Manual Controlador EC25N2

Service Manual
Controller
MC
EC22N2 ATB30-00011-49999
EC25N2 ATB30-50001-99999
EC25EN2 ATB31-00011-29999
E25LN2 ATB31-30001-49999
EC30N2 ATB31-50001-99999
EC30LN2 ATB32-00011-49999
99759-8N200
FOREWORD
This service manual is a guide for servicing Cat® lift truck.
The long productive life of your lift truck(s) depends on regular and proper servicing
consistent with what you will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of the
components before attempting to start a test, repair, or rebuild the lift truck.
The descriptions, illustrations, and specifications contained in this manual are for lift trucks
with serial numbers in effect at the time of printing.
Cat Lift Trucks reserves the right to change specifications or designs without notice and
without incurring obligations. For your convenience the instructions are grouped by
systems as an easy reference.
Safety Related Signs and Meanings
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury.
NOTE: NOTE indicates a condition that can cause damage to or shorten the service life
of the machine.
Unauthorized copying and lending is prohibited.
Safety
WARNING
- The proper safe lubrication and maintenance for these lift trucks, recommended
by Cat Lift Trucks, are outlined in the SERVICE MANUAL. Read and understand
the SERVICE MANUAL before performing any lubrication or maintenance on
these lift trucks. Improper performance of lubrication or maintenance procedures
is dangerous and could result in injury or death. The serviceman or mechanic may
be unfamiliar with many of the systems on this lift truck. This makes it important
to use caution when performing service work.
- DO NOT operate these lift trucks unless you have read and understood the
instructions in the SERVICE MANUAL. Improper lift truck operation is
dangerous and could result in injury or death.
A knowledge of the system and/or components is important before the removal or
disassembly of any component.
Because of the size of some of the lift truck components, the serviceman or mechanic
should check the weights noted in this manual.
Use proper lifting procedures when removing any components.
The following is a list of basic precautions that should always be observed:
1. Read and understand all warning plates and decals on the lift truck before operating,
lubricating or repairing the product.
2. Always wear protective glasses and protective shoes when working around lift
trucks. In particular, wear protective glasses when using a hammer or sledge on any
part of the lift truck or its attachments.
3. Use welders gloves, hood/goggles, apron, and other protective clothing appropriate
to the welding job being performed. DO NOT wear loose fitting or torn clothing.
Remove all rings from fingers when working on machinery.
4. DO NOT work on any lift truck that is supported only by lift jacks or a hoist. Always
use blocks or jack stands to support the lift truck before performing any disassembly.
5. Lower the forks or other implements to the ground before performing any work on
the lift truck. If this cannot be done, make sure the forks or other implements are
blocked correctly to prevent them from falling unexpectedly.
6. Use steps and assist grips (if applicable) when mounting or dismounting a lift truck.
Clean any mud or debris from steps, walkways, or work platforms before using.
Always face lift truck when using steps, ladders, and walkways. When it is not
possible to use the designed access system, provide ladders, scaffolds, or work
platforms to perform safe repair operations.
7. To avoid back injury, use a hoist when lifting components which weigh 23 kg (51 lb)
or more. Make sure all chains, hooks, slings, etc., are in good condition and are of
the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be
side loaded during a lifting operation.
8. To avoid burns, be alert of the hot sections and hot fluids in lines, tubes, and
compartments, even when lift truck is idle or off.
9. Be careful when removing cover plates. Gradually remove the last two bolts or nuts
located at opposite ends of the cover or device and pry cover loose to relieve any
springs or other pressures, before removing the last two bolts or nuts completely.
10. Be careful when removing filler caps, breathers, and plugs on the lift truck. Wrap a
cloth around the cap or plug to prevent being sprayed or splashed by liquids under
pressure. Be aware that the danger of being sprayed or splashed is ever greater if it is
immediately after stopping the lift truck, as fluids is very hot.
11. Use well maintained tools in a proper way.
12. Install all fasteners with same part number. DO NOT use a lesser quality fastener if
replacements are necessary.
13. If possible, make all repairs with the lift truck parked on level, hard surface.
Block lift truck so it does not roll while working on or under lift truck.
14. Before starting to work on lift truck, hang "DO NOT Operate" tag in the Operator
Compartment.
15. Repairs, which require welding, should be performed only with the appropriate
reference information and by personnel adequately trained and knowledgeable in
welding procedures. Determine the type of metal and select the correct welding
procedure and electrodes, rods, or wire to provide a weld metal strength equivalent
at least to that of parent metal.
16. DO NOT damage wiring during the removal process. DO NOT reuse the damaged
wiring. Install the wiring making sure not to contact sharp corners or hot parts. Place
wiring away from oil pipe.
17. Be sure all protective devices including guards and shields are properly installed and
functioning correctly before starting a repair. If a guard or shield must be removed
to perform the repair work, use extra caution.
18. Always support the mast and carriage to keep carriage or attachments raised when
maintenance or repair work is performed, which requires the mast in the raised
position.
19. Loose or damaged fuel, lubricant, hydraulic lines, tubes, and hoses could cause fires.
DO NOT bend or strike high pressure lines or install ones which have been bent or
damaged. Inspect lines, tubes, and hoses carefully. DO NOT check for leaks with
your hands. Pin hole (very small) leaks could result in a high velocity oil stream that
will be invisible close to the hose. This oil could penetrate the skin and cause
personal injury. Use cardboard or paper to locate pin hole leaks.
20. Tighten connections to the correct torque. Make sure that all heat shields, clamps
and guards are installed correctly to avoid excessive heat, vibration or rubbing
against other parts during operation. Shields that protect against oil spray onto hot
exhaust components in event of a line, tube, or seal failure, must be installed
correctly.
21. Relieve all pressure in air, oil or water systems before any lines, fittings or related
items are disconnected or removed. Place blocks to prevent a device from falling if
it is in the raised position. Release the residual pressure when removing a
pressurized device.
22. DO NOT operate a lift truck if any rotating part is damaged or contacts any other
part during operation. Any high speed rotating component that has been damaged or
altered should be checked for balance before reusing.
Symbols and Abbreviations

Symbol or abbreviation Meanings
OP. Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
- SI Units are used in this manual.
- The following table shows the conversion of SI unit and customary unit.
Item SI unit Metric unit Yard-pound unit
Force 1N 0.102 kgf 0.225 lbf
Pressure 1 MPa 10.1972 kgf/cm2 145.038 psi
Torque 1 N·m 0.102 kgf·m 0.7376 lbf·ft
1 mm - 0.039 in.
Length
1m - 3.281 feet
Weight 1 kg - 2.205 lb
Temperature 1 °C - °F=1.8 x °C+32
Volume 1L - 0.264 US.gal.
TABLE OF CONTENTS
CHAPTER 1 CONTROLLER
1.1 Controller System
1.1.1 System Layout
1.1.2 Controller Area Network (CAN)
1.1.3 Outline of Logic Unit
1.1.4 Outline of Inverter
1.2 Traction Controller Feature
1.2.2 Powering
1.2.3 Regeneration
1.3 Lifting Controller Feature
1.3.1 Setting and Limitation of Lift Work Speed
1.3.2 Lift Stop
1.4 Steering Control Features
1.5 Meter Panel
1.5.1 Configuration of Meter Panel
1.5.2 Meter Panel Screen
1.5.3 Meter Panel Screen Transition
1.5.4 Diagnostic Code
1.5.5 Password Entry
1.5.6 User Setting Function
1.6 Other Features
1.6.1 PDS (Presence Detection System) Feature
1.6.2 Stall Timer
1.6.3 Password Certification
1.6.4 BDI (Battery Discharge Indicator)
1.6.5 Service Indicator
1.6.6 Tire Size Speed Adjustment
1.7 Setup Option
1.7.1 Outline
1.7.2 Details of Setup Options (Group-1)
1.7.5 Setup Options (Group 1)
1.8 Diagnostics
1.8.1 Outline
1.8.2 Operation Procedure
1.8.3 Self-Diagnostics
1.8.4 Run Time Diagnostics
1.9 Removal and Installation
1.9.1 Inverter Discharging Procedure
1.9.2 Replacing Inverter
1.9.3 Insuring Proper Thermal Transfer
1.9.4 Replacing DSP (Digital Signal Processor) Card
1.9.5 Replacing Logic Unit
1.9.6 Replacing Logic Card
1.9.7 Replacing Power Supply Card
1.10 Basic Check
1.10.2 Testing Tools
1.10.3 Measurement of Card Voltage
1.10.4 Checking Contactor Coil
1.10.5 Checking Contactor Tips
1.10.6 Checking Inverter
1.10.7 Regeneration Check
1.11 AC Motor System Basics
1.11.1 Feature of AC motor
1.11.2 Speed Control of Induction Motors
1.11.3 Inverter
1.12 AC Motor Troubleshooting
1.12.1 Motor Noises
CHAPTER 2 TROUBLESHOOTING FOR CONTROL
CIRCUITS
2.1 General Information
2.1.1 Before Replacing Devices
2.1.2 Connection of the Service Tool
2.1.3 How to Clean Harness Connectors and System Components
2.2 List of Diagnostic Codes
2.3 Troubleshooting
2.3.1 Traction Motor, Overheating (E0)
2.3.2 Pump Motor, Overheating (E2)
2.3.3 Traction Inverter, Overheating (E5)
2.3.4 Pump Inverter, Overheating (E7)
2.3.5 Traction Motor, Current Sensor Fault (14)
2.3.6 Traction Motor, Over-Current (15)
2.3.7 Traction Motor, Stall Timer (16)
2.3.8 Pump Motor, Current Sensor Fault (34)
2.3.9 Pump Motor Over-Current (35)
2.3.10 Line Contactor, Fault (40)
2.3.11 Traction Motor, Open (45)
2.3.12 Pump Motor, Open (47)
2.3.13 Steering Motor, Fault (49)
2.3.14 Accelerator Sensor, Fault (51)
2.3.15 Traction Motor, Pulse Input Fault (52)
2.3.16 Pump Motor, Pulse Input Fault (57)
2.3.17 Direction Lever or Accelerator, Faulty Setting (E)
2.3.18 Seat Switch, Faulty Setting for Traction ((E))
2.3.19 Seat Switch, Faulty Setting for Hydraulic ((L))
2.3.20 Lift Lever, Faulty Setting (H1)
2.3.21 Tilt Lever, Faulty Setting (H2)
2.3.22 Attachment 1 Lever, Faulty Setting (H3)
2.3.23 Attachment 2 Lever, Faulty Setting (H4)
2.3.24 Meter Panel, Communication Fault (60)
2.3.25 Logic Card, Initialize Failure (61)
2.3.26 Logic Unit, Fault (62)
2.3.27 Traction Inverter, Fault (63)
2.3.28 Pump Inverter, Fault (65)
2.3.29 Contactor, Coil Fault (72)
2.3.30 Hydraulic Lock Solenoid, Fault (74)
2.3.31 Electromagnetic Brake, Solenoid Fault (75)
2.3.32 PDS Buzzer, Fault (76)
2.3.33 Battery, Voltage Too Low (78)
2.3.34 Battery, Voltage Too High (79)
2.3.35 Battery, Consumption Too Much (Lo)
2.3.36 Battery, Consumption Much ((L0))
2.3.37 Brake Fluid, Low Level
2.3.38 RTC Battery, Low
CHAPTER 3 HOW TO READ CIRCUIT DIAGRAMS
3.1 Description of Circuit Diagrams
3.1.2 Circuit Diagrams
3.1.3 Connector Diagrams
3.2 How to Read Circuit Diagrams
3.2.2 Symbols
3.2.3 Sheet Symbol
3.2.4 Connecting Lines
3.2.5 Equipment
3.2.6 Relay Contactor and Coil
3.2.7 Connectors
3.2.8 Indication of Connecting Line
3.2.9 Indication of GND (Earth)
3.2.10 Indication of Another Specification
3.3 How to Read Connector Diagrams
Chapter 1 CONTROLLER
1.1 CONTROLLER SYSTEM
1.1.1 SYSTEM LAYOUT
The lift truck is controlled by the logic unit and the inverter.
The logic unit is the main part of the control system and controls the travel, lifting and
safety function systems. The logic unit is connected to the inverter, meter panel and other
control switches.
The inverter controls the AC induction traction motor and the AC induction pump motor.
The logic unit, the inverter, and meter panel are linked together by the Controller Area
Network (CAN) to communicate with each other. The logic unit sends the motor control
command to the inverter and the inverter sends the sensing data to the logic unit.
The meter panel indicates the lift truck conditions and setting data.
1.1.2 CONTROLLER AREA NETWORK (CAN)
Each controller is linked with the lift truck harness to form a network as follows:
The terminal resistors are built into the traction inverter and the pump inverter.
If the terminal resistors are not properly connected, a communication failure may occur
between the logic unit and the inverters.
For details, refer to Traction Inverter, Fault (63) and Pump Inverter, Fault (65) in Before
Replacing Devices.
The data are expressed with electric potential difference in high- and low-level signals as
follows:
They are transferred to each controller through the serial communication protocol.
Main specifications
Item Specifications
Non-return to zero method
Communication protocol CAN bus 2.0B passive
Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes
1.1.3 OUTLINE OF LOGIC UNIT
Logic unit
The logic unit consists of the logic card and the power supply card.
The logic card has the CPU chips and controls all the jobs for the lift truck.
The logic unit calculates the traction motor control command through the input of the
direction lever or accelerator pedal and sends the command to the traction inverter. It also
monitors malfunctions of the traveling control system.
The logic unit calculates the AC induction pump motor control command through the input
of the hydraulic levers and sends the command to the pump inverter. It also monitors
malfunctions of the lifting control system.
The logic unit communicates with the meter panel through the CAN bus. The lift
truck speed and residual battery power are monitored and shown on the meter panel. The
seat belt and brake fluid level are also monitored and shown on the meter panel.
The logic unit sets the model information and optional default data into internal memory.
The information is secured even if the power supply for the logic unit is turned OFF. This
information is set at the factory.
The following table shows the model information. The system will not work properly if the
actual controller system is different from the model information.
Model Information
Item Description SUO No.
Lift truck model Model set #40
Battery voltage 36 V, 48 V #41
Battery type Battery type #42
Mast type Mast type #44
Valve section Number of valves #45
Battery voltage adjustment Battery voltage adjustment #46
Foot direction Optional equipment #47
The current information is available to confirm and modify.
Refer to Outline.
The model information and various features are set by the Setup Option (SUO).
The power supply card changes the battery voltage and supplies power to the logic card and
the DSP card.
Logic unit
Logic card
1. LOGIC CARD SIDE CN1 3. MAIN HARNESS SIDE E-03
2. MAIN HARNESS SIDE E-02 4. MAIN HARNESS SIDE E-04
Power supply card
1. POWER SUPPLY CARD SIDE CN1

2. MAIN HARNESS SIDE E-01
1.1.4 OUTLINE OF INVERTER
The inverter is a motor drive controller that consists of Digital Signal Processor (DSP) card,
Insulated Metal Substrate (IMS) module and their drive boards.
It drives the AC induction motors according to the motor control command from the logic
unit. It also monitors malfunctions of motors and its own condition.
When a malfunction occurs, it stops the motors and informs the logic unit.
The DSP card has the DSP chips that enables high-speed calculation and controls the AC
induction motors.
The IMS module has plural MOS-FET modules and converts the battery DC current into
AC current for supplying to the traction and pump motors. Also refer to Feature of AC
motor .
Traction and pump inverters
1. DSP CARD
Traction and pump inverter DSP card
1) TRACTION INVERTER CARD SIDE CN2

PUMP INVERTER CARD SIDE CN2
2) MAIN HARNESS SIDE, TRACTION E-06
MAIN HARNESS SIDE, PUMP E-05
1.2 TRACTION CONTROLLER

FEATURE
The line contactor closes in the following conditions when the key switch is turned ON.
This enables the inverter to control the traction motor.
All the following must be satisfied:
- The seat switch is turned ON.
- The lifting operation is not performed (the hydraulic lever input does not occur).
- The traveling operation is not performed: The direction lever is placed to NEUTRAL
and the accelerator pedal is not pressed.
- Warning related to the traveling and lifting operations does not occur.
1.2.2 POWERING
Normal traveling
Travel speed is controlled by the accelerator pedal depression. The speed is also controlled
by the accelerator pedal depression when descending a grade and it is controlled only in the
output torque range of the traction motor.
The controller supplies power to the traction motor according to the acceleration rate and
the torque characteristic when the accelerator pedal is pressed.
Description SUO No.

Acceleration rate Acceleration of traction #8
Powering
Traveling power Max. power, amount of battery consumption #9
*1 Brake limit: Torque value resulting from reduction in current when the service brake or
parking brake is applied.
*2 Thermal, BDI Level [0] or Service indicator: Curve of limited torque under a condition
of overheating or battery voltage low or maintenance time over.
Boost
When lift truck travel is blocked by a step, the boost function prevents stalling of the lift
truck. This function allows the lift truck to bypass a step regardless of the value setting of
the motor maximum torque.
Fully depress the accelerator pedal for 2 seconds. The boost function increases the motor
maximum torque for 5 seconds. If the pressure on the accelerator pedal is reduced or the
direction lever is moved, the boost function will be canceled immediately.
SUO
Item Description
No.
When the service brake pedal is pressed or the parking brake is applied,
the boost function is not activated.
Boost If the service brake pedal is pressed or the parking brake is applied when #9
the boost function is being activated, the boost function will be canceled
immediately.
NOTE: The lift truck is equipped with a stall timer. If the lift truck travel is blocked by
an obstruction or is traveling on too steep a grade and the accelerator is fully
depressed, the stall timer will only allow the boost function to operate for a
preset duration of time to prevent overheating and damage to the traction motor.
If the preset stall time is exceeded, diagnostic code 16 will be present.
Limitation of maximum travel speed
This function limits the maximum travel speed of the lift truck.
The limitation that functions at all times and is used to keep the speed within the limits.

Maximum travel speed limit Always effective #7
1.2.3 REGENERATION
There are three types of regeneration control: the accelerator regeneration, lever
regeneration, and brake regeneration.
Accelerator regeneration
The accelerator regeneration starts when the accelerator pedal is released with the direction
lever shifted into the FORWARD or REVERSE position during traveling.
SUO
Item Description
No.
Accelerator
The amount of regeneration is determined by the
regeneration #23
accelerator regeneration characteristic
(Auto regeneration)
Lever regeneration
The lever regeneration starts when the direction lever is shifted into the position opposite of
the traveling direction with the accelerator pedal depressed during travel.
SUO
Item Description
No.
Lever The amount of regeneration is determined by the lever
#22
regeneration regeneration characteristic.
Brake regeneration
Brake regeneration starts when the brake pedal is pressed.
NOTE: Brake regeneration also starts when the parking brake is applied.
SUO
Item Description
No.
Brake The amount of regeneration is determined by the setting
#21
regeneration value
Controlled roll-back
This function prevents hazardous descending of the lift truck on a grade.
The controlled roll-back is activated when the accelerator pedal is released on a grade with
the direction lever shifted into the FORWARD or REVERSE position.
The descending speed changes with the steepness of grade and the weight of load.
NOTE: This is not a function to stop the lift truck when the accelerator pedal is released
on a grade. This function is activated only in the output torque range of the
traction motor.
1.3 LIFTING CONTROLLER FEATURE

1.3.1 SETTING AND LIMITATION OF
LIFT WORK SPEED
Each lift work speed can be set. The lift work speed can be limited or stopped when
specific switch input occurs.
Triple input signals are selectable and available to set limit value to each signal.
Feature of lifting work speed setting

Start lift speed Start lift speed setting #2
Top lift speed Top lift speed setting #3
Normal Tilt speed Tilt speed setting #4
Auxiliary 1 speed Attachment 1 #5
Auxiliary 2 speed Attachment 2 #6
Refer to Outline.
1.3.2 LIFT STOP

This will stop the lifting operations in progress when the auxiliary SW input can choose
close or open.
To release the stop function, bring the lever to the NEUTRAL position, and start the
operation.
SUO
Item Description
No.
Auxiliary input for lift and Stops lift when auxiliary input 1
#11
drive speed 1 close/open
Condition #14
#17
1.4 STEERING CONTROL FEATURES

The steering contactor closes and drives the steering motor when all the conditions for
closing the line contactor (described in the traction control features) are satisfied. This
enables the power steering operation.
After the steering contactor is closed, if the key switch is not turned OFF or if warning
related to the steering operation does not occur, the steering contactor will open when the
seat switch is opened.
1.5 METER PANEL

1.5.1 CONFIGURATION OF METER PANEL
Meter panel
1. WARNING LED
2. SCREEN
3. FRONT PANEL BUTTONS
1. Warning LED
In addition to a text message on the screen, this red
warning LED will illuminate in the case of a detected
warning, which limits lift truck operation.
2. Screen
For details, refer to Meter Panel Screen.
3. Front panel buttons
These directional buttons are used to make adjustments to items shown on the screen
and to access the main menu where further set-up options and diagnostics features
are housed.
1.5.2 METER PANEL SCREEN
1. OVERHEATED WARNING ICON
2. PARKING BRAKE WARNING ICON
3. SEATBELT WARNING ICON
4. TRAVEL DIRECTION INDICATOR
5. TRAVEL SPEED/MESSAGE CENTER
6. MAST INTERLOCK INDICATOR ICON
7. SERVICE BRAKE FLUID WARNING ICON
8. SERVICE INDICATOR
9. SLOW SPEED MODE ICON
10. ADVISORY AREA
11. BATTERY DISCHARGE INDICATOR
12. BATTERY WARNING ICON
1. Overheated warning icon
The thermometer icon glows if an over
temperature condition develops in the
traction motor, pump motor, or the
controller.
2. Parking brake warning icon
When the brakes are engaged on the traction motors, this icon will be illuminated.
3. Seatbelt warning icon
This warning icon glows when the seat belt is not worn or when the seat belt is not
properly buckled.
4. Travel direction icon
Displays the approximate direction of travel during regular driving, based on
direction selected.
Item Icon Item Icon
FORWARD NEUTRAL (ON)
REVERSE NEUTRAL (OFF)
5. Travel speed / Message center

Displays the lift truck speed during normal operation and displays text messages
when there is a warning or fault detected. The travel speed display can be switched
between KPH and MPH.
6. Mast interlock indicator icon
The lift and/or tilt lever can not be operated when the operator is not sitting properly
in seat for approximately 2 seconds.
7. Service brake fluid warning icon
When the icon is ON, service brake fluid is low level.
8. Service indicator
The wrench icon glows when it is time for planned maintenance.
9. Slow speed mode icon
The turtle icon glows when maximum travel speed has been reduced, due to an over
temperature condition, low battery condition, or when the carriage has been raised
above free lift.
10. Advisory area
- Date
Displays the current date. The date display can be switched between the following
formats: MM/DD/YYYY, DD/MM/YYYY, or YYYY/MM/DD.
- Hour meter
The lift truck hour meter will be displayed in this area for approximately 3 seconds
after the key switch is turned to the ON position. This hour meter is helpful to
determine the next periodic inspection.
- Clock
Displays the current time. The time can be switched between a 12-hour and a 24-
hour clock.
Item Display form
MM/DD/YYYY
Date
DD/MM/YYYY
YYYY/MM/DD
Vehicle hours HV 12345.6
Drive hours HD 12345.6
Hour meter
Pump hours HP 12345.6
Steering hours HS 12345.6
HH: MM (24H)
Time
HH: MMA, HH: MMP (12H)
11. Battery discharge indicator
The battery charge status is
indicated by the ten element
indicator.
When fully charged, all
elements are lit through to the
right side. As the battery
discharges, the indicator
elements decrease toward the
left side. When only one
element is ON, the remaining
battery charge warning light
will glow. When the indicator
completely goes OFF. The
remaining battery charge
warning light will be
continuously lit and the lift
truck enters power reduction
mode.
12. Battery warning icon
This icon will glow when there is only one element left on the 10-element battery
discharge indicator, indicating that it is time to charge the current battery.
1.5.3 METER PANEL SCREEN TRANSITION
The screen transition on the meter panel and the operation procedures are as follows:
Screen operation procedures
(1) Press button with the speed data displayed.
When the warning is being displayed, first press button to display the speed data,
then press button.
(2) Press or button to display "Adjustment Menu", then press button.
(3) Press or button to choose from "Date", "Clock", "Speed", "Date format", "Clock
format", "Brightness", "Truck mode", "Software version", and "Exit” for setup.
(4) Press or button to display "Exit", then press button.
1.5.4 DIAGNOSTIC CODE
Diagnostic code display
The diagnostic code is displayed in the indication area when a malfunction occurs.
When multiple faults occur simultaneously, the codes are displayed alternately every three
seconds as shown in the figure.
Item Description
Diagnostic code Indicates the code assigned to the fault.
Warning
Glows (or blinks) while the fault is occurring.
1.5.5 PASSWORD ENTRY

How to enter password
Enter the password by using the following procedures:
Confirm “0000” is shown on the password entry screen, and press button to increase or
decrease the number. Press button r to shift to the next digit.
1.5.6 USER SETTING FUNCTION
User setting function
This function changes the user setting data: “Date”, “Clock”, “Speed unit”, “Date format”,
“Clock format”, “Display brightness”, “Truck mode”, and “Software version”.
These data settings are stored in the built-in memory and read to display the data in the
format set previously when turning ON the power.
Press or button to change the figure (or selection). Press button to determine it.
To display these user data settings, perform steps 1 and 2 of the display operation
procedures (refer to Meter Panel Screen Transition), select the required user data settings
with button or , then press button .
1. Date
Adjust date.
2. Clock
Adjust clock.
3. Speed unit
Select MPH or KM/H.
4. Date format
Select US, EU or JPN.
5. Clock format
Select 24H or 12H.
6. Display brightness
Select brightness
[0 (dark) thru 10 (light)].
7. Truck mode display
Truck mode change.
8. Logic software version
Select software version.
1.6 OTHER FEATURES

1.6.1 PDS (PRESENCE DETECTION SYSTEM) FEATURE
This controller is part of the "Presence Detection System" (PDS) of the lift truck. This
system features an enhanced, integral computer based feed back system which provides
"certain product intelligence" to the operator. The table shows processes for traction and
lifting.
PDS features
Item Protect condition Result Release method

Sit → Sit and
Seat
Traction Leave Slowdown and Direction lever: N
control Direction Stop Accelerator pedal:
F or R Release
lever
Hydraulic Sit →
Seat Stop Sit and
control Leave
Control valve SW: All
open
PDS status transfer chart
NOTE: In the initial state, E, H1, H2, H3 or H4 may appear.
Prevention result
Operated item When turning ON When operator is on seat again
power after leaving seat
Traveling, lifting, and
Traveling and lifting stop.
Direction lever or steering stop.
Travel direction “N” of meter
accelerator pedal Diagnostic code “E”
panel glows
glows
steering stop.
Lift lever Mast interlock indicator of meter
Diagnostic code “H1”
panel glows
glows
steering stop.
Tilt lever Mast interlock indicator of meter
panel glows
glows
steering stop.
Attachment 1 lever Mast interlock indicator of meter
panel glows
glows
steering stop.
Attachment 2 lever Mast interlock indicator of meter
panel glows
glows
Preventing lift down
This function prevents the lift from lowering when the lift lever is operated with the key
switch turned OFF.
The lift does not lower as the lift lock valve is closed when the key switch is turned OFF
(when the control system is not controlled by the controller).
Warning buzzer
- Parking brake warning
The buzzer sounds when the key switch is turned OFF or the operator leaves the
operator's seat with the parking brake not applied.
- Seat belt warning
The buzzer sounds when the seat belt is not fastened with the operator on the
operator's seat.
1.6.2 STALL TIMER
Traction Motor Stall Timer (Diagnostic code 16) warning occurs to prevent the traction
motor from overheating when the lift truck travel is blocked for several seconds and the
accelerator pedal is fully depressed.
Stall timer The time to shut down the lift truck can be set. #20
1.6.3 PASSWORD CERTIFICATION

Password effective time can be changed within the preset time range. If the lapse time from
key-OFF to key-ON is within the set time, input of password can be omitted.
SUO
Item Description
No.
Password Effective time can be set within the range of 0 to 90
#38
certification min.
1.6.4 BDI (BATTERY DISCHARGE INDICATOR)
The BDI shows the remaining battery capacity of the current battery voltage with 11 levels
from BDI 0 to BDI 10.
Set the BDI by SUO #41 and SUO #42 depending on the installed battery type and voltage.
If the previous indication is BDI 4 or less and the following indication is not BDI 7 or more
when turning ON the key switch, the BDI will show the previous indication.
When the battery voltage lowers, the following output power control is activated by the
BDI function to protect the battery:
Control by BDI 1: Traveling is limited.
Control by BDI 0: Traveling and lifting are limited, and simultaneous operations of
traveling and lifting are inhibited.

Battery voltage Selects battery voltage #41
Battery type Selects battery types #42
1.6.5 SERVICE INDICATOR
The service indicator starts blinking 20 hours before the set maintenance time, and remains
lit when the lift truck hour meter indication reaches the set time.
If the output power control is selected, the output power control will also be activated at the
same time to limit the traveling and lifting operations.
SUO
Item Description
No.
Service The maintenance time and the selection of output power
#10
indicator control can be set.
1.6.6 TIRE SIZE SPEED ADJUSTMENT
Tire diameter change resulting from tire wear can be compensated for.
This setting is used to adjust the travel speed indication when it differs from the actual
speed by tire wear.

Tire size speed adjustment Adjust travel speed by tire size. #27
1.7 SETUP OPTION

1.7.1 OUTLINE
The logic unit is equipped with a type of memory module to hold recorded data even if the
main power is turned OFF.
The model information and various features are set during factory shipment.
The setup options are categorized from Group 1 to Group 3 according to the feature levels.
Setup group
Group Description
Group 1 Basic function (#1 to #10)
Group 2 Detailed function (#11 to #38)
Group 3 Model information (#40 to #47)
The Group 1 and 2 are available to set the default value in a one-step operation and can be
customized in accordance with applications. Since the Group 3 is for model information, it
is required to be set to the same value as actual control system. It will not work properly if
the model information is different.
When setting the setup option data for the first time after the assembly is completed or the
logic card is replaced, be sure to set Group 3 data first, then the default data of Group 1 and
2 with service tool in each setup mode.
1.7.2 DETAILS OF SETUP OPTIONS (GROUP-1)
#1 Application presets (Lift truck operation mode)
Lift truck operation mode can be selected from A to E, each with preset values for start lift
speed, top lift speed, tilt speed, maximum travel speed, acceleration rate, traveling power,
brake regeneration, and accelerator regeneration.
These 8 settings are automatically set by changing the value of this setting.
Preset values for each setting are as follows. The setting range is A to E.
48V type mode setting
SUO
#
Mode A B C D E
Feature/Applicati Preset Preset Preset Preset 1
Preset 3
on 1 2 4 5
Lift Fast Fast Medium Fast Fast
Tilt Slow Slow Slow Slow Slow
Travel Mediu Mediu
Fast Slow Fast
speed m m
Characteristic Acceleratio Mediu Mediu

Fast Medium Fast
n m m
Standar Powerf Econom Standar Powerf
Power
d ul y d ul
Regenerati Mediu Mediu Mediu Mediu
Medium
on m m m m
Default value Start lift
1 1 1 1 1 2
(Standard) speed
Top lift
9 10 8 9 10 3
speed
Tilt speed 1 1 1 1 1 4
Maximum
15 18 12 17 15 7
travel speed
Acceleratio
3 5 2 3 5 8
n rate
Traveling
2 3 1 2 3 9
power
Brake
regeneratio 7 7 7 7 7 21
n
Accelerator
n
Start lift
1 1 1 1 1 2
speed
Top lift
8 8 8 8 8 3
speed
Maximum
14 14 14 14 14 7
travel speed
Default value Acceleratio

2 2 2 2 2 8
(EE) n rate
Traveling
1 1 1 1 1 9
power
Brake
n
Accelerator
n
You can modify these 8 settings afterwards individually.
When settings are changed the indication (A to E) will blink to indicate that the settings are
modified.
36V type mode setting
SUO
#
Mode A B C D E 1
Feature/Applicati Preset Preset Preset Preset
Preset 3
on 1 2 4 5
Lift Fast Fast Medium Fast Fast
Tilt Slow Slow Slow Slow Slow
Travel Mediu Mediu
Fast Slow Fast
speed m m
Characteristic Acceleratio Mediu Mediu

Fast Medium Fast
n m m
Standar Powerf Econom Standar Powerf
Power
d ul y d ul
Regenerati Mediu Mediu Mediu Mediu
Medium
on m m m m
Start lift
1 1 1 1 1 2
speed
Top lift
9 10 8 9 10 3
speed
Maximum
15 17 12 17 15 7
travel speed
Default value Acceleratio

3 5 2 3 5 8
(Standard) n rate
Traveling
2 3 1 2 3 9
power
Brake
n
Automatic
n
Start lift
1 1 1 1 1 2
Default value speed
(EE) Top lift
8 8 8 8 8 3
speed
Maximum
12 12 12 12 12 7
travel speed
Acceleratio
2 2 2 2 2 8
n rate
Traveling
1 1 1 1 1 9
power
Brake
n
Automatic
n
#2 Start lift speed
This setting affects pump speed when you start the lifting operation.
Speed when lift switch 1 is turned ON
Lift speed of the rise direction will become faster if the setting value is increased.
The setting range is 1 to 10 for all models.
#3 Top lift speed
This setting affects pump speed when you pull the lift lever. If you set a smaller value than
#2, then the #2 setting will be ignored.
Speed when lift switch 2 is turned ON
Lifting speed will become faster if the value setting is increased.
Pump motor output characteristics (lift-up operation)

#4 Tilt speed
This setting affects pump speed when you pull the tilt lever.
Speed when tilt switch is turned ON.
Tilting speed will become faster if the value setting is increased.
#5 Auxiliary 1 speed
This setting affects pump speed when you operate the attachment 1 lever.
Speed when attachment 1 switch is turned ON
Attachment 1 speed will become faster if the value setting is increased. The range setting is
1 to 10 for all models.
#6 Auxiliary 2 speed
This setting affects pump speed when you operate the attachment 2 lever.
Speed when attachment 2 switch is turned ON
Attachment 2 speed will become faster if the value setting is increased. The range setting is
1 to 10 for all models.
#7 Maximum travel speed limit
This setting affects maximum lift truck speed without load. Travel speed with load will be
less than this setting. This setting affects top speed, and does not affect traveling on a grade
or acceleration.
The range setting is 5 to 18 [km/h].
[When #41 is set for “36 volts”: 5 to 17.]
[When #40 is set for “EE type”, #41 is set for “36 volts”: 5 to 12 and when #41 is set for
“48 volts (EE type)”: 5 to 14.]
#8 Acceleration rate
This setting affects response time to calculate speed order from accelerator pedal position.
Acceleration of lift trucks becomes faster if the value setting is increased.
The range setting is 1 (slowest) to 5 (fastest).
(When #40 is set for “EE type”: 1 to 2.)
#9 Traveling power mode
This setting affects the required torque which is calculated from the accelerator pedal
position.
The values are selected from three types: ECONOMY, STANDARD, and POWER.
The figure shows the torque characteristic to the speed.
Torque value resulting *2 Thermal, BDI [0] or Service indicator: Curve

*1
from reduction in BDI [0], or of limited torque under a condition of
Brake
current when the brake Service overheating or battery voltage low or
limit:
is applied. indicator: maintenance time over.
#10 Service indicator
This setting sets the maintenance time. The time set here is added to the lift truck hour
meter and that value is stored in memory as the "maintenance time."
When the lift truck hour meter reaches maintenance time, the service indicator icon on the
meter panel turns ON.
It will glow 20 hours before the time.
You can reduce the traveling power when the service indicator icon on the meter panel
glows by setting the service indicator selection. You can also set the demo-mode, which
shows the service Indicator function in a short period of time.
The setting value is as follows:
In
6 min
Maintenance time [hour] - 100 150 increments 950 1000
(test)
of 50
Invalid 0
Only
Set data on meter 0.1 100 150 ---- 950 1000
warning
panel
Torque
=0.1 =100 =150 ---- =950 =1000
limit
#11 Auxiliary input for lift and drive speed 1
(Harness pin No. 40)
This setting defines the function of "Auxiliary 1" switch. This value has an effect on #12
and #13 when 2, 3, 5, or 6 is selected.
The setting value is as follows:
Value Lift Travel

0 - -
1 Disable lift *1 (switch closed) -
Speed limit
2 -
(switch closed)
3 - Power reduction (switch closed)
4 Disable lift *1 (switch opened) -
Speed limit
5 -
(switch opened)
6 - Power reduction (switch opened)
*1 Place the lever in NEUTRAL. Lift starts moving by operating the lever again.
#12 Auxiliary travel speed limit 1
This setting defines maximum speed when the “Auxiliary 1” switch is closed or opened.
The setting range is 5 to 18 [km/h]. Effective when the data of #11 is 2 or 5.
#13 Auxiliary power reduction rate 1
This setting defines traction power reduction when the “Auxiliary 1” switch is closed or
opened.
The setting range is 0 to 100 [%]. Effective when the data of #11 is 3 or 6.
This setting defines the function of “Auxiliary 2” switch. This value has an effect on #15
The setting value is the same as that of #11.
opened.
This setting defines the function of “Auxiliary 3” switch. This value has an effect on #18
The setting value is the same as that of #11.
opened.
#20 Stall timer
This setting shuts down the lift truck when the traction motor torque is very high (about
90% of maximum) and the wheels are not turning. This function is used to detect pulse
sensor faults and to prevent the controller from overheating.
The setting range is 2 to 10 seconds for all models.
#21 Brake regeneration
This works when the brakes are applied.
When the setting value is higher than “#23”, regenerative power will increase by stepping
on the brake.
When the setting value is lower than “#23”, the regenerative rate will be the same as the
“#23.”
#22 Lever regeneration
This setting defines the “Lever regeneration” characteristic.
When the direction lever is shifted into the position opposite to the traveling direction, the
“Lever regeneration” function is activated. The “Lever regeneration” characteristic is
shown in the diagram. The setting range is 1 to 10.
#23 Accelerator regeneration
This setting defines amount of deceleration when "Accelerator regeneration" is activated.
#24 Chat timer

This setting turns OFF power when the lift truck is not operated in order to cut down
electric power consumption.
Time setting is available from 0 to 40 seconds.
#26 Speed alarm 1
This setting defines speed of turning on the "Speed alarm 1" light.
The setting range is 5 to 18 [km/h].
#27 Tire size speed adjustment
This setting is used to adjust the travel speed indication when it differs from the actual
speed by tire wear. Tire diameter change resulting from tire wear can be compensated for.
The setting value is -20, 0, or 20 [mm].
#30 Auxiliary input for travel speed (Harness pin No. 31)
When the speed limit signal is ON, travel speed or power is limited to set value. The
amount of maximum speed is defined at #31. The amount of power reduction is defined at
#32.
The setting range is 0 or 1. (0: Disable, 1: Enable)
#31 Auxiliary maximum travel speed setting (Harness pin No. 31)
This setting defines the lift truck speed limit set up by #30.
The setting range is 5 to 18 [km/h].
#32 Auxiliary output power limit
This setting defines the traction power reduction ratio set up by #30.
The setting range is 0 to 100 [%].
#38 Password certification
This defines the password certification ON/OFF after key switch OFF.
The setting range is 0 to 90 [min].

#40 Truck model
This setting defines the type of lift truck.
The setting value is as follows.
Display Model
1 EC22N2
2 EC22N2EE
3 EC25N2
4 EC25N2EE
5 EC25EN2
6 EC25N2EE
7 EC25LN2
8 EC25LN2EE
9 EC30N2
10 EC30N2EE
11 EC30LN2
12 EC30LN2EE
CAUTION
If the lift truck model setting is incorrect, the lift truck may show
unexpected movement.
#41 Battery voltage

This setting defines the voltage of battery installed in the lift truck.
The setting value is 36 or 48 [V].
#42 Battery type
This setting defines the type of battery carried in the lift truck.
The setting value is 0, 1, or 2.
0: Normal BDI 1: Tubular BDI 2: Gel BDI
This value selects Battery Discharge Indicator (BDI) table. The table is as follows:
Normal BDI
BDI# 36V 48V

0 - 34.4 - 45.9
1 34.5 - 34.8 46.0 - 46.4
2 34.9 - 35.2 46.5 - 46.9
3 35.3 - 35.6 47.0 - 47.4
4 35.7 - 36.0 47.5 - 47.9
5 36.1 - 36.4 48.0 - 48.4
6 36.5 - 36.7 48.5 - 48.9
7 36.8 - 37.0 49.0 - 49.8
8 37.1 - 37.3 49.4 - 49.7
9 37.4 - 37.6 49.8 - 50.1
10 37.7 - 50.2 -
Tubular BDI
BDI# 36V 48V

0 - 35.2 - 46.9
1 35.3 - 35.5 47.0 - 47.3
2 35.6 - 35.8 47.4 - 47.7
3 35.9 - 36.1 47.8 - 48.1
4 36.2 - 36.4 48.2 - 48.5
5 36.5 - 36.7 48.6 - 48.9
6 36.8 - 37.0 49.0 - 49.2
7 37.1 - 37.2 49.3 - 49.5
8 37.3 - 37.4 49.6 - 49.8
9 37.5 - 37.6 49.9 - 50.1
10 37.7 - 50.2 -
Gel BDI
BDI# 36V 48V

0 - 32.9 - 43.8
1 33.0 - 33.5 43.9 - 44.7
2 33.6 - 34.0 44.8 - 45.4
3 34.1 - 34.5 45.5 - 46.1
4 34.6 - 35.0 46.2 - 46.7
5 35.1 - 35.5 46.8 - 47.3
6 35.6 - 35.9 47.4 - 47.8
7 36.0 - 36.2 47.9 48.3
8 36.3 - 36.5 48.4 - 48.7
9 36.6 - 36.7 48.8 - 48.9
10 36.8 - 49.0 -
#44 Mast type
This setting defines the type of the mast. The setting value is 0, 1, or 2.
0: 2FF (2-stage full-free)
1: 3FF (3-stage full-free)
2: 2SP (2-stage panorama)
#45 Valve section
This setting defines the number of valve sections. The setting value is 1 or 2.
1: 3-way (lift, tilt, attachment 1)
2: 4-way (lift, tilt, attachment 1, 2)
#46 Battery voltage adjustment
This setting corrects the difference between the actual battery voltage and controller-
recognized battery voltage. The meter panel shows battery voltage which the controller
recognizes.
Measure actual battery voltage using a tester (or a multimeter) and operate service tool.
Measurement of battery voltage
1. BATTERY
2. LINE CONTACTOR (POSITIVE)
3. TESTER OR MULTI-METER
4. TRACTION INVERTER (NEGATIVE)
#47 Foot direction
This setting defines the foot direction option. This setting is 1 or 2.
1: Standard direction lever
2: Foot Direction Control (FoDiCo)
1.7.5 SETUP OPTIONS (GROUP 1)

Option Default
Title Description Range
# Value
The value setting of the following 1: A
Application 8 items are registered beforehand: 2: B
presets Start lift speed, top lift speed, tilt 3: C
#1 1 (3)
(operation speed, maximum travel speed, 4: D
mode) acceleration rate, traveling power, 5: E
brake regeneration, and See NOTE (1)
accelerator regeneration. Refer to
the explanation for details.
Beginning lift speed
1 (Slow) to 10
#2 Start lift speed Start lift speed cannot exceed top 1
(Fast)
lift speed.
Lift speed when operating the 1 (Slow) to 10
#3 Top lift speed 9 (3)
lever at maximum (Fast)
1 (Slow) to 10
#4 Tilt speed Speed setting for tilt 1
(Fast)
Auxiliary 1 1 (Slow) to 10
#5 Speed setting for attachment 1 3
speed (Fast)
Auxiliary 2 1 (Slow) to 10
#6 Speed setting for attachment 2 3
speed (Fast)
Maximum 5 to 18 [km/h] or
#7 travel speed Maximum travel speed 5 to 17 [km/h] 15 (3)
limit See note (2), (3)
1 to 5 See NOTE
(3)
Acceleration
#8 Choice of acceleration rate (1: Slowest, 2: 3 (3)
rate
Slow, 3: Middle,
4: Fast, 5: Fastest)
1, 2, 3 See NOTE
(3)
Traveling
#9 Choice of powering characteristic (1: ECONOMY, 2 (3)
power
2: STANDARD,
3: POWER)
This function notifies service
0, 0.1,
personnel that maintenance time
100, 150, ...950,
is approaching or has passed.
1000,
It means the lapsed time when =0.1 (6 min.),
setting up. =100, =150, =950,
Service
#10 =1000 0
indicator Approached: Service indicator
(In increments of
icon on meter panel blink (20
50 [hour])
hour)
“=”: power
Passed: The icon glows and reduction
power reduction (selected) 0: no action
NOTE: (1) Before changing, when parameter data are different from the values of the
selected mode, the lift truck operation mode indicator (A to E) blinks.
When the lift truck operation mode is changed, all parameter data is
replaced by the set values of the selected mode.
(2) When #41 is set for “36 volts”, the setting range is 5 to 17 [km/h].
For setting other than above, the setting range is 5 to 18 [km/h].
(3) When #40 is set for “EE type”, the setting range and default value of each
Setup Option data are as follows:
Option # Range Default Value

#1 A to E C
#3 1 to 10 8
#41 “36 volts” 5 to 12 12
#7
#41 “48 volts” 5 to 14 14
#8 1 to 2 2
#9 1 only 1

Option Default Harness
# Value Pin No.
0: Disable
1: Disable
lift (switch
closed)
2: Speed
limit (switch
When the auxiliary input closed)
1 signal is ON, travel 3: Power
speed or lift speed is reduction
Auxiliary input limited to the set value. (switch
#11 for lift and The maximum speed is closed) 0 40
drive speed 1 defined at #12. 4: Disable
The amount of power lift (switch
reduction is defined at opened)
#13. 5: Speed
limit (switch
opened)
6: Power
reduction
(switch
opened)
Auxiliary travel 5 to 18
#12 Travel speed limit for #11 12 40
speed limit 1 [km/h]
Auxiliary
Traction power reduction
#13 power 0 to 100 [%] 70 40
ratio for #11
reduction rate 1
0: Disable
1: Disable
lift (switch
closed)
2: Speed
limit (switch
When the auxiliary input closed)
2 signal is ON, travel 3: Power
speed or lift speed is reduction
Auxiliary input limited to set value. (switch
#14 for lift and The maximum speed is closed) 0 41
drive speed 2 defined at #15. 4: Disable
The amount of power lift (switch
reduction is defined at opened)
#16. 5: Speed
limit (switch
opened)
6: Power
reduction
(switch
opened)
Auxiliary
Traction power reduction
#16 power 0 to 100 [%] 70 41
ratio for #14
reduction rate 2
0: Disable
1: Disable
lift (switch
When the auxiliary input
closed)
3 signal is ON, travel
2: Speed
speed or lift speed is
limit (switch
Auxiliary input limited to set value.
closed)
#17 for lift and The maximum speed is 0 30
3: Power
drive speed 3 defined at #18.
reduction
The amount of power
(switch
reduction is defined at
closed)
#19.
4: Disable
lift (switch
opened)
5: Speed
limit (switch
opened)
6: Power
reduction
(switch
opened)
Auxiliary
Power reduction ratio for
#19 power 0 to 100 [%] 70 30
#17
reduction rate 3
This setting allows to shut
down equipment when
#20 Stall timer the traction motor torque 2 to 10 [sec] 5 -
is very high and the
wheels are not turning.
1 to 10
Brake 10 steps to set for brake (1: SLOW
#21 7 -
regeneration regeneration to 10:
FAST)
1 to 10
Lever 10 steps to set for lever (1: SLOW
#22 7 -
regeneration regeneration to 10:
FAST)
1 to 10
Accelerator 10 steps to set for (1: SLOW
#23 7 -
regeneration accelerator regeneration to 10:
FAST)
Sets the time for chat
#24 Chat timer 0 to 40 [sec] 20 -
timer
Sets speed for turning on 5 to 18
#26 Speed alarm 1 12 61
alarm 1 light. [km/h]
Adjusts the amount of tire 0: -20 mm
Tire size speed
#27 wear. It changes travel 20: 0 mm 20 -
adjustment
speed recognition. 40: +20 mm
This setting defines the
function of speed limit
Auxiliary input 0: Disable
#30 switch. 0 31
for travel speed 1: Enable
According to the
combination of #30 and
#31, you can reduce
travel speed.
Auxiliary
maximum 5 to 18
travel speed [km/h]
setting
Auxiliary out Traction power reduction
#32 0 to 100 [%] 70 31
put power limit ratio for #30
0: 0 [min]
3: 3 [min]
Password certification 10: 10 [min]
Password
#38 ON/OFF after key switch 30: 30 [min] 255 -
certification
OFF. 60: 60 [min]
90: 90 [min]
255: Disable
Option Default
# Value
This option is used to set the 12 patterns "Details of
size and type of the model. Setup Options
#40 Truck model -
Refer to the explanation for (Group-3)" for model
details. names.
Battery This option is used to set the
#41 36, 48 [V] -
voltage voltage of the battery.
This option is used to set the
type of the battery. 0: Normal BDI
#42 Battery type The electric discharge 1: Tubular BDI -
characteristic of a battery 2: Gel BDI
changes with battery type.
0: 2FF (2-stage full-
free / Duplex mast)
1: 3FF (3-stage full-
This option is used to set the
#44 Mast type free / Triplex mast) -
type of the mast.
2: 2SP (2-stage
panorama / Simplex
mast)
1: 3V (Lift, tilt, and
Valve This option is used to set the attachment1)
#45 -
section number of valve section 2: 4V (Lift, tilt, and
attachment1,2)
This setting corrects the gap of
the battery voltage which the
controller recognizes, and
Battery actual battery voltage.
#46 voltage Measure actual battery voltage 5.0 to 120.0 [V] -
adjustment and use service tool in order to
adjust the value which is
shown on the service tool
actual battery voltage.
1: Standard direction
This option is used to enable
Foot lever
#47 the function for foot direction -
direction 2: Foot Directional
option.
Control (FoDiCo)
NOTE: (1) The data of group 3 have no default value, but it needs to set data by the
actual lift truck model. If the value and the lift truck model are not in
agreement, the lift truck does not operate normally.
(2) When you set up for the first time, set up group 3 first, and then set
default data of group 1 and 2.
(3) This value was adjusted at the time of LOGIC CARD inspection.
Adjust the value if the value shown on the service tool is different from
actual battery voltage.
(4) Use this option to achieve the lift lockout at the designed battery
voltage.
(5) Setting volts lower than battery volts will activate lift lock out at a
higher voltage.
(6) Setting higher than battery voltage will discharge the battery to a deeper
level.
1.8 DIAGNOSTICS
1.8.1 OUTLINE
The controller monitors status of various input/output equipment to allow diagnostics of lift
truck’s malfunction. There is a diagnostics called “Self Diagnostics”, which performs an
equipment check during maintenance.
Mode Description
Diagnostics Self diagnostics Checks function of electrical systems.
Self diagnostics that exclusively checks the power steering system is also available.
1.8.2 OPERATION PROCEDURE

Turn ON the key switch and enter the diagnostics mode using the service tool.
Perform diagnostics by following the procedure below.
Preparatory operations (excluding steering)
1. Place the parking brake lever in the locked position.
2. Turn OFF the key switch.
3. Disconnect the battery plug/connector.
4. Discharge all inverters. Refer to Inverter Discharging Procedure.
5. Place the direction lever in the NEUTRAL position.
6. Remove the fuses (500 A) on traction and pump inverters and steering fuse (60 A).
7. Connect the battery plug/connector.
Diagnostics procedure
Perform the procedure using the “Self-Diagnostics” table (refer to Self-Diagnostics) in
accordance with the following guide.
1. Start diagnostics with the Step 0 in the table. Without sitting in the seat, turn ON the
key switch according to the instruction in the “Action” column on the Step 0 line. If
the item passes the check without any problem, the next Step “01” appears on the
meter panel.
If the item involves any problem and fails in the check, “dd” is shown on the meter panel.
The meter panel also shows “dd” when diagnostics is started without removing the fuse. In
this case, diagnostics is prohibited from going even to the first step.
2. When the Step 0 has passed the check, diagnostics may advance the Step 1 (seat
switch). Cycle the seat switch OFF 6 ON 6 OFF according to the instruction in the
“Action” column on the Step 1 line. If the item passes the check, the next step
number “02” appears on the meter panel.
Do likewise for the succeeding items, following the instructions in the “Action” column
boxes. If the step fails in the check, diagnostics does not advance automatically. In this
case, diagnostics can be forcibly advanced to the next step by pressing the next button on
the service tool.
NOTE: Diagnostic items can be skipped by pressing the Skip button on the service tool.
1. DIAGNOSTICS RESULT INDICATION

3. When all the steps have been checked
through, turn OFF the key switch. Be sure to
install the 500 A fuses and 60 A steering fuse.
- Turn OFF the key switch to exit from the diagnostics mode.
- Repair all faults found immediately after diagnostics.
Follow the instructions in the diagnostics procedure guide above as well as “Self-
Diagnostics” table in the applicable “Action” column.
1.8.3 SELF-DIAGNOSTICS
Controller Contactor
Step Item Action Result Display
check this operation
Close line Pass 1 Line
contactor and contactor and
Line voltage Turn ON key steering dd steering
0 See
(Fuse check) switch contactor, and Fail contactor
check power NOTE close and
line voltage. (1) open.
Release, press, Input Pass 2
1 Seat SW and release seat OFF - ON -
SW OFF Fail 1
Cycle direction Pass 3

Input
Direction lever.
2 N-R-N-F-
change SW N - R - N - F - Fail 2
N
N
Apply and Input Pass 4
Parking
3 release parking Release - Apply
brake SW Fail 3
brake - Release
Input Pass 5
Release and
Service Release -
4 depress service
brake SW Depress - Fail 4
brake
Release
Depress and Pass See NOTE (2)
release
5 Accel SW accelerator and Fail -
see meter panel.
Skip button - 7
Check battery Pass 8
Battery
7 Automatic voltage: (34V-
voltage Fail 7
51V)
Input Pass 9
Lift lever Pull and release
8 Release - Pull
SW lift lever. Fail 8
(lift up)-Release
Tilt lever Pull and release Pass 10

9 Input
SW tilt lever. Fail 9
Release - Pull -
Release
Attachment Pull and release Input Pass 11
10 lever 1 Attachment1 Release - Pull -
switch lever. Release Fail 10
Attachment Pull and release Input Pass 13

11 lever 2 Attachment 2 Release - Pull -
switch lever. Release Fail 11
Pull any lever Pass See NOTE (3)

Hydraulic and see meter
13 pump speed panel. Fail -
check
Skip button - 14
Contactor
Pass 14
closes.
See line
contactor close Contactor
Fail 14 does not
Line closes.
14
contactor Contactor
Pass 16
opens.
Skip button Contactor
Fail 16 does not
open.
Contactor
Pass 16
closes.
See steering
contactor close Contactor
Fail 16 does not
Steering closes.
16
contactor Contactor
Pass 17
opens.
Skip button Contactor
Fail 17 does not
open.
Release, fasten, Input Pass OK
17 Seatbelt SW and release OFF - ON - -
seatbelt OFF Fail 16
NOTE: (1) “dd” indicates the fuse needs to be removed.

(2) Input (ON/OFF) to the accelerator switch and travel of the accelerator
pedal (0 to100%) appears.
(3) Setting of hydraulic speed (0 to 10) appears when any lever is pulled.
1.8.4 RUN TIME DIAGNOSTICS
Availability of operation:
: Yes, X: No, *: Applicable
Meter panel
Icon
Return
Co How to
Fault Result to
de detect
normal
Traction
Thermistor Power
motor,
E0 (150°C, - * - reducti Cool *
Overheatin
25°C) on
g
Pump
Thermistor Power
motor,
E2 (150°C, - * - reducti Cool *
Overheatin
25°C) on
g
Thermistor
(IMS
Traction
100°C, - Power
Inverter,
E5 25°C) * - reducti Cool *
Overheatin
Capacitor on
g
(110°C, -
25°C)
Thermistor Power
(IMS reducti
Pump
100°C, - on
Inverter,
E7 25°C) * - (Transi Cool *
Overheatin
Capacitor stor
g
(110°C, - Control
25°C) Type)
Line
Traction contact
Out of Turn
motor, or
14 normal * 14 OFF *
Current OFF(*)
range key
sensor fault Steerin
g
contact
or Hold
More than
Line
985 Arms
contact
Traction (1.6 ms),
or OFF Turn
motor, 990 Arms
15 * 15 Steerin OFF *
Over- (1 ms),
g key
current 1018 Arms
contact
(a
or Hold
moment)
Line
Measures
contact
time (set
Traction or OFF Turn
by
16 motor, Stall * 16 Steerin OFF *
SUO#20)
timer g key
while
contact
stalling
or Hold
Line
contact
Pump or
Out of Turn
motor, OFF(*)
34 normal * 34 OFF *
Current Steerin
range key
sensor fault g
contact
or Hold
More than
Line
985 Arms
contact
Pump (1.6 ms),
or OFF Turn
motor, 990 Arms
35 * 35 Steerin OFF *
Over- (1 ms),
g key
current 1018 Arms
contact
(a
or Hold
moment)
Line
contact
Checks or
Line Turn
voltage of OFF(*)
40 contactor, * 40 OFF *
power Steerin
Fault key
circuit. g
contact
or Hold
Line
contact
Traction or OFF Turn
Traction
45 motor, * 45 Steerin OFF *
motor open
Open g key
contact
or Hold
Line
contact
Pump or OFF Turn
Pump
47 motor, * 47 Steerin OFF *
motor open
Open g key
contact
or Hold
Line
Steering
contact
motor’s
Steering or OFF Turn
warning
49 motor, * 49 X Steerin OFF *
signal is
Fault g key
open
contact
(high)
or OFF
- Accel
sensor
voltage 1 is
out of
range from
0.15 to 4.2
V.
- Accel
sensor 2 Line
input value contact
Accelerator when or OFF Turn
51 sensor, multiplied * 51 Steerin OFF *
Fault by two is g key
out of contact
range from or Hold
0.15 to 4.2
V.
-
Difference
in input
between
accelerator
sensors 1
and 2
(multiplied
by two) is
0.4 or
more.
Line
Out of contact
Traction
normal or OFF Turn
motor,
52 range * 52 Steerin OFF *
Pulse input
(5800 min- g key
fault
1) contact
or Hold
- Out of
normal Line
range (- contact
Pump
200 min-1) or OFF Turn
motor,
57 - Out of * 57 Steerin OFF *
Pulse input
normal g key
fault
range contact
(5800 min- or Hold
1)
FNR
Line
lever/accel
contact
is not Seat
or OFF
NEUTRA switch
E X Steerin
L at ON
Direction g
power-ON Directio
lever or contact
and seat n lever
E accelerator, SW ON or OFF
is in
Faulty
Slow NEUTR
settin Seat SW is
down AL
turned ON accel
and
after * - OFF
Line
lever/accel
contact
is operated
or OFF
Line Seat
Seat contact switch
switch, Seat SW is or OFF ON
(E) Faulty OFF at - X Steerin Directio
setting for power-ON g n lever
traction contact is in
or OFF NEUTR
Slow AL
down accel
Seat SW is and OFF
* -
OFF Line
contact
or OFF
Line
contact
Seat SW is or OFF Seat
Seat OFF at - X Steerin switch
switch, power-ON g ON
(L) Faulty contact Lever is
setting for or OFF in
hydraulic Disable NEUTR
Seat SW is s lever AL
-
OFF operati
on
Lever is Line
not contact
NEUTRA or OFF Seat
L at H1 X Steerin switch
Lift lever, power-ON g ON
H1 Faulty and seat contact Lever is
setting SW ON or OFF in
Seat SW is Disable NEUTR
turned ON s lever AL
* -
after lever operati
is operated on
Lever is Line
not contact
NEUTRA or OFF Seat
Tilt lever, power-ON g ON
H2 Faulty and seat contact Lever is
setting SW ON or OFF in
* -
after lever operati
is operated on
Lever is Line Seat
Attachment
H3 not H3 X contact switch
1 lever,
NEUTRA or OFF ON
Faulty L at Steerin Lever is
setting power-ON g in
and seat contact NEUTR
SW ON or OFF AL
Seat SW is Disable
turned ON s lever
* -
after lever operati
is operated on
Lever is Line
not contact
NEUTRA or OFF Seat
Attachment power-ON g ON
2 lever, and seat contact
H4 Lever is
Faulty SW ON or OFF in
setting
* -
after lever operati
is operated on
When “Comn
Meter
serial fault” Turn
panel,
60 communic * - - is OFF *
Communic
ation is not display key
ation fault
going on ed
SUO
Line
Group #3
contact
and default
Logic card, or OFF Turn
setting are
61 Initialize * 61 X Steerin OFF *
not set
failure g key
- Inverter
contact
setting
or OFF
warning
- Sum
check of
ROM Line
- Memory contact
check of or OFF Turn
Logic unit,
62 RAM * 62 X Steerin OFF *
Fault
- Sum g key
check of contact
SUO data or OFF
(EEPROM
)
- Sum
check of
ROM
- Memory
check of Line
RAM contact
Traction - Initial or OFF Turn
63 inverter, mode SW * 63 X Steerin OFF *
Fault setting g key
fault contact
- When or OFF
CAN
communic
ation is not
going on
- Sum
check of
ROM
- Memory
check of Line
RAM contact
Pump - Initial or OFF Turn
65 inverter, mode SW * 65 X Steerin OFF *
Fault setting g key
fault contact
- When or OFF
CAN
communic
ation is not
going on
- Contactor Line
coil current contact
sensor or OFF Turn
Contactor,
72 - Line * 72 X Steerin OFF *
Coil fault
contactor g key
- Steering contact
contactor or OFF
Checks
Hydraulic current of Disable
Turn
lock lift lock s lever
74 * 74 OFF *
solenoid, valve operati
key
Fault power on
circuit.
Checks Line
current of contact
Electromag
electromag or OFF Turn
netic brake
75 netic brake * 75 Steerin OFF *
solenoid,
valve g key
Fault
power contact
circuit. or Hold
Only
PDS warnin
buzzer g
PDS Turn
short- display
76 buzzer, * 76 OFF *
circuit and
Fault key
protection buzzer
is activated stoppag
e
Line
contact
Battery, Voltage or OFF Turn
78 Voltage too class is not * 78 X Steerin OFF *
low correct. g key
contact
or OFF
Line
contact
Battery, Voltage or OFF Turn
79 Voltage too class is not * 79 X Steerin OFF *
high correct. g key
contact
or OFF
Line
contact
Too much
or OFF
Battery, consumpti
(*) Turn
Consumpti on with (L
Lo * X Steerin OFF
on too small o)
g key
much capacity
contact
battery
or OFF
(*)
Much Power
Battery,
(Lo consumpti reducti Charge
Consumpti * -
) on with on battery
on much
small (econo
capacity my
battery table)
Brake Level Turn
- fluid, Low sensor * - - OFF
level (Contact) key
Battery Calend
RTC Turn
voltage for ar date
- battery, * - OFF
calendar is
Low key
IC is low wrong
NOTE: - E0, E2, E5, and E7 do not appear on the meter panel, but are
stored in the memory.
- “Line contactor OFF (*)/Steering contactor OFF (*)” means
that the contactor will open immediately when a fault is
detected.
“Line contactor OFF” means that the contactor will open
when current goes to 0.
- Contactor “hold” means no change. When a warning occurs
while the contactor is turned ON, it stays ON.
1.9 REMOVAL AND INSTALLATION
1.9.1 INVERTER DISCHARGING PROCEDURE
Discharge electric charges stored in the inverters by using the following procedure.
2. Disconnect the battery plug/connector.
3. Remove the rear cover.
1. REAR COVER
4. Place a 150 Ω/25 W resistor between P and N terminals in the
traction inverter to discharge electric charges stored in the inverter.
5. After touching the resistor to the P and N terminals for approx. five seconds, measure
the voltage between the terminals with a multimeter and confirm a reading of 5V or
less.
6. Perform the same procedure for the pump inverter in order to discharge electric
charges from all inverters.
Check whether the resistance between + and - of the battery plug/connector on the lift
truck side is 1 kΩ or more when connecting the battery plug/connector for the first time
after maintenance.
NOTE: Discharge electric charges completely before measuring. Longer measurement
time reduces resistance value.
Item Part No.
Discharge tool 16A68-02600
1.9.2 REPLACING INVERTER

Removal
1. Raise the front wheels.
2. Perform Steps (1) through (6) in Inverter Discharging Procedure.
CAUTION
Be sure to discharge electric charges from all inverters before working on the electrical
system.
3. Disconnect all five power cables from F, N, U, V and W terminals.

4. Disconnect the connector.
CAUTION
When disconnecting the connector, hold the connector housing and plug, and
unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable may
cause wire breakage.
5. Remove
M8 nuts
(five
places)
fixing
the
inverter,
then
remove
the
inverter.
1.9.3 INSURING PROPER THERMAL TRANSFER
Mounting Instructions for DC/AC Inverters
In the design of this family of DC/AC Inverters, performance assumptions were made
based on heat transfer between the inverter and the ambient environment. The lift
truck mounting surface acts as a heat sink, which increases the effective surface area for
heat dissipation. If this assumed heat transfer is not achieved during inverter installation
and operation, the inverters will fall short of their anticipated performance. It should be
noted that the condition of the mounting surface, and the quality of the resulting interface
between the control and the lift truck, can significantly hinder heat transfer from the
inverter. This is why each inverter has a heat sink between the inverter and the frame of
the lift truck.
TRACTION AND HYDRAULIC INVERTER

The presence of contaminants or air voids created by surface inconsistencies in either
the lift truck or the heat sink will degrade the inverter’s capacity for heat transfer. The
inverter’s performance is de-rated proportionally as its own thermal sensors reduce its
operation to protect it from damage due to excessive heating.
Contained within the software of the controls are several diagnostic status codes related to
controller thermal performance. Failure to follow these mounting recommendations
increases the likelihood of encountering these status codes.
Careful surface preparation, including adequate application of thermal compound, as
detailed in the following paragraphs, must be completed during the installation of the
controls. There are many techniques for applying thermal compound. One approach is
outlined below that has shown to apply a consistent thickness of material.
Necessary tools
Recommended use of the following components, or equivalent substitutions, during the
control installation process:
1. Thermal compound, (5P9837), maintained per the manufacturer’s recommendations
and free of contaminants
2. 3/32" notched trowel, such as an adhesive spreader, P/N SE000049
3. Calibrated torque wrench (0 – 15 ft-lbs)
The inverters
During the manufacture of the control, the surface flatness is maintained at 0.005" per
linear inch (not to exceed 0.025" per 10.0 inches). The surface finish of the control has a Ra
(average roughness) of 64 (micro inches), or better. This finish is consistent with cold
rolled or extruded aluminum. Care should always be taken in the handling and storage of
controllers. The base of the control should be free from nicks, bumps, protrusions, or any
other foreign object that would prevent the control from sitting flush with the lift
truck mounting surface. Examine the base of the control to verify that it is in good
condition and free from damage or contamination.
Lift truck mounting surface
The quality of the lift truck mounting surface is critical for optimum heat transfer between
the inverter and the ambient environment. Conduction through the base of the inverter is
the inverter’s only means of heat rejection. While the inverters are highly efficient, a few
percent of the electrical energy will be converted into heat. As previously mentioned, if this
energy is not dissipated through the base of the inverter, a thermal protector will reduce the
performance of the inverter until the temperature stabilizes. For optimal heat transfer from
control to lift truck, the flatness of the lift truck mounting surface should be equivalent to
the flatness of the control surface (0.005" per linear inch). Use a straight edge or dial
indicator to verify the mounting surface. The biggest hindrance to heat transfer is the
presence of rust, scale, weld splatter or paint on the lift truck mounting surface. If any of
these items are noted, prepare the surface per the following guidelines:
1. Clean the mounting surface with a rotary wire brush until the metal surface is
exposed.
2. Using 80-100 grit emery paper, sand the surface until the metal shines.
3. Flush the surface clean with an appropriate liquid de-greaser or parts cleaner.
CAUTION
Apply thin and even heat sink grease since it works to release
generated heat from the inverter to the lift truck body.
Application of thermal compound

Due to the small differences in the inverter mounting surface and the lift truck mounting
surface, small pockets of air will be created. These air pockets will add to the overall
thermal resistance of the interface. To avoid these air pockets and improve thermal
conductivity, thermal compound must be applied between the control base plate and the lift
truck mounting surface. The function of this compound is to conform to surface
discrepancies, filling gaps and optimizing the metal-to-metal contact of the inverter and
the lift truck.
1. Prepare the two mounting surfaces (Inverter and lift truck) as indicated above.
2. Using a triangular notched trowel of 3/32" (.09" +/- .01), apply the grease to the lift
truck mounting surface.
3. Use straight, non-crossing strokes of the trowel to apply the compound.
4. Make multiple vertical passes until a uniform consistency is achieved.
Mounting the inverter

After inverter mounting surface is prepared with heat sink grease
1. Prepare mounting surface of lift truck using the same procedure as the inverter heat
sink.
2. Place the inverter with desired orientation on mounting surface of lift truck with
mounting holes aligned.
3. Move the inverter slightly in all directions to eliminate voids and enhance the
distribution of the thermal compound.
4. Insert all of the mounting hardware 10 mm, 1.25 thread pitch, with washers (4 bolts
necessary for the mounting of the respective inverter).
5. Tighten these bolts to half of the nominal torque value 34.8 N-m (3.5 kgf-m) 34.8 ft-
lb.
6. Lastly, tighten the bolts to the nominal torque value 69.6 N-m (7.1 kgf-m) 51.4 ft-lb.
7. Torque wrench, extension and socket required to complete installation.
Installation
1. Wipe off the dirt and heat sink grease from the inverter mounting surface and remove
dirt from the mounting surface and the aluminum base paste of the inverter.
2. Apply heat sink grease approx. 1 mm (0.04 in) thick to the area where the aluminum
base plate of the inverter comes into contact with the lift truck body.
CAUTION
Apply thin and even heat sink grease since it works to release generated heat from the
inverter to the lift truck body.
3. Attach the inverter with M8 bolts.

4. Connect the power cables to F, N, U, V, and W terminals. Proper stack method is:
Cable, flat washer, Belleville washer and nut.
NOTE: Retighten bolts of the cables one month after delivery or one month after the
cable installation.
CAUTION
Use the correct power cables and terminate marked cable ends to the correct terminals
marked on the motor.
Cables terminated at the wrong terminals on the motor may cause the motor to rotate in
the opposite direction when activated.
Tightening
Item
torque
16 ± 1.0 N·m
(1.63 ± 0.10
P, N, U, V,
kgf·m)
W
[11.80± 0.74
Power lbf·ft]
cables 10 ± 1.0 N·m
(1.02 ± 0.10
F kgf·m)
[7.38 ± 0.74
lbf·ft]
5. Connect the main harness connector to the inverter.
CAUTION
You need to hold the DSP card connector when installing the harness
connector to prevent any damages to the DSP card. Ensure the connector is
seated and the latch is locked.
Forcibly pressing the connector may cause damage to the DSP card. Hold the
connector housing and press the connector, it may not be easy to lock.
NOTE: - It is recommended to check or replace the inverters every 10,000 hours of

service operation.
- It is recommended to torque the U, V, W, P, N, and F terminals after 30
days service and at 1000 hour intervals.
1.9.4 REPLACING DSP (DIGITAL SIGNAL
PROCESSOR) CARD
Removal
1. Perform Steps 1 through 6 in Inverter Discharging Procedure.
CAUTION
Make sure to discharge inverters before working on the
electrical system.
2. Push and lift up at the four corners of the card cover to remove the cover.
3. Disconnect the connector.
CAUTION
When disconnecting the connector, hold the connector housing and plug, and
unlock the connector.
Holding the case may cause damage to the inside card, while holding the cable
may cause wire breakage.
4. Unlock
the
connector
that is
connected
to the flat
cable.
Hold the
both ends
of the
white part
of the
connector
and pull it
straight
up.
5. Pull the flat cable to disconnect it. If it cannot be disconnected smoothly, raise the
lock again to unlock.
6. Pinch the plastic spacers at the four corners of the DSP card with pliers to unlock and
remove the card.
CAUTION
Be careful not to damage mounted parts with the pliers since the card has a number of
fragile parts.
Installation
1. Align the four mounting holes of the new DSP card with the plastic spacer
positions and press it into place.
NOTE: Press at the card edges.
Make sure that the spacer lock works completely and the card cannot be removed.
2. Confirm that the flat cable connector is unlocked by raising the connector lock.
3. Insert the flat cable into the connector. Press down the connector lock.
CAUTION
Do not forcibly bend the flat cable. Insert its conductive surface in the direction
shown in the illustration.
Also, confirm that the cable is not tilted.
4. Connect
the main
harness
connector
to the
inverter.
CAUTION
Do not push the flat cable by the inside of the inverter cover. Do not forcibly bend
the flat cable.
Make sure that the cable will not be pinched underneath the cover. Confirm that the
cover is completely locked.
5. Install
the
cover
while
pushing
the flat
cable
toward
the card
side
slightly.
CAUTION
Forcibly pressing the connector may cause damage to the DSP card. Hold the
connector housing and press the connector, it may not be easy to lock. Insert
connectors surely until they are locked.
1.9.5 REPLACING LOGIC UNIT

Removal
2. Disconnect the battery plug.
1. METER PANEL
2. CUP HOLDER
3. GSE CONNECTOR CAP
3. Disconnect the connector (CN1, CN2, CN3) from the logic
card and the connector (CN4) from the power supply card.
1. LOGIC UNIT
2. MC MAIN HARNESS
1) CH 1
2) CN 2
3) CN 3
4) CN 4
CAUTION
When disconnecting the connector, hold the connector housing and plug, and unlock the
connector.
Holding the case may cause damage to the inside card, while holding the cable may
cause wire breakage.
4. Remove M8 bolts (two places) and remove the logic unit.
1. BOLT, WASHER (2 PCS)

Installation
Follow the removal sequence in reverse.
1.9.6 REPLACING LOGIC CARD

NOTE: When replacing the logic card, it is
recommended to replace the logic unit as an
assembly.
When the cover is removed from the logic unit
case, its tapped holes may be damaged. Replace
the cover if the tapped holes of the cover are
damaged.
Removal
1. Perform Steps (1) through (4) in “Replacing Logic Unit”.
2. Remove M3 flat head screws (four places) from the bottom, and M3 screws (five
places) from the side of the logic unit to remove the cover.
3. Remove M3 screws with washers (five places) fixing the logic card to the logic unit
case to remove the logic card.
4. Remove the grommet from the logic card.
1. COVER
2. LOGIC UNIT CASE
Installation
1. HEAT SINK
2. LOGIC CARD
1. GROMMET
2. LOGIC CARD
CAUTION
When installing the logic card onto the logic unit case, carefully tighten the
logic card and heat sink fixing screws to the specified torque to avoid excessive
stresses. Repair the heat sink first.
Item Tightening torque

0.98 ± 0.20 N·m
M3 screw {0.10 ± 0.02 kgf·m}
[0.72 ± 0.15 lbf·ft]
0.30 ± 0.10 N·m
M3 flat head screw {0.03 ± 0.01 kgf·m}
[0.22 ± 0.074 lbf·ft]
NOTE: Apply LOCTITE No.242 to M3 screws (five
places) on the side of the logic unit when
installing.
1.9.7 REPLACING POWER SUPPLY CARD
NOTE: When replacing the power supply card, it is recommended to replace the logic
unit as an assembly.
When the cover is removed from the logic unit case, its tapped holes may be
damaged. Replace the cover if the tapped holes of the cover are damaged.
Removal
1. Perform Steps (1) through (4) in “Replacing Logic Unit”.
2. Remove M3 flat head screws (four places) from the bottom and M3 screws (five
places) from the side of the logic unit to remove the cover.
3. Remove M3 screws with washers (four places) fixing the power supply card to the
logic unit case to remove the power supply card.
4. Remove the grommet from the power supply card.
1. COVER
2. LOGIC UNIT CASE
Installation
1. HEAT SINK
2. POWER SUPPLY CARD
1. GROMMET
2. POWER SUPPLY CARD
CAUTION
When installing the power supply card onto the logic unit case, carefully
tighten the power supply card and heat sink fixing screws to the specified
torque to avoid excessive stresses. Apply a small amount of heat sink
compound before installing.
Item Tightening torque

0.98 ± 0.20 N·m
M3 screw {0.10 ± 0.02 kgf·m}
[0.72 ± 0.15 lbf·ft]
0.30 ± 0.10 N·m
M3 flat head screw {0.03 ± 0.01 kgf·m}
[0.22 ± 0.074 lbf·ft]
NOTE: Apply LOCTITE No.242 to M3 screws (five
places) on the side of the logic unit when
installing.
1.10 BASIC CHECK
Always follow basic troubleshooting steps.
- Talk to the operator.
- Confirm his description of the problem with an operational check.
- Visually inspect cables, connectors, contactor tips, etc.
- Perform basic battery cables to frame resistance test. (at least 20 k ohm)
- Check battery condition.
Always check each option and write down the reading.
1.10.2 TESTING TOOLS

NOTE: The illustrations show digital circuit testers. In these testers,
the positive (+) terminal is applied with positive charge, and
the negative (–) terminal with negative charge. It should be
noted that the terminals must be connected inversely when
using an analog meter tester.
1. CIRCUIT TESTER
2. CLAMP METER
3. IC CLIP
WARNING
Disconnect the battery plug before inspecting or adjusting the
controller.
1.10.3 MEASUREMENT OF CARD VOLTAGE
WARNING
To prevent accidental movement of the lift truck, place wood blocks under
the lift truck to lift the front wheels off the ground. Do not place wood blocks
close to the front wheels.
1. Tilt the mast

fully
BACKWARD.
Place blocks
under the
mast, and tilt
the mast
FORWARD.
2. Turn the key switch OFF.
3. Disconnect the battery plug. Remove the cover.
4. Reconnect the battery plug.
5. Turn the key switch ON. Connect the negative terminal of the circuit tester to the V
GND terminal of the card.
6. Set the circuit tester to the 100-VDC range.
7. Connect the positive terminal of the circuit tester to each pin of connectors.
NOTE: Be careful not to short-circuit pins. For normal voltage see the following chart.
Logic card voltage chart
Card side connector No.: CN1, Main harness side connector No.: E-02, E-03, and E-04
No. Name Note

1 GND-L E-02
2 +15VL E-02
3 GND-L E-02
4 +5VL E-02
5 CAN_H E-02
6 CAN_L E-02
7 Boot E-02
8 FWE E-02
9 GND (GSE) E-02
10
11
12
13
14
15 KEY OFF 2 E-02
16
17 TxD (GSE) E-02
18 RxD (GSE) E-02
19 POS Voltage E-02
20 Accelerator analog input 1 E-02
21
22
23
24 +5V (Power out) E-02
25 GND (Power out) E-02
26
27
28 Accelerator analog input 2 E-03
29
30 Lift limit SW3 E-03
31 Speed limit SW E-03
32 Seatbelt E-03
33 Seat E-03
34 Parking brake E-03
35 Service brake E-03
36 Reverse E-03
37 Forward E-03
38 Brake fluid E-03
39
40 Lift limit SW 1 E-03
41 Lift limit SW 2 E-03
42
43 GND E-04
44 PDS buzzer E-04
45
46
47
48 Attachment 2 E-04
49 Attachment 1 E-04
50 Tilt E-04
51 Lift 2 E-04
52 Lift 1 E-04
53
54
55
56 Steering motor fault E-04
57 Lift lock valve + E-04
58 Lift lock valve - E-04
59 Line contactor E-04
60 Steering contactor E-04
61 Alarm 1 E-04
62 Steering motor enable E-04
63 Con VE E-04
64 Electromagnetic brake E-04
Power supply card voltage chart
Card side connector No.: CN1, Main harness side connector No.: E-01
No. Name Note

1
2
3 +VL (Inverter) E-01
4 +8V (Inverter) E-01
5 +VG (Inverter) E-01
6 GND (Inverter) E-01
7
8
9 +VL (Logic unit) E-01
10 +5V (Logic unit) E-01
11 GND (Logic unit) E-01
12 GND (Logic unit) E-01
13 V POW E-01
14 V POW E-01
15 V GND E-01
16 V GND E-01
DSP card voltage chart
Card side connector No.: CN2, Main harness side connector No.: E-05 and E-06
No. Name Note

1 Motor thermal + E-05,06
2 Motor thermal - E-05,06
3 CAN_H E-05,06
4 CAN_L E-05,06
5 Rotary sensor +12V E-05,06
6 Rotary sensor A E-05,06
7 Rotary sensor B E-05,06
8
9 Mode 2 E-05,06
10 Boot
11 GND E-05,06
12 TxD (GSE)
13 TxR (GSE)
14 CAN_L E-05,06
15 CAN_H E-05,06
16 +VG (Power IN) E-05,06
17 +VL (Power IN) E-05,06
18 +8V (Power IN) E-05,06
19 Rotary sensor GND E-05,06
20 GND (Power IN) E-05,06
1.10.4 CHECKING CONTACTOR COIL
CAUTION
Disconnect the battery plug and discharge the inverter before working on electrical
system.
1. Disconnect
the lead
wire of
coil.
2. Set the circuit tester to 200 ohm range.
3. Measure coil resistance.
The resistance must be 44 ohm at -30°C (-22°F) to 65 ohm at 80°C (176°F).
- If the measured value deviates from the above range, replace the contactor assembly.
4. With the lead wire of contactor coil connected, set the circuit tester to 200-VDC
range.
5. Connect the negative (–) terminal of the circuit tester to the negative-side coil
terminal (small terminal) and the positive (+) terminal of the circuit tester to the
positive side coil terminal (large terminal).
6. Connect the battery, and operate the control device that activates the contactor.
7. The circuit tester should indicate about 24V after the contactor operates. If the
contactor is found normal during the coil resistance test and if the measured voltage
is not 24V, replace the logic card.
1.10.5 CHECKING CONTACTOR TIPS
1. Visually inspect the contactor tips for melting, adhesion, heat seizure, and pitting
corrosion.
2. To check for interference, press the tips and release them.
3. Visually inspect the contactor assemblies. Make sure there are no foreign materials in
the assemblies to interfere with contactor movement.
4. Measure the gap at each contactor tips using a thickness gauge.
NOTE: - It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)
- If you find any trouble, replace or repair contactor.
5. Check for free movement of contactor.
1.10.6 CHECKING INVERTER
CAUTION
Disconnect the battery plug and discharge the inverter before working on electrical
system.
1. Disconnect all five power cables from F, N, U, V, and W terminals.

2. Check the resistance between terminals shown in the following table.
Positive probe Negative probe Resistance (ohm)

U
N V
W
8 k to 11 K ∞
U
V P
V
NOTE: Short-circuit/disconnection of the
inverter MOSFET can be
confirmed by this check. Other
faults cannot be determined.
NOTE: On diode scale you will read about .460 volts on all test.
1.10.7 REGENERATION CHECK
The AC motor uses a common circuit for current flow in both loading and regeneration.
This allows the following procedure to confirm regeneration:
1. Place the ammeter clamp onto the cable connected to the inverter’s F terminal (use
DC current range). This is positive direction as current flows from the battery to the
inverter.
2. Drive the lift truck FORWARD. With the direction lever shifted in FORWARD
position, release the accelerator pedal. Then perform a full-reverse operation.
3. The ammeter clamp should show a negative value. This value becomes the
regeneration current.
Energy is generated when a motor is rotated with external force. The regeneration power is
produced when this energy is larger than the one that is consumed by the controller and
motor. This means that the regeneration current is not measured if the speed or load
changes gradually.
1.11 AC MOTOR SYSTEM BASICS

1.11.1 FEATURE OF AC MOTOR
The AC motor model lift trucks covered by this manual use AC motors (three-phase
induction motors) as the traction motor and pump motor. AC motors have the following
advantages over DC motors:
1. AC motors are simple in construction. As they have no such friction parts as brushes
and commutators, daily maintenance load is significantly reduced.
2. AC motors are compatible with high-speed operation.
3. An AC motor of a certain size produces higher power than a DC motor of the same
size.
1.11.2 SPEED CONTROL OF INDUCTION MOTORS
Speed control of DC motors depends on regulation of the field and armature current
amounts, while that of AC motors basically depends on adjustment of the frequency of the
alternating current power supply. The speed of an AC motor is determined by the frequency
of the power supply AC current and the load on the motor.
In addition, the voltage and current to the motor must be controlled properly so that the
motor operates in its optimum characteristic range.
The frequency and voltage can be controlled by a variety of methods including the “vector
control method” employed in the AC motor model lift trucks. This method provides highly
responsive control according to ever changing lift truck operating conditions through high
speed calculation on huge amount of data. The vector control calculation is performed by
the inverter.
1.11.3 INVERTER
The lift truck battery delivers DC current, so the current must be converted into AC current
to drive an AC motor. The device that converts direct current into alternating current is
generally called an “inverter.” The processes involved in creating AC current from DC
current are described below.
1. Changing DC voltage cyclically
If the switch in a circuit like the one shown below is turned ON for time T1 and then
turned OFF for time T2 and this ON-OFF operation is repeated many times, the
average of the voltage applied to the load is determined by the ratio between T1 and
T2. Varying the ratio, therefore, results in varying voltage. The ratio between T1 and
T2 is called “duty ratio.” By changing the duty ratio cyclically, it is possible to obtain
cyclically changing DC voltage shown below.
2. Converting DC power into AC power
Driving a three-phase AC motor using battery delivered power requires creating
three phase outputs (U, V, W) of an identical waveform that differ in phase by 120°
using a circuit with six switches S1 to S6 that are arranged as shown below. The
outputs created forms a three-phase alternating current. The graphic below shows
ON-OFF condition of each switch (arm) and output voltage variation.
Functioning as switches in the inverter of the AC motor lift trucks are MOS-FET
transistors. The MOS-FET transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current.
1.12 AC MOTOR TROUBLESHOOTING

1.12.1 MOTOR NOISES
1. Problem
Clunking on direction changes.
Check
To see if stator is loose in frame of motor.
2. Problem
Motor/lift truck chatters or shutters with wheel off floor and accelerator pedal slightly
pressed; the wheels move in one direction, then the other. Check forward and backward.
Check
Forward and reverse.
Check sensor bearing.
Check sensor bearing connector and wiring.
3. Problem
Motor makes squealing sound like a bearing noise.
Check
Check sensor bearings to see if signals are OK. Check motor connections and stator
windings. In order to check and isolate bearing sounds using a stethoscope. If the sound is a
general area sound then use a piece of flexible tubing or hose to locate the source of the
sounds. Stators can make a squealing sound when windings are not correct or when
windings are open (broken wire) or shorted.
4. Problem
Motor has lower power, but reaches full speed.
Check
Check connections at motor terminals both out of motor and at the inverter connections.
Check stator windings. You will need a meter that checks insulation or can measure in the
million ohm range. From (-) to (-). Normal readings are shown in the chart below.
Normal readings
Phase line resistance Part

Remarks Description
(mΩ) Nominal Number
20°C 97N20-
2 to 4 Traction AC Motor
(68°F) 00300
20°C 97N20- Traction AC Motor (for seat
2 to 4
(68°F) 00700 operated parking brake option)
20°C 97N20-
2 to 4 Pump AC Motor (for EE)
(68°F) 01600
20°C 97N20-
2 to 4 Pump AC Motor
(68°F) 00400
20°C 97N20-
2 to 4 Pump AC Motor (for EE)
(68°F) 01500
Chapter 2 TROUBLESHOOTING FOR CONTROL
CIRCUITS
2.1 GENERAL INFORMATION
2.1.1 BEFORE REPLACING DEVICES
Do not replace devices casually even if replacement is required as a result of
troubleshooting. Be sure to check the following items before replacing devices (logic unit,
logic card, power supply card, inverters and inverter DSP cards):
- Loose battery connectors
- Abnormal wire harness connections
- Loose connectors or pins pushed back in connector.
- Broken, bent or loose connector pins
- Dirty connectors
If connectors are dirty, remove and clean the connectors. Refer to How to Clean
Harness Connectors and System Components.
- Ensure that the main harness is not short-circuited to the lift truck body by using the
following procedures:
If any of these items (above items) is a source of the trouble, the device will be damaged
even if it is replaced with a new one. Be sure to check the above items and replace
carefully.
NOTE:
2.1.2 CONNECTION OF THE SERVICE TOOL
(1) Turn OFF the key switch.
(2) Remove the cup holder
(3) Find the connector to the service tool near the logic unit.
(4) Remove the cover and connect the PC as shown.
(5) Turn ON the key switch.
(6) Start the service tool software.
1. DIAGNOSTIC CODE DISPLAY

2. LOGIC UNIT
2.1.3 HOW TO CLEAN HARNESS CONNECTORS AND

SYSTEM COMPONENTS
(1) Open-circuits are often caused by dirty harness connectors and components. Dust
together with greasy matter forms grime which, in time, penetrates electrical
connections resulting in loose metal-to-metal contact or, for worse, electrical
separation of surfaces in contact. For this reason, it is essential that the connectors
and components should be cleaned at each periodic inspection and when servicing
the lift truck. Instead of a commonly used solvent, use electronic parts cleaner (in the
manner illustrated on the right).
1. ELECTRONIC PARTS CLEANER
Electronic parts cleaner

SE000003
NOTE: The cleaner liquid is volatile. All you have to do is just give a strong spray to
wash off grime. No need to wipe off the sprayed liquid.
(2) After checking the connector for continuity, wash it as shown. Then, uncouple the
connector and spray contact surface activator onto contact surfaces. Install and
remove the connector several times to wet the surfaces thoroughly with the
activator liquid. After coupling up the connector, make sure that it is in locked
state.
1. ELECTRONIC PARTS CLEANER
1) CONTACT SURFACE ACTIVATOR
Contact surface activator

SE000003
NOTE: - Do not spray too much liquid into the connector.
- Do not completely fill connectors with Nyogel from kit or you may push
pins out of connector.
- Cleaner liquid reacts differently with some resins (plastic materials).
*Products contained in Terminal Maintenance Kit (SE000003)
2.2 LIST OF DIAGNOSTIC CODES

Code Code
Diagnostic codename Diagnostic codename
No. No.
E0 Traction motor, Overheating H1 Lift lever, Faulty setting
E2 Pump motor, Overheating H2 Tilt lever, Faulty setting
Attachment 1 lever, Faulty
E5 Traction inverter, Overheating H3
setting
Attachment 2 lever, Faulty
E7 Pump inverter, Overheating H4
setting
Traction motor, Current sensor Meter panel, Communication
14 60
fault fault
15 Traction motor, Over-current 61 Logic card, Initialize failure
16 Traction mother, Stall timer 62 Logic unit, Fault
34 Pump motor, Current sensor fault 63 Traction inverter, Fault
35 Pump motor, Over-current 65 Pump inverter, Fault
40 Line contactor, Fault 72 Contactor, Coil fault
45 Traction motor, Fault 74 Hydraulic lock solenoid, Fault
Electromagnetic brake,
47 Pump motor, Open 75
Solenoid fault
49 Steering motor, Fault 76 IPS buzzer, Fault
51 Accelerator sensor, Fault 78 Battery, Voltage too low
52 Traction motor, Pulse input fault 79 Battery, Voltage too high
Battery, Consumption too
57 Pump motor, Pulse input fault Lo
much
Direction lever or accelerator,
E (Lo) Battery, Consumption much
Faulty setting
Seat switch, Faulty setting for
(E) None Brake fluid, Low level
traction
Seat switch, Faulty setting for
(L) None RTC battery, Low
hydraulic
2.3 TROUBLESHOOTING
2.3.1 TRACTION MOTOR, OVERHEATING (E0)
Diagnostic code: E0
Controller/motor overheat indicator ON. Poor pulling power and
Situation acceleration. Normal pump motor and power steering operations. Service
tool "Alarm status" and "E0" displayed.
Overheating of traction motor, faulty traction motor or thermal sensor,
Possible faulty or open harness wiring, faulty traction inverter DSP card, abnormal
cause power supply of logic unit, brake or parking brake drag, abnormality in
front axle, and faulty meter panel.
Motor temperature is out of range of -25 °C to 150 °C (-13 °F to 302 °F).
Trigger of
Recovers when motor temperature is in range of -20 to 70 °C (-4 to 158
this code
°F).
Checks
2.3.2 PUMP MOTOR, OVERHEATING (E2)
Diagnostic code: E2
Controller/motor overheat indicator ON. Lifting speed slower than normal.
Situation Normal traction motor and power steering operations. Service tool "Alarm
status" and "E2" displayed.
Overheating of pump motor, faulty pump motor or thermal sensor, faulty or
Possible open harness wiring, faulty pump motor inverter DSP card, abnormal
cause power supply of logic unit, abnormal oil pressure of gear pump or
hydraulic lines, and faulty meter panel.
Motor temperature is out of range of -25 °C to 150 °C (-13 °F to 302 °F). It
Trigger of
becomes normal when motor temperature is in range of -20 °C to 70 °C (-4
this code
°F to 158°F).
Checks
2.3.3 TRACTION INVERTER, OVERHEATING (E5)
Diagnostic code: E5
Controller/motor overheat indicator ON. Poor pulling power and
Situation acceleration. Normal pump motor and power steering operations. Service
tool "Alarm status" and "E5" displayed.
Overheating of traction inverter, faulty traction inverter thermal sensor,
Possible open harness wiring, faulty traction inverter PC board, abnormal power
cause supply of logic unit, faulty temperature of traction inverter, and faulty
meter panel.
Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212
Trigger of °F). Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to
this code 230 °F). It becomes normal when temperature is in range of -20 to 70 °C (-
4 to 158 °F).
Checks
2.3.4 PUMP INVERTER, OVERHEATING (E7)
Diagnostic code: E7
Controller/motor overheat indicator ON. Lifting speed slower than normal.
Situation Normal traction motor and power steering operations. Service tool "Alarm
status" and "E7" displayed.
Overheating of pump inverter, faulty pump inverter thermal sensor, open
Possible
harness wiring, faulty pump inverter PC board, abnormal power supply of
cause
logic unit, faulty temperature of pump inverter, and faulty meter panel.
Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212
Trigger of °F). Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to
this code 230 °F). It becomes normal when temperature is in range of -20 to 70 °C (-
4 to 158 °F).
Checks
2.3.5 TRACTION MOTOR, CURRENT SENSOR FAULT (14)
Diagnostic code: 14
Display: "14". All lift truck operations inhibited. This fault occurs only
Situation when turning ON power. Line contactor OPEN and steering contactor
HOLD.
Faulty contact or wire breakage of DSP flat cable in traction inverter,

Possible
faulty traction inverter DSP card, faulty traction inverter, faulty main
cause
harness, and faulty logic unit.
Trigger of When turning ON power, current sensor voltage is out of range of -120 A
this code to 120 A.
Checks
2.3.6 TRACTION MOTOR, OVER-CURRENT (15)
Diagnostic code: 15
Display: "15". All lift truck operations inhibited. Line contactor OPEN and
Situation steering contactor HOLD.
Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty
Possible traction inverter DSP card, faulty traction inverter, faulty traction motor,
cause faulty contact or wire breakage of traction motor speed sensor harness,
faulty main harness, and faulty logic unit.
Motor current is more than 1018 Arms (Moment). Motor current is more
Trigger of
than 990 Arms (Fixed time 1). Motor current is more than 985 Arms (Fixed
this code
time 2).
2.3.7 TRACTION MOTOR, STALL TIMER (16)
Diagnostic code: 16
Display: "16". All lift truck operations inhibited. Line contactor OPEN
Situation and steering contactor HOLD.
Stall current flowed more than set time (#20) in traction motor, faulty
Possible
traction inverter current sensor, shorted harness wiring, faulty traction
cause
inverter DSP card, and faulty logic unit.
Trigger of
Stall timer set time (set by Setup Option #20) is measured while stalling.
this code
Checks
2.3.8 PUMP MOTOR, CURRENT SENSOR FAULT (34)
Diagnostic code: 34
Display: "34". All lift truck operations inhibited. This fault occurs only
Situation when turning ON power. Line contactor OPEN and steering contactor
HOLD.
Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty
Possible
pump inverter DSP card, faulty pump inverter, faulty main harness, and
cause
faulty logic unit.
Trigger of When turning ON power, current sensor voltage is out of range of -120 A
this code to 120 A.
Checks
2.3.9 PUMP MOTOR OVER-CURRENT (35)
Diagnostic code: 35
Possible pump inverter DSP card, faulty pump inverter, faulty pump motor, faulty
cause contact or wire breakage of pump motor speed sensor harness, faulty main
Trigger of Motor current is more than 1018 Arms (Moment). Motor current is more
this code than 990 Arms (1 mS). Motor current is more than 985 Arms (1.6 mS).
Checks
2.3.10 LINE CONTACTOR, FAULT (40)
Diagnostic code: 40
Display: "40". Traction and pump motor operation inhibited. Line and
Situation steering contactor HOLD. If this fault occurs before steering contactor
CLOSE, all operations inhibited except mast lowering operation.
Break of line fuse, faulty line contactor, faulty traction inverter or pump
Possible
inverter, faulty DSP card in traction inverter, faulty main harness, and
cause
faulty logic unit.
Trigger of
Inverter voltage data is checked when contactor is closed.
this code
Checks
2.3.11 TRACTION MOTOR, OPEN (45)
Diagnostic code: 45
Faulty contact or wire breakage of traction motor cable, faulty traction

motor, faulty contact or wire breakage of traction inverter connector, faulty
Possible
contact of DSP flat cable in traction inverter, wire breakage of main
cause
harness, faulty logic unit power supply card, faulty traction inverter DSP
card, faulty traction inverter, and when restarting after motor shorted.
Trigger of Motor voltage is abnormal when power is turned ON. Current does not flow
this code when torque instruction is requested.
Checks
2.3.12 PUMP MOTOR, OPEN (47)
Diagnostic code: 47
Faulty contact or wire breakage of pump motor cable, faulty pump motor,
faulty contact or wire breakage of pump inverter connector, faulty contact
Possible
of DSP flat cable in pump inverter, wire breakage of main harness, faulty
cause
logic unit power supply card, faulty pump inverter DSP card, faulty pump
inverter, and when restarting after motor shorted.
Trigger of Motor voltage is abnormal when power is turned ON. Current does not flow
this code when rotational speed instruction is requested.
Checks
2.3.13 STEERING MOTOR, FAULT (49)
Diagnostic code: 49
Situation and steering contactor OPEN.
Faulty steering motor, faulty steering contactor, faulty harness, and

Possible cause
faulty logic unit.
Trigger of this Steering motor's warning signal is high (open), when steering motor
code warning signal is ON.
Checks
2.3.14 ACCELERATOR SENSOR, FAULT (51)
Diagnostic code: 51
Possible Improper accelerator pedal linkage, faulty accelerator sensor, faulty main
cause harness, and faulty logic unit.
Accel sensor 1 voltage is out of range from 0.15 to 4.2 V. Accel sensor 2
Trigger of input value multiplied by two is out of range from 0.15 to 4.2 V.
this code Difference in input between accelerator sensors 1 and 2 (multiplied by
two) is 0.4 or more.
Checks
2.3.15 TRACTION MOTOR, PULSE INPUT FAULT (52)
Diagnostic code: 52
Faulty contact of traction inverter connector, faulty connection of traction
Possible motor connector and cable, faulty 12V input voltage of traction inverter,
cause faulty contact or wire breakage of traction motor speed sensor harness,
faulty traction inverter DSP card, and faulty traction motor speed sensor.
Trigger of
Motor rotation speed is more than 5800 min-1.
this code
Checks
2.3.16 PUMP MOTOR, PULSE INPUT FAULT (57)
Diagnostic code: 57
Faulty contact of pump inverter connector, faulty connection of pump

Possible motor connector and cable, faulty 12V input voltage of pump inverter,
cause faulty contact or wire breakage of pump motor speed sensor harness, faulty
pump inverter DSP card, and faulty pump motor speed sensor.
Trigger of Motor rotation speed is more than -200 min-1 and is more than 5800 min-1.
this code Motor rotates in reverse.
Checks
2.3.17 DIRECTION LEVER OR ACCELERATOR, FAULTY SETTING
(E)
Diagnostic code: E
Display: "E". All lift truck operations inhibited. Line contactor and steering
Situation contactor OPEN when turning ON power. Line contactor OPEN (when lift
truck stops) and steering contactor HOLD except when turning ON power.
Key switch turned ON while direction lever was left either in FORWARD
Possible or REVERSE position, key switch turned ON while accelerator pedal was
cause depressed, seat switch turned OFF while running, faulty direction lever
switch, faulty accelerator sensor, faulty main harness, and faulty logic unit.
Trigger of Detects the following signal when turning ON power: Direction lever: F or
this code R Accelerator sensor voltage: More than 1.4 V
Checks
2.3.18 SEAT SWITCH, FAULTY SETTING FOR TRACTION ((E))
Diagnostic code: (E)
.
Display: "E" blinking. All lift truck operations inhibited. Line contactor
Situation and steering contactor OPEN when turning ON power. Line contactor
OPEN (when lift truck stops) and steering contactor HOLD except when
turning ON power.
Operator not in the seat, seat switch turned OFF during running, improper
Possible
seat suspension adjustment, faulty seat switch, faulty main harness, and
cause
faulty logic unit.
Trigger of
Detects seat switch opening when turning ON power or while running.
this code
Checks
2.3.19 SEAT SWITCH, FAULTY SETTING FOR HYDRAULIC ((L))
Diagnostic code: (L)
Display: "L" blinking. All lift truck operations inhibited. Line contactor
Situation
and steering contactor OPEN when turning ON power. Line contactor
turning ON power.
Operator not in the seat, seat switch turned OFF during pump motor
Possible
operation, improper seat suspension adjustment, faulty seat switch, faulty
cause
main harness, and faulty logic unit.
Trigger of Detects seat switch opening when turning ON power or during pump
this code operation.
Checks
2.3.20 LIFT LEVER, FAULTY SETTING (H1)
Diagnostic code: H1
Display: "H1" blinking. All lift truck operations inhibited. Line contactor
Situation
turning ON power.
Possible Key switch turned ON while operating lift lever, faulty lift switches 1 and
cause 2, faulty lift down switch, faulty main harness, and faulty logic unit.
Trigger of
Detects lift microswitch 1 or 2, when turning ON power.
this code
Checks
2.3.21 TILT LEVER, FAULTY SETTING (H2)
Diagnostic code: H2
Situation .
turning ON power
Possible Key switch turned ON while operating tilt lever, faulty tilt switch, faulty
cause main harness, and faulty logic unit.
Trigger of
Detects tilt microswitch when turning ON power.
this code
Checks
2.3.22 ATTACHMENT 1 LEVER, FAULTY SETTING (H3)
Diagnostic code: H3
Situation OPEN (when lift truck stops) and steering contactor HOLD except when
turning ON power.
Possible Key switch turned ON while operating attachment 1 or 2 lever, faulty
cause attachment 1 or 2 switch, faulty main harness, and faulty logic unit.
Trigger of
Detects attachment 1 or 2 microswitch when turning ON power.
this code
Checks
2.3.23 ATTACHMENT 2 LEVER, FAULTY SETTING (H4)
Diagnostic code: H4
Situation OPEN (when lift truck stops) and steering contactor HOLD except when
turning ON power.
Possible Key switch turned ON while operating attachment 2 lever, faulty
cause attachment 2 switch, faulty main harness, and faulty logic unit.
Trigger of
Detects attachment 2 microswitch when turning ON power.
this code
Checks
2.3.24 METER PANEL, COMMUNICATION FAULT (60)
Diagnostic code: 60
Situation Display: "60". Normal lift truck operation.
Possible cause Faulty main harness, faulty meter panel, and faulty logic unit.
Trigger of this code Communication is impossible. Meter panel is abnormal.
Checks
2.3.25 LOGIC CARD, INITIALIZE FAILURE (61)
Diagnostic code: 61
Setup Option Group 3 data not set, Setup Option Group 1 and 2 default
Possible cause
data not set, faulty Setup Option data, and faulty logic unit.
Trigger of this
Setup Option data is in abnormal setting range.
code
Checks
2.3.26 LOGIC UNIT, FAULT (62)
Diagnostic code: 62
Possible
Faulty EEPROM data and faulty logic unit.
cause
ROM SUM value of logic card is different from check data. EEPROM
Trigger of
SUM value of logic card is different from check data. RAM of logic card
this code
is faulty.
Checks
2.3.27 TRACTION INVERTER, FAULT (63)
Diagnostic code: 63
Situation steering contactor OPEN.
Faulty contact or wire breakage of DSP flat cable in traction inverter,

Possible
faulty traction inverter DSP card, faulty traction inverter, faulty main
cause
Traction inverter is connected as pump inverter (E-06-9 is connected to
Trigger of GND). ROM SUM value of taction inverter is different from check data.
this code RAM of traction inverter is faulty. Communication with traction inverter is
impossible.
Checks
2.3.28 PUMP INVERTER, FAULT (65)
Diagnostic code: 65
Possible
pump inverter DSP card, faulty pump inverter, faulty main harness, and
cause
faulty logic unit.
Pump inverter is connected as traction inverter (E-05-9 is opened). ROM
Trigger of
SUM value of pump inverter is different from check data. RAM of pump
this code
inverter is faulty. Communication with pump inverter is impossible.
Checks
2.3.29 CONTACTOR, COIL FAULT (72)
Diagnostic code: 72
Display: "72". All operations inhibited. Line contactor OPEN and
Situation
steering contactor OPEN.
Faulty line contactor, faulty steering contactor, faulty main harness,
Possible cause
and faulty logic unit.
Trigger of this
With short circuit detection signal of logic card.
code
Checks
2.3.30 HYDRAULIC LOCK SOLENOID, FAULT (74)
Diagnostic code: 74
Display: "74". Pump motor operation inhibited. Normal traction motor
Situation
operation and power steering operation.
Possible cause Faulty lift lock valve, faulty main harness, and faulty logic unit.
Trigger of this
code
Checks
2.3.31 ELECTROMAGNETIC BRAKE, SOLENOID FAULT (75)
Diagnostic code: 75
Situation and steering contactor HOLD.
Faulty electromagnetic brake valve, faulty main harness, and faulty

Possible cause
logic unit.
Trigger of this
code
Checks
2.3.32 PDS BUZZER, FAULT (76)
Diagnostic code: 76
Situation Display: "76". All operations available except for the buzzer.
Possible cause Faulty PDS buzzer, faulty main harness, and faulty logic unit.
Trigger of this code By short circuit detection signal of logic card.
Checks
2.3.33 BATTERY, VOLTAGE TOO LOW (78)
Diagnostic code: 78
Faulty or discharged battery, low voltage battery, improper battery voltage
Possible
setting (Setup Option #41), improper battery voltage adjustment setting
cause
(Setup Option #46), faulty main harness, and faulty logic unit.
Trigger of Corrected battery voltage is too low. Battery voltage is corrected with #46
this code value. 36 V battery: less than 30 V 48 V battery: less than 42 V
Checks
2.3.34 BATTERY, VOLTAGE TOO HIGH (79)
Diagnostic code: 79
Faulty or highly charged battery, high voltage battery, improper battery

Possible
voltage setting (Setup Option #41), improper battery voltage adjustment
cause
setting (Setup Option #46), and faulty logic unit.
Trigger of Corrected battery voltage is too high. Battery voltage is corrected with
this code #46 value. 36 V battery: more than 42 V 48 V battery: more than 60 V
Checks
2.3.35 BATTERY, CONSUMPTION TOO MUCH (LO)
Diagnostic code: (Lo)
Display: "Lo" blinking. Battery low indicator ON. All lift truck
Situation operations inhibited. Line contactor OPEN and steering contactor
OPEN.
Possible
Extremely consumed battery, faulty main harness, and faulty logic unit.
cause
Trigger of Corrected battery voltage is less than 22 V. Battery voltage is corrected
this code with #46 value.
Checks
2.3.36 BATTERY, CONSUMPTION MUCH ((L0))
Diagnostic code: None
Battery low indicator blinks. Traction motor operation restricted to
Situation "ECONOMY" mode. Normal pump motor and power steering
operations.
Possible Consumed battery, improper battery voltage adjustment setting (Setup
cause Option #46), faulty main harness, and faulty logic unit.
Trigger of Corrected battery voltage is less than 25 V. Battery voltage is corrected
this code with #46 value.
Checks
2.3.37 BRAKE FLUID, LOW LEVEL
Situation Lower brake fluid indicator ON. Normal lift truck operation.
Insufficient brake fluid, faulty brake fluid level sensor, shorted wiring,
Possible cause
faulty logic unit, and faulty meter panel.
Trigger of this
Sensor signal is open or shorted.
code
Checks
2.3.38 RTC BATTERY, LOW
Situation Date or clock is abnormal.
Possible cause Battery voltage for calendar IC is low.
Trigger of this code Signal from calendar IC.
Checks
Chapter 3 HOW TO READ CIRCUIT DIAGRAMS

3.1 DESCRIPTION OF CIRCUIT DIAGRAMS
The circuit diagrams consist of the schematic diagrams and connector diagrams.
3.1.2 CIRCUIT DIAGRAMS

All circuits including the power supply and ground are divided into the power circuit, GND
circuit and system circuits.
Power circuit diagram
The power circuit diagram indicates the power circuit including the battery, fuse, ignition
switch, etc.
GND circuit diagram
The GND circuit diagram indicates the circuits from each electric component to the body
ground or from each component to the battery negative terminal.
System circuit diagrams
The system circuit diagrams indicate the circuits of each system from fuse to GND (earth)
excluding the above power supply and GND circuit portions.
3.1.3 CONNECTOR DIAGRAMS

The connector shapes, terminal shapes and terminal arrangements of all connectors in the
circuit diagrams are indicated.
3.2 HOW TO READ CIRCUIT DIAGRAMS

The circuit of each system from fuse to GND (earth) is indicated. The circuits indicate the
direction of signal flow. In figures, it flows from top (positive) to bottom (negative).
1. DEPARTURE EQUIPMENT NAME 11. USED PLACE OF RELAY COIL
2. DEPARTURE SHEET NUMBER (DESCRIPTION(1))
3. CABLE DIAMETER & COLOR 12. INDICATES SAME CONNECTOR
(DESCRIPTION(2)) 13. INDICATES CONNECTION WITH GND
4. CIRCUIT NUMBER CIRCUIT
5. BOUNDARY (DESCRIPTION(4)) 14. SHEET NUMBER OF GND CIRCUIT
6. EQUIPMENT NAME 15. USED PLACE OF RELAY CONTACT
7. TERMINAL NUMBER OF (DESCRIPTION (1))
CONNECTOR 16. DESTINATION SHEET NUMBER
8. CONNECTOR NUMBER 17. DESTINATION EQUIPMENT NAME
(DESCRIPTION(3)) 18. INDICATES CONNECTION WITH
9. INDICATES CONNECTION WITH NEGATIVE CIRCUIT
BODY GND 19. SHEET NUMBER OF NEGATIVE CIRCUIT
10. EQUIPMENT NUMBER
3.2.2 SYMBOLS
Symbols are used in the figures for easy reading of circuit diagrams.
General Symbols
Symbol Name
GND (Harness)
GND (Body)
Negative
Conductors and Coupling Parts
Symbol Name
Connector (Socket/Plug)
Terminal (Socket)
Terminal (Plug)
Terminal
Twist wire
Shield wire
Branching
Standard Passive Parts
Symbol Name
Resistor
Variable Resistor
Semiconductors and Electronic Tubes
Symbol Name
Diode
LED
Auto light sensor (Photo diode)
Generation and Conversion of Electric Energy
Symbol Name
Generator
Three phase Induction motor
DC motor
Stepping motor
Battery
Switches, Control, and Protective Devices
Symbol Name
Switch (N.O)
Switch (N.C)
Two position switch
Emergency switch
Push button switch
Switch (Auto return)
Oil pressure switch

Magnetic contactor
Fuse
Thermistor
Magnetic coil
Proximity sensor
Indicators, Lamps, and Signal Devices
Symbol Name
Lamp
Buzzer
Horn
Special symbols
The following symbols are used when the representation by general symbols is difficult.
This diagram shows that No. 1 and No. 3 terminals are connected when the switch position
is placed in N position.
1. SWITCH POSITION
2. TERMINAL
3.2.3 SHEET SYMBOL
A sheet symbol is provided in each circuit diagram sheet so that the relationship between
diagrams can be clarified. The sheet symbol consists of "SH" and two digit numbers, for
example, “SH-01" or “SH-02".
3.2.4 CONNECTING LINES

(1) There are two thicknesses of the line which connect between elements in the circuit
diagram. Each line is used as follows:
- Thick line: Connecting lines for the electric wires size of 20 mm2 (0.78 in2) or
above.
- Thin line: All other connecting lines except the above.
(2) Connecting lines are represented by the circuit number, wire diameter and wire
color. For the connecting lines of 0.5 mm2 (0.02 in2) wire size, the wire diameter is
omitted.
1. WIRE DIAMETER, WIRE COLOR

2. CIRCUIT NUMBER
3. WIRE COLOR
4. WIRE DIAMETER
(3) Here are two types of wires: the one having only
one color and the one having a colored stripe
(combination of two colors).
1. BASE COLOR
2. STRIPE COLOR
3. BASE COLOR
4. STRIPE COLOR
Symbol Color
B Black
Br Brown
G Green
Gr Gray
L Blue
Light
Lg
green
O Orange
P Pink
R Red
Sb Sky blue
V Purple
W White
Y Yellow
3.2.5 EQUIPMENT
1. Equipment is represented by a box. The symbol of connector that belongs to the
equipment is indicated inside the box.
2. The items listed under the item category symbol have a specific symbol
(equipment number) for classification of items and identification of identical
items.
Equipment number system
1. EQUIPMENT NAME 5. EQUIPMENT NUMBER

2. BOX 6. CLASSIFICATION NUMBER (SERIAL
3. CONNECTOR FOR HARNESS NUMBER)
4. CONNECTOR BELONGS TO 7. ITEM CATEGORY SYMBOL

EQUIPMENT
Item category symbol
Symbol Item Symbol Item

F Fuse MC Contactor
SBF Slow-blow fuse R Resistor
FLW Fusible link C Capacitor
RY Relay D Diode
3.2.6 RELAY CONTACTOR AND COIL
(1) For the relay contactor, the sheet symbol in which its coil is represented is provided
so that you can find its coil easily. However, when the coil is represented in the same
sheet, the sheet symbol is omitted.
1. EQUIPMENT NAME
2. EQUIPMENT NUMBER
3. SHEET SYMBOL WHERE COIL IS REPRESENTED
(2) For the relay coil (contactor coil),
the sheet symbol in which its
contact is represented is provided
so that you can find the location of
contacts. However, when the
contact is represented in the same
sheet, the sheet symbol is omitted.
1. EQUIPMENT NAME
2. EQUIPMENT NUMBER
3. SHEET SYMBOL WHERE THE CONTACT IS REPRESENTED
3.2.7 CONNECTORS
(1) The connectors are represented by the connector number for identification. The
connector number is enclosed with a box.
(2) The same connector number is allocated to a plug connector (male connector) and its
mating socket connector (female connector) as a pair.
(3) The connector terminal number is indicated next to the connector symbol. However,
for the terminals such as round shape terminal, plug terminal, and flat shape
terminal, etc., the terminal number is indicated.
(4) When the connectors located side by side are the identical but have a different
number, the line between the connectors are indicated by a dotted line.
1. TERMINAL 4. CONNECTOR NUMBER
NUMBER 5. INDICATES THAT THE CONNECTOR IS THE SAME.
2. CONNECTOR
NUMBER
3. TERMINAL
NUMBER
3.2.8 INDICATION OF
CONNECTING LINE
(1) When a connecting wire crosses to another sheet, it is indicated by the arrow with
the sheet symbol next to it. Also, the name of destination equipment is indicated for
better understanding.
1. DESTINATION SHEET SYMBOL

2. DESTINATION EQUIPMENT NAME
(2) A connecting wire from another sheet is also
indicated by the arrow with the sheet symbol
next to it. Also, the name of sender equipment is
indicated for better understanding.
1. SENDER EQUIPMENT NAME
2. SENDER SHEET SYMBOL
3.2.9 INDICATION OF GND (EARTH)
The GND (earth), depending on the connection type, is represented as shown below.
(1) When connecting directly to the body.
1. TERMINAL CONNECTOR NUMBER

2. GRAPHIC SYMBOL
(2) When connecting to body or battery negative
terminal through GND circuit and negative
circuit.
1. GRAPHIC SYMBOL
2. DESTINATION SHEET SYMBOL
3. THIS INDICATES THE CONNECTION TO GND CIRCUIT
4. THIS INDICATES THE CONNECTION TO NEGATIVE CIRCUIT.
3.2.10 INDICATION OF ANOTHER SPECIFICATION
When there is another specification, the portion of circuit, for which another
specification is available, is enclosed with an alternate long and two short dashes line,
and the circuit of another specification is enclosed by a thick solid line.
1. THE CIRCUIT PORTION WHICH 2. THE CIRCUIT OF ANOTHER

DIFFERS DEPENDING ON THE SPECIFICATION
SPECIFICATION
3.3 HOW TO READ

CONNECTOR
DIAGRAMS
For all connectors included in the circuit diagrams; the connector shapes, terminal
arrangements, and terminal shapes (plug or socket) are indicated.
Socket terminal (female terminal)
1. CONNECTOR NUMBER 4. THIS INDICATES NO.4 TERMINAL OF B-
2. LOCK 01 CONNECTOR
3. TERMINAL ARRANGEMENT 5. SOCKET TERMINAL
TERMINAL NUMBER 6. PLUG TERMINAL
Plug terminal (male terminal)
1. LOCK (BLACKENED)
(1) The connector diagram is a view from its mating face.
(2) For the connectors that are connected to the equipment, only the wire harness side
connector is indicated.
(3) For intermediate connectors, the connector diagram of both plug terminal (male) and
socket terminal (female) are indicated.
(4) The lock portion of the plug terminal (male) is represented by blackening to
distinguish from the socket terminal (female).
(5) Unused terminals are represented by the terminal number “-” Also, the terminal
number marked with * indicates a gold-plated terminal.
1. GOLD-PLATED TERMINAL
2. UNUSED TERMINAL
(6) The terminal shapes are simplified as shown below.
© 2019 MCFA. All rights reserved. CAT, CATERPILLAR, their respective logos,
“Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product
identity used herein, are trademarks of Caterpillar and may not be used without permission.
All registered trademarks are the property of their respective owners. Some products may
be shown with optional equipment.
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Service Manual

Symbols and Abbreviations

1. POWER SUPPLY CARD SIDE CN1

1) TRACTION INVERTER CARD SIDE CN2

1.2 TRACTION CONTROLLER

Description SUO No.

Item Description SUO No.

1.3 LIFTING CONTROLLER FEATURE

Item Description SUO No.

1.3.2 LIFT STOP

1.4 STEERING CONTROL FEATURES

1.5 METER PANEL

FORWARD NEUTRAL (ON)

REVERSE NEUTRAL (OFF)

5. Travel speed / Message center

1.5.5 PASSWORD ENTRY

1.6 OTHER FEATURES

Item Protect condition Result Release method

Item Description SUO No.

1.6.3 PASSWORD CERTIFICATION

Item Description SUO No.

Item Description SUO No.

1.7 SETUP OPTION

Characteristic Acceleratio Mediu Mediu

Default value Acceleratio

Characteristic Acceleratio Mediu Mediu

Default value Acceleratio

Pump motor output characteristics (lift-up operation)

Torque value resulting *2 Thermal, BDI [0] or Service indicator: Curve

Value Lift Travel

#24 Chat timer

1.7.4 DETAILS OF SETUP OPTIONS (GROUP-3)

#41 Battery voltage

BDI# 36V 48V

BDI# 36V 48V

BDI# 36V 48V

1.7.5 SETUP OPTIONS (GROUP 1)

Option # Range Default Value

1.7.6 SETUP OPTIONS (GROUP 2)

1.8.2 OPERATION PROCEDURE

1. DIAGNOSTICS RESULT INDICATION

Cycle direction Pass 3

Tilt lever Pull and release Pass 10

Attachment Pull and release Input Pass 13

Pull any lever Pass See NOTE (3)

NOTE: (1) “dd” indicates the fuse needs to be removed.

1.9.2 REPLACING INVERTER

3. Disconnect all five power cables from F, N, U, V and W terminals.

TRACTION AND HYDRAULIC INVERTER

Application of thermal compound

Mounting the inverter

3. Attach the inverter with M8 bolts.

NOTE: - It is recommended to check or replace the inverters every 10,000 hours of

1.9.5 REPLACING LOGIC UNIT

4. Remove M8 bolts (two places) and remove the logic unit.

1. BOLT, WASHER (2 PCS)

1.9.6 REPLACING LOGIC CARD

Item Tightening torque

Item Tightening torque