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FOREWORD This Manual (Volume 1) contains maintenance, specifications and repair procedures for the chassis, body and material handling system of the TOYOTA ELECTRIC POWERED FORKLIFT 7FB10 to 30 series and 7FBJ35 For diagnosis and service procedures of electrical controller, refer to Volume (Pub No CE316-1) Please use these manuals for providing quick, correct servicing of the corresponding forklift models This manual deals with the above models as of September 1999 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 GENERAL BATTERY CHARGER CONTROLLER MLUTI-DISPLAY FUNCTIONS ELECTRICAL SYSTEM TROUBLESHOOTING MOTOR DRIVE UNIT FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE SAS FUNCTIONS (OPT) APPENDIX Sections indicated by solid characters are included in this manual Sections indicated by half-tone characters: See vol SECTION 10 11 12 13 14 15 16 17 18 19 0-1 GENERAL Page EXTERIOR VIEWS 0-2 Page TIGHTENING TORQUE TABLE 0-14 VEHICLE MODEL 0-3 PRECOAT BOLTS 0-15 FRAME NUMBER 0-4 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 0-15 HOW TO USE THIS MANUAL 0-5 EXPLANATION METHOD 0-5 TERMINOLOGY 0-6 ABBREVIATIONS 0-6 SI UNITS 0-7 OPERATIONAL TIPS 0-8 JACK-UP POINT 0-9 HOISTING THE VEHICLE 0-10 WIRE ROPE SUSPENSION ANGLE LIST 0-16 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE 0-16 COMPONENTS WEIGHT 0-17 RECOMMENDED LUBRICANT QUANTITY & TYPES 0-18 CAUTION FOR TOWING 0-10 LUBRICATION CHART 0-19 CIRCUIT TESTER 0-11 PERIODIC MAINTENANCE 0-20 STANDARD BOLT & NUT PERIODIC REPLACEMENT OF TIGHTENING TORQUE 0-13 PARTS AND LUBRICANTS 0-26 BOLT STRENGTH TYPE IDENTIFICATION METHOD 0-13 0-2 EXTERIOR VIEWS 0-3 VEHICLE MODEL Classification Series Vehicle model Controller type Voltage (V) 7FB10 AC Micon controller 48 7FBH10 ↑ ↑ 7FB14 ↑ ↑ 7FBH14 ↑ ↑ 7FB15 ↑ ↑ 7FBH15 ↑ ↑ 40-7FB15 ↑ ↑ 7FB18 ↑ ↑ 7FBH18 ↑ ↑ 7FB20 ↑ ↑ 7FBH20 ↑ ↑ 40-7FB20 ↑ ↑ 7FB25 ↑ ↑ 7FBH25 ↑ ↑ 40-7FB25 ↑ ↑ 3.0 ton model 7FB30 ↑ 80 3.5 ton model 7FBJ35 ↑ ↑ Model 1.0 ton model 1.35 ton model ton series 1.5 ton model 1.8 ton model 2.0 ton model ton series 2.5 ton model ton series 0-4 FRAME NUMBER Drive motor model Vehicle model Punching format Punching position 7FB10 7FBH10 7FB14 7FBH14 ton series AP11 7FB18–10001 7FB15 Frame number punching position r 7FBH15 7FB18 7FBH18 40-7FB15 7FB20 AP15 7FBH20 7FB25–10001 7FB25 ton series 7FBH25 40-7FB20 AP15 407FB25–10001 40-7FB25 7FB30 ton series AP16 7FBJ35–10001 7FBJ35 Note: in place of [–] on vehicles for EEC 0-5 HOW TO USE THIS MANUAL EXPLANATION METHOD Operation procedure (1) The operation procedure is described in either pattern A or pattern B below Pattern A: Explanation of each operation step with illustration Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, 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-lbf] • Step Nos are partially sometimes omitted in illustrations T = 46.1 ~ 48.1 (470 ~ 490) [34.0 ~ 35.5] Disassembly Procedure Remove the cover [Point 1] Remove the bushing [Point 2] ỗ Operation explained later Remove the gear Point Operations Explanation of key point for operation with an illustration í [Point 1] Disassembly: Put a match mark when removing the pump cover [Point 2] Inspection: Measure the bush inside diameter Limit: 19.12 mm (0.7528 in) 0-6 How to read components figures (1) The components figure uses the illustration 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 (Example) 3201 FIG number in parts catalog 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 (partially described) TERMINOLOGY Caution: Important matters of which negligence may cause accidents Be sure to observe them Note: Important 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) Meaning Abbreviation (code) Meaning ASSY Assembly SAS System of active stability LH Left hand SST Special service tool LLC Long life coolant STD Standard M/T Manual transmission T= Tightening torque OPT Option T/C Torque converter & transmission O/S Oversize ¡¡T Number of teeth (¡¡) PS Power steering U/S Undersize RH Right hand W/ With SAE Society of Automotive Engineers (USA) L/ Less 0-7 SI UNITS Meaning of SI SI represents the International System of Units, which has been established for unifying various systems of units used in the past, for smoother international technical communication New Units Adopted in SI Conversion rate*1 (1 [conventional unit] = X [SI unit]) Characteristic New unit Conventional unit Force*2 N (newton) kgf Torque*2 (moment) N•m kgf•cm kgf•cm = 9.80665 N•m Pressure*2 P (pascal) kgf/cm2 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa ↑ ↑ mmHg mmHg = 0.133322 kPa Revolving speed r/min rpm Spring constant*2 N/mm kgf/mm Volume L cc cc = mL Power W PS PS = 0.735499 kW Heat quantity W•h cal kcal = 1.16279 W•h Specific fuel consumption g/W•h g/PS•h kgf = 9.80665 N rpm = r/min kgf/mm = 9.80665 N/mm g/PS•h = 1.3596 g/kW•h *1: X represents the value in SI unit as converted from [in conventional unit], which can be used as the rate for conversion between conventional and SI units 2: * In the past, kilogram [kg] representing the mass was often used in place of weight kilogram [kgf] that should be used as the unit of force Conversion between Conventional and SI Units Value in SI unit = Conversion rate × value in conventional unit Value in conventional unit = Value in SI unit ÷ Conversion rate Conversion rate: Figure corresponding to X in the conversion rate column in the table above Caution: At the time of conversion, change the unit of the value in conventional or SI unit to the one in the conversion rate column in the table above before calculation When converting 100 W to the value in conventional unit PS, change it to 0.1 kW first and divide by 0.735499 as the conversion rate 0-8 OPERATIONAL TIPS Safe operation (1) After jacking up, always support with wooden blocks or rigid stands (2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity (3) Always disconnect the battery plug before the inspection or servicing of electrical parts Tactful operation (1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation (2) Before disconnecting wiring, 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, inspection and reassembly (6) Replace, gaskets, packing and O-rings with new ones each time they are disassembled (7) Use genuine Toyota parts for replacement (8) Use specified bolts and nuts Observe the specified tightening torque at the time of reassembly (Tighten to the center of the specified tightening torque range.) If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table Protection of functional parts (1) Thoroughly check each connector for any failure in or imperfect connection before reconnecting the battery plug after the end of vehicle inspection or maintenance Failure in or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers Confirming defect status Do not start immediate disassembly or replacement, but first confirm if such disassembly or replacement is actually needed Handling of waste fluid, etc When draining waste fluid from the vehicle, always receive it with an appropriate container Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other harmful substance may cause adverse affect to people or environmental destruction, sort each waste and always ask an authorized contractor for appropriate disposal Handling of electronic parts (1) Never apply impacts to electronic parts such as a microcomputer or relay (2) Never let electronic parts be exposed to a high temperature or humidity (3) Do not touch connector pins since they may be deformed or be damaged due to static electricity 19-25 P1 terminal 19-26 19-27 With voice warning Motor A Motor B N1 terminal N1 terminal 19-28 AC plug AC plug Battery capacity 48V 330 ~ 565 AH Only for battery capacity: 48V 330 ~ 565 AH AC plug AC plug Battery capacity 48V 600 ~ 845 AH, 80V 370 ~ 470 AH AC plug AC plug AC plug Timer terminal Timer terminal Timer terminal Timer terminal Timer terminal Timer terminal Timer terminal Timer terminal 19-29 1) When the lifting height is 2,000 or more, excluding 2) and 3) below [Note: Nos 1, and on the TAB side are unconnected for FV2000.] 2) When the lifting height is 4500 or more for V or SV mast vehicles with single tires for domestic market 3) When the lifting height is 4500 or more for FSV mast vehicles with single tires for domestic market 19-30 When the lifting height is 4500 or more for V or SV mast vehicles with single tires for domestic market When the lifting height is 4500 or more for FSV mast vehicles with single tires for domestic market When the lifting height is 4500 or more for V or SV mast vehicles with single tires for domestic market When the lifting height is 4500 or more for FSV mast vehicles with single tires for domestic market 19-31 19-32 19-33 Surge absorber Surge absorber N1 terminal 19-34 For volume selectable buzzer Forward/reverse travel chime DM Wiper motor Wiper (Options shown in this circuit diagram also apply to vehicles with SAS.) Forward travel For ton series (80 V) (The circuit is the same as the one for 48 V for other than the portion below.) Reverse travel For forward/reverse travel rotating lamp 19-35 CONNECTING DIAGRAM (FOR VEHICLE WITHOUT SAS) For ton series (80 V) (The circuit is the same as that for 48 V for other than the portion below.) Reverse travel For forward/reverse travel rotating lamp AC plug 19-36 CONNECTING DIAGRAM (FOR VEHICLE WITH SAS) Forward travel 19-37 WIRING DIAGRAM (FOR VEHICLE WITHOUT SAS) ACCEL VRAD P22 (91,GR) (90,O) LSAT2 LSOPT1 LSOPT2 OPTO AOPT BIBC (92,R-B) MH2-1 MH1 GNDD M15V MH2-2 LSAT1 SWTK (62,L) LSTR LSTF ATT (63,G-B) (61,G-R) (60,G-W) LSL LSD (66,B-W) LSB LSPB DSF (67,B-Y) (46,G) (65,Y-G) (45,W) (51,R-L) POTT POTT+ LS- SPL+ SPL POTA+ SWAC POTA (52,GR) (53,R-B) (64,R-Y) (44,LG) (44,LG) (51,R-L) VBMB POT- (P2,Y) VBP2 VBMB (41,Y) (41,Y) B48V (1,2 ton) (43,B-Y) VBKY B80V (3 ton) VBBT (41,L-O) (16,W-L) (15,LG-B) (13,V-R) C20V C15V D15V GNDC (100,Y) (14,B-Y) CPU BD D To PB MD PB MMP To +side G A S P15 (V) P16 CD (W) To +side G S TMD BU PB MMPD CU D To PB MD PB MMP To +side G To +side G S S SSD P5 (U) B To PB MD PB MMPD To +side G To CSBATT TMDCD-SD (N2,Y-B) TMDCD-G TMDCD2+ TMDCD1+ (160,BR) (161,W-B) TMDCU-G TMDCU2+ TMDCU-SD (160,O) (P9,B-W) (159,L-R) TMDCU1+ (158,GR) TMDBD-SD (158,P) TMDBD2+ TMDBD-G (N2,B-Y) (156,L) TMDBD1+ TMDBU-G TMDBU2+ TMDBU-SD (156,LG) (P6,GR-B) (155,W-Y) (154,V) TMDBU1+ AD To PB MD To +side G P14 CSP TMP TMD AU PB MMPD AM P P6 STMP TMD TMD AD D To PB MD PB MMP D To PB MD PB MMP To +side G To +side G S S S BD TMD P7 CSD P8 B AM D STMD P9 CD D To PB MD PB MMP To +side G S N2 F DIRECTION SWITCH, FORWARD DS R DIRECTION SWITCH, REVERSE PB MMP PRINT BOARD, MMP DS FO DIRECTION SWITCH, FORWARD OPTIONAL BU DIRECTION SWITCH, BACK-UP MB P1 CSBATT BATT 80V F LIMIT SWITCH, LIFT ATT LIMIT SWITCH, ATTACHMENT TMD AU TRANSISTOR, MAIN, DRIVE, PHASE A UPR LS ST LIMIT SWITCH, STOP LAMP LS B LIMIT SWITCH, BRAKE BATT BATTERY TMD BU TRANSISTOR, MAIN, DRIVE, PHASE B UPR F1 FUSE, DRIVE TMD CU TRANSISTOR, MAIN, DRIVE, PHASE C UPR LS PB LIMIT SWITCH, PARKIG BRAKE F3 FUSE, POWER STEERING TMD AD TRANSISTOR, MAIN, DRIVE, PHASE A LWR LS TF LIMIT SWITCH, TILT FR F4 FUSE, LAMP TMD BD TRANSISTOR, MAIN, DRIVE, PHASE B LWR LS TR LIMIT SWITCH, TILT RR P2 F (P0,B) F P3 F F6 P4 GNDD (41,Y) PB CPU (101,R) Note.3 B80V FUSE, CONTROL CIRCUIT TMD CD TRANSISTOR, MAIN, DRIVE, PHASE C LWR SW AC SWITCH, ACCEL FUSE, SK/PS&SOLENOID TMP AU TRANSISTOR, MAIN, PUMP, PHASE A UPR SW K SWITCH, KEY F7 FUSE, DC-DC COMVERTER TMP BU TRANSISTOR, MAIN, PUMP, PHASE B UPR SW L SWITCH, LIGHT LED DISP LED DISPLAY TMP CU TRANSISTOR, MAIN, PUMP, PHASE C UPR SW F SWITCH, FLASHER TMP AD TRANSISTOR, MAIN, PUMP, PHASE A LWR SW H SWITCH, HORN THCD THERMO, DRIVE TMP BD TRANSISTOR, MAIN, PUMP, PHASE B LWR THCP THERMO, PUMP TMP CD TRANSISTOR, MAIN, PUMP, PHASE C LWR SW MODE SWITCH, MODE AM D MOTOR, DRIVE TMPS TRANSISTOR, MAIN, POWER STEERING AM P MOTOR, PUMP L H-L LAMP, HEAD LH L ST-L LAMP, STOP LH CO CAPACITOR, OVERALL L H-R LAMP, HEAD RH L ST-R LAMP, STOP RH LAMP, ROTALY SW BZ N1 PB DC/MD (171,B) P21 BIBD B80V F3 F5 BIBC (18,BR) P0 48V F6 +15V LED DISP (44,LG) (18,SL) LS Note.1 (Circuit except for the above is the same In case of ton series (80V) with that of the 48V vehicle) Note.2 (125,GR) (127,R-Y) BZ (120,Y-R) DS PRINT BOARD, DC/MD (103,R-W) PRINT BOARD, COMPUTER DC/MD (103,R-W) CPU (126,R-L) PL W PILOT LAMP, WORKING CSBATT CURRENT SENSOR, BATTERY L C-L LAMP, CLEARANCE LH L R CSD A CURRENT SENSOR, DRIVE, PHASE A L C-R LAMP, CLEARANCE RH L BU-L LAMP, BACK-UP LH CSD B CURRENT SENSOR, DRIVE, PHASE B L T-L LAMP, TAIL LH L BU-R LAMP, BACK-UP RH CSP A CURRENT SENSOR, PUMP, PHASE A L T-R LAMP, TAIL RH CSP B CURRENT SENSOR, PUMP, PHASE B L L-L BUZZER LAMP, LICENCE LH BZ FAN D FAN, DRIVE L L-R LAMP, LICENCE RH CHIF CHIME, FORWARD FAN P FAN, PUMP L W LAMP, WORKING CHIR CHIME, REVERSE VRAD VARI-OHM, ACCEL, DRIVE HORN L F-LR LAMP, FLASHER LH (REAR) H SLL SENSOR, LEQUID LEVEL L F-RR LAMP, FLASHER RH (REAR) FR M PS CONTACTOR, PS L F-L LAMP, FLASHER LH MB CONTACTOR, BATTERY L F-R LAMP, FLASHER RH HM Y RELAY, FLASHER METER, HOUR (N1,W-B) PB PB Circuit for the volume controllable buzzer Circuit of forword / reverse traveling part Forword/reverse travelingpart (N1,W-B) BIBD (145,Y-R) (146,R) (16,R) (14,BR) (87,P) (86,B-Y) (82,B-W) (83,BR) (81,W-L) (80,G-R) (54,L) (75,W-Y) A (72,R) (76,Y-B) - - (71,W) (77,R-Y) (79,Y-W) (6,R-L) (5,B-R) M PS + (1,W-R) MB (88,Y-G) (85,W-G) (84,B-R) (N2,B) (N2,B) (74,O) (75,Y-L) (76,W-B) (73,P) (35,Y) (34,Y) (26,Y) (26,Y) (25,Y) (24,Y) (23,Y) (22,Y) (21,Y) (20,Y) (33,Y) (33,Y) (32,Y) (31,Y) CSD THCD S SSP CSP TMP D To PB MD PB MMP LSL D15V TD+ SSD2 SSD- SSD+ SSD1 CSBATT CSDB CSD+ CSD- CSDA THCP SOLT- SOLT+ SOLL- SOLL+ MB- TP- MB+ TP+ SSP- SSP+ N2 N2C CSPB CSP+ CSP- CSPA CKPV TMDD+ CKDV TMDU+ TMDCD- TMDBD- TMDAD- TMDCU- TMDBU- TMDAU- TMPD+ TMPU+ TMPCD- TMPBD- TMPAD- TMPCU- (30,Y) (29,Y) TMDAD-SD (154,R) (157,G-W) S P13 TMP L R DS MOTOR, POWER STEERING To PB MD To +side G S CO DM PS N1 DM PS (14,B-W) CHGFAN GNDD (98,Y) (99,Y) CKFANP- (97,Y) CKFAND- CKFANP+ (40,Y) (94,Y) (39,Y) DDC FAN+ PDC CKFAND+ (37,Y) (38,Y) (36,Y) FANCD P21 CHI F L F-R (N1,W-B) To PB MD To +side G TMD CU PB MMPD P12 -RR CHI R L F-L S M PS (108,R-Y) (109,G-Y) (48,P) -LR To PB MD To +side G TMP BU PB MMPD BZ L F HM TMP AU PB MMPD -R H TMPBU- TMPAU- To PB MD L BU SLL TMDAD-G TMP -L L F (N2,W-L) (153,R-Y) TMDAU-SD TMDAD2+ (152,Y) TMDAU-G TMDAU2+ TMDAD1+ (152,W) (P5,SL) TMDAU1+ (150,G) (150,B) TMPCD2+ TMPCD-SD L BU SW F SW MODE LS TR LS THCP (151,L-G) (P13,B-Y) (167,G-W) (120,Y-R) (28,Y) TMPAD-SD TMPBU2+ F3 (110,GR) SA (103,R-W) FR Y SW H (27,Y) TMPAD-G TMPBU-G (166,L) LS TF TMPBU1+ (N2,SL) (166,LG) TMPCD1+ (N2,B-W) TMPAU-SD TMPAD2+ TMPCD-G (165,L-R) (172,G) (164,GR) -R (172,B) PL W (173,L-G) L H-R TMPCU2+ L T-R LS L TMPAU-G TMPAD1+ TMPCU-SD L C-R L ST LS PB LSD TMPAU2+ (P16,W-L) L L-R (164,P) TMPCU1+ (P12,Y-B) TMPCU-G (163,W-B) BATT 48V N2 (170,Y) (162,BR) DS FO TMPAU1+ (170,W) DS BU -L PB DC/MD LS B N2 (N2,B) (162,O) PB DS R TD- (N2,B) L ST LW L H-L FANP- (171,R-Y) L T-L FANP+ (10,GR) TMPBD2+ L C-L P (111,R-L) (102,R-G) (107,R-B) (104,G-R) FAN L L-L FAND- (9,O) TMPBD-SD HM TMPBD1+ HS (8,W) D TMPBD-G T VBMB FAND+ (7,P) FAN FANCP LS ST (N2,GR-B) (101,R) DS F (169,W-Y) F4 SW L + DSR SW AC - (43,B-Y) TMPBU-SD (41,Y) (168,R) F5 (168,V) (P1,B) SW K THCD P4 (78,L-R) F1 P3 CSBATT P1 THC+ 44 (2,LG-R) P2 MB F6 + CPU (89,W-R) To PB 19-38 WIRING DIAGRAM (FOR VEHICLE WITH SAS) F6 To PB CPU MB P3 P2 P4 F1 CSBATT ACCEL VRAD P21 F3 F5 SW K (41,Y) SW MH1 TILT VRAT + - (43,B-Y) (105, L-R) DS F DS R LS B LS PB LS D LS L LS TF LS TR LS SW TK ATT F4 (166,LG) TMPAD-SD SOL -RR (A) CHI F DM PS (P24, Y) L R SCPU To PB SCPU To PB MD PB MMPD (160,BR) (92,R-B) MH2-1 MH1 LSAT2 LSOPT1 LSOPT2 OPTO AOPT (91,GR) (90,O) MH2-2 GNDD M15V TD- (93,R) (70,BR) SWTK LSAT1 LSTR (62,L) (63,G-B) (61,G-R) (60,G-W) LSL LSTF (66,B-W) (67,B-Y) LSPB LSD (46,G) LSB P15 B AM P CD TMD (W) AD To PB MD PB MMPD To +side G To +side G TMD CSD TMD BD To PB MD PB MMPD AM STMD D P9 CD To PB MD PB MMPD To +side G P8 B To +side G To V W SW L SWITCH, LIGHT TRANSISTOR, MAIN, PUMP, PHASE C UPR SW F SWITCH, FLASHER BOXCHG BOX, CHARGER TMP AD TRANSISTOR, MAIN, PUMP, PHASE A LWR SW H SWITCH, HORN THCD THERMO, DRIVE TMP BD TRANSISTOR, MAIN, PUMP, PHASE B LWR SW TK SWITCH, TILT KNOB N1 In case of ton series (80V) THCP THERMO, PUMP TMP CD TRANSISTOR, MAIN, PUMP, PHASE C LWR SW MH1 SWITCH, HIGHT NO.1 AM D MOTOR, DRIVE TMPS TRANSISTOR, MAIN, POWER STEERING SW MH2 SWITCH, HIGHT NO.2 AM P MOTOR, PUMP SH SHANT, POWER STEERING L H-L LAMP, HEAD LH L ST-L LAMP, STOP LH MOTOR, POWER STEERING CO CAPACITOR, OVERALL L H-R LAMP, HEAD RH L ST-R LAMP, STOP RH CSBATT CURRENT SENSOR, BATTERY L C-L LAMP, CLEARANCE LH L R LAMP, ROTALY PL W PILOT LAMP, WORKING SOL S SOLENOID, SWING CSD A CURRENT SENSOR, DRIVE, PHASE A L C-R LAMP, CLEARANCE RH L BU-L LAMP, BACK-UP LH SOL ST SOLENOID, STEERING CSD B CURRENT SENSOR, DRIVE, PHASE B L T-L LAMP, TAIL LH L BU-R LAMP, BACK-UP RH SOL L SOLENOID, LIFT CSP A CURRENT SENSOR, PUMP, PHASE A L T-R LAMP, TAIL RH SOL T SOLENOID, TILT CSP B CURRENT SENSOR, PUMP, PHASE B L L-L LAMP, LICENCE LH BZ BUZZER FAN D FAN, DRIVE SYR SENSOR, YAWRATE L L-R LAMP, LICENCE RH CHIF CHIME, FORWARD FAN P FAN, PUMP SS SENSOR, SPEED L W LAMP, WORKING CHIR CHIME, REVERSE VRAD VARI-OHM, ACCEL, DRIVE SST SENSOR, STEERING L F-LR LAMP, FLASHER LH (REAR) H HORN VRAT VARI-OHM, TILT SLL SENSOR, LEQUID LEVEL L F-RR LAMP, FLASHER RH (REAR) FR VRAH VARI-OHM, TIRE(HANDLE) SUS SENSOR, ULTRA SONIC L F-L LAMP, FLASHER LH VRAS VARI-OHM, SWING MB CONTACTOR, BATTERY L F-R LAMP, FLASHER RH VW Y SGSOLS SGSOLST RELAY, FLASHER VOICE WARNING (Circuit except for the above is the same with that of the 48V vehicle) PB DC/SD RESOL SOL S SOL ST (184,BR-R) AVD4 AVD3 AVD2 AVD(+) AVD1 CHGLED4 CHGLED3 CHGLED2 CHGLED1 CHGSW3 CHGSW2 CHGSW1 (336,Y) (337,Y) PB VRAH Tire angle VRAS SWING (127,Y-W) LED4 (126,Y-G) LED3 CHG SCPU SST SS SYR SH- TRANSISTOR, MAIN, PUMP, PHASE B UPR TMP CU BOX (P24,Y) (N1,B) TMP BU LCD DISPLAY (335,Y) SH+ FUSE, DC-DC COMVERTER LCD DISP (334,Y) SYR- F7 (333,Y) (340,G) SWITCH, KEY TMPSG SW K SYR+ SYR TRANSISTOR, MAIN, PUMP, PHASE A UPR (321,GR) (322,GR) TMP AU CKSOLS CKSOLST GNDD FUSE, SK/PS&SOLENOID DRSOL- PB DC/MD SS- F6 P21 SS+ SWITCH, ACCEL To TMPS (325,G-B) SW AC To N1 To 43 N1 48V SSTXA LS TRANSISTOR, MAIN, DRIVE, PHASE C LWR SXTSK TRANSISTOR, MAIN, DRIVE, PHASE B LWR TMD CD (332,Y) (324,Y-R) TMD BD FUSE, CONTROL CIRCUIT (331,Y) (125,Y-B) LIMIT SWITCH, TILT RR FUSE, LAMP F5 DRSOL+ F3 (353,Y) (124,Y-R) TR F4 B80V LED2 LIMIT SWITCH, TILT FR LED1 TF SXTSA LS SSTXK TRANSISTOR, MAIN, DRIVE, PHASE A LWR (123,G) TMD AD SW3 FUSE, POWER STEERING (352,Y) STSC F3 GNDSC SW2 LIMIT SWITCH, PARKIG BRAKE (121,O) PB SMTDA (351,Y) SW1 LS SC15V STS+ TRANSISTOR, MAIN, DRIVE, PHASE C UPR GNDPS (311,W-R) (312,G-W) TMD CU (101,R) (137,R-G) FUSE, DRIVE F4 (138,W-R) F1 (P0,B) P0 48V +15V SDTMK SL/L- LIMIT SWITCH, BRAKE SL/L+ LIMIT SWITCH, STOP LAMP B SPOT- ST LS (320,W-R) LS TRANSISTOR, MAIN, DRIVE, PHASE B UPR POTS TRANSISTOR, MAIN, DRIVE, PHASE A UPR TMD BU (319,Y-G) TMD AU PS20V (350,Y) (309,Y) (310,Y-R) SWITCH, TRANS, THERMO BATTERY (44,Y) SSTMK STT BATT PB CPU SSTMA LIMIT SWITCH, ATTACHMENT AC-S GNDD SMTDK SDTMA B80V POTS+ ATT (41,Y) (318,G-W) LS (18,BR) F5 (308,G-Y) FUSE, CHARGER F7 (307,W-R) F CH LIMIT SWITCH, LIFT SMTSK LSL SMTSA DS PRINT BOARD, DC/SD (18,SL) PRINT BOARD, SK/PS COMPUTER DC/SD (171,B) SCPU PB POTH DIRECTION SWITCH, BACK-UP PB DIODE, CHARGER LCD DISP AC-R (S,R) POTH+ BU RELAY, THERMAL D CH BATT 80V SLL MS CH (R,W) (317,GR) DIRECTION SWITCH, FORWARD OPTIONAL STT (95,L) (316,B-Y) FO CPU To N1 SOLST- DS To PB P4 (44,LG) (330,GR ) PRINT BOARD, MMP F1 F6 (44 ,Y-G) MMP P3 VBMB PB P2 CSBATT SOLST+ MAGNET SWITCH, CHARGER MB P1 SOLS- R Note.1 (329,B-Y) DC/MD DIRECTION SWITCH, REVERSE (328,R-L) DIRECTION SWITCH, FORWARD N1 F DS SOLS+ DS PRINT BOARD, DC/MD (N1,W-B) PRINT BOARD, COMPUTER (327,G-L) CPU PB + PB TRANSFORMER (139,P) - CHARGER TF (140,B) (183,BR-W) N2 (182,G-B) S (181,G-Y) S (180,G-W) S S STS- S (315,BR) S (141,W-R) (142,R-B) (143,R-Y) (144,G-R) (16,R) (14,BR) (87,P) (86,B-Y) (82,B-W) (83,BR) (80,G-R) (81,W-L) (54,L) (72,R) (76,Y-B) (75,W-Y) A P6 STMP P16 To PB MD PB MMPD To +side G (V) P7 SH THR SMTDA SDTMK SDTMA D15V SMTDK TD+ SSD2 SSD- SSD1 SSD+ CSBATT CSDB CSD+ CSD- CSDA (71,W) (N2,Y-B) (161,W-B) (160,O) (158,GR) (P9,B-W) CSP TMP BD To PB MD PB MMPD To +side G CH DM PS (159,L-R) (158,P) (156,L) (N2,B-Y) (157,G-W) (156,LG) (P6,GR-B) (155,W-Y) (154,V) (N2,W-L) (152,Y) (153,R-Y) (152,W) (P5,SL) (150,G) (151,L-G) (150,B) (154,R) TMP AD SSD CSD (U) P13 TMP S P5 STS2 (N1,W-B) L F-R To PB To +side G S P14 A CU To PB MD PB MMPD To +side G S SSP CSP TMD BU To PB MD PB MMPD To +side G S CO (B) DC/SD (122,Y) CHI R N1 CH S TMD AU To PB MD PB MMPD To +side G P12 (P23, R-W) VW L F-L MS (N2,SL) (172,G) (173,L-G) (172,B) (P16,W-L) (170,Y) S TMD CU To PB MD PB MMPD To +side G BZ L F SLL STT TM PS TMP BU To PB MD PB MMPD To +side G and PB STS1 -LR (108,R-Y) (109,G-Y) (48,P) L F TMP AU To PB MD PB MMPD -R H (171,R-Y) TMP -L L BU F CH (170,W) (N2,GR-B) (169,W-Y) (168,V) (168,R) (P13,B-Y) (120,Y-R) L BU SW F SCPU (313,R-Y) (314,L) (110,GR) (103,R-W) Z Z 60H 50H (167,G-W) To PB LCD To DISP THCD THCP T To CSBATT L TMDCD-SD TMDCD2+ TMDCD1+ TMDCD-G TMDCU2+ TMDCU-SD TMDCU-G TMDCU1+ TMDBD2+ TMDBD-SD TMDBD-G TMDBD1+ TMDBU-SD TMDBU-G TMDBU2+ TMDBU1+ TMDAD2+ TMDAD-SD TMDAD1+ TMDAD-G TMDAU2+ TMDAU-SD TMDAU1+ TMDAU-G TMPCD-SD SOL TMPCD-G TMPBU-G TMPBU2+ TF SA (78,L-R) THCD TMPBU1+ (166,L) D CH DSR (77,R-Y) (79,Y-W) (6,R-L) (4,GR) (5,B-R) (3,W-G) (2,LG-R) (89,W-R) + (1,W-R) MB (88,Y-G) (85,W-G) (84,B-R) (N2,B) (N2,B) (74,O) (75,Y-L) (76,W-B) (73,P) (35,Y) (34,Y) (26,Y) (26,Y) (25,Y) (24,Y) (23,Y) (22,Y) (21,Y) (20,Y) (32,Y) (33,Y) (33,Y) TMPAD-G - (N2,B-W) FR Y THC+ THCP SOLT- SOLT+ SOLL- SOLL+ MB- MB+ SSP+ SSPTP+ TP- N2C N2 CSPB CSP+ CSP- CSPA TMDD+ CKPV CKDV TMDU+ TMDCD- TMDBD- TMDCUTMDAD- TMDBU- TMDAU- TMPD+ TMPU+ TMPCD- TMPBD- TMPAD- (31,Y) TMPAD2+ (165,L-R) SW H (65,Y-G) (45,W) (51,R-L) LS- DSF POTT+ SPL+ POTT (56,G) (57,G-W) (58,G-B) (59,Y-G) SPL POTA+ SWAC POTA (52,GR) (53,R-B) (64,R-Y) (P2,Y) (41,Y) (41,Y) (43,B-Y) (44,LG) VBMB (44,LG) VBMB (51,R-L) POT- VBP2 B48V (1,2 ton) VBBT B80V (3 ton) VBKY (13,V-R) (41,L-O) C20V (16,W-L) (15,LG-B) C15V D15V GNDC (100,Y) (14,B-Y) (14,B-W) GNDD CHGFAN (98,Y) (97,Y) (40,Y) (99,Y) CKFANP- CKFAND- CKFANP+ CKFAND+ (39,Y) (94,Y) PDC DDC (37,Y) (38,Y) FAN+ (36,Y) FANCD TMPBU- TMPAU- TMPCU- (30,Y) (29,Y) TMPAD1+ (164,GR) -R (27,Y) TMPAU-SD (164,P) L ST PLW TMPCU-SD L H-R TMPCD2+ L T-R TMPCU-G L C-R (28,Y) TMPAU-G (P12,Y-B) L L-R CPU TMPAU2+ (163,W-B) TMPCD1+ -L BATT 48V N2 TMPBD-SD W1 (6) PB DC/MD TMPAU1+ (162,BR) DS FO TMPCU2+ V1 (4) DS BU PB N2 (N2,B) (162,O) L ST L W L H-L (N2,B) TMPBD-G U1 (2) L T-L FANP- TMPCU1+ (L) L C-L FANP+ TMPBU-SD L L-L FAND- (9,O) TMPBD2+ THR 95 (10,GR) TMPBD1+ 96 P (111,R-L) W FAN HM (107,R-B) V (102,R-G) U MS CH (104,G-R) T (8,W) + S D - (A2) R HS VBMB FAND+ (7,P) FAN FANCP LS ST T (A1) MH2 (101,R) SW L CH SW SUS SPL (323,GR) (P1,B) + - SW AC P1 44 Edited by Published by 1st Printing: Apr 2000 Pub No CE315-1 Printed in Japan C