Nissan 1B2

CONTROL SYSTEM
SECTION CS
CONTENTS
TECHNICAL DESCRIPTION .............................. CS-2 Knob Position Control System (Option) ........ CS-72
METER PANEL ................................................. CS-12 Tilt Leveling Device (Option) ........................ CS-73
Meters, Indicators and Lamps ...................... CS-12 TROUBLE DIAGNOSTIC PROCEDURES ....... CS-77
Setting Adjustment Items (Normal Mode) .... CS-12 Precautions .................................................. CS-77
Meter Panel Explanation .............................. CS-14 How To Follow Flow Chart ........................... CS-78
LCD MONITOR ................................................. CS-25 Symbol Identification .................................... CS-79
Adjustment Mode ......................................... CS-25 Voltage and Resistance Measurement
Manager Mode ............................................. CS-33 Procedures ................................................... CS-80
Diagnostic Mode ........................................... CS-37 TROUBLE DIAGNOSIS FOR CONTROLLER
TABLE OF ERROR CODE ............................... CS-48 SYSTEM ............................................................ CS-81
PRECAUTIONS ................................................ CS-49 REFERENCE DATA OF CONTROL SYSTEM . CS-82
LOCATION OF UNITS (LAYOUT) .................... CS-50 List of Error Code ......................................... CS-82
Standard Equipment ..................................... CS-50 Display of Controller Internal Error Code ..... CS-84
Tilt Leveling Device (Option) ........................ CS-51 Method for Inspection According to
CONTROLLER .................................................. CS-52 Error Code .................................................... CS-85
Removal and Installation .............................. CS-52 Controller Terminal Voltage .......................... CS-93
Controller Element Inspection ...................... CS-55 Controller Trouble Symptom by Meter
UNIT INSPECTION AND ADJUSTMENT ......... CS-61 Display ....................................................... CS-101
Control System ............................................. CS-61
TECHNICAL DESCRIPTION
System (Contd)
New model (1B1/1B2)
CS-2
System (Contd)
CORRELATION DIAGRAM OF SYSTEM
Drive system
CSM0226
CS-3
System (Contd)
AC motor control
CSM0227
DRIVE SYSTEM FUNCTION
Item Function Outline

Drive control Drive control type Induction motor AC inverter vector control
Drive control Speed control (With turning speed/acceleration control)
Regeneration control Switchback, brake, accelerator off regeneration
Performance adjustment Power level (3 steps+ accurate adjustment 5 steps)/Acceleration Level (8 steps),
Regeneration level (8 steps each)
Anti-roll (8 steps)
Anti-roll control Anti-roll braking force control on slope
Various limitation Speed, high lift height, power cut (brake, parking brake)
Pump control Drive control Induction motor AC inverter vector control
Drive control Speed control by loading operation
Regeneration control Loading regeneration when loading operation stopped
Performance adjust. Power level (3 steps + accurate adjust 5 steps) Acceleration Level (8 steps)
Various limitation High lift height, high driving speed, cutout when reverse drive, pump cut
Mast lowering control Mast lowering lock when key switch is off
PS control Drive control type Electronic controlled hydraulic power steering
Drive control method Common pump motor control for loading
Control function Starting with steering operation detected/steering speed sensing control
Knob position control (OPTION) Compensate steering angle and tire angle offset by magnetic valve control
CS-4
System (Contd)
Item Function Outline
System control Inhibitor control Accelerator, FR SW, Loading, Seat

Meter communication Trace truck mode changeover by meter indication
Meter display of various truck conditions, diagnoses and adjustments
Log in function Setting of each truck by pass word input
Diagnosis function Diagnosis function in normal mode/self checking/dialog checking
Adjustment function Drive, pump, power steering system adjustment and memory
Accessory control Automatic power off/Parking brake warning
Cooling fan drive/External accessory source relay/Flasher
Truck model variation Automatic model variation change by harness
FEATURE OF DRIVE SYSTEM


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 

 
 
 
CS-5
System (Contd)
COMPARISON OF FORKLIFT MOTOR CONTROL
CSM0089
CS-6
System (Contd)
CSM0090
CSM0091
CS-7
System (Contd)
PRINCIPLE OF AC MOTOR
CSM0092
CS-8
System (Contd)
KNOB POSITION CONTROL SYSTEM (OPTION)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)
Input Output
Steering wheel angle sensor

angle 1 signal
Steering wheel Power steering correction
angle 2 signal
solenoid
neutral signal
Tire angle sensor
CS-9
System (Contd)
Knob position control system
CSM0203
CS-10
System (Contd)
TILT LEVELING DEVICE (OPTION)
When forward tilt is commanded while the tilt leveling switch is ON, the tilt operation automatically stops as soon as
the fork is held at a level position.
Tilt leveling switch
Vehicle condition Tilt operation
ON OFF
Stops at a level position
Unladen
Normal operation (No tilt leveling)
Stops when switch is pressed.
Loaded
Normal operation (No tilt leveling)
No tilt leveling is performed in backward tilting.

When the fork is loaded level, the tilt operation is stopped as soon as the tilt leveling switch is pressed.
Once the tilt leveling is activated, the operator cannot perform further tilt operations unless the tilt leveling switch
and tilt operation lever are restored.
NOTE:
The neutral level for the tilt angle sensor must be adjusted individually for each vehicle. (To absorb any variants in
sensor mounting and mast differences.) With a completed vehicle, hold the mast upright (with the fork held at a level
position) and register the tilt angle sensor value at that time in controller.
CS-11
METER PANEL
MET ER PANEL
Meters, Indicators and Lamps
Setting Adjustment Items (Normal Mode)

Shift to adjust
Adjustment item Adjustment Details Function lock
mode
Push FN1 The items displayed become darkened, and the display becomes darker.
LCD contrast Lock OFF
Push FN2 The items displayed become faded, and the display becomes brighter.
Traction and loading power mode Push FN3 Lock ON
Hour meter select/Instantaneous

Push FN4 Lock ON
energy consumption indicator
Push FN3 Hour Minute Day

Push FN1 +
Clock setting Push FN1 The digit is increased, or the day is advanced. Lock OFF
FN2
Push FN2 The digit is decreased, or the day is set back.
Push FN5 Setting complete.
Push FN2 +
Alarm setting Push FN1 The digit is increased, or the day is advanced. Lock OFF
FN4
Push FN2 The digit is decreased, or the day is set back.
Push FN3 D-ACC P-LEVEL
Push FN4 D-ACC P-LEVEL
Push FN1 +
Acceleration level Push FN1 Increase Lock ON
FN4
Push FN2 Decrease
Default setting (tilt horizontal level Push FN1 +
Push FN5 Setting complete. Lock ON
and simple load indicator) FN5
CS-12
METER PANEL
Setting Adjustment Items (Normal Mode)

(Cont'd)
Shift to adjust
Adjustment item Adjustment Details Function lock
mode
Push FN1 The digit is increased.
Alarm weight setting (simple Push FN4 +
Push FN2 The digit is decreased. Lock ON
load indicator option only) FN5
Push and hold
Help menu The operating method of the function switch is displayed.
FN5
Push FN2 +
FN5
+
Push FN5
+
Push FN2 The function LCD contrast, clock setting and alarm setting
Function lock/unlock
+ cannot be locked in the lock ON position.
Push FN3
+
Push FN5
+
Push FN5
CS-13
METER PANEL
Meter Panel Explanation

DESCRIPTION
The meter panel consists of two sections: LCD (Liquid Crystal
Display) monitor and function keys.
1. Function keys
Function keys control the LCD contrast, display changes and
other adjustments. Function key operation is described in the
individual part descriptions and in the items related to
adjustment.
NOTE:
In case an incorrect operation is performed, the malfunction code
shall be displayed occasionally. If the malfunction code is displayed,
turned the key switch to the OFF position and then turn it to the ON
position again.
2. LCD
When the key switch is in the ON position, backlighting makes
the displays clearly visible to the forklift operator. It displays
normal operation (battery capacity meter, hour meter, clock,
steering wheel angle gauge, speedometer, etc.), malfunction
and adjustment data.
DRIVER RECOGNITION MODE
CSM0258
Registering a password can restrict the drivers of the forklift.

You can register a password for up to 5 persons.
CS-14
METER PANEL
Meter Panel Explanation (Contd)

LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
Push function key FN1, the letters are dark and the display is
dimmed. Push function key FN2, the letter are light and the display
is brightened.
HOUR METER (4 MODE)/INSTANTANEOUS ENERGY

CONSUMPTION INDICATOR
This hour meter has 4 modes (functions).
1. Key ON time : Equal to the total operating hours when the
key switch is in the ON position.
2. Operating time : Equal to the traveling or loading time (the
time for whichever operation in progress is displayed).
3. Traveling time : Equal to the total time that the traction motor
is operational.
4. Loading time : Equal to the total time that the forks are
operational (tilting and lifting).
5. Instantaneous energy consumption indicator : Electric
power consumed by each operation is displayed (When -
(minus) kW is displayed, the regeneration mark is displayed,
too).
The hour meter operates when the key switch is in the ON position,
and it indicates the total operating period in hours (key ON time).
SPEEDOMETER
The speedometer shows forklift speed in either kilometers per hour
(km/h) or miles per hour (mph). The maximum vehicle speed and
speed alarm can both be set.
NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)
For speed alarm setting, refer to Adjustment Mode.
CSM0099
CS-15
METER PANEL

SIMPLE LOAD INDICATOR (OPTION)
Cargo weight is displayed.
Display condition:
The vehicle speed is 3 km/h (2 MPH) or less.
For 5 seconds after cargo lifting has been stopped.
Display range: 100 kg (220 lb) to maximum load
Minimum display unit: 20 kg (44 lb)
CAUTION:
In vehicles equipped with a 2F or 3F mast, the cargo weight is
displayed by converting the pressure from the full-free cylinder.
Therefore, if a load is applied which exceeds the full-free range,
it may not be possible to display the cargo weight.
DEFAULT SETTING
Perform the initial value setting after operating the vehicle into the
following position.
Mast: vertical
Lift: 30 cm (11.8 in) up (no load or tare weight (palette, etc)
condition)
NOTE:
If the vehicle is equipped with the tilt horizontal function (option),
simple load indicator (option), the mast angle and the load indicator
are set to the zero position after performing the initial value setting.
1. When FN1 and FN5 are pressed at the same time, the clock
display switches to the initial value setting screen.
2. When FN5 is pressed, the initial values are set and the screen
returns to the clock display.
OVER SETTING WEIGHT

When this function is used, if the cargo weight on the lift exceeds the
value that has been set as the alarm weight, a buzzer and an
indicator will alert the operator.
CS-16
METER PANEL

ALARM WEIGHT SETTING
1. When FN4 and FN5 are pressed at the same time, the clock
display switches to the alarm weight setting screen.
2. Push FN1 to increase the weight (in increments of 20 kg (44
lb)).
3. Push FN2 to decrease the weight (in increments of 20 kg (44
lb)).
Push and hold for 5 seconds to increase/decrease in
increments of 200 kg (440 lb).
4. When FN5 is pressed, the alarm weight is set and the screen
returns to the clock display.
REGENERATION MARK
When the instantaneous energy consumption indicator is displayed
and then when - (minus) kW is displayed, the regeneration mark is
displayed, too.
CS-17
METER PANEL

POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function key FN3 is pressed, the power
mode is switched.
Mode M: Manual mode:

The power levels for traveling and loading can be individually set
according to customer requests.
Factory defaults:
Traveling power level: Level 1
CSM0100 Loading power level: Level 1
Adjustable range for traveling and loading power levels: Levels 1 - 5
For traveling and loading power level, refer to Adjustment Mode.
Mode E: Economy mode:

For work requiring operation time to be saved or customers using
the machine for a long time (Traveling and loading power levels:
Level 1)
Mode P: Power mode:

Factory setting (Traveling and loading power levels: Level 3)
Mode H: High-power mode:

For work or customers requiring higher power (Traveling and loading
power levels: Level 5)
CLOCK/ALARM/ACCELERATION ADJUSTMENT
Clock/alarm
When the key switch is in the ON position, both the day and time are
displayed.
Push function keys FN1 and FN2 simultaneously. The time set mode
will appear.
AM and PM hour adjustment: The hour display will advance by 1

hour each time function key FN1 or FN2 is pushed.
CSM0101
Minute adjustment: The minute display will advance by 1 minute

each time function key FN1 or FN2 is pushed.
Day-of-the-week adjustment: The day-of-the-week display will

advance by one day each time function key FN1 or FN2 is pushed.
After setting the clock to the correct time, push function key FN5.
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
Push function key FN1 to increase the numerical value or
advance one day of the week.
Push function key FN2 to decrease the numerical value or
reverse one day of the week.
Push function keys FN2 and FN4 simultaneously. The alarm time
set mode will appear. This setting is the same procedure for the
time setting.
CS-18
METER PANEL

If an alarm is set, appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press function key FN5 to stop the buzzer. The day of
the week can be set to every day (ALL: every day).
Acceleration adjustment
This control adjusts acceleration during forklift starting and
subsequent operation.
Simultaneously press function keys FN1 and FN4. The clock will
move to the traction acceleration control mode.
The acceleration level can be adjusted in a series of 8 steps.
For faster acceleration (Quick): Push function key FN1.

CSM0102
Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.
For slower acceleration (Slow): Push function key FN2.
decrease by 1 step.
For slower acceleration (Slow): Push function key FN2.
decrease by 1 step.
After setting the acceleration level, push function key FN5. The
acceleration level will appear, and clock will return to its original letter
mode.
NOTE:
Acceleration factory setting at time of shipping:
D-ACC NOM SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After acceleration level adjustment, operate the forklift slowly
and carefully until you become accustomed to the new
acceleration level. Be especially careful when the acceleration
level has been increased. Higher acceleration levels can cause
loads to shift, to fall off or to be unstable during starts.
CS-19
METER PANEL

Pump acceleration adjustment
Simultaneously push function keys FN1 and FN4. Next, push
function key FN3. The clock will move to the pump acceleration
control mode.
The acceleration level can be adjusted in a series of 8 steps.
For faster acceleration (Quick): Push function key FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
CSM0103
For slower acceleration (Slow): Push function key FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.
After setting the acceleration level, push function key FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.
PARKING BRAKE WARNING MARK

This mark is displayed whenever the parking brake pedal is in the
locked position. The mark disappears whenever the parking brake
pedal is released.
SEAT BELT WARNING MARK

This lamp indicates that the seat belt is not fastened securely. It will
lights up if the seat belt is not fastened when the ignition switch is
turned to the ON position, and it will turn off when the seat belt is
fastened.
CS-20
METER PANEL

MALFUNCTION AND WARNING INDICATIONS
CSM0298
If any malfunction occurs when the key switch is in the ON position,

the LCD will show a wrench mark or a battery mark .
Simultaneously, the LCD will display letters explain the details of the
malfunction.
NOTE:
During forklift operation, periodically check the battery capacity.
Make every effort to recharge the battery before the battery warning
mark and wrench mark appear.
Wrench mark
The controller and the sensors act together to regulate the forklifts
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.
Control system malfunction (Traction, Cargo-handling, Power

steering)
Overheating controller or motor
Low brake fluid level
Low battery fluid level
CS-21
METER PANEL

BATTERY WARNING MARK
Pump cut warning
Pump cut warning is displayed when the battery capacity meters
remaining capacity indication changes from 2/6 to 1/6.
When function key FN5 is pressed, the display will switch.
CSM0105
After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
CSM0106
When function key FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
CSM0105
The vehicle may be operated during the pump cut warning.

However, move the vehicle to a safe location, and promptly charge
the battery.
CSM0106
CS-22
METER PANEL

Low voltage lock warning
If the vehicle is subjected to continuous operation after the pump cut
warning was activated, the low voltage lock warning will be
activated. Then, the display will appear as shown below, and the
warning buzzer will be activated.
When function key FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
CSM0105
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
For pump cut time setting, refer to Adjustment Mode.
CSM0106
CS-23
METER PANEL

MALFUNCTION INDICATIONS
Affected system or area Indication Malfunction description
Control system (Traction, D-FET SHORT A malfunction has occurred in NOTE:

Cargo-handling, Power the forklift traction system. A display example is shown on the
steering): Units, Further operation of the forklift is left.
Sensors, Motors, not possible.
Switches, FETs
P-FET OPEN A malfunction has occurred in
the forklift cargo-handling
system. Further lifting (lifting and
tilting) operation is not possible.
The forks cannot be raised or
tilted.
TIRE ANGLE SENSOR LOW A malfunction has occurred in

the forklift power steering
system. Forklift steering control
is possible.
D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor WARNING:
is overheating. Immediately stop Ignoring the warning
forklift operation. Park the forklift indication and continuing to
in a safe area where there is no operate the forklift can result
pedestrian or vehicular traffic. in serious motor damage.
Allow the controller and/or the Always stop operation
motor to cool. immediately after the warning
Either the controller or the motor indication appears. Have the
P/MO TEMP SENSOR HIGH TEMP
is overheating. Immediately stop forklift inspected.
forklift operation. Park the forklift Check the specifications of
in a safe area where there is no the forklift you are using
pedestrian or vehicular traffic. before operation as this
Allow the controller and/or the function is not available on
motor to cool. some forklifts.
Essential fluids BRAKE FLUID LEVEL DOWN The brake fluid level has fallen WARNING:
below the specified level. Do not allow open flames in the
BAT FLUID LEVEL DOWN The battery fluid level has fallen battery inspection or fluid
below the specified level. As replenishment area.
NOTE: soon as possible, replenish the
In the case of a local battery, this function is battery fluid with distilled water CAUTION:
not operated without a battery fluid sensor. up to the specified level. Exercise extreme care when
replenishing the battery fluid. Fill
the battery with distilled water to
the specified level only. Do not
overfill. Resulting spillage may
cause a battery short circuit.
CS-24
LCD MONITOR
LCD MONITOR
Adjustment Mode
CS-25
LCD MONITOR
Adjustment Mode (Contd)

NOTE:
This mode is only available for qualified technicians to perform
various adjustments on setting values other than traction/loading
acceleration adjustments in the normal mode.
CAUTION:
Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.
CS-26
LCD MONITOR
CS-27
LCD MONITOR
CS-28
LCD MONITOR
CS-29
LCD MONITOR
CSM0229
CS-30
LCD MONITOR
CS-31
LCD MONITOR
CS-32
LCD MONITOR
Manager Mode
CS-33
LCD MONITOR
Manager Mode (Contd)

CAUTION:
Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.
CS-34
LCD MONITOR
CS-35
LCD MONITOR
CS-36
LCD MONITOR
Diagnostic Mode
CS-37
LCD MONITOR
Diagnostic Mode (Contd)

There are two types of diagnostic method. One type is self-diagnosis
and the other is interactive diagnosis. Self-diagnosis allows for
controller diagnosis of a system, while the interactive diagnosis is
used for diagnosing switches and sensors. When malfunctions
occur in systems or components, check and eliminate probable
causes of the malfunction using either self-diagnostic or interactive
diagnostic techniques. After the malfunctioning area has been
repaired, confirm the malfunction has been eliminated by using the
appropriate diagnostic method.
NOTE:
When checking each component, operate each component if
necessary.
CS-38
LCD MONITOR
CS-39
LCD MONITOR
CSM0232
CS-40
LCD MONITOR
CSM0263
CS-41
LCD MONITOR
CSM0233
CS-42
LCD MONITOR
CSM0264
CS-43
LCD MONITOR
CS-44
LCD MONITOR
CSM0265
CS-45
LCD MONITOR
OSM0199
CS-46
LCD MONITOR

CAUTION:
If an interactive diagnostic result indicates that a unit is
abnormal, also check the condition of the associated harness
and connector.
NOTE:
The number of malfunctions which have occurred in each system
is recorded in the FAIL LOG row on the display, without regard
to the nature of the malfunctions experienced.
For unit inspection procedures, refer to UNIT INSPECTION AND
ADJUSTMENT on page CS-61.
RESULT OF SELF-CHECK
If the error is not detected:
CSM0235
If the error is detected:

NOTE:
The 3-digit number in the figure indicates the error code of the
component for which the error is detected. For the error code, refer
to Table of Error Code on page CS-48.
CAUTION:
If a self-diagnostic result indicates that an element or
component is abnormal, also check the condition of the
associated harness and bus bar.
CSM0236
NOTE:
For element inspection procedures, refer to Controller Element
Inspection on page CS-55.
CS-47
TABLE OF ERROR CODE
TABLE OF ERROR CODE
Table of Error Code
Error Detect mode Reference Error Detect mode Reference

Failure part Fail mode Remarks Failure part Fail mode Remarks
code Work Self page code Work Self page
CONTROLLER ACTUATOR
Main contactor Short 400 Lift down valve Short 500
CS-57 - CS-70 -
Open 401 Open 501
Main fuse Open 401 CS-58 - PS correction valve Short 502 Knob
Battery voltage Low voltage 404 - Open 503 position
CS-72
control
Over 405 - - -
(Option)
voltage
Tilt Horizontal valve Short 504 Tilt
CONT capacitor Abnormal 406 - - - horizon
Open 505 CS-74
Drive FET Short 408 device
Open 409 (Option)
CS-55 - SENSOR
Pump FET Short 412
F/R Switch Same ON 450 - CS-62 -
Open 413
Accel sensor Low output 452
Drive current U Low output 414 CS-64 -
sensor High output 453
High output 415
- - Tire angle sensor Low output 454 Knob
V Low output 416
High output 455 position
High output 417 CS-70
control
D/Mo TEMP Abnormal 422 (Option)
sensor CS-59 - Tilt angle sensor Low output 456 Tilt
Overheat 423 -
High output 457 horizon
D/CONT TEMP Abnormal 426 CS-75
- - device
sensor Overheat 427 - (Option)
Pump current U Low output 430 LIFT ACCEL Low output 466 Special
sensor High output 431 - arrange-
- - ment
V Low output 432
Tilt H switch Short 468 Tilt
High output 433 horizon
Open 469 CS-73
P/Mo TEMP Abnormal 434 device
sensor CS-59 - (Option)
Overheat 435 -
Steer Angle sensor Abnormal 470 - CS-63 -
P/CONT TEMP Abnormal 436
sensor - - Weight sensor Low output 472 Tilt
Overheat 437 -
(Oil pressure sensor) High output 473 horizon
D/Mo REV Abnormal 438 - CS-73
device
sensor (Option)
CS-60 -
P/Mo REV Abnormal 442 - Battery current Low output 476
sensor sensor CS-56 -
High output 477
CONT Abnormal 444 - - -
DC receive Abnormal 610 -
communication - -
CONT type Abnormal 446 - - 620 -
select PC receive Abnormal 602 -
- -
Meter 622 -
Meter Abnormal 558 - - -
communication
CS-48
PRECAUTIONS
PRECAUTIONS
WARNING:
Before starting to remove the controller parts, be sure to
perform either a. and b. bellow.
a. Disconnect battery connector, and connect a 50 to 100
resistor (do not use a metal-film resistor) between the VB
(positive) terminal and (negative) terminal at controller
ASSY to discharge condenser.
b. Wait at least 10 minutes after battery connector has been
disconnected.
CAUTION:
Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body
and do not pull on the cord.
When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.
Inadvertent current flow may damage the element or other
parts being checked.
Before using flow charts as a guide to troubleshoot units and
parts, become familiar with the instructions outlined under
TROUBLE DIAGNOSTIC PROCEDURES.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
CS-49
LOCATION OF UNITS (LAYOUT)
LOCATION OF UNITS (LAYOUT )
Standard Equipment
CSM0204
CS-50
LOCATION OF UNITS (LAYOUT)
Tilt Leveling Device (Option)
CS-51
CONTROLLER
CONTR OLLER
Removal and Installation
1. Traction motor cable (U) 7. Pump motor cable (V) 13. Contactor
2. Traction motor cable (V) 8. Pump motor cable (W) 14. Battery current sensor
3. Controller cable (+) 9. Body harness 15. Fuse (F1)
4. Battery plug cable (-) 10. Fusible link (cable) 16. Boost charge resistance (RCH)
5. Traction motor cable (W) 11. Battery cable (-) 17. Chopper ASSY for traction motor
6. Pump motor cable (U) 12. Contactor unit 18. Chopper ASSY for pump motor
Sec. A, Sec. B: Detail of minus terminal part.
C: Connector for 2 ton. 2 ton vehicle is connect connector.
D: Connector for GOM. Connect connector.
CS-52
CONTROLLER
Removal and Installation (Contd)

NOTE:
When installation on aluminum base of inverter unit is apply thermal
conductivity silicon compound (Shin-Etsu Chemical Co., Ltd.: G-746,
or equivalent) to the reverse surface of the inverter unit. Applying
this compound will ensure that heat is conducted efficiently to the
aluminum base. Always apply the compound when removing or
replacing the inverter unit (controller). Before application, check that
there are no scratches, metal dust or burrs on the surface that the
compound will be applied to.
CS-53
CONTROLLER
Construction (Contd)
No. QTY. Part name No. QTY. Part name
1 1 Bus bar (-) 7 1 Harness 1

2 1 Bus bar (+ : VB) 8 4 Resistor
3 1 Chopper ASSY (for traction motor) 9 1 Heatsink holder
4 1 Chopper ASSY (for pump motor) 10 6 Cooling fan
5 1 Heatsink 11 1 Cooling fan box
6 1 Harness 2
CS-54
CONTROLLER
Controller Element Inspection

CAUTION:
For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( ).
For checking the current sensor, only measure voltage.
When checking controller elements, also check the
associated harnesses and bus bars.
The following tables list resistance values measured across
respective terminals and should be used as reference
information. Keep in mind the resistance values vary with the
type of circuit tester (such as analog or digital) used for
measurements.
NOTE:
Measure resistance between terminals listed in the following tables
to check each element.
TRACTION CHOPPER ASSY, LOADING CHOPPER

ASSY
Specifications
Item Specification
Type N38F30164 / DRIVE, N38F30165 / PUMP
Service data
Measurement
terminals Normal value ( )
Judge of abnormal
(Reference value)
Tester Tester
(+) (-)
VB U Several k 0 (short) or (open) is faulty.
Different by charge condition of main
U VB Several k -
circuit condenser. 0 (short) is faulty.
VB V Several k 0 (short) or (open) is faulty.
V VB Several k -
VB W Several k 0 (short) or (open) is faulty.
W VB Several k -
U N Several k 0 (short) or (open) is faulty.
N U Several k -
V N Several k 0 (short) or (open) is faulty.
N V Several k -
W N Several k 0 (short) or (open) is faulty.
N W Several k -
NOTE:
Measurement with analog tester and circuit tester range selector
must be set to X1000 .
CS-55
CONTROLLER
Controller Element Inspection (Contd)

BATTERY CURRENT SENSOR
Specifications
Item Specification
Type L05Z800S05
Actual current ±800 A
Signal voltage 1.0 - 4.0 V
Service data
Item Normal NG
Output V Approx. 2.5V between 3-4 Failed sensor

Source V Approx. 5.0V between 1-2 Failed CPU board
FAN ASSEMBLY
Specifications
Item Specification
Type 2410ML-05W-B70-BQ7
6 pieces/controller
Numbers of fan
One piece/external fan
Rated voltage 24 V
CSM0124 Service data
Item Normal NG
Operation check with

Operation Failed cooling fan
Constant voltage
CS-56
CONTROLLER

CONTACTOR ASSEMBLY
Specifications
Item Specification
Rated current 300 A / 50 % conduction ratio

Cutout current 2000 A
Mechanical life 2.5 million cycle
(1) Coil
(2) Coil connector
Service data
Item Normal NG
Coil resistance 20 / At 20°C (68°F)

Abnormal contact
Contact wear limit Movable/fixed 0.5 mm (0.02 in) Max
1. Contactor 6. Cover 9. Base holder

2. Fuse (F1) 7. Contactor plate (second side 10. Coil
3. Battery current sensor contact) 11. Coil housing
4. Boost charage resistance (RCH) 8. Contact ASSY (second side
5. Bus bar contact)
CS-57
CONTROLLER

Fuse
Specifications
Model Capacity
1B1, 1B2 500A
(1) Fuse
Inspection
Using a circuit tester, check continuity of each fuse.
Normal indication Abnormal (open-circuit) indication

Continuity
NOTE:
The circuit tester range selector must be set to x1 .
Boost charge resistance (RCH)

Inspection
Measurement resistance of between terminals.
Normal indication Abnormal (open-circuit) indication

39
(1) Boost charge resistance

(2) Connector with red mark
NOTE:
The circuit tester range selector must be set to x100 .
CS-58
CONTROLLER

MOTOR (TRACTION, LOADING)
CSM0238
Temperature sensor
Specifications
Item Specification
R 100°C (212°F) = Approx. 0.97 - 1.06 k

Resistance
R 25°C (77°F) = Approx. 9.8 - 11.8 k
(1) Temperature sensor connector
Service data
Item Normal NG
Sensor resistance
Resistance Failed temp. Sensor
25°C (77°F) = Approx. 9.8 - 11.8 k
Revolution sensor
Specifications
Item Specification
Temperature range -20 to +120°C (-68 to +248°F)

Anti vibration 30 G
Type Magnetic induce
(1) Temperature sensor connector
CS-59
CONTROLLER

Service data
Item Normal NG
Self check by revolution

Revolution sensor Failed revolution sensor
sensor IC detection
(1) Revolution sensor
NOTE:
When replace the bearing with revolution sensor (1), also remove
the end cap (2).
CS-60
UNIT INSPECTION AND ADJUSTMENT
Control System
CAUTION:
Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
When checking a unit, also check the condition of the
associated harness and connector.
All units can be checked using interactive diagnostic
procedures. (Refer to LCD MONITOR on page CS-25.)
NOTE:
The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
This section deals with only resistance measurement procedures
for unit inspection.
FORWARD REVERSE SWITCH
CS-61
Control System (Contd)

Inspection
Check continuity at each lever position between the following
terminals.
Lever position Terminal with continuity
Forward -
Neutral -
Reverse -
CSM0132
CS-62

STEERING WHEEL ANGLE SENSOR
Specifications
Rated voltage (V) 12

Rated load current (mA) 10 - 50
Low Less than 0.5
Output voltage (V)
High 2.5 - 3.5
Pulse (1, 2) (pulse/rotation) 45
Neutral position signal (pulse/rotation) 1
Service data
Measuring points (terminals) Standard value (V)

- 12
CSM0133
CS-63

ACCELERATOR SENSOR
CSM0208
Specification
Vcp1 - Ep1 2.5 - 5.0 (Reference value)
Total resistance (k )
Vcp2 - Ep2 5.0 - 10.0 (Reference value)
Service data
Measuring points Standard value

Remarks
(terminals) (V)
Vcp1 - Ep1 (GND) 5.02 - 5.22 Always

0.668 - 0.868 When the accelerator pedal is released.
CSM0138
Aps1 - Ep1 (GND) When the accelerator pedal is fully
4.454 - 4.654
depressed.
CAUTION:
When measurement, be sure to using digital tester. Because,
the resistance of acceleration sensor may be destroyed
depending on the model of analog tester.
CS-64

Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0139 : 1.5 - 1.8 Nm (0.15 - 0.19 kg-m, 13 - 16 in-lb)
CS-65
CSM0209
Linkage stroke adjustment

Fully-closed position adjustment
1. Depress the accelerator pedal until the accelerator linkage is
fully opened.
2. Rotate the stopper bolt counterclockwise by 180 degrees, and
then tighten the nut.
CAUTION:
The accelerator linkage operation should move smoothly
with no binding. When releasing the pedal, immediately
return it to the fully-closed position.
The return spring should be securely installed as shown in
the figure.
Move the accelerator pedal, and then check that the
accelerator pedal roller moves smoothly in the groove.
CS-66

BRAKE SWITCH
Inspection
Check continuity between brake switch terminals when the brake
pedal is depressed 8 to 12 mm (0.31 to 0.47 in). Continuity must
exist.
<Reference data>
Brake switch ON/OFF Pedal height: 100 mm (3.94 in) (1.5 - 2.5 ton)
switching point 111 mm (4.37 in) (3.0, 3.5 ton)
(from floor upper surface)
CSM0141
Adjustment
CSM0210
1. Adjust the height of brake pedal point P to 107 mm (4.21 in) (1.5
- 2.5 ton), 117 mm (4.61 in) (3.0, 3.5 ton) from the floor upper
surface by the stopper bolt, and then tighten the lock nut.
: 12 - 15 Nm (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
2. When depressing the pedal within 8 - 12 mm (0.31 - 0.47 in)
(pedal height: 100 mm (3.94 in) (1.5 - 2.5 ton), 111 mm (4.37 in)
(3.0, 3.5 ton)), adjust the brake switch so that the brake switch
is ON, and then tighten the lock nut.
: 12 - 15 Nm (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
3. Make sure that the brake switch is OFF when the pedal is
released.
CS-67

CONTROL VALVE SWITCHES (LIFT, TILT, 3RD, 4TH,
5TH SWITCHES)
Inspection
When the control lever is operated, continuity must exist between
terminals affected.
NOTE:
Circuit continuity must be checked after removing the affected
switch connector.
Check for audible sounds which indicate control valve switches
are operating.
If switches do not operate, adjust the switch position, then
recheck the switches operation. Refer to Adjustment on page
CS-65.
CSM0142
CS-68

Adjustment
Using adjusting nuts and , adjust the dog-to-switch clearance
to specifications indicated in the figure below.
CAUTION:
The control valve must be set in Neutral and switches must be
freed during clearance adjustments.
Centering adjustment
Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.
CST0039
CS-69

LIFT SOLENOID (MECHANICAL CONTROL VALVE)
Specifications

Coil resistance ( ) 36 at 20°C (68°F)
(Reference value)
44 at 90°C (194°F)
Inspection
Measure resistance between lift solenoid terminals.
<Reference value>
CSM0211
36 20°C (68°F)
44 90°C (194°F)
TIRE ANGLE SENSOR

Specifications
Total resistance (k ) 1.6 - 2.4 (Reference value)
Service data
Measuring points
Standard value Remarks
(terminals)
- 0 2k The resistance value decreases as the

shaft is rotated.
- 2k The resistance value remains unchanged
regardless of the shaft rotation.
CSM0207
CS-70

Adjustment
CSM0239
Tire angle sensor fixes the kingpin plate to the kingpin as shown in
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the knob
position control system function correctly. Notes concerning
assembly are as follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.
CSM0240
CS-71
Knob Position Control System (Option)

PS KNOB POSITION SOLENOID VALVE
Specifications

Coil resistance ( ) 21.8±5%
(Reference value) at 20°C (68°F)
Inspection
Check resistance between terminals using circuit tester.
21.8±5% 20°C (68°F)
CSM0152
Neutral setting
1. Set rear tire to the straight-ahead position.
2. Call up ADJUSTMENT MODE 1-2. SENSOR 16
SENSOR INITIAL SET.
3. Push function key FN3 to set the vehicle to the straight-ahead
position.
CS-72
Tilt Leveling Device (Option)

INSPECTION
Tilt horizontal switch
Check continuity.
When press button: Continuity should not exist.
When do not press button: Continuity should exist.
CSM0245
Mast height sensor

Key switch is turned on with the harness connected, and move the
metal close to the lift up level detection switch. At this time, make
sure that switch operation indicator lamp turns on.
CSM0246
Oil pressure sensor

Key switch is turned on and check out put voltage while connecting
harness.
Output voltage (V): 0.25 - 4.75
Battery voltage (V): 5 ± 0.5 (Power supply - GND)
CSM0299
Tilt angle sensor

Key switch is turned on and check out put voltage while connecting
harness.
Output voltage (V): 0.5 - 4.5 (2 - 3)
Battery voltage (V): 5 ± 0.5 (1 - 3)
CSM0242
CS-73
Tilt Leveling Device (Option) (Contd)

Tilt horizontal solenoid valve
Check resistance.
Item Resistance
Normal ( ) 30 - 77
Malfunction ( ) 0 or
CSM0243
REMOVAL AND INSTALLATION

Mast height sensor
CSM0212
CS-74

Tilt angle sensor
CSM0213
SETTING
1. Park the vehicle on a flat, level road.
2. Set rear tire to the straight-ahead position. (Knob can take any
position.)
3. Set the mast to vertical.
4. Raise the fork approximately 300 mm (11.8 in) from the ground.
5. After calling up ADJUSTMENT MENU 1-2. SENSOR
16 SENSOR INITIAL SET, push function key FN3 and turn
OFF to ON.
NOTE:
Procedure is same as Knob Position Control and Neutral Setting
as above.
SETTING OF TILT HORIZONTAL (SIMPLE SETTING)

Push function keys FN1 + FN5 to turn the normal display to the tilt
horizontal setting display. Push function key FN5 to set the tilt
leveling condition.
CS-75

CONFIRMATION OF OPERATION
Check the movement of following table at tilt forward (with tilt switch:
ON) from tilt back. Check operation indicated in Table below.
Stop angle tilt back

No load 1° ± 1°
(Mast standard)
Loaded No movement
CSM0244
CS-76
TROUBLE DIAGNOSTIC PROCEDURES
TROUBLE D IAGNOSTIC PROCEDURES
Precautions
CAUTION:
Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
Basic trouble diagnostic procedures must be performed as
follows:




 

 
 

  

 
 




NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)
CST0062
CS-77
How To Follow Flow Chart

Trouble diagnostic procedures for controllers (including charging
system) are indicated in flow charts. Inspection and confirmation
procedures are shown in illustrations, making the respective flow
charts more comprehensive. Circuit diagrams are also included
where necessary, along with applicable flow charts.
NOTE:
The entire system wiring diagram and circuit diagram are included at
the end of this manual. Refer to these diagrams as necessary during
diagnostic procedures.
MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.
PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Probable trouble areas or parts are indicated in relation to
malfunctions that may occur.
WORK FLOW

Inspection and/or confirmation 

procedures must be explained
as required in the illustration.
 





  

  

   
CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.

 

About temporary tool:

A temporary tool refers to a circuit tester whose test probe ends are
temporarily wrapped with thin conductive wires. The tip ends of
respective wires are attached to connector terminals on the print
board side during required voltage measurements. Refer to
Precautions on page CS-77.
CS-78
Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
Connector guides for male terminals are shown in black.
Connector guides for female terminals are shown in white.
CST0063
Connector direction
Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.
CST0064
Controller or other single unit connectors

Controller connector symbols are indicated so that connectors are
being shown from the terminal side; enclosed by a single line with
connector guides shown in black.
CST0065
KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.
Check after connecting Turn key switch to the ON

harness connector. position.
Check after disconnecting Check after connecting

battery plug. battery plug.
CS-79
Voltage and Resistance Measurement

Procedures
VOLTAGE MEASUREMENT
Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
To facilitate voltage measurements for parts or terminals (adjacent
to controllers), it is best to use an alligator clip with the black
(ground) test probe of a circuit tester and fasten it to the battery
ground terminal during measurements.
CST0066
RESISTANCE MEASUREMENT
Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
CST0067
CS-80
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
TROUBL E D IAGNOSIS FOR CONTROLL ER SYSTEM
WARNING:
Before starting to remove the controller parts, be sure to
perform either a. and b. bellow.
a. Disconnect battery connector, and connect a 50 to 500
resistor (do not use a metal-film resistor) between the VB
(positive) terminal and (negative) terminal at controller
ASSY to discharge condenser.
b. Wait at least 10 minutes after battery connector has been
disconnected.
CSM0266
CAUTION:
To perform an accurate diagnosis, carefully listen to the
users complaints and check the actual vehicle to fully
understand under what conditions the symptoms occur.
For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( ).
For checking the current sensor, only measure voltage.
When checking controller elements, also check the
associated harnesses and bus bars.
If the cause of the malfunction may be in the mechanical
systems, always check the mechanical systems that are not
included in the flowchart.
CS-81
REFERENCE DATA OF CONTROL SYSTEM
List of Error Code

CONTROLLER SYSTEM
Related reference
Trouble
Item Error code Element parts According to code
symptom Diagnosis mode
inspection inspection
Short 400
Main contactor CS-57
Open 401
Main fuse Open 401 CS-58
Low voltage 404
CS-43 CS-85
Battery voltage Excess of
405
voltage
CONT condensor Abnormal 406
Short 408
Traction FET
Open 409 CS-86
CS-45 CS-55
Short 412
Loading FET CS-89
Open 413
Output small 414
U
Output large 415
Traction current sensor CS-43
Output small 416
V CS-86
Output large 417
Abnormal 422
D/Mo temperature sensor CS-41 CS-59
Over heating 423
Abnormal 426
D/CONT temperature sensor CS-87
Over heating 427
Output small 430
U
Output large 431
Loading current sensor CS-43 CS-89
Output small 432
V
Output large 433
Abnormal 434
P/Mo temperature sensor CS-41 CS-59
Over heating 435
CS-90
Abnormal 436
P/CONT temperature sensor
Over heating 437
D/Mo revolution sensor Abnormal 438 CS-87
CS-45 CS-60
P/Mo revolution sensor Abnormal 442 CS-90
CONT communication (Meter to controller) Abnormal 444
CS-82
List of Error Code (Contd)

ACTUATOR SYSTEM
Related reference
Trouble
Short 500
Lift down valve
Open 501
CS-91
Short 502
PS correct valve CS-43
Open 503
Short 504
Tilt horizontal valve
Open 505
SENSOR SYSTEM
Related reference
Trouble
Simultaneous
F/R switch 450
OK
Output small 452
Accelerator sensor CS-64 CS-87
Output large 453
Output small 454 CS-39
Tire angle sensor
Output large 455
Output small 456
Tilt angle sensor CS-75 CS-90
Output large 457
Lift acceleration Output small 466
Short 468
Tilt horizontal switch CS-41
Open 469
Steering sensor Abnormal 470 CS-39 CS-63 CS-91
Output small 472

Pressure switch (loading sensor)
Output large 473
Output small 476
Battery voltage sensor CS-87
Output large 477
CS-43
PC received Abnormal 602
CS-92
DC received Abnormal 610
CS-83
Display of Controller Internal Error Code

DESCRIPTION
Current errors are indicated by the traction status LED (1) and the
loading status LED (2) which are located on the chopper ASSY of
the controller (traction and loading). Error codes are displayed in 2
digits and details of these are outlined in Method for inspection
according to error code later in this manual. The 3rd digit (1) at the
start of some codes indicates an omission of the code.
HOW TO CHECK ERROR CODE

<Display when normal>
<Example of display of abnormality (error code 23: boost

charge fault)>
NOTE:
If multiple errors occur, the error code for the last error detected
by the controller will be displayed.
When an error has been repaired or reset, check that the
controller display is normal and matches the meter error display.
CS-84
Method for Inspection According to Error

Code
TRACTION SYSTEM
When an error cannot be reset using the method for repair and
inspection described, replace the traction chopper ASSY.
Error code
Error code
by Faulty symptom of Method for inspection and repair Reset
by meter Trouble symptom Remarks
controller vehicle (Proceed in order, (1) (2) ... ) method
display
display
(1) Place accelerator, forward SW and Accelerator : When seated with key
Return to
reverse SW in neutral OFF ON (seat SW: ON),
neutral Traction inhibitor detected
Traction not (2) Inspect neutral conditions of accelerator, Forward SW : detection is performed
(Inhibitor 1 (No error if this occurs due
possible forward SW and reverse SW using on- OFF with forward SW,
detection to improper operation)
board diagnosis Reverse SW : reverse SW or
displayed)
(3) Inspect forward SW and reverse SW OFF accelerator ON
No error (1) Sit on seat
Seat SW OFF detected
code (2) Inspect seat SW using on-board Seated
(No error if this occurs due Traction/loading/
displayed 2 diagnosis (Seat SW :
to the driver not being PS not possible
(Seat SW (3) Inspect harness between seat SW and ON)
seated)
OFF) controller
(1) Inspect contactor
(Adhesion of contact points, protrusion,
etc.)
(2) Check connection of battery cable
Traction/loading/ Key SW :
400 11 Contactor short (Secondary side of contactor (outlet Contactor adhesion
PS not possible OFF
side) and check for + electric potential
leak)
(3) Inspect harness between contactor coil
and traction chopper ASSY
(1) Inspect contactor
(Foreign matter between contact points,
Contactor open Traction/loading/ protrusion, coil, etc.) Key SW :
401 12
(fuse open) PS not possible (2) Inspection of fuses OFF
(3) Inspect harness between contactor coil
and traction chopper ASSY
(1) Inspect battery voltage Detect with battery
Traction/loading If voltage is low immediately after voltage at 28V or lower
not possible charging, inspect charging device (PS does not process
Detect low voltage (fall of Key SW :
404 9 (PS drive (2) Check voltage between terminal and drive stop until drive is
battery voltage) OFF
processing in terminal CN1-24 (119) of traction not longer possible
progression) chopper ASSY (D) due to decrease in
(Normal value: battery voltage) voltage)
Detect with battery
Detect abnormal battery Traction/loading/ Key SW :
8 Inspect battery voltage voltage at 63V or
voltage PS not possible OFF
higher
405 (1) Check connection condition of battery Automatically
Excess voltage fault Detect with battery
Traction/loading/ connector reset by
86 (Battery loose while voltage at 72V or
PS not possible (2) Check inspection method for connector inputting
regenerating) higher
open (error code 401) normal value
Error codes 408 and
Boost charge fault (1) Check inspection method for traction 412 also displayed
(Charging fault in FET short (error code 408) Key SW : (due to charging not
406 23
condenser between VB (2) Check inspection method for loading OFF being possible to
and N) FET short (error code 412) condenser between
VB and N)
Chopper ASSY (1) Inspect connection condition of battery
15
(Upper/lower FET short) cable Because the traction
(Check for potential leak in secondary and the loading
19 Chopper ASSY side of contactor) chopper ASSY are
119 (Upper FET short) (2) Remove motor cable from terminals U, V connected by a
and W and inspect for leaks between busbar, a loading FET
motor cable and terminals VB and N short (error code 412)
(3) Inspect for looseness of busbar between will also be displayed.
traction and loading chopper ASSY The opposite case is
408 (4) Check for foreign materials on and the same.
PS not possible OFF
around terminals VB and N and Because charging is
21 Chopper ASSY terminals U, V and W not possible to the
121 (Lower FET short) (5) Inspect connection condition of terminal condenser between
CN1-24 (119) of traction chopper ASSY VB and N, a boost
(D) charge fault (error
(6) Inspect boost charge resistance code 406) due to a
(7) Boost charge resistance of traction traction unit FET short
chopper ASSY will also be displayed
(Inspect harness between contactor unit)
CS-85

Code (Contd)
Error code
Error code
display
display
Traction chopper ASSY
16 (U phase upper FET
open)
115
(U phase lower FET open)
17
(V phase upper FET open)
Traction not Inspect for looseness of motor terminals and Key SW :
409 Traction chopper ASSY
117 possible disconnection of cables OFF
(V phase lower FET open)
18 (W phase upper FET
open)
118 (W phase lower FET
open)
V phase current detection
24
fault (input small)
124
416 fault (input large) Traction not Key SW :
Replace traction chopper ASSY
417 V phase current sensor possible OFF
25
offset fault (input small)
V phase current sensor
125
offset fault (input large)
W phase current detection
26
fault (input small)
126
414 fault (input large) Traction not Key SW :
Replace traction chopper ASSY
415 W phase current offset possible OFF
27
fault (input small)
W phase current offset
127
fault (input large)
Load short circuit (1) Check for foreign materials on and
22 (Motor interphase short around terminals U, V and W
circuit) (2) Check for short circuit between motor
cables (looseness of terminals, holes in
tubing of wire, foreign materials inside
motor)
Traction not (3) Inspect harness of terminal CN1-24 Key SW :
415, 417
possible (119) of traction chopper ASSY (D) OFF
91 Overcurrent detection (4) Check inspection method for contactor
open (error code 401)
(5) Check inspection method for W phase
current fault (error codes 414/415) and V
phase current fault (error codes 416/
417)
(1) Inspect for looseness of motor
temperature sensor connector
Voltage of temperature
(2) Inspect harness between traction Automatically
Traction motor sensor when fault is
Traction output chopper ASSY and motor temperature reset by
422 35 temperature sensor fault detected: 0.15V or
limited sensor inputting
(AD input range fault) lower, or 4.92V or
(3) Inspect voltage and resistance of motor normal value
higher
temperature sensor
(Replace motor if there is a fault)
CS-86

Code (Contd)
Error code
Error code
display
display
Traction possible
Detection at 163°C Reset at
Traction motor (325°F) or higher (1) Stop traction and cool down 160°C Normal voltage values
36 (2) Inspect harness between traction for temperature sensor
temperature increase (Current limitation (320°F) or
starts at 160°C chopper ASSY and motor temperature lower (within ±10%):
423 (320°F) or higher) sensor 25°C (77°F) : 3.6 V
(3) Inspect voltage and resistance of CN2 50°C (122°F) : 2.65 V
Traction not connector 152 and terminal 915 of 100°C (212°F) : 0.98 V
Reset at
Traction motor possible controller (D) 150°C (302°F) : 0.36 V
37 under 175°C
temperature fault Detection at 175°C
(347°F)
(347°F) or higher
Temperature sensor 1
(TDM 1) fault in traction
31 Voltage of temperature
chopper ASSY Automatically
(input range fault) sensor when fault is
Traction output reset by
426 Replace traction chopper ASSY detected: 0.2V or
Temperature sensor 2 limited inputting
lower, or 4.92V or
(TDM 2) fault in traction normal value
32 higher
chopper ASSY
(input range fault)
Traction possible
Detection at 94°C (1) Stop traction and cool down Reset at
Traction chopper ASSY (201°F) or higher (2) Inspect vehicle ventilation port
33 90°C (194°F)
temperature increase (Output limitation (3) Inspect installation of traction chopper or lower Check for insufficient
starts at 94°C ASSY
427 (201°F) or higher) cooling due to faulty
(4) Inspect connection of fan harness
fan operation
Traction not (5) Inspect harness between controller and
fan Reset at less
Traction chopper ASSY possible
34 (6) Inspect fan individually than 109°C
(228°F)
(228°F) or higher
73 Revolution sensor fault Traction not (1) Inspect harness between traction Detection is performed
173 (Pulse out) possible chopper ASSY and revolution sensor Automatically during accelerator ON
(2) Inspect motor pickup (mismatching of reset by and there is maximum
438
Revolution sensor fault Traction output sensor and vehicle gear, magnetic inputting torque current and no
74 foreign materials, etc.) normal value revolution sensor
(Bearing) limited
(3) Inspect revolution sensor separately signal
(1) Check setting condition of machine
select harness on left side of traction
Normal drive chopper ASSY installation portion Key SW :
446 94 Machine settings fault
possible (2) Inspect harness between traction OFF
chopper ASSY and connection portion of
select harness
(1) Inspect harnesses between traction
Automatically
chopper ASSY and forward SW/reverse
Forward SW, reverse SW Traction not reset by
450 7 SW
fault possible inputting
(2) Inspect forward SW and reverse SW
normal value
separately
Accelerator fault detected (1) Inspect connection of connector on For the normal voltage
6 Automatically
(input small) accelerator sensor side value of the
452 reset by
Traction not possibl (2) Inspect harness between traction accelerator sensor,
453 Accelerator fault detected inputting
106 chopper ASSY and accelerator sensor refer to Controller
(input large) normal value
(3) Inspect accelerator sensor separately terminal voltage
Tire angle sensor Wheel steering
52 (1) Inspect connection of connector on tire
(input small) angle control not
angle sensor side
454 possible Key SW :
(2) Inspect harness between traction
455 Tire angle sensor Knob position OFF
152 chopper ASSY and tire angle sensor
(input large) correction control
(3) Inspect tire angle sensor
not possible
Battery current detection
68
fault (input small) (1) Inspect for damage and adhesion of
foreign materials on and around battery
Battery current detection current sensor of contactor unit
168 Operates with
476 fault (input large) (2) Inspect harness between traction Key SW :
electric power at
477 Battery current detection chopper ASSY and battery current OFF
69 0V
fault (input small) sensor
(3) Inspect battery current sensor
Battery current detection separately
169
fault (input large)
CS-87

Code (Contd)
Error code
Error code
display
display
Tilt horizontal solenoid Tilt horizontal
48
short solenoid operation
not possible
chopper ASSY and tilt horizontal
PS correction
solenoid Key SW :
504 solenoid operation
Tilt horizontal solenoid (2) Inspect harness between terminal CN1- OFF
49 not possible
load short circuit 23 (118) of controller (D) and battery
Lift down solenoid
(3) Inspect tilt horizontal solenoid separately
operation not
possible
The EMG relay is
driven by the loading
chopper ASSY and tilt horizontal
Automatically chopper ASSY unit.
Tilt horizontal solenoid
Tilt horizontal solenoid reset by Also inspect harness
505 47 solenoid operation (2) Inspect harness between traction
open inputting between terminal
not possible chopper ASSY and EMG relay
normal value CN1-23 (118) of
(3) Inspect EMG relay separately
controller (D) and
(4) Inspect tilt horizontal solenoid separately
battery
(1) Inspect connection condition of terminals
Loading not CN1-13 (693), CN1-14 (694) and CN1-
If the traction chopper
Loading data possible 15 (690) of traction chopper ASSY (D) Automatically
ASSY cannot receive
communication fault PS correction (2) Inspect connection condition of terminals reset by
602 63 loading chopper ASSY
(Communication wire control not possible CN1-1 (695) and CN1-3 (691) of inputting
data after the key
disconnection) PS idle revolution controller (P) normal value
switch is switched ON
in progression (3) Inspect CAN communication harness
(4) Inspect CAN communication register
(1) Inspect connection condition of terminals
CN2-11 (711) and CN2-12 (710) of
Normal operation Automatically
Meter data receipt fault traction chopper ASSY (D) Traction and loading
possible reset by
414 65 (Communication wire (2) Inspect connection condition of motors are limited to
Mode setting not inputting
disconnection) connectors on meter side 1,300 rpm or lower
possible normal value
(3) Inspect communication harness
(RS232C line)
82 EEPROM sum error Normal operation Replace traction chopper ASSY if there are Key SW :
446, 610
83 EEPROMACK error possible repeated errors OFF
CS-88

Code (Contd)
LOADING SYSTEM
When an error cannot be reset using the method for repair and
inspection described, replace the loading chopper ASSY.
Error code
Error code
display
display
Return to (1) Set all loading operation levers to neutral When seated with key
neutral Loading inhibitor detected (2) Inspect neutral condition of all loading ON (seat SW: ON),
Loading not No loading
(Inhibitor 1 (No error if this occurs due operation levers using on-board detection is performed
possible operation
detection to improper operation) diagnosis with operation of
displayed) (3) Set all loading operation levers to neutral loading lever
(1) Check connection condition of battery Automatically
Excess voltage fault
Traction/loading/ plug reset by Detection at 72V or
405 86 (Battery loose while
PS not possible (2) Check inspection method of contactor inputting higher
regenerating
open (error code 401) normal value
Loading chopper ASSY (1) Inspect connection condition of battery
15
(Upper/lower FET short) cable (potential leak in secondary side of Because the traction
contactor) and loading chopper
19 Loading chopper ASSY (2) Remove motor cable from terminals U,V ASSY are connected
119 (Upper FET short) and W and inspect for leaks between by a busbar, a traction
motor cable and terminals VB and N FET short (error code
(3) Inspect for looseness of busbar between 408) will also be
traction unit and loading chopper ASSY displayed.
unit The opposite case will
412 (4) Check for foreign materials on and be the same.
PS not possible OFF
around terminals VB and N and Because charging is
21 Loading chopper ASSY terminals U, V and W not possible to the
121 (Lower FET short) (5) Inspect connection condition of terminal condenser between
CN1-24 (206) of loading chopper ASSY VB and N, a quick
(P) charge fault (error
(6) Inspect boost charge resistance code 406) due to a
(7) Inspect harness between loading traction unit FET short
chopper ASSY and boost charge will also be displayed
resistance (contactor unit)
Loading chopper ASSY
16 (U phase upper FET
open)
116
(U phase lower FET open)
17
(V phase upper FET open)
Loading/PS not Inspect for looseness of motor terminals and Key SW :
413 Loading chopper ASSY
117 possible disconnection of cables OFF
(V phase lower FET open)
18 (W phase upper FET
open)
118 (W phase lower FET
open)
24
fault (input small)
124
432 fault (input large) Loading/PS not Key SW :
Replace loading chopper ASSY
433 V phase current sensor possible OFF
25
V phase current sensor
125
26
fault (input small)
126
430 fault (input large) Loading/PS not Key SW :
Replace loading chopper ASSY
431 W phase current sensor possible OFF
27
W phase current sensor
127
CS-89

Code (Contd)
Error code
Error code
display
display
Load short circuit (1) Check for foreign materials on or around
22
(Motor phase short circuit) terminals U, V and W
(2) Check for short circuit between motor
cables (looseness of terminals, holes in
tubing of wire, foreign materials inside
motor)
Loading/PS not (3) Inspect harness of terminal CN1-24 Key SW :
431, 433
possible (206) of loading chopper ASSY (P) OFF
91 Overcurrent detection (4) Check inspection method of contactor
open (error code 401)
(5) Check inspection method of W phase
current fault (error codes 430/431) and U
phase current fault (error codes 432/
433)
(1) Inspect for looseness of motor
temperature sensor connector
Temperature sensor
(2) Inspect harness between loading Automatically
Loading motor voltage during fault
Loading output chopper ASSY and motor temperature reset by
434 35 temperature sensor fault detection: 0.15V or
limited sensor inputting
(input range fault) lower, or 4.92V or
(3) Inspect resistance and voltage of motor normal value
higher
temperature sensor
(Replace if there is a fault)
Loading/PS
possible
Reset at
Detection at 163°C (1) Stop loading and cool Normal voltage values
Loading motor 160°C
36 (325°F) or higher (2) Inspect harness between loading for temperature sensor
temperature increase (320°F) or
(Current limitation chopper ASSY and motor temperature (within ±10%):
lower
435 starts at 160°C sensor 25°C (77°F) : 3.6 V
(320°F) or higher) (3) Inspect resistance and voltage between 50°C (122°F) : 2.65 V
Loading/PS not CN2 connector 160 and terminal 919 of 100°C (212°F) : 0.98 V
loading chopper ASSY (P) Reset at 150°C (302°F) : 0.36 V
Loading motor possible
37 under 175°C
(347°F)
(347°F) or higher
Temperature sensor 1
(TMD1) of loading
31 Voltage of temperature
chopper ASSY Automatically
(input range fault) sensor when fault is
Loading/PS output reset by
436 Replace loading chopper ASSY detected: 0.2V or
Temperature sensor 2 limited inputting
lower, or 4.92V or
(TMD2) of loading normal value
32 higher
chopper ASSY
(input range fault)
Loading/PS
possible
Detection at 94°C (1) Stop loading and cool down Reset at
Loading chopper ASSY (2) Inspect vehicle ventilation port
33 (201°F) or higher 90°C (194°F)
temperature increase (3) Inspect installation of loading chopper
(Output limitation or lower Check whether cooling
starts at 94°C ASSY
437 is insufficient due to
(201°F) or higher) (4) Inspect connection of fan harness
improper fan operation
(5) Inspect harness between loading
Loading/PS not chopper ASSY and fan Reset when
Loading chopper ASSY possible (6) Inspect fan separately
34 under 109°C
temperature fault Detected at 109°C
(228°F)
(228°F) or higher
73 Revolution sensor fault Loading not (1) Inspect harness between loading Detected when there is
173 (Pulse out) possible chopper ASSY and revolution sensor Automatically loading operation
(2) Inspect motor pickup (mismatching of reset by (handle), no revolution
442
Revolution sensor fault Loading output sensor and vehicle gear/magnetic inputting sensor signal and
74 foreign materials etc.) normal value maximum torque
(Bearing) limited
(3) Inspect revolution sensor separately current
Tilt angle sensor fault (1) Check connection condition of tilt angle For normal voltage
56
(input small) Automatic tilt sensor connector value of tilt angle
456 Key SW :
horizontal function (2) Inspect harness between loading sensor, refer to
457 Tilt angle sensor fault OFF
156 stopped chopper ASSY and tilt angle sensor Controller terminal
(input large) (3) Inspect tilt angle sensor separately voltage
CS-90

Code (Contd)
Error code
Error code
display
display
For normal voltage
(1) Check connection condition of lift lever value of tilt angle
Automatically
Lift lever sensor fault Loading not sensor connector sensor, refer to
reset by
466 6 detected possible (2) Inspect harness between loading Controller terminal
inputting
(input small) (PS possible) chopper ASSY and lift lever sensor voltage
normal value
(3) Inspect lift lever sensor separately Except for FTC
vehicles
Tilt horizontal SW open <When tilt horizontal SW: N.C.>
468 154
fault (1) Inspect harness between loading
chopper ASSY and tilt horizontal SW (for
open)
Automatic tilt
(2) Inspect tilt horizontal SW separately Key SW : Detected when key
horizontal function
Tilt horizontal SW short <When tilt horizontal SW: N.O.> OFF SW is placed ON
469 54 stopped
fault (1) Inspect harness between loading
chopper ASSY and tilt horizontal SW (for
leak)
(2) Inspect tilt horizontal SW separately
Detected when the
steering angle change
(1) Check connection condition of connector
is 0 even though the
on steering sensor side
tire angle changes
PS correction (2) Inspect harness between loading
Key SW : more than the
470 53 Steering sensor fault limitation not chopper ASSY and steering sensor
OFF specified amount, or
possible (3) Check inspection method for tire angle
when the turning angle
sensor fault (error codes 454/455)
of the tire angle and
(4) Inspect steering sensor separately
steering angle are
inconsistent
Loading sensor fault (1) Inspect connection condition of For the normal voltage
51 Automatically
detected (input small) Determine based connector on loading sensor side value of the loading
472 reset by
on condition of (2) Inspect harness between loading sensor, refer to
473 Loading sensor fault inputting
151 cargo chopper ASSY and loading sensor Controller terminal
detected (input large) normal value
(3) Inspect loading sensor separately voltage
42 Lift down solenoid short Tilt horizontal
solenoid operation
not possible
chopper ASSY and lift down solenoid
PS correction
(2) Inspect harness between terminal CN1- Key SW :
500 Lift down solenoid loading solenoid operation
43 23 (720) of loading chopper ASSY (P) OFF
short circuit not possible
and battery
Lift down solenoid
(3) Inspect lift down solenoid separately
operation not
possible
chopper ASSY and lift down solenoid
Automatically
Lift down solenoid chopper ASSY and EMG relay The EMG relay is
reset by
501 41 Lift down solenoid open operation not (3) Inspect harness between terminal CN1- driven by the loading
inputting
possible 23 (720) of loading chopper ASSY (P) chopper ASSY unit
normal value
and battery
(5) Inspect lift down solenoid separately
PS correction solenoid Tilt horizontal
45 (1) Inspect harness between loading
short solenoid operation
chopper ASSY and PS correction
not possible
solenoid
PS correction
(2) Inspect harness between terminal CN1- Key SW :
502 solenoid operation
PS correction solenoid 23 (720) of loading chopper ASSY (P) OFF
46 not possible
loading short circuit and battery
Lift down solenoid
(3) Inspection PS correction solenoid
operation not
separately
possible
chopper ASSY and PS correction
solenoid
Automatically
PS correction chopper ASSY and EMG relay The EMG relay is
PS correction solenoid reset by
503 44 solenoid operation (3) Inspect harness between terminal CN1- driven by the loading
open inputting
not possible 23 (720) of loading chopper ASSY (P) converter unit
normal value
and battery
(5) Inspect PS correction solenoid
separately
CS-91

Code (Contd)
Error code
Error code
display
display
(1) Inspect connection conditions of
Loading not
terminals CN1-13 (693), CN1-14 (694)
possible If the loading chopper
Traction data and CN1-15 (690) of chopper ASSY (D) Automatically
PS correction ASSY cannot receive
communication fault (2) Inspect connection conditions of reset by
610 61 limitation not traction chopper ASSY
(communication wire terminals CN1-1 (695) and CN1-3 (691) inputting
possible data after the key
open) of chopper ASSY (P) normal value
PS idle revolution switch is switched ON
(3) Inspect CAN communication harness
in progress
(4) Inspect CAN communication register
82 EEPROM sum error Normal operation Replace loading chopper ASSY if there are Key SW :
446, 602
83 EEPROMACK error possible repeated errors OFF
CS-92
Controller Terminal Voltage

TRACTION SYSTEM CHOPPER ASSY CN1
Actual measurement value (reference)

(Numerical value without unit is V)
Harness
Pin NO. terminal Harness Item Lift Tilt
NO. color (UP/ DOWN) (Forward/back)
Battery ON Key ON
FR SW Traction
(F/R) (F/R)
1 CAN (L)
2
3 CAN (H)
4 133 W Mode select 2 (Domestic) 0 - 200 mV 6 4.6 6/6 0
5 315 L Parking brake SW 0.3 6 4.6 (Both seating, leave seat of PKB OFF, ON) Hork the buzzer by PKB
OFF, key OFF
6 127 Y Key SW2 (Restart) 0 0 When restart : 50.9
7 129 OR Key SW1 0 50.7 50.7 / 50.7 49 / 49
8 130 OR Key SW1 0 50.7 50.7 / 50.7 49 / 49
9 450 G Power for turn signal lamp 0 50.7
10 254 W L turn signal output 0 0 Turn signal Left ; 50 V 0 V Right ; 0 V 20 mV
Back-up charge resistance
11 282 PU 1 (+) 43.3 43.3
Back-up charge resistance

12 283 B 1 (-) 0 0
13 693 P CAN (L) 0 200 mV 2.4

14 694 P CAN (LRt) 0 200 mV 2.4
15 690 L CAN (H) 0 200 mV 2.6
16 105 R Seat SW 0 Leave seat ; 4.7 / Seating ; 0
17 Mode select 5
CN1 18 661 L Forward SW 0.3 5.3 0 / 5.3 0 / 5.3
19 669 W Brake SW 50.3 50.3 When press brake pedal ; 0
Mode select 4
20 135 Y (1 ton/2 ton) 0.3 / 0 5.2 / 0
21 Mode select 3
22 284 PU Main contactor coil (+) 51 50.6
23 118 P Solenoid power return 51 50.6
24 119 P Detect battery power 51 50.6
25
26
27
28 930 B 0V 0 0
29 931 B 0V 0 0
30 Mode select 1
31 662 GY Reverse SW 0.3 50.7 50 / 0 48 / 0
32 126 G APO relay drive 0 0.6
33 421 L When 36 V spec FAN drive 51 51 When fan drive ; 14.2
34 422 BR When 48 V spec FAN drive 51 51 When fan drive ; 0.9
35 285 B Main contactor coil (-) 51 42.5
Tilt horizontal solenoid
36 724 P 0.9 50.5 When stopping automatically ; 31
drive
CS-93
Controller Terminal Voltage (Contd)

Standard voltage (reference)
Numerical value without unit is V.
Pin NO. VB means battery voltage. Remarks
Key ON and not operating Key ON and operating

1 2.4 - 2.5
2
3 2.5 - 2.6
4 4.6 (Open) 0 (Short) When short : Connect to 980 (B)
5 5.4 (Pull) 0 (Release)
6 VB (When key SW2 OFF is 0)
9 VB Power for turn signal
10 0 When drive : Changing between 0 and VB
11 Approx. 85 % of VB
13 2.4 - 2.5
14 2.4 - 2.5
15 2.5 - 2.6
When 0 V : Seat SW is turn ON, running is
16 4.6 (Leave seat) 0 (Seating)
possible
17 4.6 (Open) 0 (Short)
18 5.4 (Open) 0 (Short) When 0 V : Forward SW is turn ON
CN1 19 VB (Release) 0 (Press) When 0 V : Brake operates (Double as lamp SW)
1 ton (Open) / 2 ton (Short)
20 4.6 (Open) 0 (Short) When short : Connect to 981 (B)
21 4.6 (Open) 0 (Short)
22 VB
23 VB
24 VB
25
26
27
28 0
29 0
30 4.6 (Open) 0 (Short)
31 VB (Open) 0 (Short) When 0 V : Reverse SW is turn ON

(Double as back-up lamp SW)
32 0.6 - 0.8 VB (AP0 relay is stop)
33 VB 0.8 - 1.0
34 VB 0.8 - 1.0
When contactor is turn OFF : VB
35 When contactor ON is approx. VB-9 (Turn ON is applied voltage of 9 V to coil)
36 VB When drive solenoid is approx. VB-20 Reference : Coil resistance 30 x 0.68 A
CS-94

TRACTION SYSTEM CHOPPER ASSY CN2

Harness
Battery ON Key ON
FR SW Traction
(F/R) (F /R)
1
2
3 144 L Traction motor revolution sensor A 0.6 4.3 / 4.3 (There is a case of 0 / 0) 2.2 / 2.2
4
5 148 G Traction motor revolution sensor B 0.6 4.3 / 4.3 (There is a case of 0 / 0) 2.2 / 2.2
6 152 R Traction motor temperature sensor 0.4 3.1
7 288 OR Battery current sensor 0 2.5 2.5 / 2.6 2.8 / 2.8
8 664 PU Accelerator sensor A 0 0.48 Accelerator fully opening (4.1)
9 665 R Accelerator sensor B 0 0.2 Accelerator fully opening (1.98)
10 670 L Tire angle sensor 0 N ; 2.2 End of right turn ; 4.6, End of left turn ; 0.66
11 711 G Meter communication (RXD) 0 2.4
12 710 BR Meter communication (TXD) 0 0
13
14
15 913 B Traction motor revolution sensor (-) 0 0 0/0 0/0
Traction motor revolution sensor
16 911 GY (Shield) 0 0 0/0 0/0
17 915 B Traction motor temperature sensor (-) 0 0 0/0 0/0

CN2 18 287 B Battery current sensor (-) 0 0 0/0 0/0
19 289 W Battery current sensor (-) 0 0 0/0 0/0
20 934 B Accelerator sensor (-) 0 0 0
21
22
23 979 R Tire angle sensor (-) 0 0 0
24
25
26
27 140 R Traction motor revolution sensor (+) 0.4 9.9 9.9 / 9.9 9.9 / 9.9
28
29
30 286 R Battery current sensor (+) 0 5.07 5.07
31
32 660 P Accelerator sensor (+) 0 5.15 5.15
33
34 671 PU Tire angle sensor (+) 0 5.12 5.12
35
36
CS-95

Pin NO. (Numerical value without unit is V) Remarks
1
2
3 0 - 4.4 2.2 (Average of under revolution) Pulse of signal low side : 0 V, high side : 4.35 V
4
Thermistor input : Signal (At 50°C (122°F) : 2.65
6 Approx. 3.60 (At 25°C (77°F)) 0.2 - 4.8 (There is changing of temperature)
V)
7 2.5 (Batt current 0) 1.0 - 4.0 (Change by detect of battery current) ±800 A / 2.5 V ± 1.5 V
8 1.2 or less 1.2 - 4.24 (Accelerator 0 % - 100 %)
9 1.2 or less Half voltage of acceleration sensor A
10 2.5 (Tire position is neutral) 0 - 5 (Change by angle) Rise voltage by right turn
11 Not standard setting Receive data from meter
12 Not standard setting Sending data to meter
13
14
15 0
16 0
17 0
CN2 18 0
19 0
20 0
21
22
23 0
24
25
26
27 9.8
28
29
30 5
31
32 5
33
34 5
35
36
CS-96

LOADING SYSTEM CHOPPER ASSY CN1

Harness
Battery ON Key ON
FR SW Traction
(F/R) (F /R)
1 695 P CAN (L) 0 2.4 2.4 / 2.4
2
3 691 L CAN (H) 0 2.6 2.6 / 2.6
4 677 BR Tilt SW 0.3 6.5 6.5 / 6.5 0/0
5 411 G Right turn SW 0.3 5.7 Turn signal right ; 0, Left ; 5.6
6 117 Y Key SW2 (Restart) 0 50.6
7 116 R Key SW1 0 50.6
8 128 R Key SW1 0 50.6
9 451 G Power for turn signal lamp 0 51
10 253 W R turn signal output 0 0 Turn signal right ; 0 50, Left ; 0
11 280 R Back-up charge resistance 2 (+) 43.6 43.6
12 281 B Back-up charge resistance 2 (-) 44 43.7
13 CAN (L)
14 CAN (LRt)
15 CAN (H)
16
17 744 P Tilt horizontal SW 0 0 SW ON 7.1
18 T15L SW
CN1 19 675 GY 5th SW 0 39
20 679 G 4th SW 0.2 6.7
21 678 Y 3rd SW 0.36 7.3
22 205 P Battery voltage 51 50.7
23 702 R Solenoid power return 30 30
24 206 P Detect battery voltage 51.3 50.9
25
26
27
28 961 B 0V 0 0
29 962 B 0V 0 0
30 676 W Lift up SW 0 8 0 / 6.8 6.7 / 6.7
31 412 G Left turn SW 0 5.8 Turn signal left ; 0, Right ; 5.6
32 746 Y EMG relay drive 51 0.6
33 460 R/Y Laser marker drive 0 0.6
34
35 722 Y Lift down solenoid drive 1.8 39 39 / 39 38 / 38
36 723 BR PS knob departure correction 1.5 50.7

solenoid drive
CS-97

Numerical value without unit is V.
Pin NO. VB means battery voltage. Remarks

1 2.4 - 2.5
2
3 2.5 - 2.6
4 4.6 (Open) 0 (Short) When 0 V short : Tilt operation
5 4.6 (Open) 0 (Short) When 0 V short : Right turn signal SW is ON
9 VB Power for turn signal
10 0 When drive : Changing between 0 and VB
13 2.4 - 2.5
14 2.4 - 2.5
15 2.5 - 2.6
16
17 4.6 (Open) 0 (Short)
18 4.6 (Open) 0 (Short)
CN1
19 4.6 (Open) 0 (Short) When 0 V short : 5th ON
20 4.6 (Open) 0 (Short) When 0 V short : 4th ON
21 4.6 (Open) 0 (Short) When 0 V short : 3rd ON
22 VB
23 VB
24 VB
25
26
27
28 0
29 0
30 4.6 (Open) 0 (Short) When 0 V short : Lift operation
31 VB (Open) 0 (Short) When 0 V short : Left turn signal SW is ON
32 0.6 - 0.8 VB (EMG relay is stop)
33 VB 0.8 - 1.0
34
35 Approx. VB- (10 - 14) When stop lift down solenoid : VB Reference : Coil resistance 36 - 44 x 0.3 A
36 VB When drive solenoid is approx. VB-24 Reference : Coil resistance 21.8 x 1.1 A
CS-98

LOADING SYSTEM CHOPPER ASSY CN2

Harness
Battery ON Key ON
FR SW Traction
(F/R) (F/R)
1 716 Y Steeering angle sensor (A) 0.5 0 or 2.8 In operation ; 1.2
2 715 W Steering angle sensor (+) 0 13.7
3 156 L Pump motor revolution sensor A 0.6 0 or 4.4 Pump motor in revolution ; 2.2
4
5 158 G Pump motor revolution sensor B 0.6 0 or 4.4 Pump motor in revolution ; 2.2
6 160 GY Pump motor temperature sensor 0.4 3
7
8 260 R Lift lever sensor 0 5.3
Most forward tilt ; 2.6,
9 704 W Tilt angle sensor 0 N;3 Most behind tilt ; 5.3
10 743 W Oil pressure sensor 0 0 No load rising ; 0.5, Most down ; 0
11
12
13 717 R Steering angle sensor (B) 0 0
14 978 B Steering angle sensor (-) 0 0
15 918 B Pump motor revolution sensor (-) 0 0
16 917 B Pump motor revolution sensor (Shield) 0 0
17 919 B Pump motor temperature sensor (-) 0 0
CN2 18
19
20 Lift lever sensor (-)
21 960 B Tilt angle sensor (-) 0 0
22
23 940 B Oil pressure sensor (-) 0 0
24
25 718 L Steering angle sensor (N) 0.5 0 or 2.8 N position ; 0, Except N position ; 2.8
26
27 154 R Pump motor revolution sensor (+) 0.45 9.8
28
29
30
31
32 260 R Lift lever sensor (+) 0 5.3
33 705 G Tilt angle sensor (+) 0 5.04
34 742 Y Oil pressure sensor (+) 0 5.1
35
36
CS-99

Pin NO. (Numerical value without unit is V) Remarks
1 0.2 - 3 1.2 (Average of under steer) Pulse of signal low side : 0.2 V, high side : 3.0 V
2 14
4
Thermistor input : Signal (At 50°C (122°F) : 2.65
6 Approx. 3.60 (At 25°C (77°F)) 0.2 - 4.8 (There is changing of temperature)
V)
7
Default setting is short at 5 V, when limit option
8 5 1.0 - 4.4 (Lift 0 % - 100 %)
setting is difference to voltage value
9 0.5 - 4.5 (Changing by operation) Rise voltage by tilt behind operation
10 0.25 - 4.75 (Changing by load) Rise voltage by load
11
12
13 0.2 - 3 1.2 (Average of under steer) Pulse of signal low side : 0.2 V, high side : 3.0 V
14 0
15 0
16 0
17 0
CN2 18
19
20 0
21 0
22
23 0
24
25
26
27 9.8
28
29
30
31
32 5
33 5
34 5
35
36
CS-100
Controller Trouble Symptom by Meter

Display
When self diagnosis When key SW ON Confirm operation
Parts Trouble symptom Remarks
Error Display Error Display Traction Loading PS
Contact open 401 Main contactor

Open 401
1 Main contactor Contact short 400 Main contactor

Short 400
Coil open 401 Main contactor

Open 401
2 Main fuse Fusing 401 Main contactor

Open 401
Connector open 476 Battery current sensor

Output small 476
Battery current sensor
Battery current R286 line open 476
Output small 476
sensor
Errors do not appear immediately
3 Battery current sensor after the key SW is placed in the
B287 line open 477 Output large 477 ON position, but appear after 7 to
8 seconds.
Harness side
Battery current sensor
OR288 line open 476
Output small 476
W289 line open
Lift down function does not
Connector open 501 Lift down valve operate. Lift up and tilt forward/
Open 501 back functions operate properly.
Lift down valve
Lift down function does not
Lift down valve
Y722 line open 501 Open 501 operate. Lift up and tilt forward/
back functions operate properly.
4
Lift down valve Lift down function does not
L732 line open 501 Open 501 operate. Lift up and tilt forward/
back functions operate properly.
Harness side
Lift down valve Lift down function does not
Coil short 502, 500 operate. Lift up and tilt forward/
Short 500 back functions operate properly.
Disconnect Accelerator sensor
connector 452 Output small 452
Accelerator sensor
B934 line open 452 Output large 453
Accelerator Accelerator sensor
sensor R665 line open 452, 453 Output small 452,
Output large 453
Accelerator sensor
5 B933 line open 453 Output large 453
Accelerator sensor
P660 line open 452 Output small 452
Harness side
Accelerator sensor
PU664 line open 452 Output small 452
Accelerator sensor
P667 line open 452, 453 Output small 452,
Output large 453
Disconnect Tires rotate slightly after jacking

connector up.
Tires rotate slightly after jacking
L144 line open
up.
Traction motor Tires rotate slightly after
revolution sensor D/Mo revolution jacking up.
R140 line open sensor Errors appear while the
Malfunction 438 accelerator pedal is ON, but
6
do not appear while it is OFF.
Tires rotate slightly after
D/Mo revolution jacking up.
Harness side B913 line open sensor Errors appear while the
Malfunction 438 accelerator pedal is ON, but
do not appear while it is OFF.
G148 line open Tires rotate slightly after jacking

up.
CS-101

Display (Contd)
Traction motor Disconnect D/Mo temperature
temperature 422 sensor
sensor connector Malfunction 422
D/Mo temperature
7 R152 line open 422 sensor
Malfunction 422
D/Mo temperature
B915 line open 422 sensor
Harness side Malfunction 422
Only mast down function
Disconnect P/Mo revolution operates. Errors appear only
connector sensor when the steering wheel is
Malfunction 442 operated or cargo is loaded/
unloaded.
P/Mo revolution operates. Errors appear only
L156 line open sensor when the steering wheel is
Pump motor Malfunction 442 operated or cargo is loaded/
revolution sensor unloaded.
8 R154 line open sensor when the steering wheel is
unloaded.
Harness side P/Mo revolution operates. Errors appear only
B918 line open sensor when the steering wheel is
unloaded.
G158 line open sensor when the steering wheel is
unloaded.
Pump motor P/Mo temperature

Disconnect 434 sensor
revolution sensor connector
Malfunction 434
P/Mo temperature
9 GY160 line open 434 sensor
Malfunction 434
P/Mo temperature
B919 line open 434 sensor
Harness side Malfunction 434
Disconnect Steering wheel cannot be turned.
Steering angle connector
sensor Steering wheel can be turned, but
R717 line open
requires extra effort to operate.
W715 line open Steering wheel cannot be turned.
10
Steering wheel can be operated
L718 line open normally.
Steering wheel can be turned, but
Y716 line oepn requires extra effort to operate.
Harness side
B978 line open Steering wheel cannot be turned.
Disconnect 454 Tire angle sensor
Tire angle sensor connector Output small 454
L670 line open 454 Tire angle sensor

Output small 454
11
R979 line open 455 Tire angle sensor
Output large 455
Harness side Tire angle sensor
PU671 line open 454
Output small 454
Upper Traction FET
+ V phase 408
short Short 408
12 Traction FET
Lower
- V phase 408 Traction FET
short Short 408
Upper
+ V phase 412 Loading FET
short Short 412
13 Loading FET
Lower
- V phase 412 Loading FET
Short 412
short
CS-102

Display (Contd)
Disconnect Neither F/R sides does not
connector operate.
L661 line open Only F side does not operate.
FR SW
GY662 line open Only R side does not operate.
Neither F/R sides does not
B910 line open operate.
14
Short of L661
line and GY662 Neither F/R sides does not
operate.
line
Harness side
Short of B910
An alarm buzzer sounds and the
line and L661 "Return to N" message is
line or GY662 displayed.
line
Disconnect Lights and turn signals does not
connector illuminate.
R220 line open Clearance lights does not

Turn signal unit illuminate.
G412(L) line Left side turn signal does not
open illuminate.
15 Y213 line open Headlights does not illuminate.
G411(R) line Right side turn signal does not

open illuminate.
Harness side B976 line (thin) Headlights and clearance lights

open does not illuminate.
B900 line (thick) Left/right turn signals does not

open illuminate.
Disconnect Tilt angle sensor Tilt function does not stop
Tilt angle sensor connector 456
Output small 456 automatically.
Tilt angle sensor Tilt function does not stop
B960 line open 457
Output large 457 automatically.
16
W704 line open 456 Tilt angle sensor Tilt function does not stop
Harness side G705 line open 456 Tilt angle sensor Tilt function does not stop
Disconnect 472 Loading sensor Load is not displayed.
Oil pressure connector Output small 472
sensor
B940 line open 473 Loading sensor Load is not displayed.
Output large 473
17
W743 line open 472 Loading sensor Load is not displayed.
Output small 472
Harness side Loading sensor
Y742 line open 472 Load is not displayed.
Output small 472
PS correction Disconnect PS correct valve Error codes are displayed during
503
valve connector Open 503 PS correction.
PS correct valve Error codes are displayed during
BR723 line open 503
Open 503 PS correction.
18
PS correct valve Error codes are displayed during
L733 line open 503
Open 503 PS correction.
PS correct valve
Harness side Coil short 500, 502
Short 502
CS-103
CS-104

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CONTROL SYSTEM

DRIVE SYSTEM FUNCTION

Item Function Outline

System control Inhibitor control Accelerator, FR SW, Loading, Seat

FEATURE OF DRIVE SYSTEM

Steering wheel angle sensor

 No tilt leveling is performed in backward tilting.

Meters, Indicators and Lamps

Setting Adjustment Items (Normal Mode)

Traction and loading power mode  Push FN3 Lock ON

Hour meter select/Instantaneous

Push FN3 Hour Minute Day

Setting Adjustment Items (Normal Mode)

Meter Panel Explanation

DRIVER RECOGNITION MODE

Registering a password can restrict the drivers of the forklift.

Meter Panel Explanation (Contd)

HOUR METER (4 MODE)/INSTANTANEOUS ENERGY

For speed alarm setting, refer to Adjustment Mode.

Meter Panel Explanation (Contd)

OVER SETTING WEIGHT

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

Mode M: Manual mode:

Mode E: Economy mode:

Mode P: Power mode:

Mode H: High-power mode:

AM and PM hour adjustment: The hour display will advance by 1

Minute adjustment: The minute display will advance by 1 minute

Day-of-the-week adjustment: The day-of-the-week display will

Meter Panel Explanation (Contd)

The acceleration level can be adjusted in a series of 8 steps.

For faster acceleration (Quick): Push function key FN1.

For slower acceleration (Slow): Push function key FN2.

For slower acceleration (Slow): Push function key FN2.

Meter Panel Explanation (Contd)

The acceleration level can be adjusted in a series of 8 steps.

PARKING BRAKE WARNING MARK

SEAT BELT WARNING MARK

Meter Panel Explanation (Contd)

If any malfunction occurs when the key switch is in the ON position,

 Control system malfunction (Traction, Cargo-handling, Power

Meter Panel Explanation (Contd)

When function key FN5 is pressed, the display will switch.

The vehicle may be operated during the pump cut warning.

Meter Panel Explanation (Contd)

For pump cut time setting, refer to Adjustment Mode.

Meter Panel Explanation (Contd)

Control system (Traction, D-FET SHORT A malfunction has occurred in NOTE:

TIRE ANGLE SENSOR LOW A malfunction has occurred in

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Manager Mode (Contd)

No tilt leveling is performed in backward tilting.

Traction and loading power mode Push FN3 Lock ON

Meter Panel Explanation (Contd)

For speed alarm setting, refer to Adjustment Mode.

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

Control system malfunction (Traction, Cargo-handling, Power

Meter Panel Explanation (Contd)

Meter Panel Explanation (Contd)

For pump cut time setting, refer to Adjustment Mode.

Meter Panel Explanation (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Adjustment Mode (Contd)

Manager Mode (Contd)

Manager Mode (Contd)

Manager Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Diagnostic Mode (Contd)

Removal and Installation (Contd)

Controller Element Inspection (Contd)

Controller Element Inspection (Contd)

Controller Element Inspection (Contd)

Controller Element Inspection (Contd)

Controller Element Inspection (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)

Control System (Contd)