This document is a service manual for the Toyota Battery Forklift 5FBE10-20 Series from September 1998. It provides instructions for servicing corresponding forklift models. The manual may disagree with actual vehicles due to design changes over time. Any modifications made by Toyota will be communicated separately. The manual is organized with sections covering various vehicle systems like electrical, front axle, battery, and more. It provides information on how to use the manual, terminology, torque specifications, maintenance procedures and more to aid technicians in servicing the vehicles.

1. FOREWORD
This manual covers the service procedures of the TOYOTA BATTERY
FORKLIFT 5FBE10-20 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of September 1998. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due to change in design and specifi-
cations. Any change or modifications thereafter will be informed by
Toyota Industrial Vehicles' Parts & Service News.
TOYOTA MaterialHandling Company
A Division of TOYOTA INWSRIES CORPORATION

2. SECTION INDEX
[FOR OTHER THAN U.S.A.] (1993.1 -1998.8)
ELECTRICAL SYSTEM TROUBLESHOOTING [FoRu.s.A.1 (1993.1 -1
ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHERTHANU.s.Ad(199889-I A A
NAME
MOTOR
SECTION
/ FRONT AXLE &TRANSMISSION (lgg3.1 - lgg8-l)
GENERAL
BATTERY
[FOR OTHER THAN U.S.A.] (1993.1- 1998.8)
CONTROL ClRCUIT IFOR u.s.A.1 (1993.1 -1999.1 -)
CONTROL CIRCUIT [FOR OTHER THAN U.S.A.] (1998.9 -) A
[FOR UL. U.S.A.. CANADA] (1999.2- )
[FOR OTHER THAN U.S.A.] (1993.1 - 1998.8)
MULTI-DISPLAY FUNCTIONS [Fouu.s.A.j (1993.1 -)
FRONT AXLE & DRIVE UNIT (1998-2-1
REAR AXLE (1993.1- 1998.1)
A
STEERING
--
BRAKE (1998.2-I
BODY & FRAME
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL
APPENDIX

3. GENERAL
Page
EXTERIOR VIEWS ........................... 0-2
VEHICLE MODEL ........................... 0-3
FRAME NUMBER ........................... 0-3
HOW TO USE THIS MANUAL ................ 0-4
EXPLANATION METHOD .......................... 0-4
TERMINOLOGY .................................. 0-5
ABBREVIATIONS ................................. 0-5
LIST OF ABBREVIATIONS AND SYMBOLS .......... 0-6
OPERATIONAL TIPS ......................... 0-7
JACK-UP POINTS ........................... 0-8
CIRCUIT TESTER ............................ 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE ................................. 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ....................................... 0-11
TIGHTENING TORQUE TABLE ..................... 0-12
...........................PRECOAT BOLTS 0-13
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ..................... 0-13
WIRE ROPE SUSPENSION ANGLE LIST ....... 0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ..................... 0-14
.....................COMPONENTS WEIGHT 0-15
RECOMMENDED LUBRICANTS
AND CAPACITIES ......................... 0-15
LUBRICATION CHART ....................... 0-16
PERIODIC MAINTENANCE ................... 0-17
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................ 0-22

4. 0-2
EXTERIOR VIEWS

5. VEHICLE MODEL
*: 36 V is provided for UL specification.
FRAME NUMBER
Load capacity
1.0 ton
1.25 ton
1.5 ton
1.75 ton
1.815 ton
Model
5FBE10
5FBE13
5FBE15
5FBE18
5FBE20
Punching
position
1 ton
series
1.5 ton
series
2.0 ton
series
Battery capacity
AH/5HR
280
t
390
t
375
Upper face of side member
of frame RH
Vehicle model
5FBE10
5FBE13
5FBE15
5FBE18
5FBE20
Voltage
V
*36 or 48
t
t
t
t
Punching format
5FBE13-10011
5FBE13E10011(EEC spec.)
(1993.1 -1993.9)
5FBE13010011 (EEC spec.)
(1993.10 - )
5FBE18-10011
5FBE18E10011(EEC spec.)
(1993.1 -1993.9)
5FBE18010011 (EEC spec.)
(1993.10 - )
5FBE20-10011
Control circuit
MCS-IIIA
t
t
t
t

6. HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustra-
tion, followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T=N.m (kgf-cm)[ft-lbfl
T =46.09 -48.05
(470-490)
134.00- 35.451
8
DisassemblyProcedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 21 Operation explained later
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 11 JDisassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528in)

7. 2. How to read components figures (Example)
(1) The components figure use the illustra-
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of
each components figure indicates the
Fig. number in the parts catalog.
FIG number in parts catalog
fl3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removed parts as required
@ visual inspection (Partiallydescribed)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents.Be sure to observe them.
Note:
lmportant items of which negligence may cause accidents or matters in operation procedure
requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code)
ASSY
EHPS
FR
I-/
LH
0PT
01s
PS
RH
Meaning
Assembly
Electrical hydraulic power
steering
Front
Less
Left hand
Option
Oversize
Power steering
Right hand
Abbreviation (code)
RR
SAE
SST
STD
T =
OOT
U/S
w/
Meaning
Rear
Society of Automotive
Engineers (USA)
Special service Tool
Standard
Tightening torque
Number of teeth (00)
Undersize
With

8. LISTOF ABBREVIATIONS AND SYMBOLS
Symbol
BATT
BZ
CA
CADIP
CH
CHIF
CHIR
CSDIP
CSps
DADIP
DCH
DC-SDD
DC-SDP
DF112
DF314
DlSP
DMDlP
DMps
DSBu
DSF
DSFo
DSR
F1
F2
F3
F4
F5
FCH
Symbol
FRY
H
IWP
LBU-~
L B U - ~
LC-L
LC-R
LF-L
L F - ~ ~
LF-R
LF-RR
LH-L
L H - ~
LR-F
L R - ~
LSAnIl2
LSB
LSD
LSL1/2
LSsT
LST-~
LsT-~
LST
LT-~
LT-~
Lw
MFL
MFR
MP
MPS
MRL
MRR
MScH
PBcpu
PBEHPs
Name
Battery
Buzzer
Absorber Capacitor
Drivelpump Absorber
Capacitor
Charger
Forward Chime
Reverse Chime
DriveIPumpCurrent
Sensor
Power Steering Current
Sensor
Drivelpump Absorber
Diode
Charger Diode
DC-DC Converter &
Source Drive (Drive)
DC-DC Converter &
Source Drive (Pump)
FLY-WHEEL Diode,
No.112
FLY-WHEEL Diode No.314
Display
DriveIPump Motor
Power Steering Motor
Back-up Direction Switch
Forward Direction Switch
Forward Optional
Direction Switch
Reverse Direction Switch
Drive Fuse
Pump Fuse
Power Steering Fuse
Lamp Fuse
Control Circuit Fuse
Charger Fuse
Name
Flasher Relay
Horn
Wheel Position Indicator
Back-up Lamp, LH
Back-up Lamp, RH
Clearance Lamp, LH
Clearance Lamp, RH
Flasher Lamp, LH
Flasher Lamp, LH (Rear)
Flasher Lamp, RH
Flasher Lamp, RH (Rear)
Head Lamp, LH
Head Lamp, RH
Rotaly Forward Lamp
Rotaly Reverse Lamp
Attachment Limit Switch
No.112
Brake Limit Switch
Dead Man Limit Switch
Lift Limit Switch No.112
Stop lamp limit Switch
Stop Lamp, LH
Stop Lamp, RH
Tilt Limit Switch
Tail Lamp, LH
Tail Lamp, RH
Working Lamp
Forward Contactor, LH
Forward Contactor, RH
Pump Contactor
Power Steering Contactor
Reverse Contactor, LH
Reverse Contactor, RH
Charger Magnet Switch
Computer Print Board
EHPS Print Board
Symbol
PBsN
PLw
RA
RADIP
PCKII 2
SA
SLL
SN1
SNCI12
SNR112
SSP
SSL
SSR
STH
SWAC
SWF
SWH
SWKy
SWL
SWPB
SWsc
TF
THR
TM
TMD
TMP
TMps
TU
VRAD
VRSP
Name
Snubber Print Board
Working Pilot Lamp
Absorber Resistor
Drivelpump Absorber
Resistor
Check Resistor No.112
Surge Absorber
Lequid Level Sensor
Sunbber No.1
Snubber Capacitor 112
Snubber Resistor 112
Steering Pressure Sensor
Speed Sensor, LH
Speed Sensor, RH
Thermo Sensor
Accel Switch
Flasher Switch
Horn Switch
Key Switch
Light Switch
Parking Brake Limit
Switch
Speed Control Switch
Transformer
Thermal Relay
Main Transistor
Main Drive Transistor
Main Pump Transistor
Main Power Steering
Transistor
Timer Unit
Accel Drive Variable
resistor
Steering Position Variable
resistor (Steering
potentiometer)

9. OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks on rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve
in load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil
pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnectingwiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange
the parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean
tools and operate in a clean location.
(5) Follow the described procedures for disassembly, inspectionand reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassem-
bly. If no tightening torque is specified, tighten the bolt or nut according to the standard
tightening torque table.
3. Grasping the troule state
When a trouble occurs, du not attempt immediate disassembly or replacement but first check
if the trouble requires disassembly or replacement for remedying.
4. How to treat liquid waste
When draining liquid waste from a vehicle, use a pan or other suitable container to collect the
liquid.
Do not throw away oil, fuel, cooling water, oil filters, batteries, or other injurious materialssince
these materialsmay adverselyaffect human health and the environment. Sort liquid waste into
different types and seek the service of experts for proper disposal.
Hoisting the vehicle
Loop wire ropes on the mast hook hole and the rear of the
head guard to hoist the vehicle.

10. JACK-UP POINTS
The vehicle often needs to be jacked up during assembly and reassembly.
Be sure to jack up the vehicle at the right positions. Placing a jack in the wrong position or jacking up
the vehicle in the wrong manner may cause an unexpected accident.
Front jack-up Rear jack-up
Front jack-up
If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with
a bearing plate at least 80 m m long.
Rear jack-up
When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the
weight on the opposite side.
The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle
maintains its balance during jack-up.

11. CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively
according to the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the mea-
sured value should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or
movement.
1. Difference in measurement results with the digital type and analog type
*The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual. Cautions when the polarities are
different between the analog type and digital type are described below.
(1) Analog circuit tester
I Measurement result example
Forward direction Reverse direction
(2) Digital circuit tester
Forward direction Reverse direction
Tester range: KR range
Analog type
Continuity
I Forward I shall exist I
Reverse
No continuity
Measurement result example
Tester range: 2 M Q range
Digital type
I
I NO continuity II Forward
1
Continuity
Reverse shall exist
2 MR

12. 2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is
used. The resistance of a semiconductor such as a diode varies with the circuit tester power
supply voltage.
The diode characteristics are shown in the figure below.
( m ~ ) The resistance values of the same semiconductor
5 measured with two types of circuit testers having
different power supply voltages are different.
Current 4
in This manual describes the results of measurement
forward
direction
with a circuit tester whose power supply voltage is
2
3.0 V.
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Voltage in forward direction lV)
3. Difference in measurement result by measurement range (analog type)
In the analog type circuit tester, changing the measurement range switches over the internal
circuit to vary the circuit resistance. Even when the same diode is measured, the measure-
ment result varies with the measurement range.
Always use the range described in the repair manual
for measurement.
Current
flow
I
4
TEwersource: 1.5 V
"0Red 6@Black
Variable resistor
,- ,Resistor
Range: x 10
(SW1)
Resistor
1 4
(SW2)
Range: x 1
,,
,

13. STANDARD BOLT AND NUT TIGHTENINGTORQUE
How to judge tightening torque of a standard bolt or nut.
1. How to judge tightening torque of a standard bolt.
Find out the type of the bolt from the list below.
Then, find the bolt tightening torque from the table.
2. How to judge tightening torque of a standard nut.
The nut tightening torque can be judged from the bolt type. (Seethe item above.)
BOLT STRENGTH TYPE IDENTIFICATIONMETHOD
1. Identification by bolt shape 2. Identification by part No.
Hexagon head bolt I
Part No.
91611-40625
T L e n g t h (mml
Diameter (mm)
iameter
Stud bolt
Part No.
92132-40614
Length (mm)
Diameter (mm)
Class
4=4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
4T
4T
5T
Shape and class
Two protruding
Four protruding
Hexagon
head bolt
Hexagon
flange bolt
Hexagon
head bolt
@-Bolt head No.
0 No mark
No mark
Two protruding
lines

14. 0-12
TIGHTENING TORQUE TABLE
5T
6T
7T
8T
14
16
6
8
10
12
14
16
6
8
10
12
14
16
6
8
10
12
14
16
6
8
10
12
14
16
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.5
I I
75 1 760 j 55
113 j 1150 i 83
6.4 1 65 i 56 in-lbf
16 j 160 12
I I
32 j 330 j 24
59 j 600 j 43
I I
91 i 930 i 67
I I
137 1 1400 1 101
7.8 j 80 1 69 in-lbf
I I
19 1 195 1 14
I I
38 j 400 29
I I
72 1 730 1 53
I I
110 j1100 i 8 0
I I
170 11750 1127
l1 1 1 1 0I 1 8
I
25 1 2 6 0 1 1 9
I I
52 i 530 j 38
I I
95 1 970 1 70
I I
147 j 1500 i 108
I I
226 1 2300 1 166L
12 i 125 j 9
I I
29 1 300 1 22I I
61 j 620 j 45
I I
108 11100 1 8 0
172 1750 i 127
I I
265 1 2700 1 195
I I
83 1 8 5 0 1 6 1
I I
- II _ I _I
7.5 1 75 j 65 in-lbf
18 j 175 j 13
I I
36 j 360 j 26
65 j 670 j 48
I I
100 1 1050 1 76
I
157 11600 i l l 6
8.8 j 90 j 78 in-lbf
I I
21 1 215 1 16
I I
1 440 j 3243 1
I
79 1 8 1 0 1 5 9
I I
123 1 1250 j 90
I I
191 11950 1141
12 j 120 j 9
I I
28 1 2 9 0 1 2 1
I I
58 j 590 j 43
I I
103 1 1050 : 76
I I
167 ,11700 j123
I I
I I- I
- I -I
l4 1I 145 9
I
32 1 330 1 24I
1 690 j 5068 I
I
123 1 1250 1 90
196 1, 2000 j 145
I I
299 1 3050 1 221

15. PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the fol-
lowing cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or
tightened) by tightness check, etc.
I I Note:
For toraue check. use the lower limit of the allowable
tighteni;lg torque range. If the bolt moves, retighten it
according to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded
hole must be washed even for replacement of the
bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded
portion of the bolt.
HIGHPRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact sur-
faces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage
on the contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and
tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter
of screw
7/16 - 20UNF
9/16 - 18UNF
314 - 16UNF
718 - 14UNF
718 - 14UNF
1.1116 - 12UNF
1.5116 - 12UNF
PF1/4
PF3/8
PF1/2
PF314
PF1
Hose inside
diameter
mm (in)
6 (0.24)
9 (0.35)
12 (0.47)
12 (0.47)
15 (0.59)
19 (0.75)
25 (0.98)
6 (0.24)
9 (0.35)
12 (0.47)
19 (0.75)
25 (0.98)
Standard tightening torque N-m(kgf-cm) [ft-lbf]
Standard
25 (250) [18.11
49 (500) [36.2]
59 (600) [43.4]
59 (600) [43.4]
78 (800) [57.9]
118 (1200) [86.8]
137 (1400) [101.3]
25 (250) [18.1]
49 (500)[36.2]
59 (600) [43.4]
118 (1200) [86.8]
137 (1400) [101.3]
Tightening range
24-26 (240-270)[17.4-19.51
47-52(480-530) 134.7-38.31
56-62 (570-630) [41.2-45.61
56-62 (570-630) [41.2-45.61
74-82 (760-840)[55.0-60.81
112-123 (1140-1250) [82.5-90.41
130-144 (1330-1470) [96.2-106.41
24-26 (240-270) [17.4-19.51
47-52 (480-530) [34.7-38.31
56-62 (570-630) 141.2-45.61
112-123 (1140-1250) [82.5-90.41
130-144 (1330-1470) [96.2-106.41

16. WlRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [lbf]
Lifting
angle
o0
30'
60'
Suspension
method
-Ll7
h0-
~~~~i~~
1.00 time
1.04 time
1.16 time
Rope
diameter
6 mm
(0.24 in)
8 mm
(0.32 in)
10 mm
(Om4in)
12.5 mm
(0.5 in)
14 mm
(0.56 in)
Lifting
angle
90"
120'
Compres-
sion
0 time
0.27 time
0.58 time
Four-rope suspension
o0
12160
(1.24)
[27341
17650
(1.8)
[39691
27460
(2.8)
L61741
43150
(4.4)
[97021
54920
(5.6)
[I23481
Tension
1.41 time
2.00 time
Cutting
load
21380
(2.18)
[48071
31480
(3.21)
[7078]
49230
(5.02)
[ I1.691
76880
(7.84)
[173871
96400
(9.83)
[216751
Single-rope
suspension
0"
3040
(0.31)
[683.6]
4410
(0.45)
[992.3]
6960
(0.71)
L1565.61
10980
(1.12)
[2469.5]
13730
(1.4)
[3087]
Two-rope suspension
30°
11770
(1.2)
[26461
17060
(1.74)
[39371
26480
(2.7)
[59541
41190
(4.2)
[9261I
52960
(5.4)
[ I19071
Compres-
sion
1.00 time
1.73 time
Suspension
method
by5
2' A
0"
6080
(0.62)
[I3671
8830
(0.9)
[I9851
14020
(1.43)
[31531
21570
(2.2)
[4851]
27460
(2.8)
[61741
60'
10400
(1.06)
[2337]
15300
(1.56)
[34401
23540
(2.4)
152921
37270
(3.8)
[83791
47070
(4.8)
[I05841
60"
5200
(0.53)
[ I1691
7650
(0.78)
[I7201
11770
(1.2)
[26461
18630
(1.9)
[4190]
23540
(2.4)
[5292]
30'
5880
(0.6)
[I3231
8530
(0.87)
[I9181
13440
(1.37)
[30211
21280
(2.1)
[4631]
26480
(2.7)
[59541
90"
8630
(0.88)
[I9401
12550
(1.28)
[2322]
19610
(2.0)
[44101
29420
(3.0)
[6615]
37270
(3.8)
[83791
90°
4310
(0.44)
[9701
6280
(0.64)
[I4111
9810
(1.0)
[22051
14710
(1.5)
[33081
18630
(1.9)
[41901

17. COMPONENTS WEIGHT
RECOMMENDED LUBRICANTS AND CAPACITIES
Item
Drive motor
(One unit)
Pump motor
Counter weight
Mast Wllift bracket
(with lift cylinder, less fork)
[max. fork height = 3000 mm (118 in)]
Weight kg [Ibl
Approx. 41 1901
Approx. 35 [771
5FBE10: Approx. 393 I8671
5FBE13: Approx. 556 112261
5FBE15: Approx. 620 [I3671
5FBE18: Approx. 785 11731I
5FBE20: Approx. 1070 I23601
*Approx. 400 [8821
**Approx. 410 19041
45s: Refrigerator specification vehicle
*: For 3000 mm (118 in) maximum fork height
**: For 6000 mm (236in) maximum fork height
Capacity
Right side: 1.7 t? (0.45 USgal)
Left side: 1.8 (0.47 USgal)
(1993.1 - 1998.1)
1.5 e (0.40 Usgal)
(1.998.2 -)
* I 6 e (4.2 USgal)
**21 e (5.5 USgal)
Proper quantity
Proper quantity
Application
Transmission
Hydraulic (total)
Brake line
Chassis part
Type
STD: Hypoid gear oil SAE85W-90
(API GL-4)
45s: Hypoid gear oil SAE75W-80W
(APIGL-4)
STD: Hydraulic oil IS0 VG32
45s: MIL-H-5606-D
STD: SAE J-1703 DOT-3
45s: SAE J-1703 DOT-3
(1993.1 - 1998.1)
Brake fluid arctic S (1998.2 -
STD: MP grease No.2
45s: MIL-G-3278-A

18. LUBRICATION CHART
1. Chain
2. Mast strip
3. Tilt cylinder front pin
4. Mast support bushing
5. Front axle hub
Transmission housing
Reservoir tank
Oil control valve link pin
Accelertor pedal link
Tilt steering locking mechanism
Brake pedal link
Oil tank
Rear wheel bearing
Rear axle bearing
Steering rack & pinion
Limit switch controller
(cold storage models only)
I lnspect every 8 hours (daily)
I1 lnspect every 40 hours (weekly)
111 lnspect every 170 hours (monthly)
IV lnspect every 1000 hours (6 monthly)
V lnspect every 2000 hours (annually)
0 lnspect and service
Replace
@ MP grease (STD)
MIL-G-3278-A (45s)
@ Engine oil
@ Hypoid gear oil
@ Brake fluid
@ Hydraulic oil

19. PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector
Every
12 months
Every
2000 hours
Every
Inspection Period 1 month
Item Every
170 hours
Every
3 months
Every
500 hours
Every
6 months
Every
1000 hours
t
t
c
c
c
M
t
t
c
C
t
t
M
t
t
+-
I
c
C
I
I
I
I
c
c
ELECTRICAL
Motor
Battery
Charger
Magnet
contactor
Microswitch
t
c
M
+-
t
c
C
C
M
t
c
M
t
C
t
t
c
+-
t
I
I
c
c
+-
+-
C
c
c
c
t
t
t
c
t
SYSTEM
Abnormal sound during revolution
Loose terminal
Insulation resistance
Brush wear and sliding contact status
Commutator fouling and damage
Brush spring fatigue
Charge
Battery fluid level
Battery fluid specific gravity
Loose terminal
Abnormality at top of battery and
battery case
Insulation resistance
Cell voltage measurement after
charging
Timer operation
Terminal loosening
Operating voltage measurement
Magnet switch function, contact
fouling and roughening
Loose contact, damage and wear
Auxiliary contact function, fouling and
wear
Arc chute installation status
Timing and functioning
Loose coil installation
Loose main circuit lead installation
Timing and operating function
Damage and loose installation
I
T
I
I
M
I
I
I
I
I
I
I
I

20. Every
6 months
Every
1000 hours
c
C
c
C
C
c
C
c
Inspection Period
Item
Every
12 months
Every
2000 hours
c
+-
t
M
c
C
c
C
t
Every
1 month
Every
170 hours
I
I
C
I
I
I
I
I
Direction lever
Controller
Fuse
Wiring
(including
charging cord)
Accelerator
POWER TRAIN
Every
3 months
Every
500 hours
c
c
c
c
t
c
C
c
Operating conditions and damage
Operation
Inside fouling and damage
Overcurrent limit valve
Loosening
Damage of wiring harness and loose
clamp
Loose connection and taping status
Battery connector damage and
connection status
Operating and damage
c
c
c
c
c
c
I
I
I
Transmission
c
c
c
Oil leak
Oil level
Gear function and sound
TRAVELING EQUIPMENT
c
c
t
t
C
@
C
C
c
c
t
c
C
C
C
C
I
I
t
t
t
t
t
t
C
C
M
I
T
M
I
I
I
I
Wheels
Front axle
Rear axle
Tire air pressure
Tire cuts, damage and uneven wearing
Loose rim and hub nuts
Tire groove depth
Metal chips, pebbles and other foreign
matter trapped in tire grooves
Rim and disc wheel damage
Abnormal sound and looseness of
front wheel bearing
Abnormal sound and looseness of rear
wheel bearing
Cracks, damage and deformation of
case
Cracks, damage and deformation of
rear axle

21. Every
12 months
Every
2000 hours
Every
6 months
Every
1000 hours
Inspection Period
Item
STEERING SYSTEM
Every
1 month
Every
170 hours
Every
3 months
Every
500 hours
t
t
t
t
t
t
Steering wheel
Hydraulic
control valve
Power steering
t
t
t
t
t
t
I
I
I
I
T
I
I
Play and looseness
Function
Oil leak
Looseness of mounting
Oil leak
Mounting and linkage Looseness
Damage of power steering hose
t
t
t
t
t
t
t
t
t
t
t
I
t
t
t
M
M
t
T
M
t
I
I
t
t
t
t
t
t
t
t
I
t
M
I
I
I
I
I
I
M
I
BRAKING SYSTEM
Brake pedal
Parking brake
Brake pipe and
hose
Brake fluid
Disk brake
t
t
t
t
t
t
t
t
t
t
Play and reserve
Braking effect
Pull margin
Braking effect
Rod and cable looseness and damage
Ratchet wear and damage
Leakage, damage and mounting status
Fluid level
Clearance between diskwheel and
lining
Pad wear and damage
Disk brake wheel wear and damage
Disk brake lever operating status
Disk brake wheel set bolt loose
Return spring fatigue
Caliper body leak brake fluid
Master cylinder and wheel cylinder
operation
Cylinder and piston cup wear and
damage

22. Inspection Period
Item
Every
1 month
Every
170 hours
MATERIAL
Forks
Mast and lift
bracket
Chain and
chain wheel
Various
attachments
HYDRAULIC
Every
3 months
Every
500 hours
HANDLING SYSTEM
Abnormality of fork and stopper pin
Misalignment between left and right
fork fingers
Cracks at fork root and welded part
Deformation and damage of each part
and crack at welded part
Mast and lift bracket looseness
Wear and damage of mast support
bush
Wear, damage and rotating condition
of rollers
Wear and damage of roller pins
Wear and damage of mast strip
Tension, deformation and damage of
chain
Chain lubrication
Abnormality of chain anchor bolt
Wear, damage and rotating condition
of chain wheel
Abnormality and mounting condition
of each part
SYSTEM
Every
6 months
Every
1000hours
Every
12 months
Every
2000 hours
I
I
I
I
I
I
I
I
I
I
I
Cylinder
Oil pump
Hydraulic oil
tank
Loosening and damage of cylinder
mounting
Deformation and damage of rod, rod
screw and rod end
Cylinder operation
Natural drop and natural forward tilt
(hydraulic drift)
Oil leak and damage
Wear and damage of pin and cylinder
bearing
Lifting speed
Uneven movement
Oil leak and abnormal sound
Oil level and contamination
Tank and oil strainer
Oil leak
c
c
4-
+-
C
c
C
t
t
t
4-
I
I
I
M
I
I
M
I
I
I
I
C
C
c
c
@
4-
t
t
t
4-
C
t
C
t
c
c
+-
C
+-
t
t
t
+-
c
c
C
t
t
c
t
4-
c
t
4-
C
C
c
C
t
t
c
t
c
c
t
4-
c
4-
I*'
t
+
I
t
I
c
t
C
c
C
4-

23. Inspection Period
Item
Every
1 month
Every
170 hours
I
I
I
I
I
I
T
I
Control lever
Oil control
valve
Hydraulic
piping
Loose linkage
Operation
Oil leak
Relief pressure measurement
Relief valve and tilt lock valve
functions
Oil leak
Deformation and damage
Loose joint
Hose tension and twisting
SAFETY DEVICES,
Head guard
Back-rest
Lighting
system
Horn
Direction
indicator
Instruments
Back up buzzer
Rear-view
mirror
Seat
Body
Other
Every
3 months
Every
500 hours
t
c
t
C
t
t
c
c
ETC.
Cracks at welded portion
Deformation and damage
Loosening of mounting
Deformation, crack and damage
Function and mounting condition
Function and mounting condition
Function and mounting condition
Functions
Function and mounting condition
Dirt, damage
Rear reflection status
Loosening and damage of mounting
Damage and cracks of frame, cross
members, etc.
Bolt looseness
Grease up
Every
6 months
Every
1000hours
c
C
c
t
c
c
t
c
Every
12 months
Every
2000 hours
t
+
t
M
t
c
c
t
c
I
I
I
I
I
I
I
I
I
I
I
I
L
+-
+
+-
t
t
t
t
c
t
c
t
t
c
c
t
c
c
c
t
t
c
c
t
c
c
t
c
c
C
t
c
c
c
c
c
c
t
t
I
T
t

24. PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
Inspection (operating hours or
months, whichever is earlier)
Brake fluid
Hydraulic oil
Hydraulic oil filter
Transmission oil
Wheel bearing grease
Master cylinder rubber parts
Wheel cylinder rubber parts
Reserve tank tube
Power steering hose
Internal rubber parts of power steering system
Material handling house
Chain
Every
1 month
Every
170 hours
(New vehicle)
Every
3 months
Every
500 hours
Every
6 months
Every
1000 hours
Every
12 months
Every
2000 hours
C
c
C
(Every 2 years)
(Every 2 years)
(Every 2 years)
(Every 2 years)
(Every 3 years)

25. BATTERY
Page
SERVICE STANDARDS ........................................ 1-2
DISPLAY INDICATION ........................................... 1-2
OVERDISCHARGE ALARM FUNCTION ..................... 1-2
BATTERY COMPARTMENT & MINIMUM
WEIGHT REQUIRED .......................................... 1-3
TROUBLESHOOTING ........................................... 1-4
BATTERY ASSY ................................................... 1-5
INSPECTION ..................................................... 1-6

26. SERVICE STANDARDS
DISPLAY INDICATION
1. The display indicates the remaining battery charge
level in 10 stages. When the remaining charge drops
to the set level or below, the indication flashes the
warn the timing for charging.
1.280 (20) [681
1.150 (20) I681
32.0
42.5
Sulfuric acid diluted with distilled water
Distilled (deionized) Water
I or more
Specific gravity in fully charged state (OC) [OF1
Specific gravity in fully discharged state (OC) [OF]
2. When the battery is discharged fully (100 %), the
overdischarge alarm function operates as follows:
Discharge end voltage
V
OVERDISCHARGE ALARM FUNCTION
36 V specification
48 V specification
1. Material handling with traveling becomes impossible.
If simultaneous operation is attempted, priority is
given to traveling and material handling is not ef-
fected. (For prevention of battery from damage by
large current flow)
Electrolyte
Fluid to be spplied
Insulation resistance Mfl
2. When material handling is attempted, all indicators on
the display flash and the buzzer sounds to alarm over-
discharge.
Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on, how-
ever, material handling operation can be performed.

27. BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by re-
ferring to the table below. Always use a case allowing fixation of the battery stopper.
f38 mm
(1.5 in)
z
Y
Y
4 i-
Maximum battery
weight (with case)
N (kg) [Ibl
6796 (693) 115301
t
9591 (978) [21591
t
t
Vehicle
model
5FBE10
5FBE13
5FBE15
5FBE18
5FBE20
Minimum required
battery weight
(with case)
N (kg) [Ibl
5099 (520) I11471
t
6865 (700)115451
t
t
Compartment dimensions m m (in)
Front to rear
length X
451
(17.76)
t
551 (21.69)
t
t
Width Y
928 (36.54)
t
997 (39.25)
t
t
Height Z
641 (25.24)
t
t
f
f

28. TROUBLESHOOTING
Pole plate corrosion Pole plate warping and
fallen acting substance
Insufficient charge
Shorting between
service
Deposition of fallen
-acting substance in Dirty terminal or plug-
Electrolyte leakage Loosened or corroded
and decrease connections

29. 1-5
BATTERY ASSY
REMOVAL-INSTALLATION
Removal Procedure
1 Disconnect the battery plug.
2 Remove the battery hood catch.
3 Open the battery hood.
4 Remove the battery stopper.
5 Remove the battery ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.

30. INSPECTION
1. Electrolyte level inspection
GS battery:
Open the cap and add distilled water if the white line
on the red float is invisible. Add water until the white
line on the float appears and stop addition there be-
cause further addition until the contact between the
float and stopper results in overfilling.
YUASA battery:
Open the cap and add distilled water if the ring of the
red float is dropped. Add water until the float ring
comes into contact with the top portion.
As the level gauge is provided on the side surface of
the battery case, the electrolyte level can generally be
checked at a glance. However, periodically inspect the
level by opening the cap.
The green indicator of the level gauge is lit to indicate
activation of the level gauge sensor, and the red indi-
cator flashes to indicate the necessity of water addi-
tion.
Insufficient electrolyte
Flashing
level
Caution:
Never change the mounting position of the plug with
sensor.
Note:
The electrolyte consumption can be calculated by the following equation:
Consumption (CC) = 5 hour rating capacity x 0.0336 x number of cells x charging frequency
2. Electrolyte inspection
(1) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.

31. Nozzle
3. Inspection of electrolyte specific gravity
(1) Use a hydrometer and measure the specific gravity
of the electrolyte
Specific gravity in fully charged state:
1.280 (at 20 O C )
Specific gravity in fully discharged state:
1.150 (at 20 OC)
The specific gravity of the electrolyte is expressed
by the value at 20 O C as the standard.
Specific gravity conversion equation
S,, = St + 0.0007 (t-20)
S,,: Specific gravity at 20 OC
St : Specific gravity at t O C
t : Temperature at the time of measurement
"How to use the hydrometer
a Insert the nozzle of the hydrometer into the wa-
ter supply port and suck the electrolyte into the
outer cylinder.
@ Let the hydrometer in the outer cylinder float
correctly without contact with the top, bottom
and side wall of the outer cylinder, and read the
graduation at the electrolyte surface as shown
at left after disappearance of bubbles in the
sucked electrolyte.
@ After the measurement wash outside and in-
side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.
4. Insulation resistance inspection
Use an insulation resistance meter (megger) and mea-
sure the resistance between the battery and battery
case.
Insulation resistance: 1 MQor more
Note:
If the insulation resistanceis less than 1MQ, remove
the battery from the vehicle and wash it with water.
Dry the battery case roughly, and measure the insu-
lation resistance again. Install the battery on the ve-
hicle after checking that the insulation resistance is
1 MQor more.

32. * Battery control table
Prepare the control table for each battery to record and retain the inspection result.
Inspection
date and
time
Inspected cell No.
Electrolyte
tempera-
ture
Remarks
Specific
gravity
Added wa-
ter volume
Inspector

33. CONTROL CIRCUIT
[FOR OTHER THAN U.S.A.] (1993.1 - 1998.8)
[FOR U.S.A.] (1993.1 - 1999.1)
Page
MCS-IIIA CONTROLLER ..................... 2-2
GENERAL ........................................ 2-2
SPECIFICATIONS ................................. 2-3
COMPONENTS ................................... 2-4
CONTROL PANEL REMOVAL.INSTALLATION ....... 2-9
....CONTACTOR PANEL REMOVAL.INSTALLATION 2-10
INSPECTION .....................................2-11
DISASSEMBLY ................................... 2-29
REASSEMBLY .................................... 2-30
PANEL PARTS TIGHTENING TORQUE .............. 2-33
CONTINUITY CHECK WITH CIRCUIT TESTER ....... 2-34
OCL (OVERCURRENTLIMIT) VALUES .............. 2-35
ACCELERATION POTENTIOMETER
ADJUSTMENT ............................ 2-37
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT ............................ 2-38
PARKING BRAKE SWITCH ADJUSTMENT ..... 2-39
MATERIAL HANDLING SWITCH
ADJUSTMENT ............................ 2-40
DIRECTION SWITCH ........................ 2-41
DISASSEMBLY-INSPECTION-REASSEMBLY ........ 2-42
PS CONTROLLER ........................... 2-44
COMPONENTS ................................... 2-44
INSPECTION (STD) ............................... 2-45
REMOVAL.INSTALLATION(EHPS) ................. 2-46
....EHPS CONTROLLER VOLTAGE MEASUREMENT 2-47
INSPECTION (EHPS) .............................. 2-48
REASSEMBLY (EHPS) ............................. 2-49
STEERING POTENT10INSTALLATION
ADJUSTMENT ............................ 2-50

34. MCS-IIIA CONTROLLER
GENERAL
The 5FBE series is provided with the diagnostic (self-diagnosis) function for automatically detecting
any abnormality in the main traveling/material handling circuit, operating system such as the acceler-
ator and sensors to sound the buzzer (bleep, bleep) and to display the abnormal portion by the corre-
sponding error code on the multi-display.
At the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken to ensure safety.
When the display is set to the analyzer (fault analysis) mode, defect detection and functional check of
the main drivelmaterial handling circuit, operating systems, and sensors are performed.
See the Multi-display section (page 3-21for the diagnosis. See the Multi-display section (page 3-7) for
the analyzer.
Control Panel ASSY Contactor Panel ASSY

35. SPECIFICATIONS
*' : 36V specification
**: The PS transistor and diode are integrated.
*3: UL specification (36VI48V)
5FBE10.13.15.18~20
225 A "'275 A
225 A "'275 A
50 A
10 A
10 A
TSM003 (3 pcs.)
TSM003 (2 pcs.)
~~1MI100~-025
30MF40
30MF40
SR250L-6s
70M30
70M30
45M30
*21M1100H-025
HS800RT
HS800RT
MBP20A-10MJN
60pF (2 pcs.)
60pF (1 pcs.)
1.5 R 120 W
1.5R 120W
ME250
ME250
ME251
C48-A11 * 3 ~ 3 6 / 4 8 ~ 1
Fuses
Transistors
Diodes
Current
sensor
Capacitors
Resistors
Contactors
Portion
F1 (Drive circuit)
F2 (Pump circuit)
F3 (PScircuit)
F4 (For lamps)
F5 (Control circuit)
TM (For drive motor)
TMP (For material handling pump: OPT)
TMps (For PS: OPT)
DAD (For drive motor)
DAP (For material handling pump: OPT)
DFI (DM flywheel)
D F ~ R(DM flywheel)
DF2L(PM flywheel)
DF3 (PM flywheel: OPT)
DF4 (PSflywheel)
CSD (For drive motor)
CSP (For material handling pump: OPT)
CSps (For PS: OPT)
CAD (Absorber for drive motor)
CAP (Absorber for pump motor: OPT)
RAD (Absorber for drive motor)
RAP (Absorber for pump motor)
MFR.MFL(For forward drive)
MRR.MRL(For reverse drive)
MP (For material handling)
MPS(For PS)

36. COMPONENTS
Control panel

37. Resistor panel

38. Control panel Wlmaterial handling chopper (OPT)

39. 2-7
Contactor panel

40. 2-8
MF-MRcontactor
MP contactor

41. CONTROL PANEL REMOVAL-INSTALLATION
1 Battery plug 4
5 Connector
6 Wiring
Removal Procedure
1 Disconnect the battery plug.
2 Remove the side panel LH.
3 Remove the side panel under cover.
4 Remove the control panel cover.
5 Disconnect the connector.
6 Disconnect the wiring.
7 Remove the control panel.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose,
the control panel elements may be damaged.

42. CONTACTOR PANEL REMOVAL.lNSTALLATlON
1 Banery plug
2 Toe board
5 Wiring
-
Removal Procedure
1 Disconnect the battery plug.
2 Remove the toe board.
3 Remove the side panel LH.
4 Remove the side panel under cover.
5 Disconnect the wiring.
6 Remove the contactor panel.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Check insufficient cable tightening or cable tightening failure before inserting the battery plug.

43. INSPECTION
Some parts can be inspected after removal from the vehicle while others can only be inspected on the
vehicle.
As the CPU board and DC-SD boards require battery voltage application, they must be inspected while
being mounted on the vehicle. (Use SST 09240-12240-71.)
Inspection after control panel removal from the vehicle is mainly explained here.
1. Insulation resistance measurement (Always inspect before starting control panel inspection.)
(1 Disconnect the battery plug and measure the insulation resistance between the battery plug
and body.
Measurement terminals
Standard
Controller side of battery plug - Body
The resistance should be as high as possible, but it varies greatly, depending on
the vehicle use status, place and weather. (Approx. 1 MQ)

44. 2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor)
(OPT)
(1) lnspection method
Disconnect the wiring of CAD and CAP after discharging the CAD and CAP with a resistor of
about 100 Q.
Standard
Inspection point
CAD (Control panel)
CAP (Controlpanel)
When circuit tester probes are brought into contact with both terminals of CAD or CAP, the pointer deflects
once to the 0 Q side and gradually deflects toward the oo Q side.
3. TM (drive circuit main transistor).TMP (pump circuit main transistor)
(1) lnspection method
Disconnect wiring from each of TM-TMP
Measurement terminals
Both terminals of CAD (DAD side - TM side)
Both terminals of CAP (DAP side - TMP side)
Circuit tester range
Q X ~ K
If any TM or TMP is found abnormal in inspection replace them (all TMs or all TMPs) as a set.
Inspection point
TM (control panel)
TMP (control panel)
Measurement terminals Standard
w Q
c o n
00 Q
(conduction)
(conduction)
cx, Q
D-S
D-G
G-S
Clrcuit tester range
Q X I K
D: (-1 probe - S: ( + ) probe
D: ( + ) probe - S: (-1 probe
D: (-1 probe - G: ( + ) probe
D: ( + ) probe - G: (-1 probe
G: (-) probe - S: ( + probe
G: ( +) probe - S: (-1 probe

45. 3-1. DRD (Direction of Reverse Conductive Diode)
(1 lnspection method
Remove the DRD.
u
Conduction
u
No Conduction
Inspection point
DRD
4. DF1 (flywheel diode No.1)
(1) lnspection method
Disconnect the wiring from DF1
Standard
Approx. 1.6 k 0
0352
Measurement terminals
Forward Anode: - probe - Cathode: + probe
Reverse Anode: + probe - Cathode: - probe
Circuit tester range
n x IK
Circuit tester range
n x i ~
Standard
Approx. 3 KQ
co Q
Inspection point
DF1
(control panel)
Measurement terminals
(Forward)
Anode: (-) probe - Cathode: ( + probe
(Reverse)
Anode: ( + ) probe - Cathode: (-1 probe

46. 5. DF2,-DF2, (flywheel diode No.2)
(1) lnspection method
Disconnect the wiring from DF2,-DF2,
6. DF3 (flywheel diode No.3 in panel with pump chopper)
(1) lnspection method
Circuit tester range
0 x 1 ~
Standard
Approx. 3 KQ
co fl
Inspection point
DF2,.DF2,
(contactor panel)
Measurement terminals
(Forward)
Anode: (-) probe - Cathode: (+) probe
(Reverse)
Anode: (+) probe - Cathode: (-1 probe
Inspection point
DF3
(control panel)
Standard
Approx. 3 Kn
con
Measurement terminals
(Forward)
Anode: (-1 probe - Cathode: ( +1probe
(Reverse)
Anode: (+) probe - Cathode: (-1 probe
Circuit tester range
n x l K

47. 7. DAD (drive circuit absorber diode).DAP (pump circuit absorber diode)
(1) lnspection method
Disconnect the wiring from DAD-DAP.
8. MFR.MFL(forward contactors).MR,.MR, (reverse contactors)-MP (material handling pump con-
tactor)
(1 Measure the coil resistance of each of MFR.MFL.MRR.MRL.MP.
Inspection point
DAD
DAP
(control panel)
Measurement terminals
(Forward)
Anode: (-) probe - Cathode: (+) probe
(Reverse)
Anode: ( + ) probe - Cathode: (-1 probe
Inspection point
(In control panel)
MFRcoil
MFLcoil
MRRcoil
MRLcoil
MP coil
Standard
Approx. 6 KQ
00 Q
Measurement terminals
, MFRcoil connector
MFLcoil connector
MRRcoil connector
MRLcoil connector
MP coil connector
Circuit tester range
6 2 x I K
Standard
Approx. 20 Q
(at 20°C)
Circuit tester range
Q x l

49. 9. RAD (drive circuit absorber resistor)-RAP (pump circuit absorber resistor)
(1) lnsepction method
Battery removal
Disconnect the wiring from RAD-RAP (RAD: CN118-RAP: CN119).
When inspecting with the battery installed, disconnect the CN117 connector.
Inspection point
RAD
RAP
CN117 (Main harness side)
Measurement terminals
Both terminals of RAD-RAP
Inspection point
RAD
RAP
Standard
Approx. 1.5 62
Measurement terminals
RAD: CN117-2- CN117-3
RAP:
CN117-1 - Controller P I I terminal
Circuit tester range
6 2 x 1
Standard
Approx. 1.5 62
Circuit tester range
6 2 x 1

50. 10. CPU board-DC-SD board
If the trouble cause is judged to be in the CPU board or DC-SD board, apply the battery voltage,
install SST09240-12240-71, and measure the applied voltage and resistance at each connector.
Caution:
Always disconnect the battery plug before removing or installing the CPU board or DC-SD board.
Note:
When replacing the CPU board or DC-SD board judged to be causing the trouble as a result of trou-
bleshooting, always measure the applied voltage and resistance at related portions before replace-
ment.
Use SST 09240-12240-71 for the measurement.
(1) SST connection method
@ Turn the key switch to OFF.
@ Disconnect the battery plug.
@ Disconnect the CPU board-DC-SD board connectors (CN101 to CN107.CN111.CN112).
@) Connect the SST.
Inspection side connector
CN107

51. (2) Lists of measurement methods and standards
@ Explanation on list format
rCircuit tester (+ probe
Circuit tester (-1 probe
Connector pin No.
I Signal (part) name -conditions for measurement
1
L ~ e v e lNo.
@ Lists
CN 101 connector Basic conditions (battery plug ON.SWKy ON)
Remarks
C A C
StandardConnector No. -Connector No.
Remarks
Voltage after
key switch
Voltage after
key switch
Voltage after
key switch
-
Conditions
1
CN102-1 CN102-9
(43, K36 V) (N,,GND)
Standard
Approx. 18 3 V
Approx. 18 & 3 V
Approx. 48 Vl36 V
OV
5 * 0.25 V
5 * 0.25 V
- 5V - -6 V
Approx. 48 Vl36 V
OV
Approx. 48 Vl36 V
0 V
Connector No. * Connector No.
CNIOI-I I
CN101-2
CN101-3 I CN101-20
(15,+30V) I (N1,GND)
I
CN101-4 I CN101-20
(15,+30V) I (N1,GND)
CN101-5 I CN101-20
(10, C36 V) I (NI, GND)
CN101-6 I CN101-20
I
(32, CHOPD + ) I (NI, GND)
CN101-7 I CN101-20
(30,VDD+) (N1,GND)
CN101-8 I CN101-20
( , - 5 V ) I (N1,GND)
CN101-9 I CN101-20
(14, VBKY) I IN1, GND)
CN101-11 CN101-20
(43, K36 V) I (N1, GND)
CN101-12
CN101-13 I
SWKy:ON
SW,,: OFF
Conditions
Unused
Unused
SWKyON
SW,, OFF
Unused
SWKyON
SW,, OFF
SW,, ON
SW,, OFF
Unused

52. CN102 connector: Basic conditions (Battery plug ON.SWKyON)
Connector No. * Connector No.
CN101-14 I CN101-20
I
(11, GND) I (NI, GND)
CN101-15 I
CN101-16 CN101-20
(11,GND) I (N1,GND)
CN101-17 I CN101-20
(33, CHOPD-) I (Nl, GND)
I
CN101-18 I CN101-20
(31, VDD-1 I (NI, GND)
CN101-19 I
CN101-20 Panel N1
(N1, GND) I terminal
CN101-21 I CN101-20
(13,VBBT) I (N1,GND)
I
CN101-22 I CN101-20
(41, 836 V) I (Nl, GND)
Conditions
Unused
Traveling stop state
Traveling stop state
Unused
Battery plug OFF
SW,, OFF
Connector No. * Connector No.
CN102-1 j CN102-9
(43, K36 V) I (Nl, GND)
CN102-2 1 CN102-9
(41, 836 VI j (N1, GND)
CN102-3 1
I
I
CN102-4 CN102-9
(P8,RCKl) I (N1,GND)
I
I
CN102-5 I CN102-9
(P9,RCKl) I (N1,GND)
CN102-6 I CN102-9
(N2, TMS) I (NI, GND)
I
CN102-7 I CN102-9
I
(41, B36 V) I (N1, GND)
CN102-8 I CN102-9
(41, D36 V) I (Nl, GND)
Standard
ov
ov
4 - 5 V
4 - 5 V
on
Approx. 48 Vl36 V
Approx. 48 Vl36 V
Conditions
SWKyON
SW,, OFF
Unused
Unused
Remarks
Battery voltage
Standard
Approx. 48 Vl36 V
O V
Approx. 48 Vl36 V
48 V vehicle:
4 3 f 5 V
36 V vehicle:
3 2 f 5 V
Approx. 48 Vl36 V
ov
Approx. 48 Vl36 V
Approx. 48 Vl36 V
Remarks
Voltage after
key switch
Battery voltage
Battery voltage
Battery voltage

53. CN103 connector: Basic conditions (Battery plug ON.SWKy ON)
Connector No. o Connector No.
CN102-9 Panel N1
(NI, GND) terminal
CN102-10
I
I
CN102-11 I CN102-9
(P8, TMD) (N1, GND)
I
I
CN102-12 I CN102-9
(92, TMG) I (Nl, GND)
Conditions
Battery plug OFF
SW,, OFF
Unused
Traveling stop state
Connector No. ++ Connector No.
CN103-1 CN103-3
(35, VDP+) I (11, GND)
CN103-2 CN103-3
(37, CHOPP+) I (11, GND)
I
CN103-3 I Panel N1
(11, GND) I terminal
CN103-4 CN103-3
(10, C36V) I (11, GND)
CN103-5 I CN103-3
(15, +30V) I (11, GND)
I
CN103-6 I CN103-3
(30, VDD + 1 (11, GND)
CN103-7 I CN103-3
(32, CHOPD+) (I1, GND)
CN103-8 I CN103-3
(11, GND) I (11, GND)
I
CN103-9 I CN103-3
(36, VDP-) I (11, GND)
CN103-10 I CN103-3
(38, CHOPP-) I (11, GND)
CN103-11 I CN103-3
(11, GND) I (11, GND)
CN103-12 CN103-3
(13, VBBT) I (11, GND)
CN103-13 CN103-3
(14,VBKY) I (11,GND)
CN103-14 CN103-3
(31, VDD-1 I (11, GND)
Standard
on
48 V vehicle:
4 3 * 5 V
36 V vehicle:
32 * 5 V
- 5 - - 6V
Conditions
Battery plug OFF.SWKyOFF
SW,, ON
SW,, OFF
Material handling stop state
SW,, ON
SWKyOFF
Traveling stop state
Remarks
Standard
5 * 0.25 V
5 * 0.25 V
on
Approx. 48 Vl36 V
OV
Approx. 1 8 3 V
5 * 0.25 V
5 *0.25 V
ov
4 - 5 V
4 - 5 v
ov
Approx. 48 Vl36 V
Approx. 48 Vl36 V
OV
4 - 5 V
Remarks
+5V
Voltage after
key switch

54. CN104 connector: Basic conditions (Battery plug ON.SWKyON)
RemarksConnector No. * Connector No.
I
CN103-15 I CN103-3
(33, CHOPD-1 I (II,GND)
I
CN103-16 I
(11,GND) I
Connector No. * Connector No.
I
CN104-1 CN104-14
(41MFR) I (Ir+ )
I
CN104-1 I CN104-8
(4, MFR) 1 (74, CSD-1
I
CN104-2 I CN104-14
15' MRR) j (I'
I
CN104-2 I CN104-8
(5, MRR) 1 (74, CSD -1
I
CN104-3 CN104-14
(2' MFL) II (I' + )
1
CN104-3 I CN104-8
(2, MFL) 1 (74, CSD-1
I
CN104-4 I CN104-14
13' MRL) I (I' + )
CN104-4 CN104-8
(3, MRL) 1 (74, CSD-1
I
CN104-5 CN104-15
(7,MP) I ( I , M + )
I7
CN104-5 CN104-8
(7, MP) f (74, CSD-)
CN104-6 CN104-8
(75, STH) 1 (74, CSD-)
Conditions
Unused
Standard
4 - 5 v
Conditions
Battery plug OFF.SWKyOFF
Measure with the tester negative
probe connected to CN104-14.
Measure with the tester positive
probe connected to CN104-1.
Battery plug OFF.SWKyOFF
Measure with the tester negative
probe connected to CN104-14.
Measure with the tester positive
probe connected to CN104-2.
Battery plug OFF.SWKyOFF
Measure with the tester negative
probe connected to CN104-14.
Measure with the tester positive
probe connected to CN104-3.
Battery plug OFF.SWKyOFF
Measure with the tester negative
probe connected to CN104-14.
Measure with the tester positive
probe connected to CN104-4.
Battery plug OFF.SWKyOFF
Measure with the tester negative
probe connected to CN104-15.
Measure with the tester positive
probe connected to CN104-5.
Standard
Approx. 20 Q
Approx. 46 Vl35 V
Approx. 20 Q
Approx. 46 Vl35 V
Approx. 20 Q
Approx. 46 Vl35 V
Approx. 20 Q
Approx. 46 Vl35 V
Approx. 20 Q
Approx. 46 Vl35 V
5f 0.25 V
Remarks
MFR
contactor
MFRcoil
MRR
contactor
MRRcoil
MFLcontactor
MFLcoil
MRLcotactor
MRLcoil
MP contactor
MP coil
+5V

55. CN105 Connector: Basic conditions (Battery plug ON.SWKyON)
Connector No. * Connector No.
CN104-8 I Panel N1
(74, CSD-) terminal
CN104-9 I CN104-8
(71, CSD) I (74, CSD -1
I
CN104-10 I CN104-8
(73, CSD +I 1 (74, CSD-
CN104-11 I CN104-8
(P2, VBP2) 1 (74, CSD-)
I
~ ~ 1 0 4 - 1 2I ~ ~ 1 0 4 - 1 3
(6' Mps) (I +
CN104-12 I CN104-8
(6, Mps) 1 (74, CSD -)
CNl04-13 I CN104-8
( I , M + ) 1 (74,CSD-)
CN104-14 CN104-8
(1, M + ) 1 (74, CSD-)
CN104-15 I CN104-8
(1, M + ) I (74, CSD-)
I
CN104-16 I CNl04-8
(76, STHl 1 (74, CSD-)
CN104-17 I CN104-8
(P9, VBP9) 1 (74, CSD-)
CN104-18 I CN104-8
(74, CSP-) 1 (74, CSD-)
CN104-19 I CN104-8
(72, CSP) 1 (74, CSD-)
CN104-20 I CN104-8
(73, CSP+) 1 (74, CSD-)
Standard
O n
Approx. 1.2 V
12f 0.6 V
Approx. 48 Vl36 V
Approx. I10n
(USA spec..: 68 n)
Approx. 46 Vl35 V
Approx. 46 Vl35 V
Approx. 46 Vl35 V
Approx. 46 Vl35 V
Greater than 0 V and
smaller than 5 V
Approx. 48 Vl36 V
ov
Approx. 1.2 V
1.2* 0.6 V
Conditions
Battery plug OFF.SWKy OFF
Traveling stop state
Battery plug OFF.SWKyOFF
Measure with the tester negative
probe connected to N104-13.
Measure with the tester negative
probe connected to CN104-12.
Traveling and material handling stop
state
Material handling stop state
Remarks
+ 1 2 V
Mps contactor
Mpscoil
+12 V
RemarksStandard
5 *0.25 V
OV
5 *0.25 V
OV
Connector No. * Connector No.
CN105-1 CN105-10
(60, LS,) I (1I,GND)
I
CN105-2 I CN105-10
(68, LSL21 I (1I,GND)
Conditions
LSLOFF
LS, ON
LSL2OFF
LSL2ON

56. CN106 Connector: Basic conditions (Battery plug ON.SWKyON)
RemarksConnector No. -Connector No.
I
CN105-3 I CN105-10
(61, LS,) I (11, GND)
CN105-4 I
I
CN105-5 I
CN105-6 I CN105-10
(63, LSATT1) ] (11, GND)
CN105-8 CN105-10
(55, VRSP+ I (11, GND)
CN105-9 CN105-10
(56, VRSP) I (11, GND)
CN105-10 Panel N1
(11, GND) I terminal
CN105-11 I
CN105-12 I
Conditions
LSTOFF
LS,, ON
Unused
Unused
LSATTl ON
LSArrl OFF
Battery plug OFF
SW,, OFF
Unused
Unused
Connector No. -Connector No.
I
CN106-1 I CN106-2
I
(82, SSR) 1 (81, SSR)-
CN106-2 CN106-1
(81, SSR) 1 (82, SS,)
CN106-3 CN106-4
(84, SSL) I (83, SSL)
I
CN106-4 I CN106-3
I
(83. SSL) 1 (84, SSL)
CN106-5 CN106-13
(45, DSF) 1 (51, GND)
CN106-6 CN106-13
(46, DSR) I (51, GND)
I
CN106-7 I CN106-13
(64, SWAc) 1 (51, GND)
CN106-8 I CN106-13
(53, VRAD+ 1 (51, GND)
CN106-9 CN106-13
( , OPTl) 1 (51, GND)
Standard
5 f 0.25 V
OV
5 f 0.25 V
OV
Approx. 5 V
Approx. 0.9 - 3.9 V
on
Standard
OV
OV
OV
OV
5 f 0.25V
OV
5f0.25 V
OV
550.25 V
OV
3 - 5 v
Conditions
Traveling stop state
Traveling stop state
Traveling stop state
Traveling stop state
DSFOFF
DSFON
DSROFF
DSRON
SWAc OFF
SWAcON
Remarks

57. CN107 connector: Basic conditions (Battery plug ON.SWKyON)
Connector No. * Connector No.
I
I
CN106-10 I CN106-13
(P6, VBP6) 1 (51, GND)
I
I
I
I
CN106-11 I CN106-13
(P61,VBP61) 1 (51,GND)
I
I
CNlO6-12 I CNlO6-13
(67, LSD) 1 (51, GND)
CN106-13 Panel N1
(51, GND) I terminal
CN106-14 CN106-13
(51, GND) (51, GNDl
CN106-15 I CNlO6-13
(77, SWsc) 1 (51, GND)
CN106-16 I CN106-13
I
(66, SWpB) 1 (51, GND)
CN106-17 CN106-13
(65,LSs) 1 (51,GND)
CN106-18 I CN106-13
(52, VRAD) 1 (51, GND)
Connector No. * Connector No.
CN107-1 CN107-6
(141, SMTDA) (17, GND)
CN107-2
(142, SDTMA)
CN107-3 CN107-6
( , VBKY) (17, GND)
CN107-4 CN107-6
(144, SMTDK) (17, GND)
CN107-5
(143, SDTMK)
CN107-6 Panel N1
(17, GND) terminal
CN107-7
CN107-8 CN107-6
(16, +30V) (17, GND)
RemarksConditions
Traveling and material handling stop
state
Traveling and material handling stop
state
LSDOFF
LSDON
Battery plug OFF
SW,, OFF
SWscOFF
SWsc ON
SWpBOFF
SWpBON
LSBOFF
LSBON
Shall vary smoothly according to the
traveling acceleration state.
Standard
48 V vehicle:
43 f 5 V
36 V vehicle:
32 f 5 V
48 V vehicle:
4 3 f 5 V
36 V vehicle:
3 2 f 5 V
5 * 0.25 V
OV
on
ov
5 f 0.25 V
OV
5 f 0.25 V
OV
OV
5 f 0.25 V
Conditions
Cannot be measured with a circuit
tester
Unused
Cannot be measured with a circuit
tester
Battery plug OFF
SW,, OFF
Unused
Standard
0 - 1 v
Approx. 48 Vl36 V
OV
ov
ov
18 * 3 V
Remarks

58. 2-26
CN111 connector: Basic conditions (Battery plug ON.SWKyON)
Connector No. -Connector No.
CN111-1
CN111-2 I-
C N l l l - 3 I CN111-20
(15,+30V) I (N1,GND)
I
CN111-4 I CN111-20
(15, +30 V) / (NI, GND)
C N l l l - 5 I C N l l l - 2 0
(10, C36 V) 1 (NI, GND)
C N l l l - 6 / C N l l l - 2 0
(37, CHOPP+ I (N1, GND)
I
CN111-7 I CN111-20
(35,VDP+) (N1,GND)
C N l l l - 8 I C N l l l - 2 0
( ,-5V) I (N1,GND)
CN111-9 I CN111-20
(14, VBKY) / (NI, GND)
CN111-10 I
CN111-11 CN111-20
(43, K36 V) / (NI, GND)
C N I I I - I 2
/CN111-13 I
I
CN111-14 I CN111-20
(11, GND) / (Nl, GND)
CN111-15
C N l l l - 1 6 C N l l l - 2 0
(11,GND) f (N1,GND)
C N l l l - 1 7 I C N l l l - 2 0
(38, CHOPP-) I (NI, GND)
C N l l l - 1 8 CN111-20
(36, VDP-1 I (NI, GND)
C N l l l - 1 9
Conditions
Unused
Unused
Unused
Unused
Unused
Unused
Unused
SWKyON
SW,, OFF
Unused
Unused
Unused
Unused
Material handling stop state
Material handling stop state
Unused
Standard
Approx. 18 + 3 V
Approx. 18 & 3 V
Approx. 48 Vl36 V
OV
5 * 0.25 V
5 * 0.25 V
- 5V - - 6V
Approx. 48 Vl36 V
ov
Approx. 48 Vl36 V
OV
OV
OV
4 - 5 V
4 - 5 V
Remarks

59. CN112 connector: Basic conditions (Battery plug ON.SWKyON)
Connector No. * Connector No.
CN111-20 Panel N1
(N1, GND) 1 terminal
CN111-21 I C N l l l - 2 0
(13, VBBT) I (NI, GND)
I
C N l l l - 2 2 I CN111-20
I (N1, GND)(41, B36 V) I
Conditions
Battery plug OFF
SW,, OFF
Unused
Standard
on
Approx. 48 Vl36 V
Approx. 48 V136 V
Remarks
Battery
voltage
Connector No. * Connector No.
CN112-1 I CN112-9
(43, K36 V) I (NI, GND)
CN112-2 1 CN112-9
(41, B36 V) I (N1, GND)
CN102-3 I
I
CN112-4 I CN112-9
IP14,RCKP) I IN1,GNDl
I
II
CN112-5 I CN112-9
(PI5, RCK2) I (Nl, GND)
CN112-6 I CN112-9
(N2, TMPS) (NI, GND)
CN112-7 I CN112-9
(41, 836 V) (N1, GND)
I
CN112-8 1 CN112-9
(41, D36 V) 1 (NI, GND)
CN112-9 PanelN1
(NI, GND) I terminal
CN112-10 I
CN112-11 CN112-9
(P14,TMPD) I (N1,GND)
CN 2-1 CN1 2-9
(93, TMPG) I (N1, GND)
Standard
Approx. 48 Vl36 V
ov
Approx. 48 Vl36 V
48 V vehicle:
2 7 f 5 V
36 V vehicle:
2 0 f 5 V
Approx. 48 V136V
ov
Approx. 48 Vl36V
Approx. 48 Vl36V
Conduction
10 - 2 5 V
- 5 - - 6V
Conditions
Unused
Unused
Unused
Unused
Unused
Unused
Unused
Material handling stop state
Remarks

60. 11. Display
If the cause of a trouble is judged to exist in the display, apply the battery voltage and measure
the voltage at the connector.
CN120 connector basic condition (battery plug ON)
Connector No. * Connector No.
CN120-9 I CN 120-19
(16, + 3 0 V ) 1 (17, GND)
CN 120-10 CN 120-20
(104, BL) I (NI, GND)
Standard
Approx. 18 =t3 V
Approx. 4 8 V
Conditions Remarks

61. DISASSEMBLY
The control panel is overhauled infrequently. Defective part replacement according to the cause of the
trouble by inspection is performed in most cases. Please perform correct operation by referring to the
component parts drawing, assembly drawing and internal connection diagram.
Cautions for Parts Replacement
Tighten the bar and harness set nuts and screws to the specified torques.
Looseness or insufficient tightening will cause other troubles.
When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indi-
cating the mounting position. At the time of reassembly, prevent incorrect installation or wiring by
referring to the memo or tag. Incorrect installation or wrong wiring will cause other troubles.
Always coat silicone grease on parts which have been coated with silicone grease. Omission of
coating may cause overheating.
After reassembly, check no contact of the bars and cables at other than the contact portions. Before
installation on the vehicle, check continuity at points with a circuit tester. (See page 2-34 for the
inspection points with the circuit tester.)

62. 2-30
REASSEMBLY
Control panel assembly drawing (STD)
DAD ( B ) CAD ( B )
( Y
P7
CSD
P2
DF 1
N 1 TMD
DCISD b

63. Control panel assembly drawing (with pump chopper)
( Y )
P 7
CSD
P 2
DF 1
DAD ( B ) CAD ( B ) CAP (L) DF3
vN 1 TMD P I 3 P 1 2 CSP TMP D'AP
CNlOO CN1 15 CN1 17
T?!AiF?d
DCISD
DClSD board
b

64. 2-32
Contactor panel assembly drawing

65. PANEL PARTS TIGHTENING TORQUE
(Control panel)
(Contactor panel)
Tightening torque N.m (kgf-cm)[ft-lbfl
2.16 - 2.75 (22 - 28) 11.59 - 2.031
1.18 - 1.77 (12 - 18) 10.87 - 1.301
2.16 - 2.75 (22 - 28) [ I.59 - 2.031
3.14 - 3.73 (32 - 38) i2.32 - 2.751
5.10 - 5.69 (52 - 58) i3.76 - 4.201
2.16 - 2.75 (22 - 28) [ I.59 - 2.031
13.44 - 14.02 (137 - 143) 19.91 - 10.351
2.16 - 2.75 (22 - 28) f1.59 - 2.031
2.13 - 2.75 (22 - 28) 11.59 - 2.031
7.85 - 11.77 (80 - 120) l5.79 - 8.681
ltem
(For power steering)
M5
M4
M5
M6
M6
M6
M I 2
M6
M5
M8
TM-TMP
DF1
DF3
DAD-DAP
Heat sink
Tightening torque N.m (kgf-cm)[ft-lbfl
2.16 - 2.75 (22 - 28) [1.59 - 2.031
21.28 - 21.87 (217 - 223) [15.70 - 16.131
7.85 - 11.77 (80 - 120) 15.79 - 8.681
2.13 - 2.75 (22 - 28) l1.59 - 2.031
2.13 - 2.75 (22 - 28) [1.59 - 2.031
7.85 - 11.77 (80 - 120) [5.79 - 8.681
ltem
Main terminals
For installation
Main terminals
For installation
Main terminals
For installation
For installation
For installation
Terminal set nuts for external connection
M6
M20
M8
M5
M5
M8
DF2,-DF2,
MFL.MFR
MRL.MRR
MP
Heat sink
Tightening torque N.m (kgf-cm) [ft-lbfl
1.96 - 2.94 (20 - 30) [ I.45 - 2.171
1.96 - 2.94 (20 - 30) 11.45 - 2.171
Item
Main terminals
For installation
Main terminals
For installation
For installation
Terminal set nuts for external connection
M5
M5
TMPS
Main terminals
For installation

66. CONTINUITY CHECK WITH CIRCUIT TESTER
Control panel (STD) Control panel (Wlchopper)
Contactor panel
Inspection method Positive ( + ) probe: Red probe Negative (-1 probe: Black probe
* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is
charged. Capacitor characteristic: The pointer deflects to 0 Q and returns to 00 Q then.
Circuit tester
Q x l K
Q x 1K
a x IK
Q x 1K
Standard
Approx. 10 to 25 Q
* a n
Approx. 1 0 to 25 62
* a n
a0 Q
a Q
Inspection points
Between P2 and N1
Between P12 and N1
Between P2 and frame
Between N1 and
frame
P2: + probe - N1: - probe
P2: - probe - N1: + probe
P12: + probe - N l : - probe
P I2: - probe - N1: + probe
Tester probes may be used in either
direction.
Tester probes may be used in either
direction.

67. OCL (OVERCURRENT LIMIT) VALUES
1. Drive circuit OCL value measurement
(1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and
shunt as illustrated below and measure the drive motor lock current.
Standard OCL value:
48 V vehicle: 460 +:; A
36 V vehicle: 610 * 60 A
Ammeter:
50 mV, 750 A
Shunt:
50 mV, 750 A
(2)Judgment method If the measured OCL value is not within the standard range, the current sen-
sor (CS) or CPU board may be defective. Make judgment as follows:
@ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks.
@ Measure the output voltage of the current sensor. (Measured offset voltage value: B)
Conditions: Battery plug ON.SWKy ON
Measurement terminals: CN104(9)71 @ - CN104(8) 74 @
Standard: Approx. 1.2V
* Use a digital voltmeter for measurement.
@ Operate the accelerator to set the speed to approx. 8 kmlh (5 milelh). Read the ammeter
and measure the current sensor output voltage on the CPU board side at the same time.
(Ammeter reading: A) (Measured current sensor output voltage: C)
Measurement terminals: CN104(9)71 @ - CN104(8)74@
* Use a digital voltmeter for measurement.
@ Calculation
Measured value C - measured value B = D
Convert the calculated value D according to the following equation. (Converted value: E)
1V = 100A
@ Judgment
Compare converted value E with measured value A in step @.
The current sensor can be judged normal if the result is within *5.
The CPU board may defective if the current sensor is judged normal. Replace the CPU
board in that case.

68. Pump circuit OCL value measurement
The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of
each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set
pressure.
As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the
OCL valve cannot be measured.

69. T = 1.57-2.35 N.m
Set screw
ACCELERATION POTENTIOMETER
ADJUSTMENT
Make adjustment in the state of acceleration potentiometer
wlfront toe board.
1. Operate the accelerator pedal and check if the acceler-
ation switch is turned ON and OFF.
Measurement terminals: 51 and 64
Standard
When the pedal is not depressed: co
When the pedal is depressed: 0 S2
2. Acceleration potentiometer installation adjustment
(1) Insert a 1.5 mm (0.06 in) thickness gauge between
the accelerator link stopper and accelerator bracket.
(2) Temporarily install the potentiometer so that the
switch (SW,,) is set to ON.
(3) Inspect the switch (SW,,) ON and OFF changeover
points.
When 1.0 mm (0.04 in) thickness gauge is inserted:
OFF
When 2.0 mm (0.08 in) thickness gauge is inserted:
ON
(4) After the end of switch ONmOFF adjustment, fully
tighten the set screws.

70. BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT
1. Adjust protrusion (A) of the brake switch (LS,) and
stop lamp switch (LS,,).
A = 26 mm (1.02 in)
2 After installing LS, and LS,,, check ON and OFF.
(1) Operate the brake pedal and check conduction at
each switch connector.
Standards
(2) Adjust each switch ONIOFF timing when the brake
pedal is operated. Make adjustment by turning the
adjusting bolt so that each switch is operated when
the brake pedal is depressed by dimension B in the
figure from the free state.
10mm (0.39 in.)
Switch
o n - a n
a n - o n
Operated
00 n
on
Switch
LSS
LSST
Not operated
on
a0 n

71. 2-39
PARKING BRAKE SWITCH ADJUSTMENT
1. Inspect parking brake switch (SW,,) ONIOFF.
Standard
Adjust the SW,, installation state.
(1) Return the lever fully to the stroke end.
(2) With the limit switch pushed to its stroke end to-
ward the lever side, fix the switch by tightening the
switch bracket set bolts 1 and limit switch set
screws 2 .
Pulled
con
Lever state
SWPB
Returned
on

72. 10-15mm
Stroke end
MATERIAL HANDLING SWITCH
ADJUSTMENT
1. Adjustment the switch (LS,,-LS,) ON timing when the
control lever is operated.
(1) Adjust LS,, .LS, roller protrusion (A).
Dimension A is a reference value for reassembly.
A = 26 mm (1.02 in)
(2) The switch shall be turned ON at dimension A at the
tip end of the control lever.
Standard
B = 5 - 20 mm (0.20 - 0.79 in)
If the standard is not satisfied, make adjustment by
changing the roller protrusion and mounting position.
1 When pump chopper (OPT)is provided:
2. Adjust the pump chopper switch (LS,,) ON timing.
(1) Adjust LS,, roller protrusion (C).
C = 26 mm (1.02 in)
(2) Adjust by turning the adjusting bolt so that the
switch (LS,,) is turned on when the lift lever is
fulled to 10 - 15 mm (0.39 - 0.59 in) before its
stroke end.

73. DIRECTION SWITCH
REMOVAL-INSTALLATION
Removal Procedure
1 Remove the steering rear cover.
2 Disconnect the direction switch connector.
3 Remove the steering tilt lever.
4 Remove the steering front cover and display.
5 Remove the direction switch.
Installation Procedure
The installation procedure is the reverse of the removal procedure.

74. Disassembly Procedure
1 Remove the plate.
2 Remove the micro switch base.
3 Remove the microswitch Wlwire harness. [Point 11
4 Remove the cam roller and spring.
5 Remove the direction lever Wlknob.
6 Remove the cam.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

75. Point Operation
[Point 11
Reassembly: Install the microswitches in the correct posi-
tions.
Reassembly: When replacing a microswitch, connect the
cables according to the cable colors in the fig-
ure.
Inspection: After assembling the direction switch, check
conduction of each microswitch before install-
ing the direction switch.

76. PS CONTROLLER
COMPONENTS
STD (Mpscontactor: The Mpscontactor is installed on the PS motor.)
EHPS

77. INSPECTION (STD)
1. P22-N1 voltage measurement
Battery plug ON.SWKyON
As seen from the motor
Measurement terminals
Circuit tester range
Standard
2. Mpscontactor coil conduction measurement
Battery plug OFF.SWKyOFF
P22 - N1
DC5 0
Battery voltage
Measurement terminals
Circuit tester range
Standard
Both terminals of connector (CN42) of MpsContactor
Q x l
Approx. 11 0 Q (at 20°C (68OF))

78. REMOVAL.INSTALLATION (EHPS)
1 Battery plug
Removal Procedure
1 Disconnect the battery plug.
2 Remove the side panel.
3 Remove the toe board.
4 Disconnect the wiring connectors.
5 Remove the PS controller.
Installation Procedure
The installation procedure is the reverse of the removal procedure.

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