TX Control Adjustment Mode
TX Control Adjustment Mode
TX Control Adjustment Mode
CONTROL SYSTEM
SECTION CS
CONTENTS
TECHNICAL DESCRIPTION ............................. CS-2 How To Follow Flow Chart .......................... CS-79
System .......................................................... CS-2 Symbol Identification ................................... CS-80
PRECAUTIONS ............................................... CS-10 Voltage and Resistance Measurement
LOCATION OF UNITS (LAYOUT) ................... CS-11 Procedures .................................................. CS-81
Standard Equipment (3 - wheel) .................. CS-11 TROUBLE DIAGNOSIS FOR CONTROLLER
Standard Equipment (4 - wheel) .................. CS-12 SYSTEM ........................................................... CS-82
Optional Equipment ..................................... CS-13 TROUBLE DIAGNOSIS FOR DRIVING
METER PANEL ................................................ CS-14 SYSTEM ........................................................... CS-90
Meters, Indicators and Lamps ..................... CS-14 TROUBLE DIAGNOSIS FOR LOADING
Setting Adjustment Items (Normal Mode) ... CS-14 SYSTEM OF MECHANICAL TYPE ................. CS-97
Meter Panel Explanation ............................. CS-15 TROUBLE DIAGNOSIS FOR LOADING
LCD MONITOR ................................................ CS-23 SYSTEM OF JOYSTICK TYPE ..................... CS-102
Adjustment Mode ........................................ CS-23 TROUBLE DIAGNOSIS FOR POWER
Diagnostic Mode .......................................... CS-31 STEERING SYSTEM ..................................... CS-108
Table of Error Code ..................................... CS-42 TROUBLE DIAGNOSIS FOR TURN SIGNAL
CONTROLLER ................................................. CS-43 LAMP SYSTEM ............................................. CS-109
Construction ................................................ CS-43 REFERENCE DATA OF CONTROL
Connector (Terminal layout) ........................ CS-45 SYSTEM ......................................................... CS-110
Controller Element Inspection ..................... CS-49 Main Print Board ........................................ CS-110
Removal and Installation (3 - wheel) ........... CS-56 Drive FET Board
Removal and Installation (4 - wheel) ........... CS-57 (for RH traction motor control) ................... CS-114
UNIT INSPECTION AND ADJUSTMENT ........ CS-58 Drive FET Board
Control System ............................................ CS-58 (for LH traction motor control) ................... CS-114
Joystick Control System (Option) ................ CS-70 Pump FET Board ....................................... CS-114
Knob Position Control System Traction Condenser Board ........................ CS-115
(Option 3 - wheel only) ................................ CS-77 Loading Condenser Board ........................ CS-115
TROUBLE DIAGNOSTIC PROCEDURES ...... CS-78 Joystick Controller ..................................... CS-116
Precautions ................................................. CS-78
CAUTION:
Where towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to
reduce possible damage to electrical system.
Bulletin issued:
Service Bulletins Issue date
SB-TX-CS0501-2 Prevention to damage controller 05-01-2006
SB-TX-CS0502 Changing ground circuit MP 29-11-2005
SB-TX-CS0601 Power mode indication scrolling on meter panel 05-05-2006
SB-TX-CS0602 Error code 558 occur with FN1+FN3 05-05-2006
SB-TX-CS0702 Incorrect measurement with damaged controller insulation 01-10-2007
CS-1
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
System
COMPARISON OF PREVIOUS TYPE AND NEW TYPE
CSM0086
CSM0087
CS-2
TECHNICAL DESCRIPTION
System (Cont’d)
AC motor control
CSM0088
Drive control Drive control type Induction motor AC inverter vector control
Drive control 2 motor turning 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
Magnetic proportional control Magnetic proportional loading control for optional unit (Joystick control system)
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 Compensate steering angle and tire angle offset by magnetic valve control
CS-3
TECHNICAL DESCRIPTION
System (Cont’d)
Item Function Outline
CS-4
TECHNICAL DESCRIPTION
System (Cont’d)
FEATURE OF DRIVE SYSTEM
Maintenance free AC Traction/Pump Motors
Pump motor is used for PS
High technology for superior function and high reliability by adoption of sensors with high performance
AC motor digital control adopting 32bit RISC CPU
Adoption of HEV (Hybrid Electric Vehicle) high responsible items such as resolver
CAN (Controller Area Network) communication between units
CSM0089
CS-5
TECHNICAL DESCRIPTION
System (Cont’d)
CSM0090
CSM0091
CS-6
TECHNICAL DESCRIPTION
System (Cont’d)
PRINCIPLE OF AC MOTOR
CSM0092
CS-7
TECHNICAL DESCRIPTION
System (Cont’d)
KNOB POSITION CONTROL SYSTEM
(OPTION 3 - WHEEL ONLY)
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
CS-8
TECHNICAL DESCRIPTION
System (Cont’d)
Knob position control system (option 3 - wheel only)
CSM0093
CS-9
PRECAUTIONS
PRECAUTIONS
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-10
LOCATION OF UNITS (LAYOUT)
LOCATION OF UNITS (LAYOUT)
CSM0094
CS-11
LOCATION OF UNITS (LAYOUT)
CSM0094EU
CS-12
LOCATION OF UNITS (LAYOUT)
Optional Equipment
CSM0095EU
CS-13
METER PANEL
METER PANEL
CSM0096EU
CS-14
METER PANEL
LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
To darken the contrast, push function switch FN2. To lighten the
contrast, press function switch FN1.
NOTE:
Only for 3 - wheel trucks
CSM0098
CS-15
METER PANEL
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)
CSM0099
POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function switch FN3 is pressed, the power
mode is switched.
CS-16
METER PANEL
Push function switches FN1 and FN2 simultaneously. The time set
mode will appear.
After setting the clock to the correct time, push function switch FN5.
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
• Push FN1 to increase the numerical value or advance one day of
the week.
• Push FN2 to decrease the numerical value or reverse one day of
the week.
• 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 FN5 to stop the buzzer. The day of the week can
be set to every day (ALL: every day).
Simultaneously press function switches FN1 and FN4. The clock will
move to the traction acceleration control mode.
Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.
Each time the key is pushed, the acceleration level (speed) will
decrease by 1 step.
After setting the acceleration level, push function switch FN5. The
acceleration level will appear, and clock will return to its original letter
mode.
CS-17
METER PANEL
For faster acceleration (Quick): Push function switch FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
CSM0103
For slower acceleration (Slow): Push function switch FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.
After setting the acceleration level, push function switch 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.
CS-18
METER PANEL
CSM0104
Wrench mark
The controller and the sensors act together to regulate the forklift’s
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.
CS-19
METER PANEL
CSM0105
CSM0106
After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
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-20
METER PANEL
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
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
CSM0106
CS-21
METER PANEL
D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor is WARNING
overheating. Immediately stop
Ignoring the warning indication and
forklift operation. Park the forklift in
continuing to operate the forklift
a safe area where there is no
can result in serious motor and
pedestrian or vehicular traffic.
controller damage.
Allow the controller and/or the
motor to cool.
Essential fluid BRAKE FLUID LEVEL DOWN The brake fluid level has fallen
below the specified level.
Battery Battery over voltage The controller has detected a high Turn the key switch OFF and ON
battery voltage again. If no error displayed, you can
operate the forklift without a
problem. If problem reoccur,
contact your NISSAN FORKLIFT
dealer.
CS-22
LCD MONITOR
LCD MONITOR
Adjustment Mode
CSM0107
CS-23
LCD MONITOR
CS-24
LCD MONITOR
CSM0109
CS-25
LCD MONITOR
CSM0110EU
CS-26
LCD MONITOR
CSM0190
CS-27
LCD MONITOR
CSM0191EU
CS-28
LCD MONITOR
CSM0192
CS-29
LCD MONITOR
CSM0193
CS-30
LCD MONITOR
Diagnostic Mode
CSM0108
CS-31
LCD MONITOR
CS-32
LCD MONITOR
CSM0111
CS-33
LCD MONITOR
CSM0112
CS-34
LCD MONITOR
CSM0194
CS-35
LCD MONITOR
CSM0195
CS-36
LCD MONITOR
CSM0196
CS-37
LCD MONITOR
CSM0197
CS-38
LCD MONITOR
CSM0198
CS-39
LCD MONITOR
CSM0199
CS-40
LCD MONITOR
RESULT OF SELF-CHECK
If the error is not detected:
CSM0113
CS-41
LCD MONITOR
CONTROLLER ACTUATOR
Main contactor Short 400 - Lift down valve Short 500
CS-52 - CS-69 -
Open 401 - Open 501
Main fuse Open 403 CS-53 - PS correction valve Short 502 Knob
Battery voltage Low voltage 404 - Open 503 position
CS-77
control
Over 405 - - -
(Option)
voltage
Tilt Horizontal valve Short 504
CONT capacitor Abnormal 406 - - - Not equipped
Open 505
Drive FET Short 408
Lift valve Pull Short 506
Open 409 Joystick
CS-49 - Open 507
Drive FET left Short 410 control
Push Short 508 (Option)
Open 411
Open 509
Pump FET Short 412
CS-50 - Tilt valve Pull Short 510
Open 413 Joystick
Open 511
Drive current U Low output 414 control
sensor Push Short 512 (Option)
High output 415
Open 513
V Low output 416
3rd valve Pull Short 514
High output 417 Joystick
CS-51 - Open 515
Drive current U Low output 418 control
sensor left Push Short 516 (Option)
High output 419 CS-72-73
Open 517
V Low output 420
4th valve Pull Short 518
High output 421 Joystick
Open 519
D/Mo TEMP Abnormal 422 control
sensor Push Short 520 (Option)
Overheat 423 -
CS-54 - Open 521
D/Mo TEMP Abnormal 424
sensor left 5th valve Pull Short 522
Overheat 425 - Joystick
Open 523
D/CONT TEMP Abnormal 426 control
sensor - - Push Short 524 (Option)
Overheat 427 -
Open 525
D/CONT TEMP Abnormal 428
sensor left - - C1 solenoid valve Short 526 Joystick
Overheat 429 - control
Open 527
Pump current U Low output 430 (Option)
sensor High output 431 SENSOR
CS-51 -
V Low output 432 F/R Switch Same ON 450 - CS-58, -
72
High output 433
Accel sensor Low output 452
P/Mo TEMP Abnormal 434 CS-64 -
sensor CS-54 - High output 453
Overheat 435 -
Tire angle sensor Low output 454 CS-61
P/CONT TEMP Abnormal 436 (3 WH)
-
sensor - - High output 455 CS-62
Overheat 437 - (4 WH)
D/Mo REV Abnormal 438 - Tilt angle sensor Low output 456
sensor Not equipped
High output 457
D/Mo REV Abnormal 440 - Lift sensor Low output 458
CS-54 -
sensor left
High output 459
P/Mo REV Abnormal 442 -
sensor Tilt sensor Low output 460
CONT Abnormal 444 - - - High output 461 Joystick
CS-72,
communication control
3rd sensor Low output 462 73
(Option)
CONT type Abnormal 446 - - High output 463
select
4th sensor Low output 464
Meter
High output 465
Meter Abnormal 558 - - -
communication LIFT ACCEL Low output 466 Not equipped
Tilt H switch Short 468
Not equipped
Open 469
Steer Angle sensor Abnormal 470 - CS-60 -
Weight sensor Low output 472
Not equipped
High output 473
CS-42
CONTROLLER
CONTROLLER
Construction
CSM0117
CS-43
CONTROLLER
Construction (Cont’d)
CSM0118
CS-44
CONTROLLER
CSM0119
Controller assy
Input/
PIN NO. Contents Notes
Output
Input D20 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
D5 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
D6 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
Output D1 A.P.O. RELAY DRIVE A.P.O. Relay ON/OFF drive, Coile load; 0.1A
Input D19 FORWARD SWITCH F Switch ON then forward
D25 REVERSE SWITCH R Switch ON then backward
D10 ACCEL SENSOR POWER Sensor power (+5.0V)
D12 ACCEL SENSOR SIGNAL A Steps in the pedal then output voltage increase
D14 ACCEL SENSOR SIGNAL B Steps in the pedal then output voltage increase B = A/2
D8 ACCEL SENSOR GND Sensor GND
P7 TIRE ANGLE SEN. POWER Sensor power +5.0V ±0.2V
P14 TIRE ANGLE SEN. SIGNAL Steering right turn then output voltage increase
P11 TIRE ANGLE SEN. GND Sensor GND
P12 STEER ANGLE SEN. POWER Sensor power +12.8V ±0.2V 0.2A
P19 STEER ANGLE SEN. SIGNAL A 45 Pulse per revolution
P21 STEER ANGLE SEN. SIGNAL B 45 Pulse per revolution, Phase late from SIG.A (90 deg)
P22 STEER ANGLE SEN. SIGNAL N For neutral detects, 1 Pulse per revolution
P8 STEER ANGLE SEN. GND Sensor GND
D31 RIGHT TURN SWITCH R SW ON (Low level) then flasher ON/OFF
D35 LEFT TURN SWITCH L SW ON (Low level) then flasher ON/OFF
Output D7 FLASHER POWER Power for flasher Lamp
D2 R FLASHER OUT Flasher drive output Right
Input D22 PARKING BRAKE SWITCH Operates a parking brake then SW ON
D23 BRAKE SWITCH Steps in the brake pedal then SW ON
P28 LIFT UP SWITCH Operates a lift up then SW ON
P29 TILT SWITCH Operates a tilt lever then SW ON
P24 3RD SWITCH Operates a 3rd lever then SW ON
P25 4TH SWITCH Operates a 4th up lever then SW ON
P26 5TH SWITCH Operates a 5th up lever then SW ON
D24 HIGH MAST SWITCH Detects SW ON (1 Shot) then Hi-Mast mode
D26 SEAT SWITCH Site on the seat then SW ON
D15 MODE SELECT 1 For 36V only
D16 MODE SELECT 2 For G1N1 48V only
D18 MODE SELECT 3 For JG1N1 only
D28 SWITCH GND Switch GND
D29 SWITCH GND Switch GND
Input/ D33 M TO C COMMUNICATION DATA Meter to Controller communication data
Output D34 C TO M COMMUNICATION DATA Controller to Meter communication data
CS-45
CONTROLLER
CS-46
CONTROLLER
CSM0120
External of meter
Input 1 Battery voltage Meter Wake up, Battery voltage and capacity detect
2 Battery power + Meter power to battery +
3 Blank terminal -
4 Brake fluid level SW Low fluid level then SW: ON
5 Seat belt SW Belt set then SW: ON
6 Parking BK Key Input Key Input for Parking BK Warning Buzzer
7 Blank terminal -
8 Blank terminal -
9 Parking brake SW Brake OFF then SW: ON
10 Blank terminal -
11 Power GND Meter GND
12 Blank terminal -
CS-47
CONTROLLER
CS-48
CONTROLLER
Item Specification
Construction 9 FET elements construction
Durable voltage 100V
Service data
CS-49
CONTROLLER
Item Specification
Type PDM5001
Durable voltage 100V
Service data
CSM0122
S1D2 G2 3MΩ
G2 S1D2
G2 S2 3MΩ
S2 G2 3MΩ
CS-50
CONTROLLER
Item Specification
Type HC-TSA800V2YP12AR
Actual current ±800A
Output voltage +0.56 ~ +2.56V ~ +4.56V
Service data
Item Normal NG
CSM0123
FAN ASSEMBLY
Specifications
Item Specification
Type 2410ML-05W-B40-BQ1
6 pieces/controller
Numbers of fan
One piece/external fan
Rated voltage 24V
Item Normal NG
CS-51
CONTROLLER
Item Specification
Service data
CSM0126
CS-52
CONTROLLER
Capacity
500A
CSM0127
Inspection
Using a circuit tester, check continuity of each fuse.
Continuity
NOTE:
The circuit tester range selector must be set to “x1 Ω”.
CST0019
CS-53
CONTROLLER
CSM0128
Temperature sensor
Specifications
Item Specification
Service data
Item Normal NG
CSM0129 Sensor resistance
Resistance Failed temp. Sensor
25°C (77°F) = Approx. 50 kΩ
Revolution sensor
Specifications
Item Specification
Service data
CSM0130
Item Normal NG
CS-54
CONTROLLER
MMM0020
CS-55
CONTROLLER
CSM0131EU
CS-56
CONTROLLER
CSM0132EUb
CS-57
UNIT INSPECTION AND ADJUSTMENT
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 30.)
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.
ELM0272
CS-58
UNIT INSPECTION AND ADJUSTMENT
Forward -
Neutral -
Reverse -
CSM0133
CS-59
UNIT INSPECTION AND ADJUSTMENT
Service data
CSM0134
CSM0135
CS-60
UNIT INSPECTION AND ADJUSTMENT
Service data
Measuring points
Standard value Remarks
(terminals)
CSM0136
Adjustment
1. Call up tire angle sensor diagnostic screen from interactive
diagnostic display.
2. Loosen tire angle sensor securing screws.
3. While observing the tire angle sensor output on the display to
check if it is within the specified range, rotate the tire angle
sensor.
4. Tighten tire angle sensor securing screws.
: 1.2 - 1.8 N•m (0.13 - 0.18 kgf-m, 11 - 15 in-lb)
CSM0137
CS-61
UNIT INSPECTION AND ADJUSTMENT
Service data
Measuring points
Standard value Remarks
(terminals)
CSM0207
CS-62
UNIT INSPECTION AND 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 steering
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-63
UNIT INSPECTION AND ADJUSTMENT
CSM0138
Specification
Total resistance (kΩ) 2.5 - 5.0 (Reference value)
Service data
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.
CSM0140 : 1.5 - 1.8 N•m (0.16 - 0.18 kgf-m, 14 - 15 in-lb)
CS-64
UNIT INSPECTION AND ADJUSTMENT
CSM0141
CS-65
UNIT INSPECTION AND ADJUSTMENT
Brake switch ON/OFF switching point Pedal height: 115.5 mm (4.547 in)
(from floor upper surface)
CSM0142
Adjustment
CSM0202
CS-66
UNIT INSPECTION AND ADJUSTMENT
CSM0143
CS-67
UNIT INSPECTION AND ADJUSTMENT
CST0038
Centering adjustment
Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.
CST0039
CS-68
UNIT INSPECTION AND ADJUSTMENT
Inspection
Measure resistance between lift solenoid terminals.
<Reference value>
CSM0144
CS-69
UNIT INSPECTION AND ADJUSTMENT
CSM0145
JOYSTICK CONTROLLER
CSM0146
CS-70
UNIT INSPECTION AND ADJUSTMENT
CSM0200
Specifications
Inspection
Check resistance between terminals using circuit tester (Ω range).
Resistance (Ω)
Terminals Remarks
(Reference value)
A (+)-A (-)
30 20°C (68°F)
B (+)-B (-)
36 20°C (68°F)
C1 (+)-C1 (-)
44 90°C (194°F)
CS-71
UNIT INSPECTION AND ADJUSTMENT
No continuity No continuity
- Continuity
( ) ( )
No continuity No continuity
- Continuity
( ) ( )
CSM0147
CSM0148
CS-72
UNIT INSPECTION AND ADJUSTMENT
CSM0149
Specification
Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).
CS-73
UNIT INSPECTION AND ADJUSTMENT
CSM0150
Inspection
Check continuity between terminals using circuit tester (Ω range).
- Continuity No continuity
CS-74
UNIT INSPECTION AND ADJUSTMENT
CSM0151
CS-75
UNIT INSPECTION AND ADJUSTMENT
CSM0152
CS-76
UNIT INSPECTION AND ADJUSTMENT
Inspection
Check resistance between terminals using circuit tester.
For steering wheel angle sensor and tire angle sensor inspections,
refer to “UNIT INSPECTION AND ADJUSTMENT” on page 58 and
59.
CS-77
TROUBLE DIAGNOSTIC PROCEDURES
TROUBLE DIAGNOSTIC 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:
Malfunction occurrence
Perform self-diagnosis.
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-78
TROUBLE DIAGNOSTIC PROCEDURES
MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.
WORK FLOW
Confirmation of malfunction
Remedial procedures
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.
A
: Current measurement in 50-ampere range (AC)
50
CS-79
TROUBLE DIAGNOSTIC PROCEDURES
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
CST0065
KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.
CS-80
TROUBLE DIAGNOSTIC PROCEDURES
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-81
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CAUTION:
• To perform an accurate diagnosis, carefully listen to the
user’s 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 ( Ω).
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-82
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
SYMPTOM:
The meter does not display. The forklift also does not operate
(in any operation of traction/loading/power steering).
CSM0153
CSM0154
CSM0155
CS-83
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0156
CSM0157
CSM0158
CS-84
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0159
CSM0160
CSM0161
CS-85
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
SYMPTOM:
The meter does not display. The forklift operates (in any
operation of traction/loading/power steering).
CSM0162
CSM0163
CSM0164
CS-86
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
SYMPTOM:
The meter displays. The forklift does not operate (in any
operation of traction/loading/power steering).
CSM0153
CSM0155
CSM0156
CS-87
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0157
CSM0158
CSM0159
CS-88
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0160
CSM0165
CS-89
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Cannot move forward and backward.
CSM0166
CSM0167
CS-90
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
CSM0168
SYMPTOM:
Cannot drive forward or backward.
CSM0169
CSM0167
CS-91
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
The traction speed is slow. The acceleration is slow. Or, there
is no power.
CSM0170
CSM0171
CS-92
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
CSM0172
CSM0173
CSM0174
CS-93
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
CSM0167
CSM0175
CS-94
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Straight-line instability
CSM0176
CSM0167
CS-95
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Regenerative braking malfunction
CSM0177
CSM0167
CS-96
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)
CSM0178
CSM0167
CS-97
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
CSM0179
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.
CSM0167
CS-98
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
The mast does not lower (but can be raised).
CSM0180
CSM0181
CSM0167
CS-99
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.
CSM0170
CSM0171
CSM0182
CS-100
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
CSM0183
CSM0167
CSM0175
CS-101
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)
CSM0184
CSM0185
CS-102
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
CSM0186
CSM0201
CSM0180
CS-103
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
CSM0187
CSM0167
CSM0179
CS-104
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.
CSM0188
CSM0167
CS-105
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.
CSM0170
CSM0171
CSM0182
CS-106
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
CSM0183
CSM0167
CSM0175
CS-107
TROUBLE DIAGNOSIS FOR POWER STEERING SYSTEM
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
SYMPTOM:
Power steering malfunction (include the knob position
malfunction of OPT mechanism)
CSM0189
CSM0167
CS-108
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
SYMPTOM:
Turn signal lamp malfunction
CS-109
REFERENCE DATA OF CONTROL SYSTEM
REFERENCE DATA OF CONTROL SYSTEM
D20 KEY SW2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
D5 KEY SW1 (IGN) VB level (key switch 1 ON) • The controller does not –
operate
D21 BATT OFF DETECT VB level (battery switch ON) • The controller does not –
operate
D81 Capacitor voltage VB level (main relay ON) • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
• Low voltage protection • Battery low voltage: 404
D1 A.P.O. RELAY DRIVE Operation (key ON) • The meter does not operate • Controller communication
malfunction: 444
D19 FORWARD SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved forward
D25 REVERSE SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved backward
D10 ACCEL SENSOR POWER 5.0±0.2V • The traction is not possible • Accelerator pedal position
• Poor acceleration/maximum sensor output large: 453
D12 ACCEL SENSOR SIGNAL A 0.2 - 4.7V (normal)
speed • Accelerator pedal position
D14 ACCEL SENSOR SIGNAL B 0.2 - 4.7V (normal) sensor output small: 452
D8 ACCEL SENSOR GND GND connection
P7 TIRE ANGLE SEN. POWER 5.0±0.2V • Straight-line instability • Tire angle sensor output
P14 TIRE ANGLE SEN. SIGNAL 0.3 - 4.8V (normal) • Poor turning ability large: 455
• Knob position malfunction • Tire angle sensor output
P11 TIRE ANGLE SEN. GND GND connection small: 454
P12 STEER ANGLE SEN. POWER 12.8±1V • Knob position malfunction • Steering angle sensor
• The steering is not possible malfunction: 470
P19 STEER ANGLE SEN. SIGNAL A 0 - 3.5V rectangular pulse
• Steering force malfunction
P21 STEER ANGLE SEN. SIGNAL B 0 - 3.5V rectangular pulse
P22 STEER ANGLE SEN. SIGNAL N 0 - 3.5V rectangular pulse
P8 STEER ANGLE SEN. GND GND connection
D31 RIGHT TURN SWITCH GND level (switch ON) • Turn signal does not blink –
D35 LEFT TURN SWITCH GND level (switch ON) • Turn signal continues
blinking
D7 FLASHER POWER VB input • Turn signal does not turn on –
D2 RIGHT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D17 LEFT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D22 PARKING BRAKE SWITCH GND level (switch ON) • The traction is not possible –
D23 BRAKE SWITCH GND level (switch ON) • The traction is not possible –
• Brake regenerative
malfunction
P28 LIFT UP SWITCH GND level (switch ON) • The lift does not rise –
• The loading motor does not
rotate
P29 TILT SWITCH GND level (switch ON) • No tilt operation –
• The loading motor does not
rotate
P24 3RD SWITCH GND level (switch ON) • No 3rd operation –
• The loading motor does not
rotate
P25 4TH SWITCH GND level (switch ON) • No 4th operation –
• The loading motor does not
rotate
CS-110
REFERENCE DATA OF CONTROL SYSTEM
CS-111
REFERENCE DATA OF CONTROL SYSTEM
P3 SOL. POWER RETURN (Solenoid chopper return line) • Unstable valve control at –
open
P54 PM TEMP SENSOR - Voltage between P52 and P54: • Loading speed decrease • PM temperature rise: 435
Approx. 3.8V (25°C) • PM temperature sensor
P52 PM TEMP SENSOR +
malfunction: 434
D60 LH TM TEMP SENSOR - Voltage between D58 and • Left traction speed decrease • Left TM temperature sensor
D60: Approx. 3.8V (25°C) rise: 425
D58 LH TM TEMP SENSOR +
• Left TM temperature sensor
malfunction: 424
D54 RH TM TEMP SENSOR - Voltage between D52 and • Right traction speed • Right TM temperature
D54: Approx. 3.8V (25°C) decrease sensor rise: 423
D52 RH TM TEMP SENSOR +
• Right TM temperature
sensor malfunction: 422
P51 PM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • PM motor revolution sensor
P47 PM REV. SEN. SIGNAL B GND GND operate malfunction: 442
CS-112
REFERENCE DATA OF CONTROL SYSTEM
D3 MAIN CONTACTOR DRIVE + VB level • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
D4 MAIN CONTACTOR DRIVE - PWM drive (VB-GND)
• The main contactor is not
input
D68 Traction current sensor power 12.5±1V • The controller does not • Traction right U-phase
D70 supply operate current sensor output large:
415
D71 • Traction right U-phase
D72 current sensor output small:
414
D73 Right U-phase traction current At no motor driving: 2.5±0.1V
• Traction right V-phase
sensor signal
current sensor output large:
D75 Right W-phase traction current 417
sensor signal • Traction right V-phase
D78 Left U-phase traction current current sensor output small:
416
sensor signal
• Traction left U-phase current
D79 Left W-phase traction current sensor output large: 419
sensor signal • Traction left U-phase current
D62 Traction current sensor power GND sensor output small: 418
supply GND • Traction left V-phase current
D69 sensor output large: 421
D74 • Traction left V-phase current
sensor output small: 420
D80
P70 Loading current sensor power 12.5±0.1V • The controller does not • Loading U-phase current
P71 supply operate sensor output large: 431
• Loading U-phase current
P72 sensor output small: 430
P73 Loading U-phase traction cur- At no motor driving: 2.5±0.1V • Loading V-phase current
rent sensor signal sensor output large: 433
• Loading V-phase current
P75 Loading V-phase traction current
sensor output small: 432
sensor signal
P74 Loading current sensor power GND
P78 supply GND
D64 Cooling fan power supply At fan driving: 24.0±3V • Internal cooling fan • Right Drive Cont.
malfunction temperature sensor
D65
malfunction: 426
• Loading Pump Cont.
temperature sensor
malfunction: 436
D102 Traction right controller tempera- Voltage between D102 and • The controller does not • Right Drive Cont.
ture + D103: Approx. 3.8V (25°C) operate temperature sensor rise:
D103 Traction right controller tempera- • Left traction speed decrease 427
• Right Drive Cont.
ture -
temperature sensor
malfunction: 426
D85 Traction left controller tempera- Voltage between D85 and • The controller does not • Left Drive Cont. temperature
ture + D86: Approx. 3.8V (25°C) operate sensor rise: 429
• Right traction speed • Left Drive Cont. temperature
D86 Traction left controller tempera-
decrease sensor malfunction: 428
ture -
P85 Loading controller temperature + Voltage between P85 and P86: • The controller does not • Pump Cont. temperature
P86 Loading controller temperature - Approx. 3.8V (25°C) operate rise: 437
• Loading speed decrease • Pump Cont. temperature
sensor malfunction: 436
CS-113
REFERENCE DATA OF CONTROL SYSTEM
D82 INV-RESET Inverter block signal: Inverter • Left traction malfunction • Traction left FET short: 412
stops at 5V or more • Traction left FET open: 411
D83 FAIL Inverter malfunction diagnosis
at GND level
D84 GND-C GND
D107 KEY1 VB level
D108 12V 12.5±1V
D109 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
P99 INV-RESET Inverter block signal: Inverter • Loading malfunction • Loading FET short: 412
stops at 5V or more • Loading FET open: 413
P100 FAIL Inverter malfunction diagno-
sis at GND level
P101 GND-C GND
P104 KEY1 VB level
P105 12V 12.5±1V
P106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
CS-114
REFERENCE DATA OF CONTROL SYSTEM
E1 Batt+ • VB level (E1-E2) (contactor • The controller does not • CONT condenser
E2 Batt- input) operate malfunction: 406
• Main contactor short: 400
E13 Batt+ • VB level (E13-E14) • Main contactor open: 401
(contactor input) • Main fuse open: 403
E14 Batt-
CS-115
MEMO
Joystick Controller
Terminal
No. Possible error mode/Related
Items Characteristic/Specification Related trouble diagnosis
(Controller symptom
side)
O25 POWER Joystick controller input power • Joystick controller –
supply: 8.5±1V malfunction
O26 POWER Joystick controller input power
supply: 8.5±1V
O27 GND Joystick controller power • Joystick controller –
supply GND malfunction
O30 GND Joystick controller power
supply GND
O32 KEY SW 2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
O31 KEY SW 1 (IGN) VB level (key switch 1 ON) • Joystick controller –
malfunction
O34 JS SENEOR POWER Proportional solenoid control • Proportional solenoid –
lever power supply: 5.0±0.2V control malfunction
• Proportional solenoid valve
malfunction
• The loading motor does not
rotate
• The loading motor speed is
slow
O36 LIFT SIGNAL 1 At lever operation • No lift operation • Lift sensor output large: 459
Between D34 voltage x 90% • The loading motor does not • Lift sensor output small:
and D34 voltage x 10% rotate 458
O37 LIFT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O35 JS SENSOR GND Proportional solenoid control • Proportional solenoid –
lever power supply GND control malfunction
• Proportional solenoid valve
malfunction
• The loading motor does not
rotate
O38 TILT SIGNAL 1 At lever operation • No tilt operation • Tilt sensor output large: 461
Between D34 voltage x 90% • The loading motor does not • Tilt sensor output small:
and D34 voltage x 10% rotate 460
O39 TILT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O40 3RD SIGNAL 1 At lever operation • No 3rd operation • 3rd sensor output large:
Between D34 voltage x 90% • The loading motor does not 461
and D34 voltage x 10% rotate • 3rd sensor output small:
O41 3RD SIGNAL 2 At lever operation • The loading motor speed is 462
Between D34 voltage x 90% slow
and D34 voltage x 10%
O42 4TH SIGNAL 1 At lever operation • No 4th operation • 4th sensor output large: 465
Between D34 voltage x 90% • The loading motor does not • 4th sensor output small:
and D34 voltage x 10% rotate 464
O43 4TH SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O44 1 STICK DETECT SW GND level (switch ON) • Unstable joystick control –
(FC-B)
O45 MULTI FUNCTION DETECT GND level (switch ON) • Unstable joystick control –
SW (JS-A)
O46 MULTI FUNCTION 1 TO 4 SW GND level (switch ON) • Multifunction lever –
4th/5th malfunction
CS-116
REFERENCE DATA OF CONTROL SYSTEM
CS-117