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FOREWORD This Manual (Volume 2) contains diagnostics service procedures of electrical controller of the TOYOTA ELECTRIC POWERED FORKLIFT 7FB10 to 30 series and 7FBJ35 For maintenance, specifications and repair procedures for the chassis, body and material handling system, refer to Volume (Pub No CE315) 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 SECTION GENERAL BATTERY CHARGER CONTROLLER (CONNECTOR INSPECTION LIST) 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 10 11 12 13 14 15 16 17 18 19 0-1 GENERAL Page EXTERIOR VIEWS 0-2 VEHICLE MODEL 0-3 FRAME NUMBER 0-4 OPERATIONAL TIPS 0-5 JACK-UP POINT 0-6 HOISTING THE VEHICLE 0-7 CAUTION FOR TOWING 0-7 CIRCUIT TESTER 0-8 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 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 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 0-6 JACK-UP POINT Strictly observe the following instructions when jacking up the vehicle • When a load is on the fork, unload it and park the vehicle on a flat floor Be sure to avoid an inclined or rugged place • Use a jack with ample capacity and jack up the vehicle at the specified jack-up point Jacking up at any other point will be dangerous • Never operate while the vehicle is held with a jack Always support the frame with a wooden block after jacking up • In any case, never let a part of the body (including hands and feet) be under the jacked-up vehicle 123 12312 12 : Jack-up point : Wooden block or stand setting point 0-7 HOISTING THE VEHICLE Always hoist each part of the vehicle at the specified position Never hoist at any other position because it is very dangerous A B Slinging the head guard can be done in two illustrated ways Case A: Remove the head guard sheet case B: If the fiber or wire rope comes into contact with a rear combination lamp, remove the lamp ASSY When hoisting the vehicle, sling with a fiber or wire rope at the mast hook hole and the rear end of the head guard CAUTION FOR TOWING When towing the forklift, always lift the rear wheels away from the ground The traveling speed in towing must not exceed the maximum traveling speed of the forklift Always set the key switch to OFF and the direction switch to the neutral position before starting towing In case of towing by connection with a wire rope with the operator on the forklift, however, set the key switch to ON (PS operation) and always set the direction switch to the neutral position Before towing, either remove the fork or take an action to prevent fork contact with the ground due to bounding 0-8 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 measured 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 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 Forward direction Reverse direction Measurement result example Tester range: kΩ range Analog type Continuity exists Forward 11 kΩ No continuity Reverse ∞ (2) Digital circuit tester Forward direction Reverse direction Measurement result example Tester range: MΩ range Digital type No continuity Forward Continuity exists Reverse MΩ 19-13 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 19-14 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 19-15 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 19-16 19-17 19-18 Surge absorber Surge absorber N1 terminal 19-19 CPU BOARD CONNECTOR DRAWING CN101 CN101 CN102 CN102 CN103 CN104 CN103 CN104 CN105 CN106 CN107 CN105 CN106 CN107 19-20 DC/MD BOARD CONNECTOR DRAWING CN108 CN109 CN110 CN108 CN109 CN110 CN111 CN112 CN113 CN111 CN112 CN113 19-21 SCPU BOARD CONNECTOR DRAWING CN140 CN140 CN141 CN141 CN142 CN142 CN144 CN145 CN146 CN144 CN145 CN146 19-22 DC/SD BOARD CONNECTOR DRAWING CN147 CN147 CN148 CN148 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 19-23 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 19-24 CONNECTING DIAGRAM (FOR VEHICLE WITH SAS) Forward travel 19-25 WIRING DIAGRAM (FOR VEHICLE WITHOUT SAS) ACCEL VRAD (108,R-Y) (109,G-Y) (48,P) LSAT2 LSOPT1 LSOPT2 OPTO AOPT BIBC (91,GR) (90,O) (92,R-B) MH2-1 MH1 GNDD M15V MH2-2 SWTK LSAT1 LSTF LSTR (62,L) (63,G-B) (61,G-R) (60,G-W) LSL LSD (66,B-W) LSPB LSB (67,B-Y) (65,Y-G) (46,G) (45,W) DSF (51,R-L) POTT POTT+ LS- SPL+ SPL (53,R-B) POTA+ SWAC POTA (52,GR) (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) (13,V-R) C20V (16,W-L) (15,LG-B) C15V D15V GNDC (100,Y) (14,B-Y) M PS TMP - AD BD D To PB MD PB MMP To +side G S B P15 (V) P16 CD (W) To PB MD PB MMPD To +side G To +side G S SSD CSD (U) CSP TMP To CSBATT TMDCD-SD TMDCD-G TMDCD2+ TMDCD1+ (160,BR) (161,W-B) (160,O) TMDCU-SD TMDCU2+ TMDCU-G (P9,B-W) (158,GR) (159,L-R) TMDCU1+ (158,P) TMDBD-SD TMDBD-G TMDBD2+ (156,L) (N2,B-Y) (157,G-W) TMDBD1+ TMP S P5 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 A CSD P8 B AM D STMD P9 CD D To PB MD PB MMP To +side G S N2 F DIRECTION SWITCH, FORWARD PB DC/MD PRINT BOARD, DC/MD DS R DIRECTION SWITCH, REVERSE MMP PRINT BOARD, MMP DS FO DIRECTION SWITCH, FORWARD OPTIONAL DS BU DIRECTION SWITCH, BACK-UP Note.1 BATT 80V TMD AU TRANSISTOR, MAIN, DRIVE, PHASE A UPR LS ST LIMIT SWITCH, STOP LAMP TMD BU TRANSISTOR, MAIN, DRIVE, PHASE B UPR LS B LIMIT SWITCH, BRAKE 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 F5 FUSE, CONTROL CIRCUIT TMD CD TRANSISTOR, MAIN, DRIVE, PHASE C LWR SW AC SWITCH, ACCEL F6 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 SW MODE SWITCH, MODE F (P0,B) F F F6 P4 GNDD (41,Y) PB CPU (101,R) Note.3 B80V In case of ton series (80V) BIBD B80V SW BZ F3 N1 BIBC (18,BR) P0 48V P21 +15V LED DISP (44,LG) (18,SL) LIMIT SWITCH, ATTACHMENT BATTERY PB DC/MD Note.2 (125,GR) (Circuit except for the above is the same with that of the 48V vehicle) (127,R-Y) BZ (126,R-L) THCD THERMO, DRIVE TMP BD TRANSISTOR, MAIN, PUMP, PHASE B LWR THCP THERMO, PUMP TMP CD TRANSISTOR, MAIN, PUMP, PHASE C LWR AM D MOTOR, DRIVE TMPS TRANSISTOR, MAIN, POWER STEERING AM P 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 CSBATT CURRENT SENSOR, BATTERY L C-L LAMP, CLEARANCE LH L R LAMP, ROTALY 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 PL W PILOT LAMP, WORKING L L-L LAMP, LICENCE LH BZ BUZZER 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 L F-LR LAMP, FLASHER LH (REAR) H 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 SLL F P3 (171,B) ATT P2 CSBATT LIMIT SWITCH, LIFT LS BATT MOTOR, PUMP MB P1 (120,Y-R) DS (103,R-W) PRINT BOARD, COMPUTER (103,R-W) CPU HM HORN Y RELAY, FLASHER METER, HOUR (N1,W-B) PB Circuit for the volume controllable buzzer Circuit of forword / reverse traveling part Forword/reverse travelingpart (N1,W-B) (146,R) BIBD (145,Y-R) (16,R) (14,BR) (87,P) (86,B-Y) (82,B-W) (83,BR) (81,W-L) (80,G-R) (54,L) (72,R) (75,W-Y) (76,Y-B) (71,W) (77,R-Y) (79,Y-W) (6,R-L) (5,B-R) + (2,LG-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) TMDBU-SD (156,LG) TMDBU-G TMDBU2+ (154,V) (P6,GR-B) (155,W-Y) TMDBU1+ (154,R) TMDAD-SD (N2,W-L) (N2,Y-B) A P13 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+ TMPBD- TMPCD- (33,Y) (32,Y) (31,Y) (30,Y) - DM PS L R PB MOTOR, POWER STEERING (14,B-W) CHGFAN GNDD (98,Y) (99,Y) CKFANP- (97,Y) CKFAND- CKFANP+ (39,Y) (38,Y) (40,Y) (94,Y) PDC CKFAND+ DDC FAN+ (36,Y) FANCD (37,Y) TMPAD- TMPCU- (29,Y) (28,Y) P21 P22 CSP CO To +side G S S SSP To PB MD PB MMP To +side G P14 CU D To PB MD PB MMP To +side G S TMD BU D To PB MD PB MMP To +side G S M PS CHI F L F-R (N1,W-B) To PB MD PB MMP To +side G TMD AU D P12 N1 DM PS TMD CU D To PB MD PB MMP To +side G S -RR CHI R L F-L TMP BU D BZ L F HM H TMP AU PB MMPD -R -LR TMPBU- TMPAU- To PB MD L BU L F TMDAD-G (153,R-Y) TMDAU-SD TMDAD2+ TMDAU-G TMDAU2+ TMDAU1+ TMPCD-SD TMPCD2+ TMDAD1+ (152,Y) (152,W) (P5,SL) (151,L-G) (150,G) (150,B) (P13,B-Y) TMP -L SLL SW MODE ATT CPU THCP L BU SW F LS TR LS THCD TMPBU2+ (167,G-W) (120,Y-R) (27,Y) TMPAD-SD F3 (110,GR) SA (103,R-W) FR Y SW H LS TF TMPBU1+ TMPBU-G (166,L) TMPAD-G TMPCD-G (166,LG) TMPAD2+ (N2,SL) (N2,B-W) TMPCD1+ (165,L-R) TMPAU-SD TMPAD1+ (172,G) (164,GR) -R (173,L-G) L ST PL W (172,B) L H-R TMPCU2+ L T-R TMPCU-SD L C-R LS L TMPAU-G TMPCU-G L L-R (164,P) LS PB LSD TMPAU2+ (P16,W-L) (P12,Y-B) TMPCU1+ (163,W-B) (170,Y) (162,BR) DS FO N2 TMPAU1+ (171,R-Y) DS BU -L BATT 48V PB DC/MD LS B N2 (N2,B) (162,O) PB DS R TD- (N2,B) L ST LW L H-L FANP- (170,W) 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 TMPBD-G HS (8,W) D (N2,GR-B) T VBMB FAND+ (7,P) FAN FANCP LS ST TMPBD1+ (101,R) SW L DS F (43,B-Y) (169,W-Y) F4 SW K TMPBU-SD (41,Y) (168,V) F5 (168,R) (P1,B) + DSR SW AC - THCD P4 THC+ F1 P3 CSBATT P1 (78,L-R) 44 (1,W-R) P2 MB F6 (89,W-R) CPU + To PB 19-26 WIRING DIAGRAM (FOR VEHICLE WITH SAS) ACCEL VRAD DS F DS R LS B LS PB LS D LS L LS TF LS TR LS SW TK ATT (166,LG) TMPAD-SD L F -RR (A) CHI F DM PS (P24, Y) L R To PB SCPU To PB SCPU (161,W-B) (160,O) (160,BR) (P9,B-W) (158,GR) (92,R-B) (91,GR) (90,O) (93,R) (70,BR) M15V LSAT1 SWTK (62,L) (63,G-B) LSTR LSTF LSL LSD (61,G-R) (60,G-W) (66,B-W) LSPB LSB (67,B-Y) (46,G) SMTDA SDTMK SDTMA D15V SMTDK SSD2 SSD- SSD1 CSBATT SSD+ CSDB CSD+ CSDA CSD- TMP AD To PB MD PB MMPD BD To PB MD PB MMPD To +side G P15 B (V) AM CSD P CD P7 A P6 STMP TMD P16 (W) To PB MD PB MMPD To +side G SSD (U) CSP TMP S P5 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 SH LCD DISP LCD DISPLAY TMP CU 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 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 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 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 HORN Y RELAY, FLASHER VOICE WARNING (Circuit except for the above is the same with that of the 48V vehicle) PB DC/SD RESOL (336,Y) (337,Y) PB SOL S SOL ST VRAH Tire angle VRAS SWING (184,BR-R) (182,G-B) AVD4 AVD3 AVD2 AVD(+) AVD1 SCPU SST SS SYR SH- (335,Y) (340,G) (18,SL) In case of ton series (80V) PL SGSOLS SGSOLST (171,B) N1 CHG TMPSG SWITCH, LIGHT BOX SYR+ SYR SWITCH, KEY SW L (334,Y) GNDD SW K TRANSISTOR, MAIN, PUMP, PHASE B UPR (333,Y) SS- TRANSISTOR, MAIN, PUMP, PHASE A UPR TMP BU (332,Y) (321,GR) (322,GR) TMP AU FUSE, DC-DC COMVERTER CKSOLS CKSOLST CHGLED4 FUSE, SK/PS&SOLENOID F7 P21 DRSOL- PB DC/MD LED4 F6 F3 SS+ SWITCH, ACCEL To TMPS (325,G-B) LIMIT SWITCH, TILT RR CHGLED3 TR SW AC CHGLED2 LS TRANSISTOR, MAIN, DRIVE, PHASE C LWR (127,Y-W) TRANSISTOR, MAIN, DRIVE, PHASE B LWR TMD CD (126,Y-G) TMD BD FUSE, CONTROL CIRCUIT (331,Y) (125,Y-B) FUSE, LAMP F5 DRSOL+ (353,Y) LED3 F4 B80V LED2 TF LIMIT SWITCH, TILT FR To N1 To 43 N1 48V SSTXA LS SXTSK TRANSISTOR, MAIN, DRIVE, PHASE A LWR (352,Y) SXTSA TMD AD SMTDA (351,Y) (324,Y-R) FUSE, POWER STEERING GNDSC CHGSW3 LIMIT SWITCH, PARKIG BRAKE SC15V CHGLED1 PB PS20V GNDPS (124,Y-R) LS (101,R) SW3 TRANSISTOR, MAIN, DRIVE, PHASE C UPR F4 LED1 TMD CU (P0,B) P0 48V SSTXK LIMIT SWITCH, BRAKE STSC LIMIT SWITCH, STOP LAMP B CHGSW2 F3 ST LS CHGSW1 FUSE, DRIVE LS TRANSISTOR, MAIN, DRIVE, PHASE B UPR (123,G) F1 TRANSISTOR, MAIN, DRIVE, PHASE A UPR (350,Y) (122,Y) TMD BU (44,Y) SW2 TMD AU BATTERY LIMIT SWITCH, ATTACHMENT PB CPU SW1 SWITCH, TRANS, THERMO BATT ATT (41,Y) STS2 STT LS SDTMK SDTMA B80V (121,O) FUSE, CHARGER F5 +15V SL/L- F CH LIMIT SWITCH, LIFT STS+ LSL (311,W-R) (312,G-W) PRINT BOARD, DC/SD (138,W-R) DC/SD (137,R-G) PB SL/L+ DIODE, CHARGER AC-S GNDD SMTDK (18,BR) SPOT- D CH F7 (320,W-R) DIRECTION SWITCH, BACK-UP SSTMK BU POTS DS POTS+ PRINT BOARD, SK/PS COMPUTER LCD DISP AC-R (S,R) (319,Y-G) SCPU To N1 (309,Y) (310,Y-R) PB (44,LG) SSTMA RELAY, THERMAL F6 SMTSK THR BATT 80V (318,G-W) DIRECTION SWITCH, FORWARD OPTIONAL (308,G-Y) FO (307,W-R) DS SMTSA PRINT BOARD, MMP POTH MMP SLL MS CH (R,W) (317,GR) PB STT (95,L) POTH+ MAGNET SWITCH, CHARGER CSBATT (139,P) CPU (316,B-Y) DIRECTION SWITCH, REVERSE SOLST- R (330,GR ) DS To PB P4 SOLST+ PRINT BOARD, DC/MD F1 (44 ,Y-G) DC/MD P3 VBMB PB P2 SOLS- TRANSFORMER MB P1 (329,B-Y) TF Note.1 (328,R-L) DIRECTION SWITCH, FORWARD (N1,W-B) F N1 DS SOLS+ PRINT BOARD, COMPUTER (327,G-L) CPU + PB - CHARGER (140,B) (181,G-Y) S (183,BR-W) S (180,G-W) S S STS- S (315,BR) S N2 (141,W-R) (142,R-B) (16,R) (143,R-Y) (144,G-R) (86,B-Y) (82,B-W) (83,BR) (81,W-L) (80,G-R) (54,L) (72,R) (75,W-Y) (76,Y-B) (71,W) (N2,Y-B) A CU To +side G S S SSP CSP To +side G P14 P13 TMP CH DM PS (159,L-R) (158,P) (157,G-W) (156,L) (156,LG) (154,V) (P6,GR-B) (155,W-Y) (154,R) (N2,W-L) (153,R-Y) (152,Y) (152,W) (P5,SL) (151,L-G) (150,G) (N2,B-Y) S CO (B) L F-R (N1,W-B) S DC/SD To PB MD PB MMPD To PB MD PB MMP To +side G P12 N1 CH (150,B) S (P23, R-W) VW L F-L MS (N2,SL) (173,L-G) (172,G) (172,B) (P16,W-L) (171,R-Y) TM PS To +side G TMD BU D To PB MD PB MMP To PB MD PB MMP To +side G TMD AU D BZ CHI R STT To +side G TMD CU D To PB MD PB MMP To PB MD PB MMP TMP BU D and PB (313,R-Y) (314,L) -LR (108,R-Y) (109,G-Y) (48,P) L F SLL TMP AU D -R H (170,Y) TMP -L L BU LCD To DISP (170,W) (N2,GR-B) (169,W-Y) (168,V) (168,R) (P13,B-Y) (120,Y-R) L BU SW F SCPU STS1 (110,GR) (103,R-W) Z Z 60H 50H (167,G-W) To PB F CH THCD THCP T To CSBATT SOL L TMDCD-SD TMDCD-G TMDCD2+ TMDCD1+ TMDCU-SD TMDCU-G TMDCU2+ TMDCU1+ TMDBD-SD TMDBD-G TMDBD2+ TMDBD1+ TMDBU-SD TMDBU-G TMDBU2+ TMDBU1+ TMDAD-SD SOL TMDAD-G TMPBU-G TMPBU2+ TF D CH THC+ THCD TMPBU1+ (166,L) SA (78,L-R) (77,R-Y) (79,Y-W) (6,R-L) (4,GR) (5,B-R) (3,W-G) (2,LG-R) MB (89,W-R) + (1,W-R) (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) (30,Y) TMPAD-G - (N2,B-W) SW H (65,Y-G) (45,W) DSF THCP SOLT- SOLT+ SOLL- SOLL+ MB- MB+ SSPTP+ TP- SSP+ N2 N2C CSPB CSP+ CSP- CSPA CKPV CKDV TMDD+ TMDU+ TMDCD- TMDBD- TMDCUTMDAD- TMDBU- TMDAU- TMPD+ TMPU+ TMPCD- TMPBD- TMPAD- TMPCU- TMPBU- TMPAD2+ (165,L-R) FR Y DSR (57,G-W) (51,R-L) LS- POTT+ SPL+ POTT (56,G) (58,G-B) (59,Y-G) SPL POTA+ SWAC POTA (52,GR) (53,R-B) (64,R-Y) (44,LG) VBMB (51,R-L) POT- (P2,Y) (44,LG) VBP2 VBMB (41,Y) (41,Y) B48V (1,2 ton) (43,B-Y) VBKY B80V (3 ton) VBBT (41,L-O) (16,W-L) (13,V-R) C20V C15V (14,B-Y) (15,LG-B) D15V GNDC (100,Y) (14,B-W) GNDD CHGFAN (98,Y) (97,Y) (94,Y) (40,Y) (39,Y) (99,Y) CKFANP- CKFANP+ CKFAND- CKFAND+ PDC FAN+ DDC (37,Y) (38,Y) (36,Y) FANCD TMPAD1+ (29,Y) (27,Y) TMPAU-SD (164,GR) -R TMDAU-SD PLW TMDAD2+ L H-R TMDAD1+ L T-R TMDAU-G L C-R (164,P) (28,Y) TMPAU-G (P12,Y-B) L L-R CPU TMPAU2+ (163,W-B) L ST TMPAU- (162,BR) DS FO TMDAU2+ DS BU -L TMDAU1+ L W L H-L TMPCD-SD L T-L BATT 48V TMPCD2+ W1 (6) TMPCD1+ V1 (4) TMPCD-G U1 (2) N2 TMPAU1+ TMPCU-SD L C-L L L-L (L) L ST PB DC/MD MH2 N2 (N2,B) (162,O) TMPCU2+ 95 (N2,B) PB TMPCU-G THR FANP- TMPCU1+ 96 (111,R-L) W (107,R-B) V (102,R-G) U MS CH (104,G-R) T + S FANP+ (10,GR) - (A2) R P TMPBD-SD FAN (A1) FAND- (9,O) TMPBD2+ HM TMPBD-G HS (8,W) D TMPBD1+ T VBMB FAND+ (7,P) FAN FANCP LS ST TMPBU-SD SW L CH SW SUS SPL MH2-1 MH1 LSAT2 LSOPT1 LSOPT2 OPTO AOPT (101,R) + - (43,B-Y) MH2-2 F4 SW K GNDD (41,Y) (105, L-R) (87,P) F5 SW MH1 TILT VRAT (14,BR) (P1,B) + - SW AC F3 TD- P21 (P24,Y) (N1,B) P4 SH+ CSBATT P1 F1 SYR- P3 44 (323,GR) P2 MB F6 TD+ To PB CPU Edited by Published by 1st Printing: Apr 2000 Pub No CE316-1 Printed in Japan C