Toyota Forklitf Mode 8FBN1530, 508FBN1520 Vol.2 Repair Manual
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FOREWORD
This Manual (Volume 2) contains diagnosis, service procedures of electrical
controller and display of the TOYOTA ELECTRICAL POWERED FORKLIFT
8FBN15 to 30, 50-8FBN15·18·20 series.
For maintenance, specifications and repair procedure for the chassis, body
and material handling system, refer to Volume 1 (Pub. No. CE349).
Please use these manuals for providing quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of January, 2012. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
SECTION INDEX
NAME
SECTION
GENERAL
0
BATTERY
1
CHARGER (OPT)
2
CONTROLLER
3
DISPLAY FUNCTIONS
4
TROUBLESHOOTING
5
FRONT MODULE
6
REAR AXLE
7
STEERING
8
BODY
9
MATERIAL HANDLING SYSTEM
10
MAST
11
CYLINDER
12
SAS-ε FUNCTIONS (OPT)
13
MATCHING
14
APPENDIX
15
Section indicated by solid characters are included in this manual.
Section indicated by half-tone characters: Refer to vol. 1 (Pub. No. CE349).
3-1
CONTROLLER
Page
GENERAL ........................................................................3-2
COMPONENTS .............................................................3-10
0
BEFORE REPAIR ......................................................... 3-11
1
INSPECTION ................................................................. 3-11
2
CONNECTOR INSPECTION ......................................3-12
3
TO USE SST .................................................................. 3-12
4
INSPECTION ................................................................. 3-12
5
MAIN CONTROLLER ..................................................3-30
REMOVAL·INSTALLATION...........................................3-30
MATERIAL HANDLING AC DRIVER .......................3-33
REMOVAL·INSTALLATION
(1 ton series and 50-8FBN20)................................... 3-33
6
7
8
9
REMOVAL·INSTALLATION
(2 · 3 ton series, except 50-8FBN20)........................ 3-36
10
DRIVE AC DRIVER ......................................................3-38
11
OCL MEASUREMENT ................................................3-39
12
13
14
3-2
GENERAL
MAIN CONTROLLER
G85703001_
Caution:
When replacing the main controller,always check the part No.
3-3
CONNECTOR-PIN ASSIGNMENT
CN101
CN102
CN103
CN104
0
1
G85703002_
CN101
No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
102 SOLLU+
SOLLU+
UNLOAD, LIFT+
103 SLTFB+
SLTFB+
TILTF, R+
104 FAN+
FAN+
RYR, FAN+
105 VBBT
VBBT
VBBT
106 SLLA2+
SOL1, 4+
SOL1, 4+
107 SLTA1+
SOL2, 3+
SOL2, 3+
108 ---
SOL5+
SOL5+
109 ---
SOL5B
SOL5B
110 ---
SOL5A
SOL5A
111 SA1PL-
SOL3B
SOL3B
112 SA1PS-
SOL3A
SOL3A
113 STPL-
SOL2B
SOL2B
114 STPS-
SOL2A
SOL2A
115 SA2PL-
SOL4B
SOL4B
116 SA2PS-
SOL4A
SOL4A
117 SLPS-
SOL1A
SOL1A
118 SLPL-
SOL1B
SOL1B
119 VBBA (only 3 ton series) VBBA
VBBA
120 VBKY
VBKY
VBKY
121 VRTA+
VRTA+
TILT ANGLE SENSOR POWER SUPPLY
122 ---
VRS+
SWING ANGLE SENSOR POWER SUPPLY
123 VRA-
VRA-
ACCELERATOR SENSOR GND
124 VRTRA+
VRTRA+
TIRE ANGLE SENSOR POWER SUPPLY
125 VRH+
VRH+
HEIGHT SENSOR POWER SUPLLY
126 VRL+
VRL+
LIFT LEVER SENSOR POWER SUPPLY
127 VRA2+
VRA2+
ACCELERATOR SENSOR 2 POWER SUPPLY
128 VRA1+
VRA1+
ACCELERATOR SENSOR 1 POWER SUPPLY
129 VRT+
VRT+
TILT LEVER SENSOR POWER SUPPLY
130 VRAT1+
VRAT1+
ATTACHMENT 1 LEVER SENSOR POWER SUPPLY
131 VRAT2+
VRAT2+
ATTACHMENT 2 LEVER SENSOR POWER SUPPLY
132 ---
VRAT3+
ATTACHMENT 3 LEVER SENSOR POWER SUPPLY
133 POT-
POT-
GND3
134 VRB2+
VRB2+
BRAKE SENSOR 2 POWER SUPPLY
135 VRB1+
VRB1+
BRAKE SENSOR 1 POWER SUPPLY
2
3
4
5
6
7
8
9
10
11
12
13
14
3-4
CN102
No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
67
---
FNDC1
FAN1
68
---
FNDC2
FAN2
69
VBMBSL
VBMBSL
VBMBSOL
70
VBMBSL
VBMBSL
VBMBSOL
71
SOLCOM
SOLCOM
SOLCOM
72
SOLCOM
SOLCOM
SOLCOM
73
SLS+
SLS+
KNOB, MPS+
74
---
OACC3
ACCESSORY 3 (for FORWARD)
75
---
OACC2
ACCESSORY 2 (for REVERSE)
76
LS-
LS-
GND2
77
---
OACC1
ACCESSORY 1 (for BRAKE)
78
---
RY2-
RYR2
79
RY1-
RY1-
RYR1
80
SLS-
SLS-
KNOB-
81
---
MPS-
SLDM-(MPS-)
82
SLLL-
SLLL-
LIFT-
83
---
SLUL-
UNLOAD-
84
---
SLTBL-
TILTR-
85
SLTFL-
SLTFL-
TILTF-
86
VRA12
VRA12
ATTACHMENT 1 LEVER SENSOR 2
87
VRA11
VRA11
ATTACHMENT 1 LEVER SENSOR 1
88
VRT2
VRT2
TILT LEVER SENSOR 2
89
VRT1
VRT1
TILT LEVER SENSOR 1
90
CSBAT
CSBAT
BATTERY CURRENT SENSOR
91
VRB2
VRB2
BRAKE SENSOR 2 (combined with SW)
92
POT-
POT-
GND4
93
---
CHK5V
5V POWER SUPPLY for CHECK
94
VRA22
VRA22
ATTACHMENT 2 LEVER SENSOR 2
95
VRA21
VRA21
ATTACHMENT 2 LEVER SENSOR 1
96
VRA1
VRA1
ACCELERATOR SENSOR 1
97
VRTRA
VRTRA
TIRE ANGLE SENSOR
98
VRA2
VRA2
ACCELERATOR SENSOR 2
99
VRB1
VRB1
BRAKE SENSOR 1 (combined with SW)
100 ---
VRS
SWING ANGLE SENSOR
101 CSBAT-
CSBAT-
BATTERY CURRENT SENSOR GND
3-5
CN103
No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
32
---
SLSW+
SWING+
33
---
SLSW-
SWING-
34
DGND
DGND
DISPLAY GND
35
KYSAT
KYSAT
KEYSTART
36
N2
N2
N2
37
LS-
LS-
GND4
38
---
SMTSA
SMTSA
39
IPL+
IPL+
SHOCK SENSOR POWER SUPPLY
40
---
CAN2H
CAN2H
41
---
CAN2L
CAN2L
42
CAN1H
CAN1H
CAN1H
43
CAN1L
CAN1L
CAN1L
44
SSTR+
SSTR+
STEERING WHEEL ANGLE SENSOR AND ULTRA SONIC
SENSOR POWER SUPPLY (combined use)
45
D7V
D7V
DISPLAY POWER SUPPLY
46
---
CHK15V
15V POWER SUPPLY for CHECK
47
---
CHK33V
3.3V POWER SUPPLY for CHECK
48
VRTA
VRTA
TILT ANGLE SENSOR
49
VRL2
VRL2
LIFT LEVER SENSOR 2
50
IPL2
IPL2
SHOCK SENSOR 2
51
---
SSTMA
SSTMA
52
---
SMTSK
SMTSK
53
---
SSTMK
SSTMK
54
---
OPTSS2
OPTSS2
55
SH2-1
SH2-1
LIFTING HEIGHT SWITCH 2-1
56
SHL
SHL
HEIGHT LIMIT SWITCH
57
VRL1
VRL1
LIFT LEVER SENSOR 1
58
---
SYR
YAW RATE SENSOR
59
VRH
VRH
HEIGHT SENSOR
60
SPLF
SPLF
PRESSURE SENSOR
61
IPL1
IPL1
SHOCK SENSOR 1
62
---
SH2-2
LIFTING HEIGHT SWITCH 2-2
63
STK
STK
AUTOMATIC FORK LEVELING SWITCH
64
---
OLM+
LASER POINTER POWER SUPPLY
65
---
VRA32
ATTACHMENT 3 LEVER SENSOR 2
66
---
VRA31
ATTACHMENT 3 LEVER SENSOR 1 (SWITCH for 4/5-way)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3-6
CN104
No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
1
B48V
B48V
B80V(B48V)
2
VBMB
VBMB
VBMB
3
CBAT+
CBAT+
MB, P+
4
N2
N2
N2
5
N2
N2
N2
6
N2
N2
N2
7
---
N2
N2
8
FNDC
MP-
MP-
9
CBAT-
CBAT-
MB-
10
CSBAT+
CSBAT+
BATTERY CURRENT SENSOR POWER SUPPLY
11
---
SYR-
YAW RATE SENSOR GND
12
SPLF+
SPLF+
PRESSURE SENSOR POWER SUPPLY
13
---
SYR+
YAW RATE SENSOR POWER SUPPLY
14
PSACC+
PSACC+
ACCESSORY POWER SUPPLY
15
PSSW+
PSSW+
POWER SUPPLY for MINI LEVER SWITCH (LOAD METER,
AUTOMATIC FORK LEVERING and SWITCH for 4/5-WAY SW)
16
---
CHKG
CHKG
17
---
OPT2
OPT2
18
SDM
SDM
SEAT SWITCH
19
DSR
DSR
DIRECTION SWITCH REVERSE
20
SPB
SPB
PARKING BRAKE SWITCH
21
---
OPTSSC
OPTSSC
22
SH1
SH1
LIFTING HEIGHT SWITCH 1
23
SWBK
SWA
SWA
24
SSTRC
SSTRC
STEERING WHEEL ANGLE SENSOR 3
(only SSC combined with SW)
25
---
OPTSS1
OPTSS1
26
DSF
DSF
DIRECTION SWITCH FORWARD
27
---
LSOPT1
LSOPT1
28
SHS
SHS
HEIGHT SELCTOR SWITCH
29
---
BMP
BMP
30
SSTR1
SSTR1
STEERING WHEEL ANGLE SENSOR 1
(only SSC combined with SW)
31
SSTR2
SSTR2
STEERING WHEEL ANGLE SENSOR 2
(only SSC combined with SW)
3-7
DRIVE·MATERIAL HANDLING AC DRIVER
1 ton model
Applicable model : 8FBN15
8FBN16
8FBN18
Material Handling AC Driver
RH side of vehicle
Vehicle front side
Drive AC Driver
Applicable model : 50-8FBN15
50-8FBN18
Material Handling AC Driver
RH side of vehicle
Vehicle front side
Drive AC Driver
G85703003_
3-8
2 ton model
Applicable model : 8FBN20
8FBN25
RH side of vehicle
Material Handling AC Driver
Vehicle front side
Drive AC Driver
Applicable model : 50-8FBN20
Material Handling AC Driver
RH side of vehicle
Vehicle front side
Drive AC Driver
G85703004_
3-9
3 ton model
Applicable model : 8FBN30
RH side of vehicle
Material Handling AC Driver
Vehicle front side
Drive AC Driver
G85703005_
3-10
COMPONENTS
1
1
3
1
1
2
4
*T1
8
7 *T3
5
9
6
10
9
11
13
9
12
*T2
7 *T3
13
8
5
14
G85703013_
* Tightening torque: T = N·m (kgf·cm) [ft·lbf]
T1 = 3.85 ~ 7.15 (39.3~ 72.9) [2.84 ~ 5.28]
T2 = 1.3 ~ 1.7 (13 ~ 17) [1.0 ~ 1.3]
T3 = 12.2 ~ 16.8 (124 ~ 171) [9.00 ~ 12.4]
No.
Parts name
QTY
No.
Parts name
QTY
1
Bolt
4
8
Bolt
8
2
Bracket
1
9
Bolt
6
3
Bracket
1
10
Bracket
1
4
Bolt
4
11
Fan motor
1
5
AC driver
1
12
Screw
4
6
Main controller
1
13
Sponge
2
7
Nut
11
14
Bracket
1
3-11
BEFORE REPAIR
INSPECTION
1
Insulation resistance measurement
Note:
Always measure before inspecting the drive/material
handling controller and the main controller.
(1) Disconnect the battery plug and measure the
resistance between battery plug and body.
G85703014_
Measurement terminals
Standard:
Controller side of battery plug-body
Resistance value depends greatly on the vehicle operating state, place and
weather.
(Approx. 1MΩ or more)
Some components can be inspected after they are removed from the vehicle, some components can be inspected
as installed on the vehicle.
Main controller must be inspected as installed on the vehicle since the battery voltage must be applied.
Disassembly Procedure
• Overhauling the contactor panel is rarely necessary. In most cases, failed parts is replaced after finding
out the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to the
figures of configuration and ASSY.
• Do not disassemble drive·material handling AC driver and the main controller, as they should be
replaced in a form of ASSY.
Caution for part replacement
• Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of
tightening may cause other failure.
• When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connection.
Incorrect connection may cause other failure.
• After installation, check that there is no interference of the bar and harness connection with other
portion.
3-12
CONNECTOR INSPECTION
TO USE SST
Use SSTs for quick and accurate measure on the 8FBCU20~32, 8FBCHU25. The check will fail if the connection
method is wrong. Since boards may be damaged by incorrect connection, the operation is needed to be careful.
Caution:
Always unplug the battery plug before SST connection and disconnection. If the battery plug is still
connected, various boards may be damaged.
Part No.
Purpose
Remarks
09230-13240-71
Measure the voltage or resistance
for main controller.
For use CN101 to CN104
09240-13241-71
Measure the voltage for AC driver.
For use CN110 to CN111
INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the board but check
the following items.
• Abnormality in related harnesses
• Looseness of the related connectors
• Bending or damage of connector pin and defective contact of any related connector pin.
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be
damaged.
Always replace the board after careful inspection.
Measurement method and standard list
How to read the list
Tester Probe +
Tester Probe -
Connecror No.
CN101-1
(45, DSF)
Connector No.
CN101-26
(51, LS-)
Terminal name
Conditions
Key switch OFF, DSF ON.
Standard
Remarks
Approx. 0V
Conditions for measurement
Electric Level No.
Connector pin No.
G85703015_
3-13
MAIN CONTROLLER
CPU board
CN101
CN102
CN103
CN104
G85703016_
Material Handling Lever
CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
Remarks
CN101-1
(3, SOLLU+)
CN102-16
(4, SLLL-)
Lift lock solenoid ON
Lift lock solenoid OFF
Approx. 11V
Approx. 0V
CN101-2
(6, SLTFB+)
CN102-19
(7, SLTFL-)
Tilt forward solenoid ON
Tilt forward solenoid OFF
Approx. 11V
Approx. 0V
CN101-3
(97, FAN+)
CN104-4
(N2, N2)
-
Approx. 48V
CN101-4
(41, VBBT)
CN104-4
(N2, N2)
-
Approx. 48V
CN101-5
(9, SLLA2+)
CN101-16
(11, SLPS-)
Variation upon changeover from
upward to downward lifting
Approx. 0V to 10V
CN101-6
(32, SLTA1+)
CN101-12
(33, STPL-)
Variation upon changeover from
forward to backward tilting
Approx. 0V to 10V
CN101-7
-
Unused
-
CN101-8
-
Unused
-
CN101-9
-
Unused
-
CN101-10
(36, SA1PL-)
CN101-6
(32, SLTA1+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
*1
CN101-11
(37, SA1PS-)
CN101-6
(32, SLTA1+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
*1
CN101-12
(33, STPL-)
CN101-6
(32, SLTA1+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
CN101-13
(34, STPS-)
CN101-6
(32, SLTA1+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
CN101-14
(39, SA2PL-)
CN101-5
(9, SLLA2+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
*2
3-14
Connector No. ⇔ Connector No.
Conditions
Standard
Remarks
*2
CN101-15
(40, SA2PS-)
CN101-5
(9, SLLA2+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
CN101-16
(11, SLPS-)
CN101-5
(9, SLLA2+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
CN101-17
(10, SLPL-)
CN101-5
(9, SLLA2+)
Resistance measurement with
battery plug disconnected
Approx. 7Ω
CN101-18
(99, VFAN)
CN104-4
(N2, N2)
FAN ON
Approx. 30V
CN101-19
(47, VBKY)
CN104-4
(N2, N2)
Key switch OFF
Key switch ON
Approx. 0V
Approx. 48V
CN101-20
(57, VRTA+)
CN101-32
(51, POT-)
CN101-21
-
CN101-22
(50, VRA-)
-
-
-
CN101-23
(316, VRTRA+)
CN101-32
(51, POT-)
-
Approx. 5V
CN101-24
(219, VRH+)
CN101-32
(51, POT-)
-
Approx. 5V
CN101-25
(28, VRL+)
CN101-32
(51, POT-)
-
Approx. 4.6V
CN101-26
(55, VRA2+)
CN101-32
(51, POT-)
-
Approx. 4.8V
CN101-27
(53, VRA1+)
CN101-32
(51, POT-)
-
Approx. 4.8V
CN101-28
(29, VRT+)
CN101-32
(51, POT-)
-
Approx. 4.6V
CN101-29
(30, VRAT1+)
CN101-32
(51, POT-)
-
Approx. 4.6V
*1
CN101-30
(31, VRAT2+)
CN101-32
(51, POT-)
-
Approx. 4.6V
*2
CN101-31
-
CN101-32
(51, POT-)
-
-
-
CN101-33
(74, VRB2+)
CN101-32
(51, POT-)
-
Approx. 4.8V
CN101-34
(72, VRB1+)
CN101-32
(51, POT-)
-
Approx. 4.8V
Unused
3 ton only
Approx. 5V
-
Unused
-
*1: W/ ATT1
*2: W/ ATT2
CN102 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
CN102-1
-
Unused
-
CN102-2
-
Unused
-
CN102-3
(19, VBMBSL)
CN104-4
(N2, N2)
Key switch OFF
Key switch ON
Approx. 0V
Battery voltage
CN102-4
(19, VBMBSL)
CN104-4
(N2, N2)
Key switch OFF
Key switch ON
Approx. 0V
Battery voltage
CN102-5
(17, SOLCOM)
CN104-4
(N2, N2)
Key switch OFF
Key switch ON
Approx. 0V
Battery voltage
Remarks
3-15
Connector No. ⇔ Connector No.
Conditions
Key switch OFF
Key switch ON
Standard
CN102-6
(17, SOLCOM)
CN104-4
(N2, N2)
CN102-7
(329, SLS+)
CN102-14
(330, SLS-)
CN102-8
-
Unused
-
CN102-9
-
Unused
-
CN102-10
(51, LS-)
-
CN102-11
-
Unused
-
CN102-12
-
Unused
-
CN102-13
(335, RY-)
CN104-4
(N2, N2)
CN102-14
(330, SLS-)
CN102-7
(329, SLS+)
CN102-15
-
CN102-16
(4, SLLL-)
CN101-1
(3, SOLLU+)
CN102-17
-
Unused
-
CN102-18
-
Unused
-
CN102-19
(7, SLTFL-)
CN101-2
(6, SLTFB+)
CN102-20
(25, VRA12)
CN102-26
(51, POT-)
Attachment 1 lever in the neutral
position
Attachment 1 lever in the forward
to backward position
CN102-21
(24, VRA11)
CN102-26
(51, POT-)
Attachment 1 lever in the neutral
position
Attachment 1 lever in the forward
to backward position
CN102-22
(23, VRT2)
CN102-26
(51, POT-)
Tilt lever in the neutral position
Tilt lever in the forward to
backward position
CN102-23
(22, VRT1)
CN102-26
(51, POT-)
Tilt lever in the neutral position
Tilt lever in the forward to
backward position
CN102-24
(304, CSBAT)
CN102-35
(305, CSBAT-)
CN102-25
(73, VRB2)
CN102-26
(51, POT-)
CN102-26
(51, POT-)
-
CN102-27
-
CN102-28
(27, VRA22)
CN102-26
(51, POT-)
Remarks
Approx. 0V
Battery voltage
Knob position correcting solenoid
ON
Knob position correcting solenoid
OFF
-
Approx. 11V
Approx. 0V
-
Key switch OFF
Key switch ON
Approx. 48V
Approx. 36V
Resistance measurement with
battery plug disconnected
Approx. 10Ω
Unused
-
Resistance measurement with
battery plug disconnected
Resistance measurement with
battery plug disconnected
Key switch OFF,
Resistance variation when
brake pedal fully depressed
Unused
Attachment 2 lever in the neutral
position
Attachment 2 lever in the forward
to backward position
Approx. 10Ω
Approx. 10Ω
Approx. 2.3V
Approx. 0.5V to 4V
*1
Approx. 2.3V
Approx. 0.5V to 4V
*1
Approx. 2.3V
Approx. 0.5V to 4V
Approx. 2.3V
Approx. 0.5V to 4V
Approx. 2.5V
Approx. 0.9V to 2.9V
Except for
models
with 50-
Approx. 2.3V
Approx. 0.5V to 4V
*2
3-16
Connector No. ⇔ Connector No.
Conditions
Standard
Approx. 2.3V
CN102-29
(26, VRA21)
CN102-26
(51, POT-)
Attachment 2 lever in the neutral
position
Attachment 2 lever in the forward
to backward position
CN102-30
(52, VRA1)
CN102-26
(51, POT-)
Key switch OFF,
Resistance variation when
Approx. 0.5V to 3.8V
accelerator pedal fully depressed
CN102-31
(317, VRTRA)
CN102-26
(51, POT-)
Tire in neutral position
CN102-32
(54, VRA2)
CN102-26
(51, POT-)
Key switch OFF,
Resistance variation when
Approx. 0.9V to 4.1V
accelerator pedal fully depressed
CN102-33
(71, VRB1)
CN102-26
(51, POT-)
Key switch OFF,
Resistance variation when
brake pedal fully depressed
CN102-34
-
CN102-35
(305, CSBAT-)
-
Unused
Approx. 0.5V to 4V
Remarks
*2
Approx. 2.0V
Approx. 0.6V to 2.6V
Except for
models
with 50-
-
-
*1: W/ ATT1
*2: W/ ATT2
CN103 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
CN103-1
-
Unused
-
CN103-2
-
Unused
-
CN103-3
(14, DGND)
-
CN103-4
(42, KYSAT)
CN104-4
(N2, N2)
CN103-5
(N2, N2)
-
-
-
CN103-6
(51, LS-)
-
-
-
CN103-7
-
CN103-8
(300, IPL+)
CN102-26
(51, POT-)
CN103-9
-
Unused
-
CN103-10
-
Unused
-
CN103-11
(145, CAN1H)
-
Immeasurable
-
CN103-12
(146, CAN1L)
-
Immeasurable
-
CN103-13
(311, SSTR+)
CN103-6
(51, LS-)
-
Approx. 14V
CN103-14
(16, D7V)
CN103-3
(14, DGND)
-
Approx. 6.5V
CN103-15
-
Unused
-
CN103-16
-
Unused
-
CN103-17
(56, VRTA)
CN102-26
(51, POT-)
Key switch OFF
Key switch ON
Approx. 0V
Battery voltage
Unused
-
Variation upon changeover from
forward to backward tilting
Approx. 5V
Approx. 1V to 4V
Remarks
3-17
Connector No. ⇔ Connector No.
Conditions
Lift lever in the neutral position
Lift lever in the forward to
backward position
Standard
Approx. 2.3V
Approx. 0.5 to 4V
CN103-18
(21, VRL2)
CN102-26
(51, POT-)
CN103-19
(302, IPL2)
CN102-26
(51, POT-)
CN103-20
-
Unused
-
CN103-21
-
Unused
-
CN103-22
-
Unused
-
CN103-23
-
Unused
-
CN103-6
(51, LS-)
Key switch OFF, mast in
uppermost position
Key switch OFF, mast in
lowermost position
Approx. 0V
CN103-24
(91, SH2-1)
CN103-6
(51, LS-)
Key switch OFF, mast height
switch ON
Key switch OFF, mast height
switch OFF
Approx. 0V
CN103-25
(221, SHL)
CN103-26
(20, VRL1)
CN102-26
(51, POT-)
CN103-27
-
CN103-28
(220, VRH)
CN102-26
(51, POT-)
Resistance variation when raising
and lowering the lift
CN103-29
(59, SPLF)
CN102-26
(51, POT-)
Forks on the ground
Approx. 1V or less
Resistance variation when raising Approx. 0.5V to 4.5V
and lowering the lift with a load
CN103-30
(301, IPL1)
CN102-26
(51, POT-)
CN103-31
-
CN103-32
(70, STK)
CN103-6
(51, LS-)
CN103-33
-
Unused
-
CN103-34
-
Unused
-
CN103-35
-
Unused
-
-
Lift lever in the neutral position
Lift lever in the forward to
backward position
Unused
Approx. 2V
Approx. 5V
Approx. 5V
Approx. 2.3V
Approx. 0.5 to 4V
-
Unused
Key switch OFF, automatic fork
leveling switch ON
Key switch OFF, automatic fork
leveling switch OFF
Approx. 0.5 to 4.3V
Approx. 2V
Approx. 0V
Approx. 5V
Remarks
3-18
CN104 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
-
Battery voltage
CN104-1
(41, B48V)
(18, B80V)
CN104-4
(N2, N2)
CN104-2
(44, VBMB)
CN104-4
(N2, N2)
Key switch OFF
Key switch ON
Approx. 0V
Battery voltage
CN104-3
(1, CBAT+)
CN104-9
(2, CBAT-)
Key switch ON
Key switch OFF
Approx. 11V
Approx. 0V
CN104-4
(N2, N2)
-
-
-
CN104-5
(N2, N2)
-
-
-
CN104-6
(N2, N2)
-
-
-
CN104-7
-
CN104-8
(98, FNDC)
-
CN104-9
(2, CBAT-)
CN104-3
(1, CBAT+)
CN104-10
(303, CSBAT+)
CN102-35
(305, CSBAT-)
CN104-11
-
CN104-12
(58, SPLF+)
CN102-26
(51, POT-)
CN104-13
-
CN104-14
(334, PSACC+)
CN104-4
(N2, N2)
-
Approx. 14V
CN104-15
(60, PSSW+)
CN104-4
(N2, N2)
-
Approx. 14V
CN104-16
-
Unused
-
CN104-17
-
Unused
-
CN104-18
(67, SDM)
CN103-6
(51, LS-)
Key switch OFF, seat switch ON
Key switch OFF, seat switch OFF
Approx. 0V
Approx. 5V
CN103-6
(51, LS-)
Key switch OFF, direction switch
backward
Key switch OFF, direction switch
neutral
Approx. 0V
CN104-19
(46, DSR)
CN103-6
(51, LS-)
Key switch OFF, parking brake
switch release
Key switch OFF, parking brake
switch lock
Approx. 0V
CN104-20
(66, SPB)
CN104-21
-
CN104-22
(90, SH1)
CN103-6
(51, LS-)
Unused
-
Resistance measurement with
battery plug disconnected
Unused
Approx. 20Ω
Approx. 5V
-
Unused
Approx. 5V
-
Unused
Mast in uppermost position, key
switch OFF
Mast raising, key switch OFF
Approx. 5V
Approx. 5V
Approx. 0V
Approx. 5V
Remarks
3-19
Connector No. ⇔ Connector No.
Conditions
Standard
Remarks
Approx. 0V
Approx. 5V
Only for
models
with 50-
CN104-23
(65, SWBK)
CN103-6
(51, LS-)
Key switch OFF, brake not
operated
Key switch OFF, brake operated
CN104-24
(314, SSTRC)
CN103-6
(51, LS-)
Steering operation
CN104-25
-
CN104-26
(45, DSF)
CN103-6
(51, LS-)
CN104-27
-
CN104-28
(68, SHS)
CN103-6
(51, LS-)
CN104-29
-
CN104-30
(312, SSTR1)
CN103-6
(51, LS-)
Steering operation
Approx. 0V to 5V
CN104-31
(313, SSTR2)
CN103-6
(51, LS-)
Steering operation
Approx. 0V to 5V
Unused
Key switch OFF, direction switch
forward
Key switch OFF, direction switch
neutral
Unused
Key switch OFF, load switch ON
Key switch OFF, load switch OFF
Unused
Approx. 0V to 5V
Approx. 0V
Approx. 5V
Approx. 0V
Approx. 5V
-
3-20
DRIVE AC DRIVER
CN110 and CN111
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
G85703017_
CN110 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
CN110-1
-
-
-
CN110-2
(14, CANGND)
( N1)
-
Approx. 0V
CN110-3
(80, SSD2)
(N1, N1)
-
L: Approx. 0.5V or
H: Approx. 1.5V
CN110-4
(79, SSD1)
(N1, N1)
-
L: Approx. 0.5V or
H: Approx. 1.5V
CN110-5
-
-
-
CN110-6
(78, SSD+)
(N1, N1)
-
Approx. 12V
CN110-7
-
-
-
CN110-8
(42, KYSAT)
(N1, N1)
-
Battery voltage
CN110-9
-
-
-
CN110-10
(146, CAN1L)
-
CN110-11
-
-
-
CN110-12
-
-
-
CN110-13
-
-
-
CN110-14
-
-
-
CN110-15
-
-
-
CN110-16
-
-
-
CN110-17
(145, CAN1H)
-
CN110-18
-
-
-
CN110-19
-
-
-
CN110-20
-
-
-
CN110-21
-
-
-
CN110-22
(87, STDM)
(N1, N1)
-
Approx. 0V
CN110-23
(86, STDM+)
(N1, N1)
-
Approx. 0.2 to 3.0V
Immeasurable
-
Immeasurable
-
Remarks
3-21
MATERIAL HANDLING AC DRIVER
CN111 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
CN111-1
-
-
-
CN111-2
(14, CANGND)
(N1)
-
Approx. 0V
CN111-3
-
-
-
CN111-4
(82, SSP1)
(N1, N1)
-
L: Approx. 0.5V or
H: Approx. 1.5V
CN111-5
-
-
-
CN111-6
(81, SSP+)
(N1, N1)
-
Approx. 12V
CN111-7
-
-
-
CN111-8
(42, KYSAT)
(N1, N1)
-
Approx. 48V
CN111-9
-
-
-
CN111-10
(146, CAN1L)
-
CN111-11
(152, SETP-)
(N1, N1)
CN111-12
(152, SETP1)
(N1, N1)
-
Approx. 0V
CN111-13
-
-
-
CN111-14
-
-
-
CN111-15
-
-
-
CN111-16
-
-
-
CN111-17
(145, CAN1H)
-
CN111-18
-
-
-
CN111-19
-
-
-
CN111-20
-
-
-
CN111-21
-
-
-
CN111-22
(89, STPM)
(N1, N1)
-
Approx. 0V
CN111-23
(88, STPM+)
(N1, N1)
-
Approx. 0.2 to 3.0V
Immeasurable
Approx. 0V
Immeasurable
-
Remarks
3-22
CONTACTOR PANEL ASSY
1 · 2 ton
3 ton
CN128
CN137
CN143
CN136
CN137
CN143
CN136
CN127
CN142
CN127
CN127
CN128
CN142
CN136
CN137
G85703018_
CN127 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No.
Conditions
Standard
-
-
CN127-1
-
CN127-2
(97, RY+)
N1 terminal
(N1, N1)
CN127-3
-
-
-
CN127-4
-
-
-
CN127-5
-
-
-
CN127-6
(19, VBMBSL)
N1 terminal
(N1, N1)
CN127-7
-
CN127-8
(17, SOLCOM)
N1 terminal
(N1, N1)
Apply the negative probe to the
N1 terminal to measure voltage.
Apply the negative probe to the
N1 terminal to measure voltage.
Apply the negative probe to the
N1 terminal to measure voltage.
Approx. 48V
1·2 ton series:
Approx. 48V
3 ton series:
Approx. 80V
1·2 ton series:
Approx. 48V
3 ton series:
Approx. 80V
Remarks
