-6161 FRONT SOLENOID REAR SOLENOID EZ PEDAL MAIN RE- NEUTRAL START RELAY RELAY RELAY A102 A103 BROWN GRAY 90980- 11155 90080- 98200 ELECTROMAGNETIC RELIEF SOLENOID RELIEF PRESSURE SENSOR…
• Page 219
  10 SST LIST AND SERVICE STANDARDS LIST 10-217 10 SST LIST AND SERVICE STANDARDS LIST 10.1 SST LIST ……………….. 217 10.2 SERVICE STANDARDS LIST ……………  218 10.1 SST LIST Section Illustration Part No. Part Name 1 2 3 4 ― Oil control valve spring re- 09610-10161-71 О…

• Page 220: Pn3 Ton Series

  10-218 10 SST LIST AND SERVICE STANDARDS LIST 10.2 SERVICE STANDARDS LIST STEERING Hydrostatic steering valve ASSY Pn1 ton 7.2 to 7.7 (73.4 to 78.5) 1ZS,4YE Standard series [1044 to 1117] Relief set pressure Pn2 ton 7.8 to 8.3 (79.5 to 84.6) 1ZS,4YE Standard series [1131 to 1204]…

• Page 221
  Published by 1st Printing: Mar. 2016 Pub. No. CE118 Printed in USA…
• Page 222
  PRINTED IN USA Pub. No. CE118…

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