2te15-18 Repair Manual Ce660

2TE15, 18
2TE15, 18
Pub. No. CE660
PRINTED IN JAPAN Pub. No. CE660 Pub. No. CE660

FOREWORD
This Manual contains maintenance, specifications and repair procedures for the
chassis and body of the TOYOTA ELECTRIC POWERED TOWING TRACTOR
2TE15 and 2TE18.
Please use this manual for providing quick and correct servicing of the corresponding
towing tractor.
This manual deals with the above model as of October 2005. Please understand that
disagreement can take place between the descriptions in the manual and actual ve-
hicles due to change in design and specifications. Any change or modifications there-
after will be informed by Toyota Industrial Equipment Parts & Service News.
The service standard values described in this manual are measured by using a
standard vehicle for examination in the condition specified by TOYOTA Industries
Corporation. In an actual operation, therefore, they may be changeable according to
the meteorological, road, servicing, or operating condition.
SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CHARGER 2
CONTROLLER 3
MULTI-DISPLAY FUNCTION 4
ELECTRICAL SYSTEM TROUBLESHOOTING 5
MOTOR 6
DRIVE UNIT 7
REAR AXLE 8
FRONT AXLE 9
SUSPENSION 10
STEERING 11
BRAKE 12
BODY 13
APPENDIX 14
0-1
GENERAL
Page Page
0
EXTERIOR VIEW ................... 0-2 BOLT & NUT TIGHTENING 0
TORQUE ............................ 0-19
VEHICLE MODELS................ 0-8 0
STANDARD BOLT & NUT
FRAME NUMBER .................. 0-8 TIGHTENING TORQUE.......... 0-19 0
HOW TO USE THIS BOLT STRENGTH CLASS
MANUAL .............................. 0-9 IDENTIFICATION METHOD AND 0
TIGHTENING TORQUE.......... 0-19
EXPLANATION METHOD .......... 0-9
HEXAGON FLANGE BOLT 0
TERMINOLOGY ........................ 0-10 TIGHTENING TORQUE.......... 0-21
ABBREVIATIONS ..................... 0-10 PRECOATED BOLTS............... 0-21
0
SI UNITS.................................... 0-11
HIGH PRESSURE HOSE 0
OPERATING TIPS ............... 0-12 FITTING TIGHTENING
GENERAL INSTRUCTIONS ..... 0-12 TORQUE ............................ 0-22 0
JACKING UP............................. 0-13 RECOMMENDED LUBRICANT
QUANTITY AND TYPES .... 0-22
0
HOISTING THE VEHICLE......... 0-14
LUBRICATION CHART ....... 0-23 0
WIRE ROPE SUSPENSION
ANGLE LIST ........................... 0-15 PERIODIC REPLACEMENT 0
SAFE LOAD FOR EACH WIRE OF PARTS AND
ROPE SUSPENSION ANGLE 0-15 LUBRICANTS .................... 0-24 0
COMPONENTS WEIGHTS ....... 0-16 PERIODIC
MAINTENANCE ................. 0-25 0
CAUTION FOR TOWING .......... 0-16
ELECTRICAL PARTS INSPECTION METHOD............ 0-25 0
INSPECTION........................... 0-17
0
0
0
0
0-2
EXTERIOR VIEW
2TE15
0-3
2TE18
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0-4
2TE15 (W/ wind top)

0-5
2TE18 (W/ wind top)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0-6
2TE15 (W/ steel cabin)

0-7
2TE18 (W/ steel cabin)

0-8
VEHICLE MODELS
Model 2TE15, 2TE18
Control method Microcomputer
Voltage (V) 80
Battery
Quantity (AH/5HR) 445 (STD) / 470 (OPT)
FRAME NUMBER
Vehicle model 2TE15 2TE18
Punching format 2TE15-10011 2TE18-10011
Punching position
Frame No. punching position

0-9
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operating procedure
(1) Operating procedures are described using either pattern A or pattern B.
Pattern A : Each step of the operation is explained with its own illustration.
Pattern B : Each step of the operation is explained with reference to step numbers in a single illustration.
Explanations in the form of point operations, cautions, and notes follow.
Example of pattern B
DISASSEMBLY • INSPECTION • REASSEMBLY

Tightening torque unit→T=N·m (kgf-cm) [ft-lbf]
• Some step numbers may be

omitted in some illustrations.
4
1
2
3
5 6
T=46.1 to 48.1
(470 to 490)
[34.0 to 35.5]
5
9 1
Disassembly Procedure
1. Remove the cover. [Point 1]
2. Remove the bushing. [Point 2] Ã Operation to be explained in following pages.
3. Remove the gear.
Point Operations
Explanation of operation point with illustration.
[Point 1] É
Disassembly:
Make match marks before removing the pump cover.
[Point 2]
Inspection:
Measure the bushing inside diameter.
Limit: 19.12 mm
0-10
2. How to read component figures

(1) The component figures use the illustration in the parts cat- (Example)
alog for the vehicle model. Please refer to the catalog to
3201
check the part name.
3. Matters omitted from this manual Parts catalog
FIG number
(1) This manual omits descriptions of the following jobs, but
perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters, negligence of which may cause accidents. Be sure to observe them.
Note:
Important items, negligence of which may cause accidents, or matters in operating procedure which require
special attention.
Standard: Value showing the allowable range in inspection or adjustment.
Limit: The maximum or minimum value allowed in inspection or adjustment.
ABBREVIATIONS
Abbreviation Meaning Abbreviation Meaning
ASSY Assembly SAE Society Automotive Engineers (USA)
ATT Attachment SST Special Service Tool
LH Left Hand STD Standard
L/ Less T= Tightening Torque
OPT Option {{T Number of teeth ({{T)
O/S Oversize U/S Undersize
PS Power Steering W/ With (what follows is included)
RH Right Hand
0-11
SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify the various
systems of units used in the past for smoother international technical communication.
New Units Adopted in SI
Item New unit Conventional unit Conversion rate *1

(1 [conventional unit] = X [SI unit])
Force *2 N (newton) kgf 1 kgf = 9.80665 N
Torque *2 (Moment) N·m kgf·cm 1 kgf·cm = 9.80665 N·m
Pressure Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
↑ ↑ mmHg 1 mmHg = 0.133322 kPa
Revolving speed r/min rpm 1 rpm = 1 r/min
Spring constant *2 N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Reference:
*1 : X is the value obtained by converting 1 [in conventional unit] into the SI unit. It is also used as the conversion
rate between conventional and SI units.
*2 : In the past, kilogram (kg), representing mass, was often used in place of weight kilogram (kgf), which should be
used as the unit of force.
Conversion between Conventional and SI Units

Equation for conversion
Value in SI unit = Conversion rate × Value in conventional unit

Conversion rate: Figure corresponding to X in the conversion
rate column in the table above
Value in conventional unit = Value in SI unit ÷ Conversion rate
0-12
OPERATING TIPS
GENERAL INSTRUCTIONS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity.
(3) Be sure to disconnect the battery plug before servicing of electrical parts.
2. Skillful operation
(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.)
and SSTs before starting operation.
(2) Check the cable color and wiring state before disconnecting any wiring.
(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly
to prevent confusion.
(4) When disassembling and inspecting a precision part such as the control valve, use clean tools and operate
in a clean location.
(5) Follow the specified procedures for disassembly, inspection and reassembly.
(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotterpins with new ones each time they
are removed.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to
the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value
given in the STANDARD BOLT TIGHTENING TORQUE table.
3. Protection of functional parts
(1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connec-
tor for any connection failure or imperfect connection.
Failure or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
4. Defect status check
Do not start disassembly and/or replacement of components immediately, but first check that disassembly and/
or replacement of them is necessary for the defect.
5. Waste fluid disposal
Always use a proper container when draining waste fluid from the vehicle.
Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human
health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposal.
0-13
JACKING UP
Always observe the following instructions when jacking up the vehicle:
• Park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any
other point is dangerous.
• Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the
vehicle with the jack only is very dangerous.
• Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-
up vehicle.
Jack-up point
Wooden stand point

0-14
HOISTING THE VEHICLE

When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist by any
other attachment section as it is very dangerous.
Caution:
Be sure to attach the belt with
a thick cloth under the belt.
Note:
For vehicles with
rear under mirror,
remove it before
attaching belt.
Caution:
Hold tightly so as not to allow the belt
to dislocate. For that, use shackles.
0-15
WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension Suspension Suspension
Tension Compression Tension Compression
angle method angle method
1 tf
0° 1.00 time 0 time 90° 1.41 time 1.00 time 90°
tf
41
1.
2t 2t
30°
30° 1.04 time 0.27 time tf 120° 2.00 time 1.73 time 120°
1.04
tf
2
2t 2t
60° 1.16 time 0.58 time 60°

f
6t
1.1
2t
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (ton:tf)
Single-rope
Rope diameter Cutting Two-rope suspension Four-rope suspension
suspension
mm load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6
(2.18) (0.31) (0.62) (0.60) (0.53) (0.44) (1.24) (1.20) (1.06) (0.88)
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8
(3.21) (0.45) (0.90) (0.87) (0.78) (0.64) (1.80) (1.74) (1.56) (1.28)
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10
(5.02) (0.71) (1.43) (1.38) (1.20) (1.00) (2.80) (2.70) (2.40) (2.00)
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5
(7.84) (1.12) (2.20) (2.10) (1.90) (1.50) (4.40) (4.20) (3.80) (3.00)
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14
(9.83) (1.40) (2.80) (2.70) (2.40) (1.90) (5.60) (5.40) (4.80) (3.80)
0-16
COMPONENTS WEIGHTS
Unit: kg (lb)
Item Weight
Battery ASSY 1150 (2535)
2TE15 102 (225)

Drive motor ASSY
2TE18 96 (212)
2TE15 400 (882)

Rear axle and drive unit W/ drive motor
2TE18 430 (948)
Front axle ASSY (W/ spring) 150 (331)
2TE15 3150 (6945)

Vehicle weight (W/ battery)
2TE18 3510 (7738)
CAUTION FOR TOWING

1. When towing the vehicle always lift the front wheels away from
the ground.
2. The traveling speed in towing must not exceed the maximum
traveling speed of the vehicle.
3. Always set the key switch to OFF and the direction switch to
the neutral position before starting towing.
In case of towing by connection with a wire rope with the oper-

ator on the vehicle, however, set the key switch to ON and al-
ways set the direction switch to the towing direction for PS
operation.
0-17
ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject to electronic parts, such as computers and
relays, to impact.
(2) Never expose electronic parts to high temperature or
moisture.
(3) Do not touch connector terminals, as they may be de-
formed or damaged due to static electricity.
3. Use a circuit tester that matches the object and purpose of measurement.
Analog type : This type is convenient for observing movement during operation and the operating condition. The
measured value should be used only for reference or rough judgement.
Digital type : A fairly accurate reading is possible. However, it is difficult to observe operation or movement.
(1) Difference between results of measurement with analog and digital types
* The results of measurements using the analog type and the digital type may be different.
Use the circuit tester according to its instruction manual.
Differences between the polarities of the analog type and the digital type are described below.
(a) Analog circuit tester
Example of measurement result
Forward Reverse Tester range: kΩ range
Forward direction: Continuity 11 kΩ
Reverse direction: No continuity ∞
Black Red Red Black
tester tester tester tester
probe probe probe probe
(b) Digital circuit tester

Example of measurement result
Forward Reverse Tester range: MΩ range
Forward direction: Continuity 2 MΩ
Reverse direction: No continuity ∞
Red Black Black Red
tester tester tester tester
probe probe probe probe
0-18
4. Difference in result of measurement with circuit tester:

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.
The diode characteristics are shown in the figure below.
The resistance values of the same semiconductor measured with two types of circuit testers having different
power supply voltages are different.
This manual describes the results of measurement with a circuit tester whose power supply voltage is 3.0 V.
(mA)
6
5
Forward current
4
Germanium
diode
3
2 Silicon diode
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
(V)
Forward voltage
5. Difference in measurement result by measurement range (analog type):

In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the
circuit resistance. Even when the same diode is measured, the measurement result varies with the measure-
ment range.
Always use the range described in the repair manual for measurement.
Resistor Meter
0Ω
Current flow
Variable resistor
Resistor
(SW1)
Range: × 10
Resistor
(SW2)
Range: × 1
Power source: 1.5 V
Red Black
0-19
BOLT & NUT TIGHTENING TORQUE

STANDARD BOLT & NUT TIGHTENING TORQUE
Tightening torques of standard bolts and nuts are not indicated throughout the manual.
Use the charts and table below to judge the standard tightening torque.
1. Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing sur-
face according to the tightening torque table by identifying the bolt strength class from the table below.
2. Judge the tightening torque for the hexagon flange bolt based on the threading diameter.
3. The nut tightening torque can be judged from its corresponding bolt type.
BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING

TORQUE
Identification by Actual Part
Type Shape and class Class
4 = 4T
5 = 5T
Number in relief or hallmark on the head 6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon head bolt

(standard) 5T
Bolt with two raised lines on head
Bolt with three raised lines on head 7T
Bolt with four raised lines on head 8T
Welded bolt 4T
No mark 4T
Stud bolt
2 mm groove(s) on one/both edge(s) 6T

0-20
Identification by Part No.
Type Part No. Shape
91611-40625
Nominal
Nominal length diameter
Hexagon bolt Nominal diameter
Class
Nominal length
92132-40614
Nominal length (mm) Nominal
diameter
Stud bolt Nominal diameter
Class
Nominal length
Tightening Torque Table
Nominal diameter Pitch Standard tightening torque

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 48 in·lbf

8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 1.0 6.5 65 56 in·lbf

8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 69 in·lbf

8 1.25 19 195 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 125 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 1.5 265 2700 195
0-21
HEXAGON FLANGE BOLT TIGHTENING TORQUE

Nominal diameter Pitch Standard tightening torque
Remarks
mm mm N·m (kgf·cm) [ft·lbf]
7.5 (76.5) [5.5]

5 0.8
Built-in washer
12.5 (128) [9.2]

6 1.0
13 (133) [9.6] Built-in washer
31 (316) [22.9]
8 1.25
64 (653) [47.2]
10 1.25
115 (1173) [84.9]

12 1.25
115 (1173) [84.9] Built-in washer
180 (1837) [133]

14 1.5
180 (1837) [133] Built-in washer
280 (2857) [207]

16 1.5
275 (2806) [203] Built-in washer
PRECOATED BOLTS
1. Do not reuse a precoated bolt without using appropriate proce-
dures as it is in the following cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
Note:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves, re-
Seal lock agent
tighten it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when replacing
the bolt with a new one.)
(2) Completely dry the washed parts by blowing with air.
(3) Apply a specified seal lock agent to the threaded portion
of the bolt.
0-22
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact surfaces with a
clean cloth to remove foreign matter and dirt. Also check that there are no dents or other damage on the contact
surfaces before installation.
2. When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Tightening torque standard N·m (kgf·cm) [ft·lbf]

Nominal diameter of Inside diameter of hose
screw mm (in.)
Standard Tightening range
7/16-20 UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16-18 UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
3/4-16 UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14 UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14 UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15 (0.59)
1·1/16-12 UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
1·5/16-12 UNF 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
PF3/8 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
RECOMMENDED LUBRICANT QUANTITY AND TYPES

Applicable portion Type Quantity
6.5 L (2TE15), 8.4 L (2TE18)

Drive unit Hypoid gear oil API GL-4,5 (until overflow from oil filler port)
The above value is for reference.
Power steering GM DexronII Approx. 1.8 L
Brake line SAE J-1703, DOT-3 Appropriate amount
Chassis parts MP Grease Appropriate amount
Battery Distilled water Appropriate amount

0-23
LUBRICATION CHART
8 hours (daily) inspection
40 hours (weekly) inspection
250 hours (6 weeks) inspection
1000 hours (6 months) inspection
2000 hours (annual) inspection
(2TE15 only)
0-24
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

z: Replacement
Replacement timing Every 6 weeks Every 3 months Every 6 months Every 12 months
Item Every Every

Every 250 hours Every 500 hours
1,000 hours 2,000 hours
Drive unit oil z
Wheel bearing grease (2TE15 only) z
Brake fluid z ←
Brake master cylinder rubber parts z
Wheel cylinder cup seals (Rear brake) z
Disk brake cylinder rubber parts (Front brake) z
Power steering fluid z ←
Power steering hose z Every 2 years
Power steering rubber parts z Every 2 years

0-25
PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection • Repair or replacement if required.
M: Measurement • Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle
Every Every Every Every
Inspection Period 6 weeks 3 months 6 months 12 months
Item Every Every Every Every

250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound I ← ← ←
Looseness in the connecting parts T ← ← ←

Insulation resistance M ← ←
Motor
Brush wear and sliding condition (For PS motor only) I ←
Commutator contamination, damage (For PS motor only) I ←
Brush spring wear (For PS motor only) M
Charge level I ← ← ←
Electrolyte level I ← ← ←
Electrolyte specific gravity M ← ← ←
Terminal looseness I ← ← ←
Battery
Abnormality in the upper portion of the battery and the I ← ← ←
case
Insulation resistance M ← ←
Voltage measurement of each battery cell after charging M
Timer operation I ← ← ←
Terminal looseness I ← ← ←
Charger
Magnet contactor operation, contact contamination and I
abrasion
Contact looseness, damage, abrasion I ← ← ←
Operating condition of the auxiliary contact, contamination, I ← ← ←

abrasion
Magnet Mounting condition of the arc shooter I
contactor
Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead wire, looseness I
Operating condition and timings I ← ← ←

Microswitch
Damage and looseness at installing portion I ← ← ←
Direction Operation condition, damage I ← ← ←

switch Contact condition I ← ←
0-26


Operation condition I ← ← ←
Controller Interior contamination, damage C ← ← ←
Drive motor OCL M
Fuse Looseness I ← ← ←
Harness deterioration, clamp damage and looseness I ← ← ←

Wiring
(including Looseness in connecting parts, taping condition I ← ← ←
charging cord)
Connecting condition and damage of the battery connector I ← ← ←
POWER TRANSFER SYSTEM
Oil leakage I ← ← ←
Drive unit Oil level I ← ← ←
Bolt or nut looseness T
DRIVING SYSTEM
Tire inflation pressure M ← ← ←
Tire cuts, damage and abnormal wear I ← ← ←
Rim and hub nuts looseness T ← ← ←
Tire groove depth M ← ← ←

Wheels Metal chips, pebbles and other foreign matter trapped in I ← ← ←
tire grooves
Rim, side ring and disc wheel damage I ← ← ←
Abnormal sound and looseness of front wheel bearing I ← ← ←
Abnormal sound and looseness of rear wheel bearing I ← ← ←

Cracks, damage and deformation of beam I
Looseness of axle beam in vehicle latitudinal and M* M
Front axle
longitudinal direction
Looseness of U-bolt set nut T
Rear axle Cracks, damage and deformation of housing I
SUSPENSION SYSTEM
Damage I
Chassis spring
Uneven deflection between left and right I
Looseness and damage of installation I

Installation
Looseness of joints I
and joints
Leaf displacement I
Shock Oil leakage and damage I

absorber Looseness of installation I
0-27


STEERING SYSTEM
Play and looseness I ← ← ←

Steering wheel
Function I ← ← ←
Oil leakage I ← ← ←
Steering valve
Looseness of mounting T ← ← ←
Oil leakage and level I ← ← ←

Power
Mounting and linkage looseness I ← ← ←
steering
Damage of power steering hose I
King pin looseness I ← ← ←

Knuckle
Cracks and deformation I
BRAKING SYSTEM
Play and depressed pedal clearance from the floor plate M ← ← ←
Brake pedal Braking effect I ← ← ←
Air entering of brake hose system I ← ← ←
Operating force I ← ← ←
Parking brake Braking effect I ← ← ←
Rod and cable looseness and damage I ← ← ←
Brake pipe Leak, damage and mounting condition I ← ← ←
Reservoir tank Leak and fluid level I ← ← ←
Master Function, wear, damage, fluid leak and mounting I

cylinder and looseness
wheel cylinder
Clearance between disc and pad M ← ← ←
Disc brake Disc wear and damage I

(Front brake) Pad wear and damage I
Disc mounting looseness I
Clearance between drum and lining M ← ← ←
Wear of shoe sliding portion and lining I
Brake drum Drum wear and damage I

and brake
Shoe operating condition I
shoe
(Rear brake) Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Backing plate Deformation, cracks and damage I

(Rear brake) Mounting looseness T
0-28


SAFETY DEVICE, ETC.
Lighting Function and mounting condition I ← ← ←

system
Horn Function and mounting condition I ← ← ←
Instruments Function I ← ← ←
Back-up Function and mounting condition I ← ← ←

buzzer
Rear-view Dirt, damage I ← ← ←

mirror Rear reflection status I ← ← ←
Seat Looseness and damage of mounting I ← ← ←
Towing device Looseness of draw bar mounting I ← ← ←
Damage and cracks of frame, cross members, etc. I

Body
Bolt looseness T
Others Grease up L ← ← ←
1-1
BATTERY
Page 1
BATTERY COMPARTMENT AND
REQUIRED WEIGHT ....................................... 1-2
1
SERVICE STANDARD ....................................... 1-3 1
DISPLAY ..................................................................... 1-3
1
TROUBLESHOOTING ....................................... 1-4
BATTERY ASSY ................................................ 1-5
1
REMOVAL • INSTALLATION ..................................... 1-5 1
INSPECTION............................................................... 1-7
1
1
1
1
1
1
1
1
1
1
1
1
1
1-2
BATTERY COMPARTMENT AND REQUIRED WEIGHT

When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required weight as
shown in the table below.
Compartment dimensions mm (in.)

Minimum required battery weight (with case)
Remarks
Kg (lb)
Depth X Width Y Height Z
Except for Europe models 680 (26.8)

1,170 (46.1) 645 (25.4) 1,045 (2,304)
Europe models 700 (27.6)
th
ep
D
Height
Width
1-3
SERVICE STANDARD
STD 445
Battery capacity (AH/5HR)
OPT 470
1
Specified gravity upon full charge 1.280 [20°C (68°F)]
Specified gravity upon end of discharge 1.150 [20°C (68°F)] 1

Specified voltage upon full charge (V) 80
1
Specified voltage upon end of discharge (V) 68
Electrolyte Refined dilute hydrochloric acid 1

Replenish fluid Distilled water
1
Insulation resistance (MΩ) 1 or more
1
DISPLAY
Battery Charge Indicator
1
The battery charge indicator indicates battery charge by 10 levels
on the LCD.
1
1
Battery charge indicator
1
1
Low Remaining Battery Charge Warning
1
Battery Display indication
discharged When the remaining battery charge drops below the set level, the
1 2 3 4 5 6 7 8 9 10
state % E F charge indicator blinks.
0 to 9
10 to 19
{ { { { { { { { { { When the key switch is turned to OFF and ON again in this state,
the buzzer sounds for 5 seconds to warn the operator. 1
{ { { { { { { { { —
20 to 29 { { { { { { { { — — Battery Overdischarge Warning Function
When the battery charge decreases further below the set level after
1
30 to 39 { { { { { { { — — —
40 to 49 { { { { { { — — — —
the remaining battery charge warning, any attempt at traveling op-
eration will cause all charge indicator segments to blink and warn 1
50 to 59 { { { { { — — — — — the operator by alarming sound.
60 to 69 { { { { — — — — — — 1
70 to 79 { { { — — — — — — —
80 to 89 { { — — — — — — — — 1
1
90 to 99 { — — — — — — — — —
100 or more — — — — — — — — — —
1
{: ON, —: OFF
1-4
TROUBLESHOOTING
1-5
BATTERY ASSY
REMOVAL • INSTALLATION
Battery Hoisting Replacement Specification 1
1
1
1
1
1
1
1
1
1
Removal Procedure
1
1.
2.
Disconnect the battery plug.
Open the battery hood.
1
3. Remove the battery case W/ battery. [Point 1]
1
Installation Procedure
The installation procedure is the reverse of the removal procedure. 1
SST
Point Operations
1
[Point 1]
Removal • Installation:
SST 25009-13201-71
1
1
1
1
1-6
Lateral Battery Sliding Replacement Specification
Removal Procedure
1. Disconnect the battery plug.
2. Open the battery hood.
3. Remove the battery side cover.
4. Operating a forklift, remove the battery.
The installation procedure is the reverse of the removal procedure.
1-7
INSPECTION
Stopper
1. Electrolyte level check
White line
Open the cap. If the white line of the red float has fallen, add
distilled water.
Add water until the white line appears.
Stop water addition when the white line appears, since addi-
tion is excessive when the tip end of the float comes into con-
tact with the stopper.
Reference:
Float The consumption of electrolyte can be calculated by the follow-
ing equation:
Consumption (cc) = 5-hour capacity × 0.0336 × Number of cells ×
Number of times charged
Battery capacity Number of cells
STD 445 AH/5HR 40
OPT 470 AH/5HR 40
2. Electrolyte inspection
Battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity. If it cannot
be checked clearly, put the electrolyte in a beaker for inspec-
tion.
3. Specific gravity inspection

Use a hydrometer and measure the specific gravity of the elec-
trolyte.
Specific gravity upon full charge:
.......................................................... 1.280 [20°C (68°F)]
Specific gravity upon end of discharge:
.......................................................... 1.150 [20°C (68°F)]
The specific gravity of the electrolyte at 20°C (68°F) is used as
the standard.
Equation for conversion

S20 = St + 0.0007 (t-20)
S20 = Specific gravity at 20°C (68°F)
St: Specific gravity measured at t°C
t: Electrolyte temperature upon measurement (°C)
Note:
t°C = 0.56 × A°F
1-8
How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the electrolyte
port and allow the electrolyte to be sucked into its outer
Hydrometer
float tube.
Rubber (2) Let the hydrometer float correctly without contact with the
bulb outer tube, top or bottom, and read the scale at the high-
Outer tube est point of the electrolyte surface as illustrated at the left
when the bubbles in the electrolyte disappear.
(3) After the measurement, wash the inside and outside of
Nozzle
the hydrometer well with clear water and store it after wip-
ing off water with clean cloth.
4. How to inspect the insulation resistance

Use an insulation resistance meter (megohmmeter) and mea-
sure the resistance between the battery and battery case.
Insulation resistance: 1 MΩ or more
Notes:
• When the insulation resistance is less than 1 MΩ, wash the
battery with water after removing it from the vehicle.
• Fully dry the washed battery and measure the insulation
resistance again. Install the battery on the vehicle after
confirming that the insulation resistance is 1 MΩ or more.
Battery inspection record table

Prepare inspection record table for each battery to record and maintain the inspection results.
Inspection date Specific Electrolyte Added water

and time Inspected cell No. gravity temperature quantity Remarks Inspector
2-1
CHARGER
Page 2
GENERAL .......................................................... 2-2
2
SPECIFICATIONS.............................................. 2-3
COMPONENTS .................................................. 2-4
2
WIRING DIAGRAM ............................................ 2-5 2
BEFORE CHARGING ........................................ 2-6 2
DISASSEMBLY • INSPECTION •
REASSEMBLY ................................................ 2-7 2
SERVICE STANDARD ..................................... 2-12 2
TIMER TEST .................................................... 2-12
2
TROUBLESHOOTING ..................................... 2-13
2
2
2
2
2
2
2
2
2
2
2
2-2
GENERAL
2-3
SPECIFICATIONS
Charger type SG3-115-80JBY-2
Item
Type CLK-50JT 2
Magnetic switch (MSch)
Rating AC220 V, 50 A
2
2
Type T-35J
Thermal relay (THR)
Set value (A) 42
Capacity (kVA) 12/10 (50/60 Hz)

2
Transformer (TF)
Insulation class Class H
2
SKR71/04 2
Silicon diode (Dch) Type
SKN71/04
2
2
Operating voltage setting value (V) 58 (microcomputer controlled)
Timer (AMT) Timer control method Microcomputer controlled
Total timer set time 16 hours

2
R1 (Ω) 100
2
Resister (R1, R2)
R2 (Ω) 200 2
Fuse capacity (Fch) (A) 80
2
2
AC side power supply capacity (A) 40/30 (50/60 Hz)
Weight kg (lb) Approx. 85 (187)

2
2
2
2
2
2
2-4
COMPONENTS
2512
2-5
WIRING DIAGRAM
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2-6
BEFORE CHARGING
Charger Circuit Set-up
If the ampere capacity at the charging location is insufficient because other electrical appliances are being used, a
separate circuit exclusively for the charger should be installed. This circuit should be provided with circuit breakers
or fuses having the capacities shown on page 2-3.
Tap Changer
1. Measure with a circuit tester the power supply voltage to be
used for charging.
Circuit tester range: AC (250 V or 1000 V)
Note:
Measure the power supply voltage at night (or, if that is im-
possible, during a time when electrical appliances are not
being operated).
2. Set the tap changer

(1) Remove the cover of each tap.
(2) Select the appropriate tap corresponding to the power
supply voltage measured in step 1 above.
(3) Manually close the magnetic switch, and measure the
voltage at each tap terminal.
Measured voltage Tap
199 V or less 200 V
200 to 209 V 210 V
210 to 219 V 220 V
220 to 229 V 230 V
Notes:
• Taps are set to 220 V at the time of shipment.
• Be sure to set the tap changer for phases U, V and W.
• For about a week after tap changer setting, keep track of the battery charging state (specific gravity and
electrolyte level) to make sure the tap setting is appropriate.
2-7
7
6
1
8
Note:
Place a tag indicating the connecting position at the time of disassembly to prevent incorrect connection at
the time of reassembly.
1. Remove the charger cover.
2. Perform inspection before disassembly.
3. Remove the magnetic switch ASSY (MSch). [Point 1]
4. Remove the timer ASSY (AMT).
5. Remove the resistor (R1•R2) [Point 2]
6. Remove the fuse (Fch). [Point 3]
7. Remove the diode (Dch). [Point 4]
8. Remove the transformer (TF). [Point 5]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-8
Point Operations
[Point 1]
Inspection:
Inspect the magnetic switch contact continuity.
Tester range Ω×1
Measurement terminals T-W, S-V and R-U
ON 0Ω
Standard
OFF ∞Ω
Inspection:
A1 Inspect by measuring the resistance of the magnetic switch coil.
A2 Resistance between A1 and A2 Tester range
CLK-50JT Approx. 400 Ω Ω×1
Inspection:
Inspect the thermal relay (THR) contact continuity.
Tester range Ω×1
Measurement terminals 95-96
Not operating 0Ω
Standard
Operating ∞Ω
95
96
Notes:
• Do not adjust the thermal relay operating current.
• If charging stops due to thermal relay activation while the
charger is in use, always check the thermal relay activat-
Not operated ing cause and reset the relay after repairing it.
• Press the reset switch lightly to reset the thermal relay.
Reset switch Operated

2-9
R1 [Point 2]
Inspection:
Inspect by measuring the resistance of R1 and R2.
R1 Approx. 100 Ω
Standard
R2 Approx. 200 Ω
R2
[Point 3]
Inspection:
Inspect the fuse (Fch) continuity.
Standard: 0 Ω
[Point 4]
Inspection:
Inspect the diode (Dch).
Tester range Ω × 1k
Measurement Forward Anode — cathode

terminals Reverse Anode — cathode
Forward Continuity
Standard
Reverse ∞Ω
Notes:
• As two diodes with different polarities are used, be sure to
install in the correct direction.
• Inspect the diodes in installed on the fin and remove only
if an abnormality is found.
2-10
[Point 5]
Inspection:
Inspect the transformer (TF) insulation.
Measurement terminals Between each coil and frame
Standard 1 MΩ or more
Inspection:
Inspect the transformer coil continuity.
Primary coil
Tester range Ω×1
U1 - V1
Measurement terminals V1 - W1
W1 - U1
Standard 0Ω
Secondary coil
Tester range Ω×1
U2 - V2
W2 - U2
Standard 0Ω
2-11
Inspection after Reassembly

1. Inspect each wiring connection.
Note:
Check each wiring connection by referring to the charger
wiring diagram.
2. Measure the transformer (TF) insulation resistance.
Measurement terminals Between each winding and frame
Standard 1 MΩ or more
3. Measure the no-load secondary voltages.

Connect the charger plug to the charger receptacle (with the
battery plug disconnected) and start the timer.
AC voltage
Tester range AC 250 V • AC 500 V
U2 - V2
W2 - U2
Standard 94 V
DC voltage
Tester range DC 250 V
Both terminals of charger plug

Measurement terminals terminal — probe
terminal — probe
Standard 127 V
2-12
SERVICE STANDARD
Item Standard value
Power supply voltage (V) 200
Non-load secondary voltage AC (V) SG3-115-80JBY-2 94
Non-load secondary voltage DC (V) SG3-115-80JBY-2 127
MSch coil resistance (Ω) Approx. 400
Forward direction 0Ω
Dch continuity (Ω)
Reverse direction ∞Ω
Dch tightening torque N·m [kgf-cm (ft-lbf)] SKR71/04, SKN71/04 4 [41 (2.9)]
Insulation resistance (DC 500 V megohmmeter) (MΩ) 1 or more
TIMER TEST
1. Main timer inspection
(1) Turn on the AC power switch.
(2) Disconnect the battery plug (to unload the charger and operate the voltage relay).
(3) Close the magnetic switch (MSch) forcibly by using an insulating bar and press the NORMAL button or
EQUAL button for 5 seconds or more until the TEST LED and CHARGING PROGRESS INDICATOR LEDs
(three LEDs excluding the uppermost one) light up. Release the button as soon as they light up, and mea-
sure with a stop watch the time until the uppermost LED comes on.
(4) If the OK LED lights up within the period of time described below after the TEST LED lights up, and all LEDs
then immediately go out, the main timer is functioning normally.
When NORMAL button is pressed : OK LED lights up in about 6 seconds
When EQUAL button is pressed : OK LED lights up in about 18 seconds
2. Total timer inspection
(1) Turn on the POWER switch.
(2) Connect the battery in discharged state (as the main timer is operated first because of voltage relay oper-
ation in the fully charged state).
(3) Press the NORMAL or EQUAL button for 5 seconds. The TEST LED lights up and charging starts.
Release the button when the TEST LED lights up and measure with a stop watch the time until the CHECK
LED lights up.
(4) If the CHECK LED lights up within the period of time described below after the TEST LED lights up, the total
timer is functioning normally. (The OK LED does not light up.)
CHECK LED lights up in 90 to 100 seconds
(5) The LEDs go off when the battery plug is disconnected.
Note:
If the NORMAL, EQUAL or STOP button is pressed when a fully charged battery is connected, the main timer
operates first to light the OK LED and not the CHECK LED. This does not indicate a total timer defect. Inspect
again as described above after replacing the battery with a discharged one.
2-13
TROUBLESHOOTING
Probable cause Inspection method Standard Corrective action
The thermal relay on the AC side operates as soon as charging starts.
1. Short circuit of MSch (1) MSch coil continuity inspection OK : Several hundred Ω Replace MSch
Measurement terminals: NG : Abnormally low resistance
A1 and A2
2. TF insulation defect or (1) TF insulation inspection OK : 0.2 MΩ or more Replace TF

short circuit between Measurement terminals: Between NG : Less than 0.2 MΩ
primary coil and each winding and frame
secondary coil
(2) Inspection for short circuit between OK : 0.2 MΩ or more
TF primary and secondary coils NG : Less than 0.2 MΩ
Measurement terminals: Between
primary and secondary coil terminals
3. Dch defect (1) Dch resistance inspection in forward OK : Forward — Several 10 Ω Replace Dch
and reverse directions or more
Measurement terminals: Both Reverse — ∞Ω
terminals (anode and cathode) of Dch NG : Forward — 0Ω
Anode Cathode Reverse — 0Ω
Forward : Anode Cathode
Reverse : Anode Cathode
4. Other short circuit in (1) Inspect the short circuit by separating Repair defective
—
main circuit each circuit portion
Charging does not start although operating charger correctly.
1. Interruption or missing (1) Voltage measurement at main outlet OK : 200 to 220 V In case of missing
phase of input power for power supply NG : 0 V phase, repair after
supply Measurement terminals: Between checking the cause
outlet terminals
2. AC plug disconnection (1) Voltage measurement between R, S OK : 200 to 220 V Repair the plug if any
and T terminals of MSch NG : 0 V phase is missing or
no voltage is
detected
3. TF primary windings (1) Voltage measurement at TF primary OK : 200 to 220 V If OK, inspect TF.
side voltage coil side between U and V, V and W, NG : 0 V
abnormality and W and U terminals
4. Dch defect (1) Dch resistance inspection in forward OK : Forward — Several 10 Ω Replace Dch
and reverse directions or more
terminals (anode and cathode) of Dch NG : Forward — 0Ω
Anode Cathode Reverse — 0Ω
5. Blown fuse on DC side (1) DC side fuse continuity inspection OK : 0 Ω Replace fuse
(Fch) Measurement terminals: Both NG : ∞ Ω
terminals of fuse
6. MSch coil (1) MSch coil continuity inspection OK : 0 Ω Replace MSch

disconnection Measurement terminals: Between NG : ∞ Ω
MSch terminals A1 and A2
7. AMT defect (1) AMT inspection OK : 0 V Replace AMT

Measurement terminals: Between NG : 200 V
AMT terminals 1 and 5
2-14
Probable cause Inspection method Standard Corrective action

8. THR contact defect (1) THR contact inspection OK : Not operating — 0 Ω Reset THR by
Measurement terminals: Between Operating — ∞Ω operating lever or
THR terminals 95 and 96 NG : Not operating — ∞ Ω replace MSch ASSY
Charging completion failure
1. TF tap changer defect (1) AC input voltage measurement Change the

Measurement terminals: Between TF connection of wiring
—
tap changer terminals to match the input
voltage
2. Missing phase in input (1) Voltage measurement at main outlet OK : 200 to 220 V In case of a missing
power supply for power supply phase, repair after
Measurement terminals: Between checking the cause
main outlet terminals
3. THR operation (1) THR continuity inspection OK : Not operating — 0 Ω Reset THR after
Measurement terminals: Between Operating — ∞Ω checking the THR
THR terminals 95 to 96 NG : Not operating — ∞ Ω operating cause
4. Dch defect (1) Inspection of Dch resistance in OK : Forward — Several ten Replace Dch
(open circuit) forward and reverse directions or more Ω
terminals (anode and cathode) or Dch NG : Forward — ∞Ω
Anode Cathode Reverse — ∞Ω
5. TF coil disconnection (1) Measurement terminals: Between TF OK : Continuity Replace TF

winding terminal NG : ∞ Ω
6. MSch contact defect (1) MSch secondary voltage OK : 200 to 220 V Repair MSch contact
measurement NG : 189 V or less or replace MSch
Measurement terminals: Between ASSY
MSch terminals U, V and W
7. TF terminal tightness (1) Inspection of each TF terminal No looseness of each terminal Retighten each
defect tightness terminal
8. Timer setting at short (1) Setting time check in test mode See Timer Test section. Replace AMT
time
9. Other contact defect in (1) Inspection of tightness and connector No looseness at each portion Repair or retighten
charging circuit state at each portion defective portion
10. Lowered battery (1) Inspection of battery electrolyte NG (Measurement after Replace battery
charge gravity, battery voltage and fluid level charging):
If the battery voltage is less than the Specific gravity : 1.150 or less
standard, inspect the voltage per cell. Voltage per cell : 1.75 V or less
Total voltage of whole cells:
68 V or less
3-1
CONTROLLER
2TE15 Page Page
3
GENERAL .............................. 3-2 REMOVAL • INSTALLATION... 3-36 3
SPECIFICATIONS.................. 3-3 PS CONTACTOR PANEL 3
ASSY .................................. 3-39
COMPONENTS ...................... 3-4
TRAVELING CONTROLLER
REMOVAL • INSTALLATION.... 3-39 3
ASSY .................................... 3-9 BOARD INSPECTION.......... 3-42
3
REMOVAL • INSTALLATION ...... 3-9 BEFORE REPLACING
PS CONTACTOR PANEL EACH BOARD ................... 3-49 3
ASSY .................................. 3-13 DISASSEMBLY.................... 3-49
REMOVAL • INSTALLATION .... 3-13 REASSEMBLY..................... 3-50
3
BOARD INSPECTION.......... 3-16 CONTACTOR PANEL 3
REASSEMBLY DRAWING..... 3-51
BEFORE REPLACING
EACH BOARD ................... 3-24 DRIVE MOTOR OCL 3
(OVER CURRENT LIMIT)
DISASSEMBLY.................... 3-24 VALUE MEASUREMENT....... 3-52 3
REASSEMBLY..................... 3-25
CONTROL PANEL
2TE15 • 18 3
REASSEMBLY DRAWING ..... 3-25 DISPLAY .............................. 3-55 3
CONTINUITY CHECKS AFTER DIRECTION SWITCH........... 3-56
REASSEMBLY OF CONTROL
PANEL ASSY.......................... 3-26 REMOVAL • INSTALLATION... 3-56
3
DRIVE MOTOR OCL DISASSEMBLY • INSPECTION •
REASSEMBLY ....................... 3-57
3
(OVER CURRENT LIMIT)
VALUE MEASUREMENT ....... 3-27 ACCELERATOR 3
POTENTIOMETER
2TE18 ADJUSTMENT ................... 3-59 3
GENERAL ............................ 3-30 BRAKE SWITCH
ADJUSTMENT ................... 3-60
3
SPECIFICATIONS................ 3-31
COMPONENTS .................... 3-32 DC-DC CONVERTER 3
ASSY .................................. 3-62
CONTROLLER ASSY .......... 3-36
REMOVAL • INSTALLATION... 3-62 3
3-2
2TE15
GENERAL
The 2TE15 is installed with a traveling controller that controls the traveling system and PS contactor. The traveling
controller is a multifunctional controller utilizing a microcomputer. It provides high performance in a wide range by
means of inverter control of the AC motor drive system.
The traveling controller has a communication circuit with the display. It provides diagnosis (by self-diagnosis function)
to automatically detect any abnormality in the main drive circuit, accelerator, PS circuit and other sensors, and dis-
plays the corresponding error code while short beeps sound. At the same time, an action such as disabling traveling
or restriction of traveling speed is automatically taken.
Faulty section detection and functional check of the main drive circuit, the control system and sensors are possible
by setting the display into the ANALYZER (fault analysis) mode.
See page 4-13 in the “MULTI-DISPLAY FUNCTION” section for the diagnosis.
See page 4-18 in the “MULTI-DISPLAY FUNCTION” section for the analyzer.
PS contactor
Traveling
controller
3-3
SPECIFICATIONS
F1 (for drive circuit) 500 A
F3 (for PS circuit) 75 A 3
Fuse
F6 (for PS) 10 A
3
3
F7 (for DC/MD) 10 A
Transistor TMD 150 V/600 A
CSBATT (for power supply) L05Z 800S15/71A

3
Current sensor
CSDA CSDB (for AC motor) L05Z 800S15/71A
3
Capacitor CO 160 V, 1800 µF × 22 pcs. 3
Contactor
MB (for power supply) Type ME 251
3
3
MPS (for PS) Type ME252
3
3
3
3
3
3
3
3
3
3
3
3-4
COMPONENTS
2401
2401
3-5
Traveling Controller Components

2401
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3-6
2401
2401
3-7
PS Contactor Panel
2402
PS Contactor
2402
3-8
DC-DC Converter
Except for Europe models
2501
For Europe models

2501
3-9
TRAVELING CONTROLLER ASSY

Caution:
Before starting the job, disconnect the battery plug and measure the voltage between P4 and N1; if there is
any voltage, insert a resistor at approx. 100 Ω between P4 and N1 to discharge the capacitor.
T=N·m (kgf-cm) [ft-lbf]
2
3
Removal Procedure
2. Remove the rear cover.
3. Remove the upper cover.
4. Remove the controller cover.
5. Disconnect the external wiring to the controller at the connectors and terminals.
6. Remove the controller set bolt and nut, and remove the controller ASSY.
3-10
Inspection
Some components can be inspected after they are removed from the vehicle, while others can only be inspected as
installed on the vehicle.
Inspect the CPU board and DC/MD board as installed on the vehicle since the battery voltage must be applied.
The explanation here is mainly for inspection of the traveling controller as removed from the vehicle.
1. Insulation resistance measurement
Notes:
• Be sure to measure the insulation resistance before inspecting the controller.
• Be sure to disconnect connectors and terminals from the controller etc.
(1) Disconnect the battery plug and measure the insulation resistance between the battery plug and body.
Measurement terminals Controller side of battery plug — Body
The higher the resistance is, the better the plug insulation against the battery is, but it
Standard varies greatly with the vehicle operating condition, place and weather.
Approx. 1 MΩ or more
2. MB (power supply contactor)

(1) Inspection method
Disconnect CN134, and measure the resistance of the MB coil.
Portion to be inspected Measurement terminals Standard Tester range
MB coil Both terminals of CN134 Approx. 20 Ω (at 20°C (68 °F)) Ω×1
CN134
3-11
3. CO (overall capacitor)
Confirm complete discharge of CO before inspection.
Portion of be inspected Measurement terminals Tester range
CO Both terminals on the back side of CO Ω × 1k
Standard:
Bring tester probes into contact with both terminals of CO. The pointer once indicates 0 Ω, then it gradually
returns to ∞ side and finally indicates ∞.
∞ Ω is indicated because the capacitor is charged by the tester current.
CO
4. TMD (drive motor transistor)

Remove CO (overall capacitor) and the insulation cover.
D1 (D2) - S1 (S2) Approx. 2 kΩ
D1 (D2) -G Approx. 12 kΩ
S1 (S2) - D1 (D2) ∞Ω
TMD Ω × 1k
S1 (S2) -G Approx. 10 kΩ
G - D1 (2) ∞Ω
G - S1 (S2) Approx. 1 kΩ
TMD
S1
D1
S2
G
D2
3-12
5. Cooling fan
Disconnect CN132 or CN133
Cooling fan FAND CN132-1 (7) - CN132-2 (8)

∞Ω Ω×1
Cooling fan FANP CN133-1 (9) - CN133-2 (10)
6. Fuse
Remove the fuses and measure the resistance of them.
Fuse Both terminals of fuse 0Ω Ω×1
F1
F6 F7
3-13
PS CONTACTOR PANEL ASSY

2
5
Removal Procedure
2. Remove the toe board.
3. Remove the contactor panel cover.
4. Disconnect the electrical wiring.
5. Remove the contactor panel ASSY.
3-14
Inspection
1. P22-N1 voltage measurement
Battery plug ON • SWky ON
Measurement terminals P22 — N1
Circuit tester range DC200 V
Standard 80 V
P22
2. Mps contactor coil resistance measurement

Battery plug OFF • SWky OFF
Measurement terminals Both terminals of connector (CN59) of Mps Contactor
Circuit tester range Ω×1
Standard Approx. 20 Ω (at 20°C (68°F))
CN59
3-15
3. F3 (PS circuit fuse) inspection

Battery plug OFF, F3 removal
Measurement terminals Both terminals of F3
Tester range Ω×1
Standard 0Ω
F3
3-16
BOARD INSPECTION
If the cause of the trouble is judged to exist in the CPU board or the DC/MD board, check the applied voltage and
the resistance at each connector.
Also check the following items, since they may damage the board in its normal state or cause a new problem.
• Abnormality of related circuit harnesses
• Looseness of related circuit connector
• Broken or bent connector pin or defective connector pin contact on related circuits
Applied voltage and resistance measurement

1. Connecting SST
(1) Disconnect battery plug and turn the key switch to OFF.
(2) Connect the SST to the connector pin to be measured.
Caution:
• Before starting the job, measure the voltage between P4 and N1; if there is any voltage, connect a
resistor at approx. 100 Ω between P4 and N1 to discharge the capacitor.
• Always disconnect the battery plug before installing or removing the controller ASSY or each
board.
• Since incorrect SST connection may damage a normal portion, always perform correct connection.
• Always disconnect the battery plug before resistance measurement.
SST 09240-23401-71
SST 09240-23401-71
Applicable connector
Traveling controller
CPU board : CN101 to CN104
DC/MD board : CN111 to CN113
SST 09230-13700-71
SST 09230-13700-71
CPU board : CN105 to CN107
DC/MD board : CN108 to CN110
3-17
2. Measuring method and standard list

(1) How to read the list
Tester probe
Tester probe
Connector pin No.
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN101-1 CN101-26
Key switch OFF and DSF ON Approx. 0 V
(45, DSF) (51, LS-)
Part name
Level No. Conditions for measurement
Traveling Controller
CPU board
CN101 basic conditions (battery plug connected, key switch ON)
CN101-1 CN101-26 Key switch OFF, DSF ON Approx. 0 V

(45, DSF) (51, LS-) Key switch OFF, DSF OFF Approx. 5 V
CN101-2 CN101-26 Key switch OFF, DSR ON Approx. 0 V

(46, DSR) (51, LS-) Key switch OFF, DSR OFF Approx. 5 V
CN101-3 CN101-26 Key switch OFF, LSB ON Approx. 5 V

(65, LSB) (51, LS-) Key switch OFF, LSB OFF Approx. 0 V
CN101-4 CN101-26 Key switch OFF, LSPB ON Approx. 5 V

(66, LSPB) (51, LS-) Key switch OFF, LSPB OFF Approx. 0 V
CN101-5 CN101-26 Key switch OFF, LSD ON Approx. 0 V Seated

(67, LSD) (51, LS-) Key switch OFF, LSD OFF Approx. 5 V Unseated
CN101-6 Unused —
CN101-7 Unused —
CN101-8 Unused —
CN101-9 Unused —
CN101-10 Unused —
CN101-11 Unused —
CN101-12 Unused —
CN101-13 Unused —
CN101-14 Unused —
CN101-15 Unused —
CN101-16 Unused —
CN101-17 Unused —
CN101-18 Unused —
3-18
CN101-19 Unused —
CN101-20 Unused —
CN101-21 Unused —
CN101-22 Unused —
CN101-23 Unused —
CN101-24 Unused —
CN101-25 Unused —
CN101-26 CN104-10 Measure resistance with battery plug

Approx. 0 Ω
(51, LS-) (N2, N2) disconnected.
CN101-27 Unused —
CN101-28 Unused —
CN101-29 Unused —
CN101-30 Unused —
CN101-31 Unused —
CN101-32 Unused —
CN101-33 Unused —
CN101-34 Unused —
CN102-1 CN102-22 Key switch OFF, SWAC ON Approx. 0 V

(64, SWAC) (51, POT-) Key switch OFF, SWAC OFF 4 to 5 V
CN102-2 CN102-22 Key switch OFF, accelerator pedal full Changeable according to
0.5 to 3 V
(52, POTA) (51, POT-) depressed amount of pedal depression
CN102-3 Unused —
CN102-4 Unused —
CN102-5 Unused —
CN102-6 CN104-10 Approx. 15 V

Vehicle in stopped state
(81, SSD1) (N2, N2) or 0 V
CN102-7 CN104-10 Approx. 15 V

Vehicle in stopped state
(82, SSD2) (N2, N2) or 0 V
CN102-8 Unused —
CN102-9 Unused —
CN102-10 CN104-10
Approx. 4.6 V
(86, TD+) (N2, N2)
CN102-11 CN104-10
1 to 4 V
(87, TD-) (N2, N2)
CN102-12 Unused —
CN102-13 Unused —
3-19
CN102-14 CN104-10
Approx. 4.6 V
(53, POTA+) (N2, N2)
CN102-15 Unused —
CN102-16 Unused —
CN102-17 Unused —
CN102-18 CN104-10
Approx. 14 V
(80, SSD+) (N2, N2)
CN102-19 CN104-10
Approx. 0 V
(83, SSD+) (N2, N2)
CN102-20 Unused —
CN102-21 Unused —

Approx. 0 Ω
(51, POT-) (N2, N2) disconnected
CN103-1 Unused —
CN103-2 Unused —
CN103-3 Unused —
CN103-4 CN104-10 Key switch OFF Approx. 0 V

(43, VBKY) (N2, N2) Key switch ON Approx. 48 V
CN103-5 CN103-6
Mps contactor ON Approx. 11 V
(5, SOLT+) (6, SOLT-)

Continuity
(6, SOLT-) (5, SOLT+) disconnected
CN103-7 CN104-10
Approx. 48 V
(41, VBBT) (N2, N2)
CN103-8 Unused —
CN103-9 Unused —
CN103-10 CN104-10
14 to 15V
(16, D15V) (N2, N2)
CN103-11 Unused —

Approx. 0 Ω
(14, GNDD) (N2, N2) disconnected
CN103-13
Immeasurable —
(144, SMTDK)
CN103-14
Immeasurable —
(143, SDTMK)
CN103-15
Immeasurable —
(142, SDTMA)
CN103-16
Immeasurable —
(141, SMTDA)
3-20
CN104-1 CN104-10
Approx. 0 V
(N2, N2C) (N2, N2)
CN104-2 CN104-10
Approx. 7 V
(54, CSBATT) (N2, N2)
CN104-3 Unused —
CN104-4 CN104-10
Approx. 80 V
(18, B80V) (N2, N2)
CN104-5 CN104-10
14 to 15 V
(75, CSD+) (N2, N2)
CN104-6 Unused —
CN104-7 CN104-10
Approx. 7 V
(71, CSDA) (N2, N2)
CN104-8 CN104-10
Approx. 7 V
(72, CSDB) (N2, N2)
CN104-9 CN104-10
Approx. 21 V
(13, C20V) (N2, N2)
CN104-10 Measure resistance with battery plug

N1 terminal Approx. 0 Ω
(N2, N2) disconnected

Approx. 20 Ω
(2, MB-) (N2, N2) disconnected
CN104-12 CN104-10
Approx. 80 V
(P4, VBP4) (N2, N2)
CN104-13 CN104-11
Approx. 11 V
(1, MB+) (2, MB-)
CN104-14 CN104-10
Approx. 80 V
(44, VBMB) (N2, N2)
CN104-15 CN104-10
Approx. 48 V
(41,B48V) (N2, N2)
CN104-16 CN104-10
14 to 15 V
(16, D15V) (N2, N2)
CN104-17 CN104-10
14 to 15 V
(15, C15V) (N2, N2)
CN104-18 Unused —
CN104-19 Unused —
CN104-20 CN104-10
1 to 4 V
(78, THCD) (N2, N2)
CN104-21 CN104-10
Approx. 5 V
(77, THC+) (N2, N2)
CN104-22 CN104-10
Approx. 80 V
(44, VBMB) (N2, N2)

Approx. 0 Ω

Approx. 0 Ω
(14, GNDC) (N2, N2) disconnected
3-21
CN104-25 Unused —
CN104-26 Unused —

Approx. 0 Ω
(76, CSD-) (N2, N2) disconnected
CN104-28 Unused —
CN105 basic conditions

(battery plug connected, key switch ON, direction switch at Neutral and motor cable disconnected)
CN105-1 CN104-10
Approx. 5 V
(38, FAN+) (N2, N2)
CN105-2 CN104-10
Approx. 5 V
(38, FAN+) (N2, N2)
CN105-3 CN104-10 Cooling fan OFF Approx. 5V
(36, FANCD) (N2, N2) Cooling fan ON Approx. 4.5 V
CN105-4 CN104-10 Cooling fan OFF Approx. 5 V
(37, FANCP) (N2, N2) Cooling fan ON Approx. 4.5 V
CN105-5 Unused —
CN105-6 CN104-10
Approx. 4 V
(39, DDC) (N2, N2)
CN105-7 Unused —
(94, CKFAND+) (N2, N2) Cooling fan ON Approx. 0.5 V
CN105-9
Immeasurable —
(97, CKFAND-)
(98, CKFANP+) (99, CKFANP-) Cooling fan ON Approx. 0.5 V
CN105-11
Immeasurable —
(99, CKFANP-)
CN105-12 Unused —
CN105-13 Unused —
CN105-14 Unused —

CN107-1 CN104-10
Approx. 5 V
(26, TMDU+) (N2, N2)
CN107-2 CN104-10
Approx. 5 V
(20, TMDAU-) (N2, N2)
CN107-3 CN104-10
Approx. 5 V
(21, TMDBU-) (N2, N2)
CN107-4 CN104-10
Approx. 5 V
(22, TMDCU-) (N2, N2)
CN107-5 CN104-10
Approx. 5 V
(23, TMDAD-) (N2, N2)
3-22

CN107-6 CN104-10
Approx. 5 V
(24, TMDBD-) (N2, N2)
CN107-7 CN104-10
Approx. 5 V
(25, TMDCD-) (N2, N2)
CN107-8 CN104-10
Approx. 5 V
(26, TMDD+) (N2, N2)
CN107-9 CN104-10
Approx. 10 V
(34, CKDV) (N2, N2)
CN107-10 Unused —
DC/MD board
CN111-1 CN111-14
13 to 15 V
(150, TMDAU1+) (P3, TMDAU-SD)
CN111-2 CN111-15
13 to 15 V
(152, TMDAD1+) (N2, TMDAD-SD)
CN111-3 CN111-16
13 to 15 V
(154, TMDBU1+) (P5, TMDBU-SD)
CN111-4 CN111-14
13 to 15 V
(153, TMDAU-G) (P3, TMDAU-SD)
CN111-5 CN111-15
13 to 15 V
(153, TMDAD-G) (N2, TMDAD-SD)
CN111-6 CN111-16
13 to 15 V
(155, TMDBU-G) (P5, TMDBU-SD)
CN111-7 CN111-24
13 to 15 V
(157, TMDBD-G) (N2, TMDBD-SD)
CN111-8 CN111-25
13 to 15 V
(159, TMDCU-G) (P7, TMDCU-SD)
CN111-9 CN111-26
13 to 15 V
(161, TMDCD-G) (N2, TMDCD-SD)
CN111-10 Unused —
CN111-11 CN111-24
13 to 15 V
(156, TMDBD1+) (N2, TMDBD-SD)
CN111-12 CN111-25
13 to 15 V
(158, TMDCU1+) (P7, TMDCU-SD)
CN111-13 CN111-26
13 to 15 V
(160, TMDCD1+) (N2, TMDCD-SD)
CN111-14
Immeasurable —
(P3, TMDAU-SD)
CN111-15
Immeasurable —
(N2, TMDAD-SD)
CN111-16
Immeasurable —
(P5, TMDBU-SD)
CN111-17 CN111-14
13 to 15 V
(150, TMDAU2+) (P3, TMDAU-SD)
3-23
CN111-18 CN111-15
13 to 15 V
(152, TMDAD2+) (N2, TMDAD-SD)
CN111-19 CN111-16
13 to 15 V
(154, TMDBU2+) (P5, TMDBU-SD)
CN111-20 CN111-24
13 to 15 V
(156, TMDBD2+) (N2, TMDBD-SD)
CN111-21 CN111-25
13 to 15 V
(158, TMDCU2+) (P7, TMDCU-SD)
CN111-22 CN111-26
13 to 15 V
(160, TMDCD2+) (N2, TMDCD-SD)
CN111-23 Unused —
CN111-24
Immeasurable —
(N2, TMDBD-SD)
CN111-25
Immeasurable —
(P7, TMDCU-SD)
CN111-26
Immeasurable —
(N2, TMDCD-SD)

CN113-1 CN113-18
Approx. 80 V
(41, B48V) (N2, N2)
CN113-2 CN113-18
Approx. 80 V
(44, VBMB) (N2, N2)
CN113-3 Unused —

(7, FAND+) (N2, N2) Cooling fan ON Approx. 24 V
CN113-5
Immeasurable —
(8, FAND-)

(9, FANP+) (N2, N2) Cooling fan ON Approx. 24 V
CN113-7
Immeasurable —
(10, FANP-)
CN113-8 Unused —
CN113-9 Unused —
CN113-10 Unused —
CN113-11 Unused —

Approx. 0 Ω

Approx. 0 Ω
(14, GNDC) (N2, N2) disconnected
CN113-14 CN113-18
14 to 15 V
(15, D15V) (N2, N2)
3-24
CN113-15 CN113-18
14 to 15 V
(15, C15V) (N2, N2)
CN113-16 CN113-18
Approx. 21 V
(13, C20V) (N2, N2)
CN113-17 Measure resistance with battery plug

N113-18 Measure resistance with battery plug

BEFORE REPLACING EACH BOARD

When the necessity of the CPU or DC/MD or another board is judged as a cause of trouble, avoid replacing the board
immediately, but check the following points:
• Abnormality in related circuit harnesses
• Play of any related circuit connector
• Chipping, bend or defective contact of any related circuit connector pin
If even one of the above is the true cause of a problem, board replacement may damage a normal board.
Always replace the board after careful inspection.
DISASSEMBLY
Control panel disassembly is rarely needed. In most cases, it is performed to replace defective parts after the source
of the problem is detected by inspection.
Therefore, perform correct operation by referring to the components and assembly drawings.
Notes for Parts Replacement

• Tighten bar and harness set nuts and screws to the specified torque levels.
Looseness or tightening failure will cause new problems.
• Accurately record the installation location or attach a tag showing the location before disconnecting each bar or
harness. At the time of reassembly, check the record or tag to avoid incorrect assembly or wiring.
Incorrect assembly or wiring will cause new problems.
• Always apply silicon grease to parts that have been applied with it.
Failure to apply it may cause overheating.
• After completing reassembly, check non-contact portions of bars and wiring for undesirable contact.
Before installation on the vehicle, use a circuit tester to check continuity at specified points.
(See P3-26 for the points requiring inspection with the tester.)
• Always replace the TMD each arm unit.
Always check the part number for identification.
3-25
REASSEMBLY
CONTROL PANEL REASSEMBLY DRAWING
T = N·m (kgf-cm) [ft-lbf]
T=7.8 to 11.8 (80 to 120) [5.8 to 8.6] T=13 to 17 (130 to 170) [8.8 to 11.6]
T=13 to 17 T=13 to 17
T=13 to 17 (130 to 170) (130 to 170)
(130 to 170) [8.8 to 11.6] [8.8 to 11.6]
[8.8 to 11.6]
T=13 to 17
(130 to 170)
[8.8 to 11.6]
T=3.1 to 3.9 (31 to 39) [2.46 to 2.54] T=3.1 to 3.9 (31 to 39) [2.46 to 2.54]
T=7.8 to 11.8 GR (Wiring A) T=2.9 to 3.9 T=2.9 to 3.9 T=2.9 to 3.9
(80 to 120) B (Wiring B) (31 to 39) (31 to 39) (31 to 39)
[5.8 to 8.6] N1 [2.46 to 2.54] [2.46 to 2.54] [2.46 to 2.54] P7
P8
B
P1
C
T=2.9 to 3.9 A
(31 to 39)
[2.46 to 2.54] F
P0 D P9
E
W R T=7.8 to 11.8 (80 to 120) [5.8 to 8.6]

T=7.8 to 11.8
(80 to 120) T=13 to 17
[5.8 to 8.6] (130 to 170)
[8.8 to 11.6] T=7.8 to 11.8
T=13 to 17 T=13 to 17 (80 to 120)
(130 to 170) (130 to 170) [5.8 to 8.6]
[8.8 to 11.6] [8.8 to 11.6]
D E F
Note:
Wiring A: Round terminal of green cable (For controlling voltage to the CPU board)
Wiring B: Round terminal of black cable (For voltage detection applied to F1 fuse)
If A and B are connected incorrectly, the vehicle does not respond to key switch ON at all (no indication
on display either). Pay sufficient attention to correct wiring.
Caution:
Be sure to install insulating sheets.
• Failure to install the insulating sheet for the TMD will damage the TMD.
• Failure to install the insulating sheet under the MB contactor will cause a critical failure.
• Check the insulation resistance between the bracket and each P terminal after controller reassembly.
Standard: 1 MΩ or more
Insulation sheet MB contactor

Insulation sheet
3-26
CONTINUITY CHECKS AFTER REASSEMBLY OF CONTROL PANEL ASSY

1. Inspection method
Always disconnect the drive motor cables.
Tester range: Ω × 10
N1 P7
P4
P1 N1 P8
P1 F1
P9
P3
P0 F6 F7
(1) Motor cable terminal inspection

N1 P4
Motor cable terminal
Capacitor
— — Approx. 50 Ω
characteristic
P7 • P8 • P9
Capacitor
Approx. 50 Ω — —
characteristic
(2) P4 - N1 inspection
P4 — N1 Capacitor characteristic
P4 — N1 Approx. 50 Ω
Capacitor characteristic: The pointer indicates to the 0 Ω position once, then it gradually returns to ∞ Ω side.
Finally it indicates ∞ Ω.
3-27
DRIVE MOTOR OCL (OVER CURRENT LIMIT) VALUE MEASUREMENT

If traveling is abnormal, or after overhauling the traveling controller, measure the drive motor OCL value to accurately
judge whether the controller functions normally.
Drive Motor OCL Value Measuring Procedure

2. Remove the rear axle upper cover.
3. Remove the rear controller upper cover.
5. Reconnect the battery plug.
6. Put the vehicle in standby state to measure drive motor OCL value. [Point 1]
7. Prepare SST to measure drive motor OCL value. [Point 2]
9. Set the clamp sensor of the SST to one of the cables connected to the drive motor. [Point 3]
11. Turn the key switch to ON.
12. Move the direction switch to the forward position.
13. Depress the accelerator pedal fully and measure the drive motor OCL value. [Point 4]
14. For the other two cables, perform procedures 8 to 14.
15. Check that the measured values are within the specified range.
Point Operations
[Point 1]
Preparation
1. Put an appropriate wood panel between a wall or steel pillar
with enough strength.
2. Move the vehicle for its front to contact with the wood panel.
Caution:
Chocks Be sure to put chocks under front wheels.
3. Turn the key switch to OFF.
[Point 2]
1. Press “POWER” button to turn ON the SST.
SST 09140-13130-71
POWER button
3-28
AC+DC A mode indicator

2. Press “MODE” button twice to select “AC+DC A” mode.
MODE button
SHIFT button available indicator 3. Press “SHIFT” button and then “SAMPLE” button to change
the display renewal rate to “SLOW.”
SHIFT button
Display renewal rate indicator
SAMPLE button
[Point 3]
1. Set the cramp sensor to the drive motor cable as shown in the
illustration.
Note:
When setting the cramp sensor, the drive motor cable
must be through the center of the cramp portion and its
angle must be 90 degrees to the cramp.
3-29
CLEAR button 2. Press “SHIFT” button and then “CLEAR” button to calibrate the
SST.
After pressing “CLEAR” button, “ADJ” blinks and the SST en-
ters calibration mode.
When the “ADJ” stops blinking, the calibration is finished.
ADJ indicator SHIFT button
[Point 4]
1. Turn the key switch to ON and move the direction switch to the
forward position.
2. Depress the accelerator pedal gradually to the fully depressed
position and hold it in its position. The SST automatically be-
gins to measure drive motor OCL value.
Notes:
• Read the OCL value 20 seconds after the SST begins to
measure it, because “O.L.” (over flow warning) may be
displayed about 10 seconds after the start of measuring,
or even after the “O.L.” disappears, displayed value may
fluctuate.
SHIFT button available indicator • Even after 20 seconds elapses and displayed value con-
tinues fluctuating, press “SHIFT” button, and then “PEAK/
Hz” button to turn the filter setting ON, and then measure
the drive motor OCL value again.
• Although it is possible to measure the drive motor OCL
value except in the previous mentioned mode and display
rate (“AC+DC A” mode, display renewal rate “SLOW”),
displayed value is not correct, because frequency of the
drive motor current is below 10 Hz.
Standard: 293 to 380 A
SHIFT button
Filter setting indicator
PEAK/Hz button
3-30
2TE18
GENERAL
The 2TE18 is installed with a main controller and traveling controller that control the traveling system and PS con-
tactor. The main controller and traveling controller are multifunctional controllers utilizing a microcomputer. They pro-
vide high performance in a wide range by means of inverter control of the AC motor drive system.
The main controller has a communication circuit with each controller and the display. It provides diagnosis (by self-
diagnosis function) to automatically detect any abnormality in the main drive circuit, accelerator, PS circuit and other
sensors, and displays the corresponding error code while short beeps sound. At the same time, an fail-safe action
such as disabling traveling or restriction of traveling speed is automatically taken.
Faulty section detection and functional check of the main drive circuit the control system and sensors are possible
by setting the display into the ANALYZER (fault analysis) mode.
See P4-48 in the “MULTI-DISPLAY FUNCTION” section for the diagnosis.
See P4-53 in the “MULTI-DISPLAY FUNCTION” section for the analyzer.
Display
Main controller
DC/DC converter
PS contactor
3-31
SPECIFICATIONS
F1 (for drive circuit) 500 A
F3 (for PS circuit) 75 A
F5 (for relays) 20 A
F6 (for cooling fan, contactor) 10 A
F7 (for main controller circuit) 10 A
F8 (for front wiper circuit) 20 A
F9 (for turn signal lamps) 10 A

Fuse
F10 (for back-up lamps, buzzer, OPS pilot lamp) 10 A
F11 (for horn, rear working lamp) 20 A
F12 (for head lamps, tail lamps) 20 A
F13 (for stop lamps) 10 A
F14 (for rear wiper) 20 A
F15 (for heater) 20 A
F16 (for relay) 10 A
MB (for power supply) Type ME251

Contactor
MPS (for PS) Type ME252
3-32
COMPONENTS
2401
Main Controller and Traveling Controller Components

2401
3-33
Main Controller and Traveling Controller

2401
3-34
Main Contactor Panel

2402
3-35
PS Contactor Panel
2402
DC-DC Converter
2501
3-36
CONTROLLER ASSY
Caution:
Before starting the job, disconnect the battery plug and measure the voltage between P3 and N2; if there is
any voltage, insert a resistor at approx. 100 Ω between P3 and N2 to discharge the capacitor.
Removal Procedure
3. Remove the controller upper cover.
5. Disconnect the external wiring to the controller at the connectors and terminals.
6. Remove the bracket next to the controller.
7. Remove the controller set bolt and nut, and remove the controller ASSY.
8. Remove the controller mount bracket.
9. Remove the main contactor panel.
3-37
The installation procedure is basically the reverse of the removal procedure, but when installing the removed parts,
mount the traveling controller, first, and then install the bracket removed in the step 6.
Note:
When installing the main controller, tighten the nuts for the bolts under the traveling controller to fix it ten-
tatively, and then install the controller mount bracket.
Inspection
1. Insulation resistance measurement
Notes:
• Be sure to measure the insulation resistance before inspecting the controllers.
• Be sure to disconnect connectors and terminals from the controllers.
(1) Disconnect the battery plug and measure the insulation resistance between the battery plug and body.
Measurement terminals Controller side of battery plug — Body
The higher the resistance is, the better the plug insulation against the battery is, but it
Standard varies greatly with the vehicle operating condition, place and weather.
2. MB (power supply contactor)

Disconnect CN134, and measure the resistance of the MB coil.
MB coil Both terminals of CN134 Approx. 20 Ω (at 20°C (68°F)) Ω×1
CN134
3-38
3. Fuse
Remove the fuse and measure the resistance of the fuse.
Fuse Both terminals of fuse 0Ω Ω×1
F7 F5
F6
F1
4. Cooling fan
Disconnect CN185 or CN186
CN185-1 (6) - CN185-2 (39)

Cooling fan for main controller ∞Ω Ω×1
CN186-1 (44) - CN186-2 (39)
3-39
PS CONTACTOR PANEL ASSY

Removal Procedure
3. Remove the contactor panel cover.
4. Disconnect the electrical wiring.
5. Remove the contactor panel ASSY.
3-40
Inspection
1. P22-N1 voltage measurement
Battery plug ON • SWky ON
Measurement terminals P22 — N1
Circuit tester range DC200 V
Standard 80 V
P22
2. Mps contactor coil resistance measurement

Battery plug OFF • SWky OFF
Measurement terminals Both terminals of connector (CN59) of Mps Contactor
Circuit tester range Ω×1
Standard Approx. 20 Ω (at 20°C (68°F))
CN59
3-41
3. F3 (PS circuit fuse) inspection

Battery plug OFF, F3 removal
Measurement terminals Both terminals of F3
Tester range Ω×1
Standard 0Ω
F3
3-42
BOARD INSPECTION
If the cause of the trouble is judged to exist in the CPU board at the main controller, check the applied voltage and
the resistance at each connector.
Also check the following items, since they may damage the board in its normal state or cause a new problem.
• Abnormality of related circuit harnesses
• Looseness of related circuit connector
• Broken or bent connector pin or defective connector pin contact on related circuits
Applied Voltage and Resistance Measurement

1. Connecting SST
(1) Turn the key switch to OFF and disconnect battery plug.
(2) Connect the SST to the connector pin to be measured.
Caution:
• Before starting the job, measure the voltage between P3 and N2; if there is any voltage, connect a
resistor at approx. 100 Ω between P3 and N2 to discharge the capacitor.
• Always disconnect the battery plug before installing or removing the controller ASSY or each
board.
• Since incorrect SST connection may damage a normal portion, always perform correct connection.
• Always disconnect the battery plug before resistance measurement.
SST 09240-23401-71
SST 09240-23401-71
Main controller
CPU board: CN101 to CN104
SST 09230-13700-71
SST 09230-13700-71
Main controller
CPU board : CN100 • CN105 • CN107
Traveling controller : CN110
3-43
2. Measuring method and standard list

(1) How to read the list
Tester probe
Tester probe
Connector pin No.
CN101-1 CN101-26
Key switch OFF and DSF ON Approx. 0 V
(45, DSF) (51, LS-)
Part name
Level No. Conditions for measurement
CPU board
CN101-1 CN101-16 Key switch OFF, DSF ON Approx. 0 V

(45, DSF) (51, LS-) Key switch OFF, DSF OFF Approx. 5 V
CN101-2 CN101-16 Key switch OFF, DSR ON Approx. 0 V

(46, DSR) (51, LS-) Key switch OFF, DSR OFF Approx. 5 V
CN101-3 CN101-16 Key switch OFF, LSB ON Approx. 5 V

(65, LSB) (51, LS-) Key switch OFF, LSB OFF Approx. 0 V
CN101-4 CN101-16 Key switch OFF, LSPB ON Approx. 5 V

(66, LSPB) (51, LS-) Key switch OFF, LSPB OFF Approx. 0 V
CN101-5 CN101-16 Key switch OFF, LSD ON Approx. 0 V Seated

(67, LSD) (51, LS-) Key switch OFF, LSD OFF Approx. 5 V Unseated
CN101-6 Unused —
CN101-7 Unused —
CN101-8 Unused —
CN101-9 CN101-16 FAN OFF Approx. 80 V

(39, FAN-) (51, LS-) FAN ON Approx. 32 V
CN101-10 Unused —
CN101-11 Unused —
CN101-12 Unused —
CN101-13 Unused —
CN101-14 Unused —
CN101-15 Unused —
CN101-16 Unused —
CN101-17 Unused —
3-44
CN101-18 Unused —
CN101-19 Unused —
CN101-20 Unused —
CN101-21 Unused —
CN101-22 Unused —
CN101-23 Unused —
CN101-24 Unused —
CN101-25 Unused —

Approx. 0 Ω
(51, LS-) (N2, N2) disconnected
CN101-27 Unused —
CN101-28 Unused —
CN101-29 Unused —
CN101-30 Unused —
CN101-31 Unused —
CN101-32 Unused —
CN101-33 Unused —
CN101-34 Unused —

CN102-1 SN102-22 Key switch OFF, SWAC ON Approx. 0 V
(64, SWAC) (51, POT-) Key switch OFF, SWAC OFF 4 to 5 V
CN102-2 CN102-22 Key switch OFF, accelerator pedal Changeable according to
0.4 to 3 V
(52, POTA) (51, POT-) fully depressed amount of pedal depression
CN102-3 Unused —
CN102-4 Unused —
CN102-5 Unused —
CN102-6 Unused —
CN102-7 Unused —
CN102-8 Unused —
CN102-9 Unused —
CN102-10 Unused —
CN102-11 Unused —
CN102-12 Unused —
CN102-13 Unused —
CN102-14 CN102-22
Approx. 4.6 V
(53, POTA+) (51, POT-)
CN102-15 Unused —
CN102-16 Unused —
CN102-17 Unused —
CN102-18 Unused —
3-45

CN102-19 Unused —
CN102-20 Unused —
CN102-21 Unused —
CN102-22
—
(51, POT-)
CN103-1
Immeasurable —
(145, CANH)
CN103-2
Immeasurable —
(146, CANL)
CN103-3 CN103-12
Approx. 0 V
(147, CANGND) (14, GNDD)

(43, VBKY) (14, GNDD) Key switch ON Approx. 48 V
CN103-5 Unused —
CN103-6 Unused —
CN103-7 CN103-12
Approx. 48 V
(41, VBBT) (14, GNDD)
CN103-8 Unused —
CN103-9 Unused —
CN103-10 CN103-12
Approx. 15 V
(16, D15V) (14, GNDD)
CN103-11 Unused —

Approx. 0 Ω
CN103-13
Immeasurable —
(144, SMTDK)
CN103-14
Immeasurable —
(143, SDTMK)
CN103-15
Immeasurable —
(142, SDTMA)
CN103-16
Immeasurable —
(141, SMTDA)
3-46
CN104-1 CN104-22
Key switch OFF Approx. 80 V
(18, B80V) (N2, N2)
CN104-2 CN104-22
Key switch ON Approx. 80 V
(18, B80V) (N2, N2)
CN104-3 Unused —
CN104-4 Unused —
CN104-5 Unused —
CN104-6 Unused —
CN104-7 Unused —
CN104-8 Unused —
CN104-9 CN104-22
Approx. 80 V
(55, CPR) (N2, N2)
CN104-10 Unused —
CN104-11 Unused —
CN104-12 Unused —
CN104-13 Unused —
CN104-14 CN104-22
Approx. 80 V
(44, VBMB) (N2, N2)
CN104-15 CN104-22
Approx. 80 V
(44, VBMB) (N2, N2)
CN104-16 Unused —
CN104-17 Unused —
CN104-18 Unused —
CN104-19 CN104-20 Measure by using CN104-20 as a

Approx. 11 V
(1, MB+) (2, MB-) probe

Approx. 20 Ω
(2, MB-) (1, MB+) disconnected
CN104-21 CN104-28 Measure by using CN104-28 as a

Approx. 11 V
(37, MPS+) (38, MPS-) probe
CN104-22
—
(N2, N2)
CN104-23
—
(N2, N2)

(39, FAN-) (N2, N2) Cooling fan ON Approx. 32 V

(42, KEYSTART) (N2, N2) Key switch ON Approx. 80 V
CN104-26 Unused —
CN104-27 Unused —

Approx. 20 Ω
(38, MPS-) (37, MPS+) disconnected
3-47
SN105 basic conditions




Cooling fan OFF Approx. 80 V

CN105-4 CN104-22 (According to the vehicle
(130, FAN1) (N2, N2) Approx. 1 V state)
Cooling fan ON
(Approx. 32 V)

Cooling fan ON
(Approx. 32 V)

Cooling fan ON
(Approx. 32 V)

Cooling fan ON
(Approx. 32 V)

Cooling fan ON
(Approx. 32 V)

Cooling fan ON
(Approx. 32 V)
CN105-10 Unused —
CN105-11 Unused —

CN107-1 CN107-2
Main controller fan ON Approx. 24 V
(127, FANR+) (128, FANR-)
CN107-2
— — —
(128, FANR-)
3-48
CN100-1 Unused —
CN100-2 Unused —
CN100-3 Unused —
CN100-4 Unused —
CN100-5 Unused —
CN100-6 Unused —
CN100-7 Unused —
CN100-8 Unused —

Approx. 20 Ω
(55, CPR) (P2, P2) disconnected
CN126-2
Unused —
(P2, P2)
CN166-1 Unused —
CN166-2 Unused —
CN166-3
Immeasurable —
(145, CANH)
CN166-4
Immeasurable —
(146, CANL)
CN166-5 Unused —
CN166-6 CN109-6
Approx. 80 V
(147, CANGND) (147, GNDD)
CN166-7 N2
Approx. 80 V
(42, KEYSTART) (N2, N2)
CN166-8 Unused —
CN166-9 CN109-10
12 V
(80, SSD+) (78, SSD2-, TD2-)
CN166-10 CN109-10
Approx. 0 V
(83, SSD-, TD-) (78, SSD2-, TD2-)
CN166-11 CN109-10
0 to 12 V
(81, SSD1) (78, SSD2-, TD2-)
CN166-12 CN109-10
0 to 12 V
(82, SSD2) (78, SSD2-, TD2-)
CN166-13
Immeasurable —
(88, TD+)
3-49
BEFORE REPLACING EACH BOARD

When the necessity of the CPU board of the main controller is judged as a cause of trouble, avoid replacing it imme-
diately, but check the following points:
• Abnormality in related circuit harnesses
• Play of any related circuit connector
• Chipping, bend or defective contact of any related circuit connector pin
If one of the above is the true cause of a problem, board replacement may damage a normal board.
Always replace the board after careful inspection.
DISASSEMBLY
• It is rare to overhaul the main controller. In most cases, it is performed to replace defective parts after the source
of the problem is detected by inspection.
Therefore, perform correct operation by referring to the components and assembly drawings.
• Do not disassemble the traveling controller. If the cause of the trouble is judged to exist in the traveling controller,
replace the controller assy.
Notes for Parts Replacement

• Tighten bar and harness set nuts and screws to the specified torque levels.
Looseness or tightening failure will cause new problems.
• Accurately record the installation location or attach a tag showing the location before disconnecting each bar or
harness. At the time of reassembly, check the record or tag to avoid incorrect assembly or wiring.
Incorrect assembly or wiring will cause new problems.
• Always apply silicon grease to parts that have been applied with it.
Failure to apply it may cause overheating.
• After completing reassembly, check non-contact portions of bars wiring for undesirable contact.
3-50
REASSEMBLY
Main Controller
3-51
CONTACTOR PANEL REASSEMBLY DRAWING

T=7.8 to 11.8
T=2.9 to 3.9 (80 to 120) [5.7 to 8.7]
(29 to 39) [2.1 to 2.8]
F5
T=2.9 to 3.9
(30 to 40) [2.1 to 2.8]
T=13 to 17 P1
(130 to 170) T=7.8 to 11.8
[9.5 to 12.5] F7 F6 (80 to 120) [5.7 to 8.7]
T=11 to 15
(112 to 153) F1 T=7.8 to 11.8
[8.1 to 11.0] (80 to 120) [5.7 to 8.7]
P2
T=2.0 to 3.0
(20 to 30)
[1.4 to 2.2]
T=7.8 to 11.8
(80 to 120)
[5.7 to 8.7]
T=13 to 17
(130 to 170)
[9.5 to 12.5]
P3
CN134 T=11 to 15
(112 to 153) [8.1 to 11.0]
CN135
CN136
Caution:
Be sure to install insulating sheets
• Failure to install the insulating sheet under the MB contactor will cause a critical failure.
• Check the insulation resistance between the bracket and each P terminal after reassembling the contactor.
MB contactor
Insulation sheet
3-52
DRIVE MOTOR OCL (OVER CURRENT LIMIT) VALUE MEASUREMENT

If traveling is abnormal, or after replacing or overhauling a controller, measure the drive motor OCL value to accu-
rately judge whether the controller functions normally.
Drive Motor OCL Value Measuring Procedure

3. Remove the rear controller upper cover.
6. Put the vehicle in standby state to measure drive motor OCL value. [Point 1]
7. Prepare SST to measure drive motor OCL value. [Point 2]
9. Set the clamp sensor of the SST to one of the cables connected to the drive motor. [Point 3]
11. Turn the key switch to ON.
12. Move the direction switch to the forward position.
13. Depress the accelerator pedal fully and measure the drive motor OCL value. [Point 4]
14. For the other two cables, perform procedures 8 to 14.
15. Check that the measured values are within the specified range.
Point Operations
[Point 1]
Preparation
1. Put an appropriate wood panel between a wall or steel pillar
with enough strength.
2. Move the vehicle for its front to contact with the wood panel.
Caution:
Chocks Be sure to put chocks under front wheels.
3. Turn the key switch to OFF.
[Point 2]
1. Press “POWER” button to turn ON the SST.
SST 09140-13130-71
POWER button
3-53
AC+DC A mode indicator

2. Press “MODE” button twice to select “AC+DC A” mode.
MODE button
SHIFT button available indicator 3. Press “SHIFT” button and then “SAMPLE” button to change
the display renewal rate to “SLOW.”
SHIFT button
Display renewal rate indicator
SAMPLE button
[Point 3]
1. Set the cramp sensor to the drive motor cable as shown in the
illustration.
Note:
When setting the cramp sensor, the drive motor cable
must be through the center of the cramp portion and its
angle must be 90 degrees to the cramp.
3-54
CLEAR button 2. Press “SHIFT” button and then “CLEAR” button to calibrate the
SST.
After pressing “CLEAR” button, “ADJ” blinks and the SST en-
ters calibration mode.
When the “ADJ” stops blinking, the calibration is finished.
ADJ indicator SHIFT button
[Point 4]
1. Turn the key switch to ON and move the direction switch to the
forward position.
2. Depress the accelerator pedal gradually to the fully depressed
position and hold it in its position. The SST automatically be-
gins to measure drive motor OCL value.
Notes:
• Read the OCL value 20 seconds after the SST begins to
measure it, because “O.L.” (over flow warning) may be
displayed about 10 seconds after the start of measuring,
or even after the “O.L.” disappears, displayed value may
fluctuate.
SHIFT button available indicator • Even after 20 seconds elapses and displayed value con-
tinues fluctuating, press “SHIFT” button, and then “PEAK/
Hz” button to turn the filter setting ON, and then measure
the drive motor OCL value again.
• Although it is possible to measure the drive motor OCL
value except in the previous mentioned mode and display
rate (“AC+DC A” mode, display renewal rate “SLOW”),
displayed value is not correct, because frequency of the
drive motor current is below 10 Hz.
Standard: 380 to 485 A
SHIFT button
Filter setting indicator
PEAK/Hz button
3-55
2TE15 • 18
DISPLAY
If the cause of trouble is judged to exist in the display, apply the battery voltage and measure the voltage at CN70-1.
CN70-1 basic condition (battery plug connected)
CN70-1-14 CN70-1-30
Approx. 10 to 18 V
(16, D15V) (14, GNDD)
3-56
DIRECTION SWITCH
Removal Procedure
2. Remove the steering cover.
3. Disconnect wiring of the display and direction switch.
4. Remove the meter cover with display.
5. Remove the direction switch.
3-57
1. Remove the connector cover and connector.
2. Remove the plate with base and micro-switch.
3. Remove the base with micro-switch. [Point 1]
4. Remove the cam.
3-58
Point Operations
[Point 1]
DSFO DSBU
Reassembly:
1. Install the micro-switch in the correct position.
DSF DSR
2. Carry out wiring according to the cable colors shown in the il-
DSF lustration when reassembling the micro-switch.
NC
NO C
45 NC 51 W-O W-BR R
46
NO DSR 46 45 43
DSBU 51 120103
NC
NO C
43 103
NC
C O B G
NO 120
DSFO
Inspection
DSF After installing the direction switch, check continuity of each switch
before installing on the vehicle.
Standard:
DSR 46 45 43
DSBU Lever position
51 120 103
Check point Neutral Forward Backward
DSF ∞Ω 0Ω ∞Ω
DSFO
DSR ∞Ω ∞Ω 0Ω
DSBU ∞Ω ∞Ω 0Ω
DSFO ∞Ω 0Ω ∞Ω
3-59
ACCELERATOR POTENTIOMETER
53
52
ADJUSTMENT
64
51 1. Check that switch turns ON and OFF as the accelerator pedal
is depressed.
Measurement terminals 51-64
Pedal not operated ∞Ω

Standard
Pedal operated Continuity (Several 10 Ω)
2. Adjustment of Accelerator Potentiometer

(1) Insert a 1.5 mm (0.0591 in.) thickness gauge between the
53 acceleration link stopper and the accelerator bracket.
52
64
51 (2) Tentatively install the potentiometer.
(3) Check the ON/OFF switching point of the accelerator
switch (SWAC).
When 1.0-mm (0.0394 in.) thickness gauge is inserted:
Standard: ∞ Ω (OFF)
When 2.0-mm (0.0787 in.) thickness gauge is inserted:
Standard: Continuity (ON)
(4) After the end of switch ON/OFF adjustment, apply 08833-

Mounting screw 76002-71 on the threaded portion of the mounting screw.
3-60
BRAKE SWITCH ADJUSTMENT

5 to 9 mm FOOT BRAKE
(0.19 to 0.35 in.)
1. Check brake pedal free play and pad position from the toe
board.
172 mm Brake pedal free play
(6.8 in.)
Standard: 5 to 9 mm (0.19 to 0.35 in.)
If the measured value is not as specified, adjust the master cyl-
Approx. 24 mm inder push rod length.
(0.94 in.)
Stopper bolt Brake pedal pad position
Standard: 170 to 174 mm (6.69 to 6.85 in.)
If the measured value is not as specified, adjust the stopper
bolt protrusion.
For stop lamp 2. Check limit switches.

(1) Check continuity of the limit switch for stop lamp.
Standard: ∞ Ω (Pedal not depressed)
0 Ω (Pedal depressed)
(2) Check continuity of the limit switch for generative brake.
Standard: 0 Ω (Pedal not depressed)
∞ Ω (Pedal depressed)
For regenerative brake
3. Check protrusion of the limit switches.

23.4 mm
(0.92 in.) (1) Limit switch for stop lamp
Check the ON/OFF switching point when depressing the
brake pedal within the free play stroke (between 5 mm to
9 mm (0.19 to 0.35 in.)).
Standard: ∞ Ω (Pedal not depressed)
0 Ω (Pedal depressed)
(2) Limit switch for the generative brake
Check the ON/OFF switching point when depressing the
brake pedal further beyond the free play stroke.
Standard: 0 Ω (Pedal not depressed)
∞ Ω (Pedal depressed)
If the measured value is not as specified, adjust the each
brake limit switch protrusion.
Standard (reference value): 23.4 mm (0.92 in.)
3-61
PARKING BRAKE
LSPB 1. Check parking brake limit switch.
Standard: ∞ Ω (Lever not operated)
0 Ω (Lever operated)
If the measured value is not as specified, adjust the brake limit
switch mounting position.
LSPB
19.5 to 21.9 mm
(0.76 to 0.86 in.)
Switch mounting
screw
3-62
DC-DC CONVERTER ASSY

Removal Procedure
2. Remove the right upper cover.
3. Disconnect the DC-DC converter wiring. [Point 1]
4. Remove the DC-DC converter assy.
The installation procedure is reverse of the removal procedure.
3-63
Point Operation
[Point 1]
12 V+
80 V+
Reassembly:
Carry out wiring according to the cable colors and connecting
B B terminals shown in the illustration.
Note:
When disconnecting DC-DC converter wirings, attach tags not
W W to take the 12 V wirings for 80 V wirings.
80 V– 12 V–
3-64
Memo
4-1
MULTI-DISPLAY FUNCTION
2TE15 Page 2TE18 Page
4
MULTI-SCREEN DISPLAY .... 4-2 MULTI-SCREEN DISPLAY .. 4-37 4
GENERAL ................................... 4-2 GENERAL................................. 4-37 4
SPECIFICATIONS....................... 4-4 SPECIFICATIONS .................... 4-40
DISPLAY INDICATION LIST ...... 4-5 DISPLAY INDICATION LIST .... 4-41
4
ABBREVIATIONS DISPLAYED ABBREVIATIONS DISPLAYED 4
ON THE SCREEN ..................... 4-6 ON THE SCREEN................... 4-42
GENERAL FUNCTIONS ............. 4-7 GENERAL FUNCTIONS........... 4-42 4
GENERAL SCREEN ................... 4-8 GENERAL SCREEN................. 4-43 4
DIAGNOSIS.......................... 4-13 DIAGNOSIS.......................... 4-48
DIAGNOSIS CODE LIST .......... 4-13 DIAGNOSIS CODE LIST .......... 4-48
4
MASK FUNCTIONS ............. 4-15 MASK FUNCTIONS ............. 4-50 4
GENERAL ................................. 4-15 GENERAL................................. 4-50
4
PASSWORD.............................. 4-16 PASSWORD ............................. 4-51
OPERATION ON MASK MENU OPERATION ON MASK MENU 4
SCREEN.................................. 4-17 SCREEN ................................. 4-52
ANALYZER ............................... 4-18 ANALYZER............................... 4-53
4
TUNING ..................................... 4-30 TUNING..................................... 4-66 4
OPTION SET ............................. 4-33 OPTION SET............................. 4-69
4
MATCHING ............................... 4-36 MATCHING ............................... 4-72
WHEEL DIA............................... 4-36 WHEEL DIA .............................. 4-72 4
4
4
4
4
4-2
2TE15
MULTI-SCREEN DISPLAY
GENERAL
The multi-screen display indicates various types of vehicle information by switching the screen.
Note:
Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button may be
damaged.
When stopped
During traveling Upon error occurrence
No. Item No. Item
Parking brake ON indicator Power select indicator
2-speed traveling speed control function set indicator Multi-screen display area
Diagnosis ON indicator 2-speed traveling speed control function set button
Overheat warning indicator Hour meter selector button
Battery charge indicator Power select button

4-3
1. Parking brake ON indicator

This indicator blinks upon activation of the parking brake. If the operator fails to release the parking brake during
forward or reverse traveling, alarm sounds (beeps) to warn the operator.
2. 2-speed traveling speed control function set indicator
This indicator turns ON/OFF every time the set button is pressed. When the indicator turns on, the 2-speed trav-
eling speed control function is activated and the vehicle maximum speed is restricted as specified on the 2- 4
speed traveling speed level setting screen.
3. Diagnosis ON indicator
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same time, the
4
corresponding error code is displayed and a buzzer sounds to warn the operator.
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to six error
codes are displayed with alternation at intervals of 2 seconds.
4
4. Overheat warning indicator
If the temperature of the controller or drive motor rises beyond
4
Overheat warning indicator
the specified level, the overheat warning indicator blinks and a
alarm sounds to warn the operator. 4
When overheated, vehicle operation is restricted and the over-
heat section indication blinks.
Displayed message C/R : Traveling controller
4
DM : Drive motor
4
Overheat section indication (abbreviation)
4
Restriction of vehicle operation during drive system overheated
C/R: Controller overheat 4
Power selection mode
H mode
Contents of restriction
1. “C/R” message is displayed and warning indicator blinks.

4
P mode
S mode
Main drive circuit overheat 2. Beep sounds for 5 seconds.
3. Maximum speed is restricted up to the one of the half throttle.

4
D/M Drive motor overheat 4
Power selection mode
Secondary restriction
4
Preliminary restriction (When D/M temperature becomes higher than
the one for preliminary restriction.)
4
1. “D/M” message is displayed and warning 1. “D/M” message is displayed and warning
H mode
indicator blinks.
2. Beep sounds for 5 seconds.

indicator blinks.
2. Beep sounds for 5 seconds.

4
3. Forces the power selection mode to switch
to S mode.
3. Restricts the maximum speed up to the one
of half throttle. 4
1. “D/M” message is displayed and warning
P mode
indicator blinks. 4
2. Beep continues to sound.
4
S mode
3. Restricts the maximum speed up to the one
of half throttle.
4
4-4
5. Battery charge indicator

The battery charge level is indicated in ten stages.
(1) Low remaining battery charge warning
The battery charge indicator blinks when the remaining battery charge drops below the set level. When the
key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to warn the operator.
(2) Battery overdischarge warning
When the remaining battery charge drops further from the low remaining battery charge warning level to
the set level*, all segments of the battery charge indicator start blinking and a buzzer sounds to warn the
operator.
*: The level can be set using TUNING function of the mask function.
Low remaining battery charge warning Battery overdischarge warning
Number of segments corresponding to All segments blink.

the remaining battery charge.
6. Power select indicator

A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by pressing the
power select button on the GENERAL screen.
7. Multi-screen display area
Displays the date and time normally, and displays the speed during traveling. It is also used to set various func-
tions and for mask function data display.
8. 2-speed traveling speed control function set button
It is possible to turn 2-speed traveling speed control function ON/OFF by pressing this button.
9. Hour meter selector button
The content displayed by the multi-hour meter function can be changed by this button.
10. Power select button
This button selects S, P or H mode. The selected mode can be changed each time the power select button is
pressed on the GENERAL screen.
Press this button for 2 seconds or more to move to the user setting screen to set the level of each function.
SPECIFICATIONS
LCD Dot matrix + fixed display
Buttons Three buttons
Back light LED type that comes on when the key switch is turned to ON
4-5
DISPLAY INDICATION LIST

To be selected by user
General screen 2-speed traveling speed ON/OFF 2-speed traveling speed control function ON/OFF setting
4
Switching to hour meter display Checking traveling system operation time
Enter password Power select Power mode selection
Press Power select To be set by user
4
button for 2 seconds
or more 2-speed traveling speed level 2-speed traveling speed level setting
Speed alarm Traveling speed setting for overspeed alarm
Power control selection Fine adjustment of traveling control level (original mode setting)
Clock set Adjustment of indicated time 4
To be set by dealer or service person
DIAG MEMORY
I/O MONITOR1
Checking past diagnosis error codes stored in memory
Checking the temperature and voltage of each functional part
4
I/O MONITOR2 Checking drive-related sensors
4
Mask function Screen ANALYZER
I/O MONITOR3 Unused
I/O MONITOR4 Checking the battery current sensor
ACTIVE TEST Forced ON/OFF test of cooling fan
No.1
No.2
Setting regenerative braking torque (switch back)
Setting regenerative braking torque (accelerator off)
4
No.3 Setting battery overdischarge warning level
No.4
No.5
Battery charge indicator correction
Setting traveling limit speed
4
No.6 Unused
TUNING
No.7
No.8
Unused
Unused
4
No.9 Unused
No.10
No.11
Unused
Unused
4
No.12 Unused
DEMO MODE
H/M START
Enabling/disabling parking brake OFF alarm before hour meter start.
Starting hour meter count
4
Enabling/disabling level setting of the traveling power control and speed
DESTI
P/C LOCK
alarm
Changing display for each destination
4
B LEVEL Unused
MPH
C/CNT RES
Selecting the traveling speed unit
Unused
4
BATTERY Setting the calculation constant for battery charge indicator
OPTION SHOU-TOKU
SET AUTO P-OFF
Unused
Activating/inactivating Auto-OFF function
4
PARKING ERR Enabling/disabling parking brake OFF alarm
TILT CONT
SWG W-LOCK
Unused
Unused
4
4
TILT F-LIM Unused
AFS Unused
ACC STAGE Unused
4
WHEEL IND Unused
TRC CONT Unused
ACCUM CONT Unused
4
TIL TL Unused
TIL TF Unused
MATCHING LOAD Unused
4
TIRE Unused
SWG Unused
WHEEL DIA WHEEL DIA Tire constant setting
4
4-6
ABBREVIATIONS DISPLAYED ON THE SCREEN
AOPT Analog input voltage SPDS (Displayed but unused)
C/R Controller SPL (Displayed but unused)
CSBATT Battery current sensor SS1 (Displayed but unused)
DM Drive motor SSC (Displayed but unused)
DSF Forward traveling switch SSD1 Drive motor rpm sensor (1)
DSR Reverse traveling switch SSD2 Drive motor rpm sensor (2)
FAND Controller cooling fan 1 SSOL (Displayed but unused)
FANP Controller cooling fan 2 SSP (Displayed but unused)
H/M Hour meter STS (Displayed but unused)
K-DIFF (Displayed but unused) STS1 (Displayed but unused)
K-POS (Displayed but unused) STS2 (Displayed but unused)
KSOL (Displayed but unused) STSC (Displayed but unused)
LOAD (Displayed but unused) SWAC Accelerator switch
LSAT1 (Displayed but unused) SWG (Displayed but unused)
LSAT2 (Displayed but unused) SWTK (Displayed but unused)
LSB Brake switch TD Drive motor temperature
LSD Seat switch TEMP Temperature on CPU board
LSL (Displayed but unused) THCD Main traveling circuit temperature
LSOPT1 Option limit switch (1) THCP (Displayed but unused)
LSOPT2 Option limit switch (2) TILTF (Displayed but unused)
LSTF (Displayed but unused) TILTL (Displayed but unused)
LSTR (Displayed but unused) TIRE (Displayed but unused)
MH (Displayed but unused) TP (Displayed but unused)
P/C Power control VBBT Battery intermediate voltage
P/M (Displayed but unused) VBMB Main battery intermediate terminal voltage
POTA Accelerator potentiometer VBKY Voltage after key switch
POTT (Displayed but unused) YAW (Displayed but unused)
SPDM Main traveling speed

4-7
GENERAL FUNCTIONS
General functions can generally be used or seen by the user.
Speedometer
Status display function 2-speed traveling speed set indicator
Parking brake operation indicator
Power select indicator
Power select
Level setting function Traveling power control level setting
2-speed traveling speed level setting
Key ON hour meter
Drive motor operation hour meter
Odometer
Multi-hour meter function
Lap time meter
Trip meter
Calendar • clock
Battery overdischarge warning
Low remaining battery charge warning
Overheat warning
Parking brake OFF failure warning

Warning function
Parking brake ON failure warning
Return to neutral warning
Overspeed alarm
Diagnosis display
4-8
GENERAL SCREEN
Operating Procedure
Button (1) Button (2)

GENERAL screen
2-speed traveling speed control function
ON/OFF setting
Hour meter display selection
Power control selection

Press button (3) for
2 seconds or more. Button (3)
2-SPEED TRAVELING SPEED LEVEL SETTING screen
Press button (3)
OVERSPEED ALARM SETTING screen
Press button (3)
POWER CONTROL FUNCTION SELECTION screen
Press button (3)
CLOCK SET FUNCTION SELECTION screen
Press button (3)
Upon returning to the general screen after moving through each screen, the power select mode is set to “S”. If nec-
essary, select the desired mode.
4-9
1. 2-speed traveling speed ON/OFF selection

2-speed traveling speed Press button (1) to turn 2-speed traveling speed function ON/
set indicator Button (1) OFF.
2. Hour meter display selection (multi-hour meter function)

Press button (2) to select the hour meter display.
Function Description
A Key ON hour meter Indicates the total key ON time.
B Drive motor operation hour meter Drive motor operation time
C Odometer Total travel distance
D Lap time meter Lap time upon key ON
E Trip meter Trip distance

C
Press button (2)
Button (3)
Press button (2)
D
A
Press button (2)
Press button (2)

E
B
Press button (2) Press button (2)
GENERAL screen
• The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.
• Press button (3) on each screen to return to the GENERAL screen.
4-10
3. Power select selection (S → P → H)

Press button (3) on the GENERAL screen to change the travel
power select mode.
When all symbols are enclosed, control is performed in the
original mode set on the POWER CONTROL LEVEL SET-
TING screen.
H : This mode provides the fastest cycle time that optimizes
vehicle’s mobility.
P : This mode provides the best compatibility between the cy-
Button (3)
Power select cle time and mobility.
indicator S : This mode provides the longest operative time.
Blinks when setting 2-speed traveling 2-SPEED TRAVELING SPEED LEVEL SETTING
speed level SCREEN
Press button (3) on the GENERAL screen to display 2-SPEED
TRAVELING SPEED LEVEL SETTING screen.
1. Press button (1) to decrease the traveling speed setting.
2. Press button (2) to increase the traveling speed setting.
3. Press button (3) to display the next screen
Button (3) (OVERSPEED ALARM SETTING screen).
2-Speed traveling speed control level
OVERSPEED ALARM SETTING SCREEN

Button (1) Button (2) The traveling speed level for the overspeed alarm is set on this
screen.
Press button (3) on the 2-SPEED TRAVELING SPEED LEVEL
SETTING screen to display the OVERSPEED ALARM SETTING
screen.
Button (3) 2. Press button (2) to increase the traveling speed setting.
Traveling speed setting
for overspeed alarm 3. Press button (3) to display the next screen (POWER CON-
TROL FUNCTION SELECTION screen).
4-11
POWER CONTROL FUNCTION SELECTION

Button (1) Button (2) SCREEN
The travel power control levels can be set independently using this
screen.
Press button (3) on the OVERSPEED ALARM SETTING screen to
display the POWER CONTROL FUNCTION SELECTION screen.
1. Press button (1) on the POWER CONTROL FUNCTION SE-
Button (3) LECTION screen, select “YES”, and then press button (3) to
Select “YES” and display the TRAVELING POWER CONTROL LEVEL SET-
press button (3)
TING screen.
TRAVELING POWER CONTROL (1) TRAVELING POWER CONTROL LEVEL SETTING screen
LEVEL SETTING screen
Press button (1) to select the lower level.
Press button (2) to select the higher level.
Press button (3) to display the next screen (CLOCK SET
FUNCTION SELECTION screen).
Press button (3)


LECTION screen, select “NO”, and then press button (3) to
display the next screen (CLOCK SET FUNCTION SELEC-
TION screen).
4-12
CLOCK SET FUNCTION SELECTION SCREEN

Year, month, day, day of week, 12/24-hour display, hour and minute can be set individually.
Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select “NO”, and press button (3), or
press button (3) on the POWER CONTROL LEVEL SETTING screen to display the CLOCK SET FUNCTION screen.

POWER CONTROL FUNCTION POWER CONTROL LEVEL
SELECTION screen Button (2) Button (2)
SETTING screen

Select “NO”
Press button (3)
Select “YES” and

press button (3)
Select “NO” and

press button (3)
Each press of button (3) will shift the selection

item in this order: month, day, ... and minute
Press button (3)
GENERAL screen (End of clock setting)
1. Press button (1) on the CLOCK SET FUNCTION SELECTION screen, select “YES”, and press button (3) to dis-
play the CLOCK SET screen.
(1) CLOCK SET screen
Press button (1) to decrease the selected (blinking) value.
Press button (2) to increase the selected (blinking) value.
Press button (3) to enter the selected (blinking) value, and proceed to the next item.
Press button (3) when “MINUTE” is selected on the CLOCK SET screen to display the next screen (GEN-
ERAL screen).
2. Press button (3) when “NO” is selected on the CLOCK SET FUNCTION SELECTION screen to display the next
screen (GENERAL screen).
4-13
DIAGNOSIS
1. When diagnosis is activated, the diagnosis ON indicator comes
Diagnosis code
on and blinks on the screen and a beep sounds to warn the op-
Diagnosis ON indicator
erator that some abnormality has occurred on the vehicle.
2. Also, up to three diagnosis error codes are displayed on the
screen. When the number of error codes is exceeds three, up
to six are displayed on alternating screens.
Abnormality detection time

(Key ON hour meter)
DIAGNOSIS CODE LIST

Displayed code : Code indicated on the display when an abnormality occurs in the vehicle
Memoried diagnosis code : Code indicated on the display when mask function (to be explained later) DIAG MEMORY
is in use
Memoried
Displayed code Code explanation
diagnosis code
A0-1 Traveling controller main circuit abnormal temperature rise

C/R
A0-4 A0-4
Controller cooling fan abnormality
A0-5 A0-5
A1 A1 Controller overvoltage
A2 CPU board abnormal temperature rise

C/R
A3-1 A3-1 Incorrect battery connection or inappropriate battery voltage
A4 A4 Accelerator switch abnormality
A8 A8 Traveling controller abnormality or fuse F1 discontinuity
AA AA CPU board temperature sensor abnormality
AF-1 AF-1
AF-2 AF-2
Traveling controller CPU board abnormality
AF-3 AF-3
AF-4 AF-4
C0-1 C0-1 Traveling controller main circuit abnormality
C0-3 C0-3 Drive circuit power supply abnormality
C0-4 C0-4 Drive circuit abnormality
C1 C1 Drive current sensor abnormality

4-14
Memoried
diagnosis code
C2-1 Drive motor abnormal temperature rise

D/M
C2-2 C2-2 Drive motor temperature sensor abnormality
C3 C3 Traveling controller main circuit temperature sensor abnormality
C4-1 C4-1
C4-2 C4-2
Accelerator potentiometer abnormality
C4-3 C4-3
C4-4 C4-4
C7 C7 Direction switch abnormality
C8-1 C8-1
Drive motor rpm sensor abnormality
C8-2 C8-2
CB-1 CB-1 Battery contactor (MB) discontinuity
EE-1 EE-1
EE-2 EE-2 Multi-display to traveling controller communication abnormality
EE-3 EE-3
EF-1 EF-1
Traveling controller EEPROM abnormality
EF-2 EF-2
EF-3 EF-3 Traveling controller CPU board abnormality
F1-1 F1-1
Traveling controller to multi-display communication abnormality
F1-2 F1-2
65-2 65-2 Power steering contactor (PS) abnormality

4-15
MASK FUNCTIONS
GENERAL
In addition to the functions described in the operator’s manual for use by general users, the multi-screen display pro-
vides the following mask functions for use by the service staff for vehicle maintenance and specification setting.
The mask functions are protected by password to prevent unintentional operation by users.
Mask Function List

When used
Function Description Board
Delivery Others
replacement
Displays the vehicle’s electrical

Upon vehicle
system operating status and reads
Analyzer — — abnormality
the error information detected by
detection
controllers.
Makes fine adjustment of traveling { As requested

Tuning —
and charge indicator functions. *2 by customer
Sets each vehicle option and other {

Specification setting — —
specifications. *1 *2 *3
Each control function enable/ Enables or disables each control {

— —
disable function. *2 *3
Option Set {
Hour meter start Starts the hour meter count. { —
*3
Upon new
Demo mode
Enables or disables the demo mode — — vehicle
(parking brake OFF warning)
demonstration
Matching Unused — — —
Makes the speedometer reading {

Tire constant set — —
appropriate. *2
*1 : This is for matching the controller and display control to the options or functions installed on the vehicle and not
for enabling/disabling each option or control function itself.
*2 : Board ..................... Traveling controller CPU board
*3 : Board ..................... Multi-screen display control board
Preparation for the MASK MENU Screen

Caution:
Before moving from the GENERAL screen to a MASK MENU
screen, be sure to jack up the vehicle until the drive wheel
leaves the floor surface, and stabilize the vehicle by support-
ing the frame with wooden blocks.
4-16
PASSWORD
Note on Password Input
1. If a mistake is made part of the way through, turn the key switch to OFF and begin the procedures below again.
If the MASK MENU screen does not appear after several attempts, the system may be faulty.
Password Input Procedure
Procedure Operation Vehicle operation
1 Press buttons (1) and (2) at the same time. A short beep sounds.
2 Press button (1). A short beep sounds.
Short beeps sound.

Press buttons (2) and (3) at the same time and hold for 2
4 After displaying the version screen for 2 seconds, the
seconds or more. (End of password input)
MASK MENU screen appears automatically.

GENERAL screen Button (2)
Within 10 seconds, press buttons Button (3)

Press buttons (1) and (2) (2) and (3) at the same time for 2
at the same time. seconds or more.
Button (1) VERSION screen
Press button (1)

within 10 seconds.
Button (2) MASK MENU screen
Press button (2)

within 10 seconds.
Note:
The GENERAL screen is displayed when the key switch is set to OFF once on each mask function screen.
4-17
Input the password on the GENERAL screen. OPERATION ON MASK MENU SCREEN
Button (1)
Button (2)
ANALYZER MENU screen Operating Procedure
1. Input the password (see the previous page) on the GENERAL
screen to display the MASK MENU screen.
2. Press button (1) or (2) to select the desired menu item, and
press button (3) (enter) to display the menu or setting screen
for each function.
Press button (1) or (2) Button (3)
to switch screen (1) ANALYZER MENU screen
TUNING screen This screen displays the vehicle’s electrical system oper-
ating status and the error code detected by the controller.
Note:
Display of ANALYZER MENU screen does not prohib-
it the vehicle’s ordinary operation.
(2) TUNING screen
Press button (1) or (2) Performs fine adjustment of traveling control, etc.
to switch screen
OPTION SET screen

(3) OPTION SET screen
Matches the controller or display control according to the
set option or control.
Press button (1) or (2)

to switch screen
MATCHING screen
(4) MATCHING screen
This screen is unused.

to switch screen
WHEEL DIA screen

(5) WHEEL DIA screen
Rewrites the tire information in the controller for correct-
ing the speed indication and trip meter.

to switch screen
END screen
(6) END screen
Press button (3) on this screen to display the GENERAL
screen.
Press button (2) on this screen to display the ANALYZER
MENU screen.
Turn the key switch to OFF, and then ON again on each
screen to display the GENERAL screen.
Press button (3)
To GENERAL screen
4-18
ANALYZER
GENERAL
1. The analyzer supports inspection and troubleshooting of the control system using the communication function
between the traveling controller and the display. Quick, easy servicing is made possible by the use of the ana-
lyzer.
2. Setting the display into the ANALYZER MENU screen makes it possible to inspect and detect abnormality in
functions of the operating system and sensors, such as main traveling circuits and the accelerator.
3. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes detected in the electrical system in the past. The diagnosis mem-
ory function displays these error codes.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/out monitor function (I/O MONITOR)
This function displays the analog input value from each sensor in the traveling system. Monitor this indica-
tion to judge the quality of the input/output signal from each circuit or sensor.
(a) I/O MONITOR1
Displays the temperature of each electrical functional part and analog input voltage values detected
by the controller at each terminal.
(b) I/O MONITOR2
Displays the ON/OFF states of switches related to traveling control and the analog input voltage values
from related sensors.
(c) I/O MONITOR3
This is unused.
(d) I/O MONITOR4
Displays the analog input voltage values from battery current sensor.
(3) Active test function (ACTIVE TEST)
The controller outputs an operation signal (ON or OFF signal) to the selected part in order to permit oper-
ation check.
4. When an error in the electrical system is detected while the I/O

monitor or ACTIVE TEST screen is being displayed, the alarm
Diagnosis ON indicator Error code sounds and an error code is displayed with the diagnosis ON
indicator in the upper right portion of the multi-screen display.
4-19
ANALYZER MENU Screen List

Description
ANALYZER MENU screen Meaning
1st row 2nd row
1. DIAG MEMORY DIAG-1 to Error codes are displayed together with Refer to the Diagnosis Error Code List.
• Diagnosis error code display DIAG-10 detection time. (See P4-13.)
I/O 1-1 THCD: +25 Main drive circuit temperature: °C
I/O 1-2 THCP: –55 (Unused) —
I/O 1-3 TD: +25 Drive motor temperature: °C
I/O 1-4 TP: –55 (Unused) —
2. I/O MONITOR1 I/O 1-5 TEMP: +25.0 CPU board surface temperature: °C
• Voltage
• Temperature I/O 1-6 VBBT: 50.0 Voltage before key switch: V
I/O 1-7 VBKY: 50.0 Voltage after key switch: V
I/O 1-8 VBP4: 80 P4 terminal voltage: V
I/O 1-9 VBMB (M): 80 Battery voltage (main input voltage): V
I/O 1-10 VBMB (S): --- (Unused)
POTA: 0.70 Accelerator potentiometer voltage: V
I/O 2-1
SWAC: 0 Accelerator switch: 0 (OFF), 1 (ON)
DSF: 0 Forward traveling switch: 0 (OFF), 1 (ON)
I/O 2-2
DSR: 0 Reverse traveling switch: 0 (OFF), 1 (ON)
LSB: 1 Brake switch: 0 (OFF), 1 (ON)
I/O 2-3
3. I/O MONITOR2 LSD: 1 Seat switch: 0 (OFF), 1 (ON)
• Traveling system SSD: 1 → 00 Drive motor rpm sensor 1: Number of pulses
I/O 2-4
2 → 00 Drive motor rpm sensor 2: Number of pulses
SPD: M10.0
I/O 2-5 Main traveling speed input: km/h or mph
S--.- (Unused)
I/O 2-6 YAW: --.- (Unused) —
I/O 2-7 SWG: --.- (Unused) —
LSL: - (Unused)
I/O 3-1
SWTK: - (Unused)
LSTF: - (Unused)
I/O 3-2
LSTR: - (Unused)
LSAT1: - (Unused)
I/O 3-3
4. I/O MONITOR3 LSAT2: - (Unused) —
I/O 3-4 SSP: -- (Unused)
I/O 3-5 MH: --- (Unused)
I/O 3-6 POTT: -.-- (Unused)
I/O 3-7 SPL: -.-- (Unused)
I/O 4-1 STS: --- (Unused) —
I/O 4-2 K-POS: ---(---) (Unused) —
K-DIFF: --- (Unused)
I/O 4-3 —
SOL: - (Unused)
5. I/O MONITOR4
I/O 4-4 TIRE: -.--(Unused) —
• Others
I/O 4-5 CSBATT: 2.50 Battery current sensor voltage: V
I/O 4-6 AOPT: 0.00 (Unused) —
LSOPT: 1 → 0 (Unused)
I/O 4-7 —
2 → 0 (Unused)
ACT-1 FAND: ON/OFF Controller cooling fan FAND
6. ACTIVE TEST ACT-2 FANP: ON/OFF Controller cooling fan FANP
• Operation test ACT-3 SSOL: ON/OFF (Unused) —
ACT-4 KSOL: ON/OFF (Unused) —
7. END Press power select button to display the MASK MENU screen.
Notes:
• It is impossible to move directly from one function screen to another. Return to the ANALYZER MENU
screen once to select other function screens.
• Values shown on the table above are not standard ones, but only examples.
4-20
Operating Procedure
1. Input the password (See P4-16) on the GENERAL screen to display the MASK MENU screen.
2. Check that “1. ANALYZER” is displayed on the mask menu screen and press button (3) (enter) to display the
ANALYZER MENU screen.
3. Press button (1) or button (2) to select the desired menu item and press button (3) (enter) to display the selected
screen.
• Button (1) To the previous menu item screen
• Button (2) To the next menu item screen
• Button (3) Enter (to the selected menu item screen)
Note:
Press button (3) on the “7.END” screen to display the MASK MENU screen.
Press button (3)

Button (1)
Button (2)
ANALYZER MENU screen END screen
Button (3)
Press button (3) Press button (1) or (2)
to switch screen.
DIAG MEMORY screen ACTIVE TEST screen
Press button
(1) or (2)
to switch screen.
Press button (1) or (2) Press button (1) or (2)
to switch screen. to switch screen.
I/O MONITOR1 screen I/O MONITOR4 screen

Press button
(1) or (2)
to switch screen.
4-21
DIAG MEMORY
The controller stores up to 10 of the most recent errors. The DIAG MEMORY screen displays these diagnosis error
codes together with their detection time (as key ON hour meter reading).
The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to DIAG-10.
Note:
As for diagnosis codes and their explanations, see pages 4-13 to 4-14.
Button (1) Operating Procedure

ANALYZER MENU screen Button (2) 1. Display the ANALYZER MENU screen.
2. Check that “1. DIAG MEMORY” is displayed and press button
(3) (enter). Past diagnosis codes are displayed sequentially
starting with the newest one.
3. The function of each button on the 1. DIAG MEMORY function
screen is as follows.
Button (3) • Button (1) → Unused
Press button (3)
• Button (2) → Unused
• Button (3) → Displays past diagnosis codes.
Press button (3)
Press button (3)

Note:
When no error codes are displayed on the screen and the
hour meter time is “0.0h”, it indicates that no error codes
are stored in the memory.
No error occurrence
Press button (3)
......
is indicated.
Notes:
• Press button (3) on the DIAG-10 screen to display the
• It is impossible to move directly from one function to
another. Return to the ANALYZER MENU screen once
to select other function screens.
Press button (3)
To ANALYZER MENU screen

4-22
Vehicle Abnormalities Not Stored in Diag Memory

There are abnormalities that are not stored in the diagnosis memory even if the controller detects them.
Alarm item Alarm content Symbol displayed
1. Parking lever ON alarm • Alarm indication: Blinking

Alarm occurs upon attempt at traveling with the direction parking brake indicator
switch at either forward or reverse position while the • Alarm sound
parking lever is kept applied.
2. Parking lever OFF alarm • Alarm sound

Alarm occurs when the operator leaves the operator’s seat
No display
without applying the parking brake (also without turning the
key switch to OFF).
3. Overdischarge alarm • Alarm indication: Blinking
Overdiscarged state of the battery is warned at the level set battery charge indicator
at the tuning (described on page 4-32). • Alarm sound
4. Return to neutral alarm • Alarm sound

Alarm occurs when an operator sits on the driver seat and
No display
turns key switch ON, with the accelerator pedal depressed
or direction lever moved to the forward or reverse position.
Input/Output Monitor Function

Current detected
I/O MONITOR No. abnormality error code (I/O MONITOR)
• I/O MONITOR is useful function to display input values from
sensors of traveling related systems. This function helps to
judge whether the circuits or sensors work properly.
• If abnormality which is currently present is detected, the error
cord, which is corresponding to the abnormality, is displayed.
Operating item
4-23
I/O MONITOR1
This function displays the temperature of each electrical functional part and the voltage at the respective terminal.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press button (2) once.
3. Check that “2. I/O MONITOR1” is displayed and press button (3) (enter). I/O1-1 to I/O1-10 are displayed.
4. The function of each button on the I/O MONITOR1 function screen is as follows:
• Button (3) → Displays I/O1-1 to I/O1-10 screens sequentially
Notes:
• Press button (3) on the I/O1-10 screen to display the ANALYZER MENU screen.
• It is impossible to move directly from one function screen to another. Return to the ANALYZER
MENU screen once to select other function screens.
Button (1)
ANALYZER MENU screen Button (2)
Button (3)
Press button (3)
I/O 1-1 screen (1) I/O1-1 screen
THCD: Main drive circuit temperature (°C)
Temperature of the main drive circuit element is dis-
played.
Check that the temperature measurement function is
functioning properly.
The temperature at the time of measurement is displayed.
Press button (3)
Unused
Press button (3)

TD: Drive motor temperature (°C)
Temperature of the drive motor is displayed.
Press button (3)

To I/O1-4 screen
4-24
Button (1) Button (2) (4) I/O1-4 screen

I/O 1-4 screen Unused
Press button (3) Button (3)

TEMP: CPU board surface temperature (°C)
The surface temperature of the traveling controller CPU
board is displayed.
Press button (3)
VBBT: Battery intermediate terminal voltage (V)
Voltage before key switch
Standard: Approx. 48 V (24 cells voltage)
Press button (3)

VBKY: Battery intermediate terminal voltage (V)
Voltage after key switch
Standard: Approx. 48 V (24 cells voltage)
Press button (3)

VBP4: P4 terminal voltage (V)
Voltage measured at terminal P4
Standard: Battery voltage
Press button (3)

VBMB (M): Main battery voltage input (V)
Main controller input voltage value after the MB contactor
Press button (3)

Unused
Press button (3)

4-25
I/O MONITOR2
This function displays the ON/OFF status of switches and analog input voltage values from sensors related to trav-
eling control.
Operating Procedure
2. Press button (2) twice.
• Press button (3) → Displays I/O2-1 to I/O2-7 screens sequentially
Notes:
(1) I/O2-1 screen
Button (1) POTA: Accelerator potentiometer voltage (V)
(a) When the accelerator pedal is not depressed
(SWAC: OFF)
Standard: 0.3 to 2.4 V
(b) Upon full accelerator pedal depression
Button (3) Accelerator voltage difference:
Press button (3)
(b) – (a) = 1.4 V or more
I/O 2-1 screen SWAC: Accelerator switch inspection
When the accelerator pedal is not depressed:
0 → OFF
When the accelerator pedal is depressed:
1 → ON
Depress the accelerator pedal to check the switch ON/
OFF switching operation.
Press button (3)

Direction switch inspection
DSF: Forward traveling switch,
DSR: Reverse traveling switch
1 → ON 0 → OFF
Indication
Operation DSF DSR
Press button (3) Forward traveling 1 0
Neutral 0 0
To I/O2-3 screen
Reverse traveling 0 1
Operate the direction lever to check the switch ON/OFF

switching operation.
4-26
(3) I/O2-3 screen

I/O 2-3 screen Button (1) Button (2) LSB: Brake switch inspection
When the brake pedal is not operated: 1 → ON
When the brake pedal is depressed: 0 → OFF
Depress the brake pedal to check the switch ON/OFF
LSD: Seat switch check
Button (3) When the operator is on the seat: 1 → ON
When the operator leaves the seat: 0 → OFF
Press button (3)
Sit on and leave the operator’s seat to check the switch
ON/OFF switching operation.
SSD1: Drive motor rpm sensor 1 (number of pulses)
SSD2: Drive motor rpm sensor 2 (number of pulses)
Inspect the rpm sensor while the vehicle is traveling actu-
ally. The number of pulse increases with the traveling
speed.
Press button (3)

SPDM: Main traveling speed (km/h or mph)
Check traveling speed by depressing the accelerator ped-
al and traveling the vehicle actually. Check that the dis-
played traveling speed increases almost at the same rate
of the actual speed increase.
Press button (3)

Unused
Press button (3)

Unused
Press button (3)

4-27
I/O MONITOR3
Unused
Operating Procedure
2. Press button (2) three times.
3. Check that “4. I/O MONITOR3” is displayed and press button (3) (enter) I/O3-1 to I/O3-7 are displayed.
4. Functions of each buttons on the I/O MONITOR3 screen is as follows:
• Button (3) → Displays I/O3-1 to I/O3-7 screens sequentially.
Notes:
• It is impassible to move directly from one function screen to another. Return to the ANALYZER
4-28
I/O MONITOR4
The screen except I/O4-5 are not used. The analog input value from battery current sensor is indicated on I/O4-5
screen.
Operating Procedure
2. Press button (2) four times.
Notes:
Button (1) (1) I/O4-1 screen
ANALYZER MENU screen Button (2) Unused
(2) I/O4-2 screen
Unused
(3) I/O4-3 screen
Unused
(4) I/O4-4 screen
Button (3) Unused
Press button (3)
I/O 4-1 screen
Press button (3)

I/O 4-2 screen
Press button (3)

I/O 4-3 screen
Press button (3)

I/O 4-4 screen
Press button (3)

CSBATT: Battery current sensor voltage (V)
Standard upon stopping traveling and PS: 2.50 V
Press button (3)

(6) I/O4-6 screen
Press button (3) (7) I/O4-7 screen
I/O 4-7 screen
Unused
Press button (3)

4-29
ACTIVE TEST
This function outputs ON/OFF signals to controller cooling fan 1, 2 and compares controller input signals with those
signals. The screens of ACT-3 and ACT-4 are not used.
Operating Procedure
2. Press button (2) five times.
3. Check that “6. ACTIVE TEST” is displayed and press button (3) (enter). ACT-1 to ACT-4 are displayed.
4. Functions of each button on ACTIVE TEST screen is as follows:
• Button (1) → Forced ON
• Button (2) → Forced OFF
• Button (3) → Displays ACT-1 and ACT-4 sequentially
Notes:
• Press button (3) on ACT-4 screen to display the ANALYZER MENU screen.
(1) ACT-1 screen
Button (1) FAND: Controller cooling fan 1
ANALYZER MENU screen Button (2) (1) → Fan ON
(2) → Fan OFF
Forcibly output the ON/OFF signal to check the controller
cooling fan operation.
Check the fan operation by air blowing from the trav-
eling controller or the operating sound.
Button (3) Press button (1) to select ON.
Press button (3)
Fan rotates and (1) is displayed.
ACT-1 screen
Press button (2) to select OFF.
Fan stops rotating and (0) is displayed.
(2) ACT-2 screen
FANP: Controller cooling fan 2
(1) → Fan ON
(2) → Fan OFF
Press button (3)
ACT-2 screen
Check the fan operation by air blowing from the trav-
eling controller or the operating sound.
Press button (1) to select ON.
Fan rotates and (1) is displayed.
Press button (2) to select OFF.
Fan stops rotating and (0) is displayed.
Press button (3) (3) ACT-3 screen
Unused
ACT-3 screen
(4) ACT-4 screen
Press button (3) Unused
ACT-4 screen
Press button (3)

4-30
TUNING
GENERAL
When the user requests to limit the maximum speed or weaken the regenerative braking force, each setting can be
performed on the TUNING screen.
12 tuning items are prepared, including spares.
Tuning item list
Tuning Level (z: Default setting position)

Item
No. 1 2 3 4 5 6 7 8
Switchback regenerative braking torque:

z
1 Changes the regenerative braking torque at Weak Strong
switchback
Acceleration OFF regenerative braking torque: z

2 Changes regenerative braking torque when None Weak Strong
accelerator pedal is released
Battery overdischarge warning set level:

Changes the activation timings of low Early
3 Late Disabled
remaining battery charge warning and battery z
overdischarge warning
Battery charge indicator adjustment:

Slow z Fast
4 Adjusts decreasing rate of battery charge
decrease decrease
indicator
Traveling speed limiter: Low High None

5
Adjusting the maximum traveling speed speed speed z
6 Spare
7 Spare
8 Spare
9 Spare
10 Spare
11 Spare
12 Spare
4-31
Operating Procedure
Button (1) Button (2) 1. Input the password on the GENERAL screen (See P4-16) to
TUNING screen
display the MASK MENU screen.
2. Press button (2) once to display “2. TUNING”. Then press but-
ton (3) (enter) to display the TUNING setting screen.
3. Press button (3) to display the tuning item desired to be set.
4. Function of each button on the tuning function setting screen
Button (3)
Press button (3) is as follows:
• Button (1) → Tuning level down
• Button (2) → Tuning level up
• Button (3) → Enter (to the next item screen)
Note:
Press button (3) on the tuning No.12 screen to display the
TUNING MENU screen.
Press button (3)
Press button (3) to

change the display
•••
from No. 1 to No. 12

sequentially.
Press button (3)

To TUNING MENU screen
4-32
Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels
(Tuning No.3)
The default setting is level 7.
How to read the figure:

Example: When selecting the level 5
When the battery discharge level is between 70% and 90%, the battery remaining charge indicator starts to blink,
and beep sound occurs 5 times after key switch ON.
When the battery discharge level exceeds 90%, all 10 segments blink and beep sound is continued while traveling
operation.
See page 4-4 about battery charge indicator.
Caution:
When selecting the level 8, the overdischarge alarm does not function. Be careful not to overdischarge the
battery with frequent checking of the battery charge indicator.
4-33
OPTION SET
OPTION SET Menu List
No. Indication Description Selection (symbol)
Enables/disables the parking brake OFF

OPT-1 DEMO MODE Enable (Y) Disable (N)
alarm.
OPT-2 H/M START Starts hour meter count. Count (Y) Not count (N)
Enables/disables level setting for traveling

OPT-3 P/C LOCK Lock (Y) Unlock (N)
power control and overspeed alarm.
Sets the data according to the destination.

OPT-4 DESTI* Japan (J) International (I)
Changes the pattern of display.
OPT-5 B LEVEL Unused (select N) — (Y) — (N)
OPT-6 MPH* Changes the traveling speed unit. Set to mph (Y) Set to km/h (N)
OPT-7 C/CNT RES Unused (select N) — (Y) — (N)
Adjusts the charge indicator calculation Local battery

OPT-8 BATTERY* — (W)
constant. mounted (L)
OPT-9 SHOU-TOKU Unused (select N) — (Y) — (N)
Enables/disables the Auto Power-OFF

OPT-10 AUTO P-OFF Enable (Y) Disable (N)
function.
Enables/disables the Parking brake OFF

OPT-11 PARKING ERR Enable (Y) Disable (N)
alarm.
OPT-12 TILT CONT Unused (select Y) — (Y) — (N)
OPT-13 SWG W-LOCK Unused (select Y) — (Y) — (N)
OPT-14 TILT F-LIM Unused (select Y) — (Y) — (N)
OPT-15 B-TYPE Battery type Type 1 (1) Type 2 (2)
* : The specifications of the vehicle is selected at the time of vehicle shipment.

Notes:
• When the controller board is replaced, it is necessary to reset according to the vehicle specifications.
• OPTION SET does not enable/disable each option or control function itself, but matches the controller
and display with the options or functions on the vehicle.
4-34
Operating Procedure
1. Input the password on the GENERAL screen (See P4-16) to display the MASK MENU screen.
2. Press button (2) twice to display “3. OPTION SET”. Then press button (3) (enter) to change <OPT-1> screen.
3. Press button (3) to display the desired option items to be set on the screen.
4. The function of each button on the option set screen is as follows:
• Button (1) N → Y, W → L, 2 → 1
• Button (2) Y → N, L → W, 1 → 2
• Button (3) Enter (to the next item screen)
Note:
Press button (3) on OPT-15 OPTION SET screen to display the MASK MENU screen.
Button (1)
OPTION SET screen Button (2) OPT-4 screen
Button (3)
OPT-1 screen OPT-5 screen

OPT-2 screen *1 OPT-6 screen

Press button (3)
Press button (3)
*1: OPT-2 (H/M START) Hour meter starting method: Press button (1) for 2 seconds or more.
And press button (2) while keeping button (1) pressed.
4-35
To MASK MENU screen OPT-7 screen

OPT-15 screen OPT-8 screen Button (2)
Button (3)


Press button (3)

4-36
MATCHING
This screen is unused. (The setting does not affect the vehicle operation.)
WHEEL DIA
It is necessary to input the tire constant to the controller according to the tire radius, for optimizing the speedometer
reading. Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire
size is changed or the tires are worn excessively to a degree affecting the speedometer indication.
Operating Procedure
2. Press button (2) four times to display “5. WHEEL DIA”. Then press button (3) (enter), to display the CONSTANT
setting screen.
3. Press button (1) or (2) to select the desired tire constant. Then press button (3) to enter the value and return to
the MASK MENU screen.
4. The function of each button operation on the CONSTANT setting screen is as follows:
• Button (1): Decreases the tire constant value.
• Button (2): Increases the tire constant value.
• Button (3): Enters the value and returns to the MASK MENU screen.
Tire constant
Standard tire size and constant:
Tire constant Button (1) Button (2)
Constant 65
Tire size 7.00 - 12 -12
Button (3)
4-37
2TE18
MULTI-SCREEN DISPLAY
GENERAL
The multi-screen display indicates various types of vehicle information by switching the screen according to need.
Note:
Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button may be
damaged.
When stopped
When turning key switch to ON Upon error occurrence
During traveling Upon low controller temperature detection
No. Item No. Item
Parking brake ON indicator Multi-screen display area
2-speed traveling speed control function set indicator 2-speed traveling speed control function set button
Diagnosis ON indicator Hour meter selector button
Overheat warning indicator Power select button
Battery charge indicator Low temperature warning indicator

4-38
1. Parking brake ON indicator

This indicator blinks upon activation of the parking brake. If the operator fails to release the parking brake during
forward or reverse traveling, alarm sounds (beeps) to warn the operator.
2. 2-speed traveling speed control function set indicator
This indicator turns ON/OFF every time the set button is pressed. When the indicator turns on, the 2-speed trav-
eling speed control function is activated and the vehicle maximum speed is restricted as specified on the 2-
speed traveling speed setting screen.
3. Diagnosis ON indicator
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same time, the
corresponding error code is displayed and a buzzer sounds to warn the operator.
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to six error
codes are displayed with alternation at intervals of 2 seconds.
4. Overheat warning indicator

Overheat warning indicator If the temperature of the controller or drive motor rises beyond
the specified level, the overheat warning indicator blinks and a
alarm sounds to warn the operator.
When overheated, vehicle operation is restricted and the over-
heat section indication blinks.
Displayed message C/R : Main controller
DCR : Traveling controller
DM : Drive motor
Overheat section indication (abbreviation)
4-39
Restriction of vehicle operation during drive system overheated

C/R: Main controller overheat
Power selection mode Contents of restriction
H mode 1. “C/R” message is displayed and warning indicator blinks.
P mode 2. Beep sounds for 5 seconds.
S mode 3. Maximum speed is restricted up to the one of the half throttle.
DCR: Traveling controller overheat

Power selection mode Contents of restriction
H mode 1. “C/R” message is displayed and warning indicator blinks.
S mode 3. Maximum speed is restricted up to the one of the half throttle.
D/M Drive motor overheat

Power selection mode Secondary restriction

Preliminary restriction (When D/M temperature becomes higher
than the one for preliminary restriction.)
1. “D/M” message is displayed and warning 1. “D/M” message is displayed and warning
indicator blinks. indicator blinks.
H mode 2. Beep sounds for 5 seconds. 2. Beep sounds for 5 seconds.
3. Forces the power selection mode to 3. Restricts the maximum speed up to the
switch to S mode. one of half throttle.
1. “D/M” message is displayed and warning
indicator blinks.
S mode
3. Restricts the maximum speed up to the
one of half throttle.
5. Battery charge indicator

The battery charge level is indicated in ten stages.
(1) Low remaining battery charge warning
The battery charge indicator blinks when the remaining battery charge drops below the set level. When the
key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to warn the operator.
(2) Battery overdischarge warning
When the remaining battery charge drops further from the low remaining battery charge warning level to
the set level*, all segments of the battery charge indicator start blinking and a buzzer sounds to warn the
operator.
*: The level can be set using TUNING function of the mask function.
Low remaining battery charge warning Battery overdischarge warning
Number of segments corresponding to

the remaining battery charge. All segments blink.
4-40
6. Power select indicator

A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by pressing the
power select button on the GENERAL screen.
7. Multi-screen display area
Displays the date and time normally, and displays the speed during traveling. It is also used to set various func-
tions and for mask function data display.
8. 2-speed traveling speed control function set button
It is possible to turn 2-speed traveling speed control function ON/OFF by pressing this button.
9. Hour meter selector button
The content displayed by the multi-hour meter function can be changed by this button.
10. Power select button
This button selects S, P or H mode. The selected mode can be changed each time the power select button is
pressed on the GENERAL screen.
Press this button for 2 seconds or more to move to the user setting screen to set the level of each function.
11. Low temperature warning

When the temperature of the traveling controller is abnormally
low, the drive motor output is restricted and the part name of
abnormal low temperature blinks on the display.
Displayed Message:
COLD DCR: Traveling controller
Low temperature part name
SPECIFICATIONS
LCD Dot matrix + fixed display
Buttons Three buttons
Back light LED type that comes on when the key switch is turned to ON
4-41
DISPLAY INDICATION LIST

To be selected by user
General screen 2-speed traveling speed ON/OFF 2-speed traveling speed control function ON/OFF selection
Switching to hour meter display Checking traveling system operation time
Enter password Power select Power mode selection
Press Power select To be set by user
button for 2 seconds
or more 2-speed traveling speed level 2-speed traveling speed level setting
Speed alarm Traveling speed setting for overspeed alarm
Power control selection Fine adjustment of traveling control level (original mode setting)
Clock set Adjustment of indicated time
To be set by dealer or service person

DIAG MEMORY Checking past diagnosis codes stored in memory
I/O MONITOR1 Checking temperature and voltage of each functional part
I/O MONITOR2 Checking drive-related sensors
Mask function screen ANALYZER
I/O MONITOR3 Unused
I/O MONITOR4 Unused
ACTIVE TEST Forced ON/OFF test of cooling fan
No.1 Switchback regenerative brake torque adjustment
Accelerator pedal OFF-switchback regenerative brake torque
No.2
adjustment (high speed range)
No.3 Low remaining battery charge warning level setting
No.4 Battery charge indicator correction
No.5 Vehicle speed limiter setting
No.6 Unused
TUNING
No.7 Unused
No.8 Unused
No.9 Auto-OFF time function activation time setting
No.10 Unused
No.11 Regenerative brake torque adjustment
Accelerator pedal OFF-switchback regenerative brake torque
No.12
adjustment (low speed range)
DEMO MODE Enabling/disabling parking brake OFF alarm before hour meter start
H/M START Starting hour meter counting
Enabling/disabling level setting of the traveling power control and speed
P/C LOCK
alarm
DESTI Changing display for applicable destination
B LEVEL Unused
MPH Selecting vehicle traveling speed unit
OPTION C/CNT RES Unused
SET BATTERY Selecting battery characteristic
SHOU-TOKU Unused
AUTO P-OFF Activating/inactivating Auto-OFF function
PARKING ERR Enabling/disabling parking brake OFF alarm
TILT CONT Unused
SWG W-LOCK Unused
TILT F-LIM Unused
B-TYPE Battery type setting
M1 Unused
M2 Unused
M3 Unused
M4 Unused
MATCHING M5 Unused
M6 Unused
M7 Unused
M8 Unused
M9 Unused
WHEEL DIA WHEEL DIA Tire constant setting
4-42
ABBREVIATIONS DISPLAYED ON THE SCREEN

AOPT Analog input voltage SSD Drive motor rpm sensor
C/R Controller SWAC Accelerator switch
DM Drive motor TBD Traveling controller CPU board temperature
DSF Forward traveling switch TD Drive motor temperature
DSR Reverse traveling switch TEMP Temperature on CPU board
FAN Controller cooling fan THCD Main traveling circuit temperature
H/M Hour meter VB80 Battery voltage
LSB Brake switch VBBD Traveling controller main circuit power supply
LSD Seat switch VBKS Key start voltage
P/C Power control VBMB(M) Voltage after MB contactor (main input) voltage
POTA Accelerator potentiometer VBSOL Coil power supply voltage
SPD Main traveling speed
GENERAL FUNCTIONS
General functions can generally be used or seen by the user.
Speedometer
Status display function 2-speed traveling speed set indicator
Parking brake operation indicator
Power select
Level setting function 2-speed traveling speed level setting
Traveling power control level setting
Key ON hour meter
Drive motor operation hour meter
Odometer
Multi-hour meter function
Lap time meter
Trip meter
Calendar • clock
Battery overdischarge warning
Low remaining battery charge warning
Overheat warning
Parking brake OFF failure warning
Warning function Parking brake ON failure warning
Return to neutral warning
Low controller temperature warning
Overspeed alarm
Diagnosis display
4-43
GENERAL SCREEN
Operating Procedure

GENERAL screen
2-speed traveling speed control function
ON/OFF setting
Hour meter display selection
Power control selection

Press button (3) for
2 seconds or more. Button (3)
2-SPEED TRAVELING SPEED LEVEL SETTING screen
Press button (3)
OVERSPEED ALARM SETTING screen
Press button (3)
POWER CONTROL FUNCTION SELECTION screen
Press button (3)
Press button (3)
Upon returning to the general screen after moving through each screen, the power select mode is set to “S”. If nec-
essary, select the desired mode.
4-44
1. 2-speed traveling speed control function ON/OFF selection

2-speed traveling speed Press button (1) to turn 2-speed traveling speed control func-
control function set indicator Button (1) tion ON/OFF. Indicator is displayed, but unused.
2. Hour meter display selection (multi-hour meter function)

Press button (2) to select the hour meter display.
Function Description
A Key ON hour meter Indicates the total key ON time.
B Drive motor operation hour meter Drive motor operation time
C Odometer Total travel distance
D Lap time meter Lap time upon key ON
E Trip meter Trip distance

C
Press button (2)
Button (3)
Press button (2)
D
A
Press button (2)
Press button (2)

E
B
To GENERAL screen
• The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.
• Press button (3) on each screen to return to the GENERAL screen.
4-45
3. Power select selection (S → P → H)

Press button (3) on the GENERAL screen to change the travel
power select mode.
When all symbols are enclosed, control is performed in the
original mode set on the POWER CONTROL LEVEL SET-
TING screen.
H : This mode provides the fastest cycle time that optimizes
vehicle’s mobility.
P : This mode provides the best compatibility between the cy-
Button (3)
Power select cle time and mobility.
indicator S : This mode provides the longest operative time.
Blinks when setting 2-speed traveling 2-SPEED TRAVELING SPEED LEVEL SETTING
speed level SCREEN
Press button (3) on the GENERAL screen to display 2-SPEED
TRAVELING SPEED LEVEL SETTING screen.
2. Press button (2) to increase the traveling speed setting.
3. Press button (3) to display the next screen
Button (3) (OVERSPEED ALARM SETTING screen).
2-speed traveling speed control level
OVERSPEED ALARM SETTING SCREEN

Button (1) Button (2) The traveling speed level for the overspeed alarm is set on this
screen.
Press button (3) on the 2-SPEED TRAVELING SPEED LEVEL
SETTING screen to display the OVERSPEED ALARM SETTING
screen.
Button (3) 2. Press button (2) to increase the traveling speed setting.
Traveling speed setting
for overspeed alarm 3. Press button (3) to display the next screen (POWER CON-
TROL FUNCTION SELECTION screen).
4-46
POWER CONTROL FUNCTION SELECTION

Button (1) Button (2) SCREEN
The travel power control levels can be set independently using this
screen.
Press button (3) on the OVERSPEED ALARM SETTING screen to
display the POWER CONTROL FUNCTION SELECTION screen.
Button (3) LECTION screen, select “YES”, and then press button (3) to
Select “YES” and display the TRAVELING POWER CONTROL LEVEL SET-
press button (3)
TING screen.
TRAVELING POWER CONTROL (1) TRAVELING POWER CONTROL LEVEL SETTING screen
LEVEL SETTING screen
Press button (1) to select the lower level.
Press button (2) to select the higher level.
Press button (3) to display the next screen (CLOCK SET
FUNCTION SELECTION screen).
Press button (3)

To CLOCK SET FUNCTION SELECTION screen

LECTION screen, select “NO”, and then press button (3) to
display the next screen (CLOCK SET FUNCTION SELEC-
TION screen).
4-47
CLOCK SET FUNCTION SELECTION SCREEN

Year, month, day, day of week, 12/24-hour display, hour and minute can be set individually.
Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select “NO”, and press button (3), or
press button (3) on the POWER CONTROL LEVEL SETTING screen to display the CLOCK SET FUNCTION screen.

POWER CONTROL FUNCTION POWER CONTROL LEVEL
SELECTION screen Button (2) Button (2)
SETTING screen

Select “NO”
Press button (3)
Select “YES” and

press button (3)
Select “NO” and

press button (3)
Each press of button (3) will shift the selection

item in this order: month, day, ... and minute
Press button (3)
GENERAL screen (End of clock setting)
1. Press button (1) on the CLOCK SET FUNCTION SELECTION screen, select “YES”, and press button (3) to dis-
play the CLOCK SET screen.
(1) CLOCK SET screen
Press button (1) to decrease the selected (blinking) value.
Press button (2) to increase the selected (blinking) value.
Press button (3) to enter the selected (blinking) value, and proceed to the next item.
Press button (3) when “MINUTE” is selected on the CLOCK SET screen to display the next screen (GEN-
ERAL screen).
2. Press button (3) when “NO” is selected on the CLOCK SET FUNCTION SELECTION screen to display the next
screen (GENERAL screen).
4-48
DIAGNOSIS
1. When diagnosis is activated, the diagnosis ON indicator comes
Diagnosis code
on and blinks on the screen and a beep sounds to warn the op-
Diagnosis ON indicator
erator that some abnormality has occurred on the vehicle.
2. Also, up to three diagnosis error codes are displayed on the
screen. When the number of error codes is exceeds three, up
to six are displayed on alternating screens.
Abnormality detection time

(Key ON hour meter)
DIAGNOSIS CODE LIST

Displayed code : Code indicated on the display when an abnormality occurs in the vehicle
Memoried diagnosis code : Code indicated on the display when mask function (to be explained later) DIAG MEMORY
is in use
Memoried
diagnosis code
30-1 30-1 Drive controller low voltage
31-1 31-1 Drive controller voltage drop
32-1 32-1 Drive controller EEPROM abnormality
33-1 33-1 Main controller to drive controller communication abnormality
A0-1 Drive controller main circuit abnormal temperature rise

C/R
A0-4 A0-4 Drive controller main cooling fan abnormality
A0-5 A0-5 Main controller cooling fan abnormality
A1-1 A1-1 Main controller high voltage
A1-2 A1-2 Drive controller high voltage
A2-1 CPU board abnormal temperature rise

C/R
A2-2 Drive controller board abnormal temperature rise

DCR
A4 A4 Accelerator switch abnormality
AA-1 AA-1 CPU board temperature sensor abnormality
AA-2 AA-2 Drive controller board temperature sensor abnormality
AC AC Semiconductor switch abnormality
AD-1 AD-1 Drive controller to main controller communication abnormality
AD-2 AD-2 Drive controller to main controller communication abnormality

4-49
Memoried
diagnosis code
AF-1 AF-1
AF-2 AF-2
CPU abnormality
AF-3 AF-3
AF-4 AF-4
C1-1 C1-1 Drive controller current sensor offset abnormality
C1-2 C1-2 Drive controller overcurrent abnormality

D/M
C2-2 C2-2 Drive motor temperature sensor abnormality
C3-1 C3-1 Drive controller main circuit temperature sensor abnormality
C4-1 C4-1
C4-2 C4-2
Accelerator potentiometer abnormality
C4-3 C4-3
C4-4 C4-4
C7 C7 Direction switch abnormality
C8-1 C8-1 Drive motor rpm sensor abnormality

CB-1 CB-1 MB contactor abnormality
EE-1 EE-1
EE-2 EE-2 Multi-display to main controller communication abnormality
EE-3 EE-3
EF-1 EF-1
Main controller EEPROM abnormality
EF-2 EF-2
EF-3 EF-3 Main controller CPU abnormality
EF-4 EF-4 Main controller EEROM abnormality
F0-1, 2, 3 F0-1, 2, 3 PS contactor abnormality
F1-1, 2 F1-1, 2 Main controller to multi-display communication abnormality
FF FF D15V overcurrent
4-50
MASK FUNCTIONS
GENERAL
In addition to the functions described in the operator’s manual for use by general users, the multi-screen display pro-
vides the following mask functions for use by the service staff for vehicle maintenance and specification setting.
The mask functions are protected by password to prevent unintentional operation by users.
Mask Function List

When used
Function Description Board
Delivery Others
replacement
Displays the vehicle’s electrical

Upon vehicle
system operating status and reads
Analyzer — — abnormality
the error information detected by
detection
controllers.
Makes fine adjustment of traveling { As requested

Tuning —
and charge indicator functions. *2 by customer
Sets each vehicle option and other {

Specification setting — —
specifications. *1 *2 *3
Each control function enable/ Enables or disables each control {

— —
disable function. *2 *3
Option Set {
Hour meter start Starts the hour meter count. { —
*3
Upon new
Demo mode
Enables or disables the demo mode — — vehicle
(parking brake OFF warning)
demonstration
Matching Unused — — —
Makes the speedometer reading {

Tire constant set — —
appropriate. *2
*1 : This is for matching the controller and display control to the options or functions installed on the vehicle and not
for enabling/disabling each option or control function itself.
*2 : Board ..................... Main controller
*3 : Board ..................... Multi-screen display control board
Preparation for the MASK MENU Screen

Caution:
Before moving from the GENERAL screen to a MASK MENU
screen, be sure to jack up the vehicle until the drive wheel
leaves the floor surface, and stabilize the vehicle by support-
ing the frame with wooden blocks.
4-51
PASSWORD
Note on Password Input
If a mistake is made part of the way through, turn the key switch to OFF and begin procedures below again. If the
MASK MENU screen does not appear after several attempts, the system may be faulty.
Password Input Procedure
Procedure Operation Vehicle operation
1 Press buttons (1) and (2) at the same time. A short beep sounds.
3 Press button (2). A short beep sound.
Short beeps sound.

Press buttons (2) and (3) at the same time and hold for 2
4 After displaying the version screen for 3 seconds, the
seconds or more. (End of password input)
MASK MENU screen appears automatically.

GENERAL screen Button (2)
Within 10 seconds, press buttons Button (3)

Press buttons (1) and (2) (2) and (3) at the same time for 2
at the same time. seconds or more.
Button (1) VERSION screen
Press button (1)

within 10 seconds.
Button (2) MASK MENU screen
Press button (2)

within 10 seconds.
Note:
The GENERAL screen is displayed when the key switch is set to OFF once on each mask function screen.
4-52
Input the password on the GENERAL screen. OPERATION ON MASK MENU SCREEN
Button (1)
ANALYZER MENU screen
1. Input the password (see the previous page) on the GENERAL
screen to display the MASK MENU screen.
2. Press button (1) or (2) to select the desired menu item, and
press button (3) (enter) to display the menu or setting screen
for each function.
Press button (1) or (2) Button (3)
to switch screen (1) ANALYZER MENU screen
TUNING screen This screen displays the vehicle’s electrical system oper-
ating status and the error code detected by the controller.
Note:
Display of ANALYZER MENU screen does not prohib-
it the vehicle’s ordinary operation.
(2) TUNING screen
Performs fine adjustment of traveling control, etc.
to switch screen
OPTION SET screen

(3) OPTION SET screen
Matches the controller or display control according to the
set option or control.

to switch screen
MATCHING screen
(4) MATCHING screen
This screen is unused.

to switch screen
WHEEL DIA screen
(5) WHEEL DIA screen
Rewrites the tire information in the controller for correct-
ing the speed indication and trip meter.

to switch screen
END screen
(6) END screen
Press button (3) on this screen to display the GENERAL
screen.
Press button (2) on this screen to display the ANALYZER
MENU screen.
Turn the key switch to OFF, and then ON again on this
screen to display the GENERAL screen.
Press button (3)
To GENERAL screen
4-53
ANALYZER
GENERAL
1. The analyzer supports inspection and troubleshooting of the control system using the communication function
between the traveling controller and the display. Quick, easy servicing is made possible by the use of the ana-
lyzer.
2. Setting the display into the ANALYZER MENU screen makes it possible to inspect and detect abnormality in
functions of the operating system and sensors, such as main traveling circuits and the accelerator.
3. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes detected in the electrical system in the past. The diagnosis mem-
ory function displays these error codes.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/out monitor function (I/O MONITOR)
This function displays the analog input value from each sensor in the traveling system. Monitor this indica-
tion to judge the quality of the input/output signal from each circuit or sensor.
(a) I/O MONITOR1
Displays the temperature of each electrical functional part and analog input voltage values detected
by the controller at each terminal.
(b) I/O MONITOR2
Displays the ON/OFF states of switches related to traveling control and the analog input voltage values
from related sensors.
(c) I/O MONITOR3
This is unused.
(d) I/O MONITOR4
This is unused.
(3) Active test function (ACTIVE TEST)
The controller outputs an operation signal (ON or OFF signal) to the selected part in order to permit oper-
ation check.
4. When an error in the electrical system is detected while the I/O

monitor or ACTIVE TEST screen is being displayed, the alarm
Diagnosis ON indicator Error code sounds and an error code is displayed with the diagnosis ON
indicator in the upper right portion of the multi-screen display.
4-54
ANALYZER MENU Screen List

Description
ANALYZER MENU screen Meaning
1st row 2nd row
1. DIAG MEMORY DIAG-1 to Error codes are displayed together with Refer to the Diagnosis Error Code List.
• Diagnosis error code display DIAG-10 detection time. (See P4-48)
I/O 1-1 THCD: +25 Main drive circuit temperature: °C
I/O 1-2 — Unused
I/O 1-3 TD: +25 Drive motor temperature: °C
I/O 1-4 — Unused
Traveling controller CPU board surface
I/O 1-5 TBD: +25.0
temperature: °C
I/O 1-6 — Unused
2. I/O MONITOR1
• Voltage I/O 1-7 TEMP: +25.0 CPU board surface temperature: °C
• Temperature I/O 1-8 VB80: 80 Battery voltage: V
I/O 1-9 VBKS: 84.0 Key start voltage: V
I/O 1-10 VBSOL: 84 Solenoid voltage: V
I/O 1-11 VBMB (M) Main battery voltage input: V
I/O 1-12 — Unused
I/O 1-13 VBBD: 84 Traveling controller DC_BUS voltage: V
I/O 1-14 — Unused
POTA: 0.70 Accelerator potentiometer voltage: V
I/O 2-1
SWAC: 0 Accelerator switch: 0 (OFF), 1 (ON)
DSF: 0 Forward traveling switch: 0 (OFF), 1 (ON)
I/O 2-2
DSR: 0 Reverse traveling switch: 0 (OFF), 1 (ON)
LSB: 1 Brake switch: 0 (OFF), 1 (ON)
3. I/O MONITOR2 I/O 2-3
LSD: 1 Seat switch: 0 (OFF), 1 (ON)
• Traveling system
I/O 2-4 SSD: 1 → 00 Drive motor rpm sensor 1: Number of pulses
I/O 2-5 SPD: M10.0 Main traveling speed input: km/h or mph
I/O 2-6 — Unused
I/O 2-7 — Unused
4. I/O MONITOR3 I/O 3-1 LSI: 000 Unused

• Spare I/O 3-2 LSDO: 0 Unused
I/O 4-1 — Unused
I/O 4-2 — Unused
5. I/O MONITOR4 I/O 4-3 — Unused

• Others I/O 4-4 — Unused
I/O 4-5 AOPT: 2.50 Unused
I/O 4-6 LSOPT1: 0 Unused
Cooling fan output
ACT-1 FAN: ON/OFF (100)
Cooling fan voltage
ACT-2 -: ON/OFF (0) Unused
6. ACTIVE TEST
• Operation test ACT-3 -: ON/OFF (0) Unused
7. END Press power select button to display the MASK MENU screen.
Notes:
• It is impossible to move directly from one function screen to another. Return to the ANALYZER MENU
screen once to select other function screens.
• Values shown on the table above are not standard ones, but only examples.
4-55
Operating Procedure
1. Input the password (See P4-51) on the GENERAL screen to display the MASK MENU screen.
2. Check that “1. ANALYZER” is displayed on the mask menu screen and press button (3) (enter) to display the
3. Press button (1) or button (2) to select the desired menu item and press button (3) (enter) to display the selected
screen.
• Button (1) To the previous menu item screen
• Button (2) To the next menu item screen
• Button (3) Enter (to the selected menu item screen)
Note:
Press button (3) on the “7.END” screen to display the MASK MENU screen.
Press button (3)

Button (1)
ANALYZER MENU screen Button (2) END screen
Button (3)
Press button (3) to switch screen.
DIAG MEMORY screen ACTIVE TEST screen
Press button
(1) or (2)
to switch screen.

Press button
(1) or (2)
to switch screen.
4-56
DIAG MEMORY
The controller stores up to 10 of the most recent errors. The DIAG MEMORY screen displays these diagnosis error
codes together with their detection time (as key ON hour meter reading).
The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to DIAG-10.
Note:
As for diagnosis codes and their explanations, see pages 4-48 to 4-49.

ANALYZER MENU screen Button (2) 1. Display the ANALYZER MENU screen.
2. Check that “1. DIAG MEMORY” is displayed and press button
(3) (enter). Past diagnosis codes are displayed sequentially
starting with the newest one.
3. The function of each button on the 1. DIAG MEMORY function
screen is as follows.
Button (3) • Button (1) → Unused
Press button (3)
• Button (3) → Displays past diagnosis codes.
Press button (3)
Press button (3)

Note:
When no error codes are displayed on the screen and the
hour meter time is “0.0h”, it indicates that no error codes
are stored in the memory.
No error occurrence
Press button (3)
......
is indicated.
Notes:
• Press button (3) on the DIAG-10 screen to display the
• It is impossible to move directly from one function to
another. Return to the ANALYZER MENU screen once
to select other function screens.
Press button (3)

4-57

There are abnormalities that are not stored in the diagnosis memory even if the controller detects them.


No display
key switch to OFF).

No display
Input/Output Monitor Function

Current detected
I/O MONITOR No. abnormality error code (I/O MONITOR)
• I/O MONITOR is useful function to display input values from
sensors of traveling related systems. This function helps to
judge whether the circuits or sensors work properly.
• If abnormality which is currently present is detected, the error
cord, which is corresponding to the abnormality, is displayed.
Operating item
4-58
I/O MONITOR1
This function displays the temperature of each electrical functional part and the voltage at the respective terminal.
Operating Procedure
2. Press button (2) once.
Notes:
Button (1)
Button (3)
Press button (3)

THCD: Main drive circuit temperature (°C)
Temperature of the main drive circuit element is dis-
played.
Press button (3)
Unused
Press button (3)

TD: Drive motor temperature (°C)
Temperature of the drive motor is displayed.
Press button (3)

To I/O1-4 screen
4-59
(4) I/O1-4 screen

I/O 1-4 screen Button (1) Button (2)
Unused

TBD: Traveling controller CPU board surface temperature
(°C)
The surface temperature of the traveling controller CPU
board is displayed.
Press button (3) The temperature at the time of measurement is displayed.
Unused
Press button (3)

TEMP: CPU board surface temperature (°C)
The surface temperature of the main controller CPU
board is displayed.
Press button (3)
VB80: Battery voltage (V)
Battery voltage
Press button (3)

VBKS: Key start voltage (V)
Power source voltage to control the traveling controller
Press button (3)

To I/O1-10 screen
4-60
Button (1) Button (2) (10) I/O1-10 screen

I/O 1-10 screen
VBSOL: Power source voltage for the solenoid (V)
Power source voltage for the solenoid

VBMB (M): Main battery voltage input (V)
Main controller input voltage after the MB contactor
Press button (3)

Unused
Press button (3)

VBBD: Voltage of the traveling controller DC_BUS (V)
Power source voltage for the main circuit of the traveling
controller
Press button (3)

Unused
Press button (3)

4-61
I/O MONITOR2
This function displays the ON/OFF status of switches and analog input voltage values from sensors related to trav-
eling control.
Operating Procedure
2. Press button (2) twice.
• Press button (3) → Displays I/O2-1 to I/O2-7 screens sequentially
Notes:
Button (2) POTA: Accelerator potentiometer voltage (V)
(a) When the accelerator pedal is not depressed
(SWAC: OFF)
(b) Upon full accelerator pedal depression
Button (3)
Press button (3) Accelerator voltage difference:
(b) – (a) = 1.4 V or more
I/O 2-1 screen
SWAC: Accelerator switch inspection
When the accelerator pedal is not depressed:
0 → OFF
When the accelerator pedal is depressed:
1 → ON
Depress the accelerator pedal to check the switch ON/
Press button (3) OFF switching operation.

Direction switch inspection
DSF: Forward traveling switch,
DSR: Reverse traveling switch
1 → ON 0 → OFF
Indication
Operation DSF DSR
Press button (3)
Forward traveling 1 0
To I/O2-3 screen Neutral 0 0
Reverse traveling 0 1
Operate the direction lever to check the switch ON/OFF

4-62
(3) I/O2-3 screen

Button (1) Button (2) LSB: Brake switch inspection
I/O 2-3 screen
When the brake pedal is not operated: 1 → ON
When the brake pedal is depressed: 0 → OFF
Depress the brake pedal to check the switch ON/OFF
LSD: Seat switch check
Button (3) When the operator is on the seat: 1 → ON
When the operator leaves the seat: 0 → OFF
Press button (3)
Sit on and leave the operator’s seat to check the switch
ON/OFF switching operation.
SSD: Drive motor rpm
Inspect the rpm sensor while the vehicle is traveling actu-
ally. The number of the drive motor revolution increases
with the traveling speed.
Press button (3)

SPDM: Main traveling speed (km/h or mph)
Check traveling speed by depressing the accelerator ped-
al and traveling the vehicle actually. Check that the dis-
played traveling speed increases almost at the same rate
of the actual speed increase.
Press button (3)

Unused
Press button (3)

Unused
Press button (3)

4-63
I/O MONITOR3
Unused
Operating Procedure
2. Press button (2) three times.
4. Functions of each buttons on the I/O MONITOR3 screen is as follows:
• Button (3) → Displays I/O3-1 to I/O3-2 screens sequentially.
Notes:
• It is impassible to move directly from one function screen to another. Return to the ANALYZER
Button (2) Unused
(2) I/O3-2 screen
Unused
Button (3)
Press button (3)
I/O 3-1 screen
Press button (3)
I/O 3-2 screen
Press button (3)

4-64
I/O MONITOR4
Unused
Operating Procedure
2. Press button (2) four times.
Notes:
• Press button (3) on the I/O4-6 screen to display the ANALYZER MENU screen
Button (1)
(1) I/O4-1 screen
Button (2) Unused
(2) I/O4-2 screen
Unused
(3) I/O4-3 screen
Unused
(4) I/O4-4 screen
Button (3) Unused
Press button (3)
(5) I/O4-5 screen
Press button (3) (6) I/O4-6 screen
I/O 4-2 screen
Unused
Press button (3)

I/O 4-3 screen
Press button (3)

I/O 4-4 screen
Press button (3)
I/O 4-5 screen
Press button (3)

I/O 4-6 screen
Press button (3)

4-65
ACTIVE TEST
This function outputs ON/OFF signals to controller cooling fan and compares controller input signals with those sig-
nals. The screens from ACT-2 to ACT-5 are not used.
Operating Procedure
2. Press button (2) five times.
3. Check that “6. ACTIVE TEST” is displayed and press button (3) (enter). ACT-1 to ACT-5 are displayed.
4. Functions of each button on ACTIVE TEST screen is as follows:
• Button (1) → Forced ON
• Button (2) → Forced OFF
• Button (3) → Displays ACT-1 and ACT-5 sequentially
Notes:
• Press button (3) on ACT-5 screen to display the ANALYZER MENU screen.
(1) ACT-1 screen
Button (1)
Button (2) FAN: Controller cooling fan
ANALYZER MENU screen (1) → Fan ON
(2) → Fan OFF
Check the fan operation by the operating sound and
the display item.
Button (3)
Press button (3) Press button (1) to select ON.
Fan rotates and fan voltage is displayed.
ACT-2 screen Press button (2) to select OFF.
Fan stops rotating and fan voltage is displayed.
Press button (3)
(2) ACT-2 screen
ACT-3 screen Unused
Press button (3) (3) ACT-3 screen

Unused
ACT-4 screen
(4) ACT-4 screen
Press button (3) Unused
(5) ACT-5 screen
ACT-5 screen
Unused
Press button (3)

4-66
TUNING
GENERAL
When the user requests to limit the maximum speed or weaken the regenerative braking force, each setting can be
performed on the TUNING screen.
12 tuning items are prepared, including spares.
Tuning item list
Tuning Level (z: Default setting position)

Item
No. 1 2 3 4 5 6 7 8
Switchback regenerative braking torque:

Changes the regenerative braking torque only z
1 Weak Strong
on switchback described at the colum of
tuning No. 2 below.
Accelerator pedal released and switchback

regenerative braking torque (high speed
z
range):
2 None Weak Strong
Changes maximum regenerative braking
torque when accelerator pedal is released and
switchback operation is performed
Battery overdischarge warning set level:

Changes the activation timings of low Early
3 Late Disabled
remaining battery charge warning and z
battery overdischarge warning
Battery charge indicator adjustment:

Slow z Fast
4 Adjust decreasing rate of battery charge
decrease decrease
indicator
Traveling speed limiter: Low High None

5
Adjusting the maximum traveling speed speed speed z
6 Spare
7 Spare
8 Spare
Auto-OFF function activating time:

Short Long
9 Setting auto-off function activating time when
z
available
10 Spare
Regenerative braking torque: z

11 Weak Strong
Changes the regenerative braking torque
Accelerator pedal released and switchback

regenerative braking torque (low speed
range): z
12 Weak Strong
Changes minimum regenerative braking
torque when accelerator pedal is released and
switchback operation is performed
4-67
Operating Procedure
Button (1) Button (2) 1. Input the password on the GENERAL screen (See P4-51) to
TUNING screen
display the MASK MENU screen.
2. Press button (2) once to display “2. TUNING”. Then press but-
ton (3) (enter) to display the TUNING setting screen.
3. Press button (3) to display the tuning item desired to be set.
4. Function of each button on the tuning function setting screen
Button (3)
Press button (3) is as follows:
• Button (1) → Tuning level down
• Button (2) → Tuning level up
• Button (3) → Enter (to the next item screen)
Note:
Press button (3) on the tuning No.12 screen to display the
TUNING MENU screen.
Press button (3)
Press button (3) to

change the display
•••
from No. 1 to No. 12

sequentially.
Press button (3)

To TUNING MENU screen
4-68
Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels
(Tuning No.3)
The default setting is level 7.
How to read the figure:

Example: When selecting the level 5
When the battery discharge level is between 70% and 90%, the battery remaining charge indicator starts to blink,
and beep sound occurs 5 times after key switch ON.
When the battery discharge level exceeds 90%, all 10 segments blink and beep sound is continued while traveling
operation.
See page 4-39 about battery charge indicator.
Caution:
When selecting the level 8, the overdischarge alarm does not function. Be careful not to overdischarge the
battery with frequent checking of the battery charge indicator.
4-69
OPTION SET
OPTION SET Menu List
No. Indication Description Selection (symbol)
Enables/disables the parking brake OFF

OPT-1 DEMO MODE Enable (Y) Disable (N)
alarm.
OPT-2 H/M START Starts hour meter count. Count (Y) Not count (N)
Enables/disables level setting for traveling

OPT-3 P/C LOCK Lock (Y) Unlock (N)
power control and overspeed alarm.
Sets the data according to the destination.

OPT-4 DESTI* Japan (J) International (I)
Changes the pattern of display.
OPT-5 B LEVEL Unused (select N) — (Y) — (N)
OPT-6 MPH* Changes the traveling speed unit. Set to mph (Y) Set to km/h (N)
OPT-7 C/CNT RES Unused (select N) — (Y) — (N)
Adjusts the charge indicator calculation

OPT-8 BATTERY* Characteristic (A) Characteristic (B)
constant.
OPT-9 SHOU-TOKU Unused (select N) — (Y) — (N)
Enables/disables the Auto Power-OFF

OPT-10 AUTO P-OFF Enable (Y) Disable (N)
function.
Enables/disables the Parking brake OFF

OPT-11 PARKING ERR Enable (Y) Disable (N)
alarm.
OPT-12 TILT CONT Unused (select Y) — (Y) — (N)
OPT-13 SWG W-LOCK Unused (select Y) — (Y) — (N)
OPT-14 TILT F-LIM Unused (select Y) — (Y) — (N)
OPT-15 B-TYPE Battery type Type 1 (1) Type 2 (2)
* : The specifications of the vehicle is selected at the time of vehicle shipment.

Notes:
• When the main controller CPU board is replaced, it is necessary to reset according to the vehicle spec-
ifications.
• OPTION SET does not enable/disable each option or control function itself, but matches the controller
and display with the options or functions on the vehicle.
4-70
Operating Procedure
2. Press button (2) twice to display “3. OPTION SET”. Then press button (3) (enter) to change <OPT-1> screen.
3. Press button (3) to display the desired option items to be set on the screen.
4. The function of each button on the option set screen is as follows:
• Button (1) N → Y, B → A, I → J, 2 → 1
• Button (2) Y → N, A → B, J → I, 1 → 2
• Button (3) Enter (to the next item screen)
Note:
Press button (3) on OPT-15 OPTION SET screen to display the MASK MENU screen.

OPTION SET screen OPT-4 screen
Button (3)

OPT-2 screen *1 OPT-6 screen

Press button (3)
Press button (3)
*1: OPT-2 (H/M START) Hour meter starting method: Press button (1) for 2 seconds or more.
And press button (2) while keeping button (1) pressed.
4-71
To MASK MENU screen OPT-7 screen

OPT-15 screen OPT-8 screen Button (2)
Button (3)


Press button (3)

4-72
MATCHING
This screen is unused. (The setting does not affect the vehicle operation.)
WHEEL DIA
It is necessary to input the tire constant to the controller according to the tire radius, for optimizing the speedometer
reading. Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire
size is changed or the tires are worn excessively to a degree affecting the speedometer indication.
Operating Procedure
2. Press button (2) four times to display “5. WHEEL DIA”. Then press button (3) (enter), to display the CONSTANT
setting screen.
3. Press button (1) or (2) to select the desired tire constant. Then press button (3) to enter the value and return to
the MASK MENU screen.
4. The function of each button operation on the CONSTANT setting screen is as follows:
• Button (1): Decreases the tire constant value.
• Button (2): Increases the tire constant value.
• Button (3): Enters the value and returns to the MASK MENU screen.
Tire constant
Standard tire size and constant:
Tire constant Button (1) Button (2)
Constant 89
Tire size 28 × 8 - 15 - 12PR
Button (3)
5-1
ELECTRICAL SYSTEM TROUBLESHOOTING

Page Page
5
BEFORE 2TE18 5
TROUBLESHOOTING ......... 5-2
SST SETTING METHOD...... 5-49 5
CONNECTOR HANDLING.......... 5-2
CPU BOARD CONNECTOR
WIRE HARNESS AND DIAGRAM ............................... 5-51 5
CONNECTOR INSPECTION
PROCEDURE............................ 5-2 MAIN CONTROLLER
CONNECTORS AND MAIN
5
HOW TO READ COMPONENTS ...................... 5-52
TROUBLESHOOTING
5
TRAVELING CONTROLLER
FLOWCHART....................... 5-4 CONNECTORS AND MAIN
COMPONENTS ...................... 5-53
5
EXPLANATION OF BOXES ....... 5-4
TROUBLESHOOTING CONTACTOR PANEL 5
ACCORDING TO CONNECTORS AND MAIN
ERROR CODE .......................... 5-5 COMPONENTS ...................... 5-54 5
PS CONTACTOR CONNECTORS
2TE15 AND MAIN COMPONENTS ... 5-55 5
SST SETTING METHOD........ 5-5 ERROR CODE LIST............. 5-56 5
CPU BOARD CONNECTOR WHEN A DIAGNOSIS ERROR
DIAGRAM ................................. 5-9 CODE IS DISPLAYED ....... 5-58 5
DC/MD BOARD CONNECTOR
DIAGRAM ............................... 5-10
WHEN NO DIAGNOSIS ERROR 5
CODE IS DISPLAYED ....... 5-99
TRAVELING CONTROLLER 5
CONNECTORS, TERMINALS
AND COMPONENTS .............. 5-11 5
ERROR CODE LIST............. 5-12
5
WHEN A DIAGNOSIS ERROR
CODE IS DISPLAYED ....... 5-14 5
WHEN NO DIAGNOSIS ERROR
CODE IS DISPLAYED ....... 5-41 5
5
5-2
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Be sure to disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. Do not pull the harness but hold the unlocked connector por-
tion to disconnect the connector.
For connection, push the connector fully in until it is locked se-
curely.
3. When applying a tester probe to the connector, bring it into

contact from the rear (harness) side of the connector.
4. If insertion from the rear side is impossible as in the case of a
waterproof connector, carefully bring each tester probe into
contact with respective connector terminal so as not to dam-
age it.
5. Do not touch each connector terminal directly with a hand.
6. When bringing a tester probe into contact with a live terminal,
be very careful to avoid careless contact with each tester
probe.
WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE
When any trouble occurs, always first inspect the related electrical
circuit connector and wire harness according to the following pro-
cedure.
Continuity Inspection
1. Disconnect the connectors at both ends of the relevant har-
ness.
2. Measure the resistance between respective connector termi-
nals at both ends.
Standard: 10 Ω or less
Note:
Measure the resistance while slightly shaking the wire har-
ness vertically and horizontally.
Reference:
If there is an open circuit, its place may be at a connector por-
tion. It is rare that an open circuit occurs on halfway of a wiring
itself. Be especially careful when inspecting the sensor con-
nector.
5-3
Short-circuit Inspection
1. Disconnect the connectors at both ends of the relevant har-
ness.
2. Measure the resistance between the respective connector ter-
minal and N1. Conduct inspection at the connectors at both
ends.
5
Note:
5
Measure the resistance while slightly shaking the wire
harness vertically and horizontally. 5
3. Measure the resistance between corresponding terminals in
the same connector. Conduct inspection at the connectors at
both ends.
5
Standard: 1 MΩ or more 5
Note:
Short circuit may be caused by cable pinched by the body or
faulty clamping. 5
5
Visual Check and Contact Pressure Inspection 5
• Disconnect the connectors at both ends of the respective har-
ness.
• Visually check the connector terminals for no rusting or foreign
5
matter trapping.
• Check the caulked portion for no loosening or damage, and 5
pull the wire harness lightly to check for no disconnection.
5
5
• Prepare the same male terminal as the connector terminal. In-
sert it to the female terminal to check for the extracting force.
The terminal where the extracting force is smaller than those
5
of other terminals may involve defective contact.
Note:
5
If there is any rust generation or foreign matter trapping be-
tween the male and female terminals, disconnecting and re-
connecting the connector may cause returning to the normal
5
state because of the change in the contact status. In such a
case, repeat disconnection and reconnection several times. If
the defect is detected even once, the terminal contact may be
5
defective.
5
5
5
5-4
HOW TO READ TROUBLESHOOTING FLOWCHART

Turn the key switch OFF once and ON again.
Is error 31-1 displayed?
ANL : I/O MONITOR 1 I/O1-13 48 V or above

VBBD: Traveling controller DC_BUS voltage • Traveling controller defect
check
Less than 48 V Go to the next step

depending on the result.
Inspection 1
Traveling controller input P3 voltage check 48 V or above
P3 • Traveling controller defect
Voltage measurement
Tester probe N1
Less than 48 V
Tester probe
Reference:
Connector No. Pin No. Potential No.
CN101-2 (46)
CN103-12 (GND)
EXPLANATION OF BOXES
A oblong box indicates the operation for inspection or check.
A single-line box indicates measurement with a circuit tester or other

ordinary operation step.
A double-line box indicates possibility of inspection using the mask

function.
5-5
TROUBLESHOOTING ACCORDING TO ERROR CODE

1. Error code appearance and disappearance may occur depending on the connector contact state.
Before starting troubleshooting, therefore, connect the battery plug and turn the key switch ON to see if the error
code reappears.
2.
If no error code appears, check the connection status of the related connector.
Once an error occurs, the error code is stored in the controller. If an error code appears temporarily but disap-
5
3.
pears later due to faulty connector contact, the error code is stored.
Troubleshooting in this manual is described starting from the point where the error code is displayed.
5
5
2TE15
SST SETTING METHOD 5
Use the SSTs for quick, accurate troubleshooting of the 2TE15 electrical system.
Incorrect connection will result in incorrect check. Be very careful since board damage may also be caused by incor-
5
rect connection.
SST No. Part number Part name

5
SST1 09231-13130-71 Cooling fan check harness (for CN105) 5
SST2 09232-13130-71 Shorting harness (for CN52 and CN57) 5
SST3 09233-13130-71 TMD drive signal check harness 1 (for CN111, CN112)
5
SST4 09234-13130-71 TMD drive signal check harness 2 (for CN107)
5
SST8 09238-13130-71 Accelerator potentiometer check harness (for CN25)
SST9 09239-13130-71 Sub harness for connection with SST1 (for CN106)
5
Caution:
5
• Disconnect the battery plug before installing or removing each SST. If the battery plug is kept connected,
board damage may occur.
• Capacitor CO may fail to fully discharge if any SST is connected.
5
5
Measure the voltage between P4 and N1 before connecting or disconnecting each board connector. If
not discharging, fully make the CO discharge before starting the troubleshooting.
5
5
5
5
5
5-6
1. SST1 and SST9 connection method

SST1 is used for two kinds of inspections.
(1) Remove CN105, 106 and 107 from the CPU board.
(2) Connect the SST1 main connector to CN105.
(3) Connect SST9 connector to CN106 of the CPU board.
(4) Connect SST1 3-pin connector to SST9 3-pin connector.
<For fan signal inspection> (In case of error A0-4 or A0-5)
(5) Connect connector (A) and connector , and inspect the fan ON/OFF signal by “ACTIVE TEST.”
(6) Select the controller-cooling fan FAND or FANP by the switch on the display.
<For DC/MD board inspection> (In case of error C0-3)
(7) Connect connectors and , and inspect power ON/OFF by “ACTIVE TEST.”
(8) Select the controller-cooling fan FAND or FANP by the switch on the CPU board.
SST1 connector (connect with CN105)

Not connected SST9
9 2 7 1 8 4 3 6 5 8 7
1 3
2 4
5
9
6
Connect with SST9

CN105 CN106

SST2 and SST8 are shorting harnesses for short-circuiting between related connector pins. Carefully connect
them since connection with wrong (number) pins may cause board damage.
5-7
3. SST3 connection method

(1) Jack up rear wheels.
(2) Disconnect drive motor cables (P7, P8 and P9).
(3) Disconnect CN111 (for drive circuit) and connect SST3.
CN111
CN111
(for drive circuit)
SST3
For CN112
CN112
LED
(reserved for drive circuit)
(red or green)
(4) Move the direction lever to either forward or reverse position.

All LEDs are lit.
(5) Depress the accelerator pedal.
As the accelerator pedal is depressed, six LEDs repeat blinking. One LED pair of red and green corre-
sponds to the transistor operation in one phase. Six LEDs in total correspond to transistor operations in
three phases. The blinking speed varies with the degree of accelerator pedal depression.
When any LED does not blink, no signal may be output from the CPU board or the DC/MD board. The blink-
ing order of three phases are opposite when moving the direction lever to another position.
5-8

The drive motor drive instruction signal is inspected using the spare circuit of the DC/MD board. If any abnor-
mality is found in the inspection using SST3, use SST4 to check the instruction signal from the CPU board to
the DC/MD board or the drive signal from the DC/MD board to the TMD.
(1) Jack up the rear wheels.
(2) Disconnect the drive motor cable (from P7, P8 and P9).
(3) Connect SST3 to CN112 connector of the DC/MD board.
(4) Disconnect the CN106 and CN107 connectors of the CPU board, and the CN110 and CN109 connectors
of the DC/MD board.
(5) Connect the 10-pin connector of SST4 to CN107 of the CPU board, and connect the 11-pin connector of
SST4 to CN109 of the DC/MD board.
(6) With the battery plug connected and key switch ON, operate the direction lever and depress the accelerator
pedal to check the LED blinking status.
CPU board
Not connected
CN107 SST4
CN107 CN106
CN106 CN105
CN112 CN105
Not connected
CN109 CN110
Not connected
CN109
SST3
CN108
CN108
Connect the vehicle
CN110 side connectors to
DC/MD board
CN105 and CN108.
5-9
CPU BOARD CONNECTOR DIAGRAM
CN107
CN101
CN106
CN102
CN103
CN105
CN104
CN101 CN102 CN103 CN104
10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 11 10 9 8 7 7 6 5 13 12 11 10 9
26 25 24 23 22 21 20 19 18 17 17 16 15 14 13 12 11 10 9 8 21 20 19 18 17 16 15 14
34 33 32 31 30 29 28 27 22 21 20 19 18 16 15 14 13 12 28 27 26 25 24 23 22
CN101 CN102 CN103 CN104

No. P J No. P J No. P J No. P J
1 45 DSF 1 64 SWAC 1 — — 1 N2 N2C
2 46 DSR 2 52 POTA 2 — — 2 54 CSBATT
3 65 LSB 3 — — 3 — — 3 — —
4 66 LSPB 4 — — 4 43 VBKY 4 18 B80V
5 67 LSD 5 — — 5 5 SOLT+ 5 75 CSD+
6 — — 6 81 SSD1 6 6 SOLT– 6 — —
7 — — 7 82 SSD2 7 41 VBBT 7 71 CSDA
8 — — 8 — — 8 — — 8 72 CSDB
9 — — 9 — — 9 — — 9 13 C20V
10 — — 10 86 TD+ 10 16 D15V 10 N2 N2
11 — — 11 87 TD– 11 — — 11 2 MB–
12 — — 12 — — 12 14 GNDD 12 P4 VBP4
13 — — 13 — — 13 144 SMTDK 13 1 MB+
14 — — 14 53 POTA+ 14 143 SDTMK 14 44 VBMB
15 — — 15 — — 15 142 SDTMA 15 41 B48V
16 — — 16 — — 16 141 SMTDA 16 16 D15V
17 — — 17 — — 17 15 C15V
18 — — 18 80 SSD+ CN 106 18 — —
19 — — 19 83 SSD– 19 — —
20 — — 20 — — 1110 9 8 7 6 5 4 3 2 1 20 78 THCD
21 — — 21 — — No. P J 21 77 THC+
22 — — 22 51 POT– 1 33 — 22 44 VBMB
23 — — 2 27 — 23 14 GNDD
24 — — CN 105 3 28 — 24 14 GNDC
25 — — 4 29 — 25 — —
26 51 LS– 1413121110 9 8 7 6 5 4 3 2 1 5 30 — 26 — —
27 — — 6 31 — 27 76 CSD–
No. P J
28 — — 7 32 — 28 — —
1 38 FAN+
29 — — 8 33 —
2 38 FAN+
30 — — 9 35 —
3 36 FANCD
31 — — 10 — —
4 37 FANCP
32 — — 11 — —
5 — —
33 — —
6 39 DDC
34 — —
7 40 CN 107
8 94 CKFAND+
10 9 8 7 6 5 4 3 2 1
9 97 CKFAND–
10 98 CKFANP+ No. P J
11 99 CKFANP– 1 26 TMDU+
12 — — 2 20 TMDAU–
13 — — 3 21 TMDBU–
14 — — 4 22 TMDCU–
5 23 TMDAD–
6 24 TMDBD–
7 25 TMDCD–
8 26 TMDD+
9 34 CKDV
10 — —
5-10
DC/MD BOARD CONNECTOR DIAGRAM
CN110
CN111
CN109
CN112
CN113
CN108
CN 108 CN 109 CN 110
1413121110 9 8 7 6 5 4 3 2 1 1110 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
No. P J No. P J No. P J

1 100 CHGFAN 1 33 — 1 26 TMDU+
2 — — 2 27 — 2 20 TMDAU–
3 — — 3 28 — 3 21 TMDBU–
4 99 CKFANP– 4 29 — 4 22 TMDCU–
5 98 CKFANP+ 5 30 — 5 23 TMDAD–
6 97 CKFAND– 6 31 — 6 24 TMDBD–
7 94 CKFAND+ 7 32 — 7 25 TMDCD–
8 40 — 8 33 — 8 26 TMDD+
9 39 DDC 9 35 — 9 34 CKDV
10 — — 10 — — 10 — —
11 37 FANCP 11 — —
12 36 FANCD
13 38 FAN+
14 38 FAN+
CN 111 CN 112
CN 113
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14 8 7 6 5 4 3 2 1
18 17 16 15141312 11 10 9

1 150 TMDAU1+ 1 — — 1 41 B48V
2 152 TMDAD1+ 2 — — 2 44 VBMB
3 154 TMDBU1+ 3 — — 3 — —
4 151 TMDAU-G 4 — — 4 7 FAND+
5 153 TMDAD-G 5 — — 5 8 FAND–
6 155 TMDBU-G 6 — — 6 9 FANP+
7 157 TMDBD-G 7 — — 7 10 FANP–
8 159 TMDCU-G 8 — — 8 — —
9 161 TMDCD-G 9 — — 9 — —
10 — — 10 — — 10 — —
11 156 TMDBD1+ 11 — — 11 — —
12 158 TMDCU1+ 12 — — 12 14 GNDD
13 160 TMDCD1+ 13 — — 13 14 GNDC
14 P3 TMDAU-SD 14 — — 14 16 D15V
15 N2 TMDAD-SD 15 — — 15 15 C15V
16 P5 TMDBU-SD 16 — — 16 13 C20V
17 150 TMDAU2+ 17 — — 17 N2 N2
18 152 TMDAD2+ 18 — — 18 N2 N2
19 154 TMDBU2+ 19 — —
20 156 TMDBD2+ 20 — —
21 158 TMDCU2+ 21 — —
22 160 TMDCD2+ 22 — —
23 — — 23 — —
24 N2 TMDBD-SD 24 — —
25 P7 TMDCU-SD 25 — —
26 N2 TMDCD-SD 26 — —
5-11
TRAVELING CONTROLLER CONNECTORS, TERMINALS AND COMPONENTS
Thermo-sensor
(Drive-circuit)
CN118 CN119
CN130
CN126 CN127
CN132 CN117
(CSDA) (CSDB)
P7
N1 P8
P1 P9
CN135
(CSBATT)
P0
CN134 CN133 CN27 CN114 CN115 CN116

5-12
ERROR CODE LIST

Memoried
Displayed code Code explanation Page
diagnosis code
C/R A0-1 Traveling controller main circuit abnormal temperature rise 5-14
A0-4 A0-4
Controller cooling fan abnormality 5-16
A0-5 A0-5
A1 A1 Controller overvoltage 5-17
C/R A2 CPU board abnormal temperature rise 5-18
A3-1 A3-1 Incorrect battery connection or inappropriate battery voltage 5-19
A4 A4 Accelerator switch abnormality 5-20
A8 A8 Traveling controller abnormality or fuse F1 open 5-21
AA AA CPU board temperature sensor abnormality 5-22
AF-1 AF-1
AF-2 AF-2
Traveling controller CPU board abnormality 5-22
AF-3 AF-3
AF-4 AF-4
C0-1 C0-1 Traveling controller main circuit abnormality 5-23
C0-3 C0-3 Drive circuit power supply abnormality 5-24
C0-4 C0-4 Drive circuit abnormality 5-25
C1 C1 Drive current sensor abnormality 5-26
D/M C2-1 Drive motor abnormal temperature rise 5-27
C2-2 C2-2 Drive motor temperature sensor abnormality 5-28
C3 C3 Traveling controller main circuit temperature sensor abnormality 5-29
C4-1 C4-1
C4-2 C4-2
Accelerator potentiometer abnormality 5-30
C4-3 C4-3
C4-4 C4-4
C7 C7 Direction switch abnormality 5-32
C8-1 C8-1
Drive motor rpm sensor abnormality 5-33
C8-2 C8-2
CB-1 CB-1 Battery contactor (MB) open 5-34
EE-1 EE-1
EE-2 EE-2 Multi-display to traveling controller communication abnormality 5-36
EE-3 EE-3
5-13
Memoried
Displayed code Code explanation Page
diagnosis code
EF-1 EF-1
EF-2 EF-2 Traveling controller EEPROM abnormality 5-38
EF-3 EF-3
F1-1 F1-1
Traveling controller to multi-display communication abnormality 5-39
F1-2 F1-2
65-2 65-2 Power steering contactor (PS) abnormality 5-40
When no diagnosis (self diagnostic function) error code is displayed Page
The vehicle does not move (traveling and power steering failure) 5-41
Traveling fails or involves knocking 5-42
The vehicle only travels too slowly 5-43
Only power steering does not function 5-45
The multi-display does not function (traveling is normal) 5-46
The vehicle does not move when the direction switch is operated after sitting on the operator’s seat
5-47
(The OPS indicator lamp comes on.)
The vehicle moves when the direction switch is operated without sitting on the operator’s seat 5-48

Some vehicle abnormalities detected by controllers may not be stored in diag memory.


No display
key switch to OFF).

No display
5-14
WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED

Related Portion
CN132
CN105-1, 2 (38, FAN+) CN108-13, 14 CN113-4 (7, FAND+)
Cooling fan
CPU CN105-3 (36, FANCD) CN108-12 DC/MD CN113-5 (8, FAND–)
FAND
board CN105-4 (37, FANCP) CN108-11 board
CN113-6 (9, FANP+)
Cooling fan
CN113-7 (10, FANP–)
FANP
CN133
CN104-21 (77, THC+)
Main drive circuit
CN104-20 (78, THCD) temperature sensor
Condition for Error Detection
The temperature detected by the main drive circuit temperature sensor exceeds the specified level.
Note:
If A0-4 and A0-5 occur at the same time, conduct troubleshooting for A0-4 and A0-5 first.
No abnormality
Stand the vehicle for some time
• Normal
(approx. 15 minutes) and operate again.
Immediate output of error A0-1
The fan Inspection 1

ANL : ACTIVE TEST ACT-1 operates. 20 V or above
CN113-4 (7)
Turn FAND ON and check if the
Voltage check
cooling fan operates.
CN113-5 (8)
• Fan connector
The fan does not operate. Less than 20 V connection defect
• Fan defect
Inspection 2
CN105-3 (36) 4.5 V or above
Voltage check
CN103-12 (GND)
• CPU board defect
Less than 4.5 V
• DC/MD board defect

A To next page • Defective harness between CN105 and CN108
5-15
The fan Inspection 3

ANL : ACTIVE TEST ACT-2 20 V or above
operates. CN113-6 (9)
Turn FANP ON and check if the
Voltage check
cooling fan operates.
CN113-7 (10)
• Fan connector
The fan does not operate. Less than 20 V connection defect
• Fan defect
Inspection 4
ANL : I/O MONITOR 1 I/O1-1 4.5 V or above
CN105-4 (37)
THCD: Read the main drive circuit
Voltage check
temperature during traveling.
CN103-12 (GND)
The value does not The value changes. • CPU board defect
change. Less than 4.5 V
• Sensor installation status check • DC/MD board defect

• Sensor defect • Defective harness between CN105 and CN108
• Sensor harness open circuit
• Fan air inlet clogging check

• Fan check for foreign matter sticking
• Sensor harness short circuit
5-16
A0-4, 5 Controller cooling fan abnormality
Related Portion
CN132
CN105-1, 2 (38, FAN+) CN108-13, 14 CN113-4 (7, FAND+)
Cooling fan
CPU CN105-3 (36, FANCD) CN108-12 CN113-5 (8, FAND–) FAND
DC/MD board
board
CN105-4 (37, FANCP) CN108-11
CN113-6 (9, FANP+)
Cooling fan
CN105-8 (94, CKFAND+) CN108-7 CN113-7 (10, FANP–)
FANP
CN105-9 (97, CKFAND–) CN108-6
CN133
CN105-10 (98, CKFANP+) CN108-5
CN105-11 (78, CKFANP–) CN108-4
Low voltage or overcurrent is detected in the cooling fan line.
• A0-4 • A0-5
Fan check signal Fan check signal
ANL : ACTIVE TEST ACT-1 1 (ON) displays ANL : ACTIVE TEST ACT-2 1 (ON) displays
Disconnect CN132 and turn FAND ON. Disconnect CN133 and turn FANP ON.
Fan check signal • Cooling fan defect Fan check signal • Cooling fan defect
0 (OFF) displays 0 (OFF) displays
Disconnect the battery, and connect Disconnect the battery, and connect
SST1 and SST9. (See P5-6) SST1 and SST9. (See P5-6)
Fan check signal Fan check signal

ANL : ACTIVE TEST ACT-1 1 (ON) displays ANL : ACTIVE TEST ACT-2 1 (ON) displays
Disconnect CN132 and turn FAND ON. Disconnect CN133 and turn FANP ON.
Fan check signal • DC/MD board defect Fan check signal • DC/MD board defect
0 (OFF) displays • Harness open circuit 0 (OFF) displays • Harness open circuit
between CN105 and between CN105 and
CN108 CN108
• CPU board defect • CPU board defect

5-17
A1 Controller overvoltage
Related Portion
P4
CN104-12 (P4, VBP4)
CPU
board
Overvoltage in P4 line is detected.
Turn the key switch OFF and ON again.
Displayed. Wrong part number

Is error A1 displayed? CPU board part number check
Not displayed. Correct part

number • CPU board replacement
Inspection 1 NG
Battery voltage check
OK
• Battery replacement
(approx. 80 V)
Was the battery plug disconnected by YES

the emergency battery plug Do not disconnect the battery plug
disconnector during traveling? during traveling in other than an
emergency state.
NO
Inspection 2 NG (∞ Ω)
F1 fuse check
OK (0 Ω)
• F1 fuse replacement
• Battery plug inspection

5-18
A2 CPU board abnormal temperature rise
Related Portion
CPU board
Temperature sensor
TH101
The temperature sensor on the CPU board detects a value above the specified level.
Note:
If A0 occurs at the same time, conduct troubleshooting for A0 first.
ANL : I/O MONITOR 1 I/O1-5 80°C or above

• Stand the vehicle for some time (approx. 30 minutes).
TEMP: CPU board temperature check
Less than 80°C
Isn’t the vehicle used continuously with YES

• Stop the vehicle and conduct the test for confirmation with
an excessive load?
the standard load 30 minutes later.
NO

5-19
A3-1 Incorrect battery connection or inappropriate battery voltage
Related Portion
F5 P0
CPU CN103-7 (41,VBBT)
board
The VBBT line voltage on the CPU board side at F5 fuse is above the specified value.
YES
Isn’t the charger plug connected to
• Disconnect the charger plug.
the controller side connector?
NO
NO
Is the battery for 2TE15 in use? • Replace with the battery for 2TE15.
YES
Inspection 1
P0 Less than 65 V
Voltage check
N1
65 V or above
• Check the battery voltage, and replace with the

conforming battery.
5-20
A4 Accelerator switch abnormality
Related Portion
CN25 CN26
CN102-1 (64, SWAC) CN25-1 CN26-2

CPU
board CN102-22 (51, POT–) CN25-2 CN26-1 Accelerator
potentiometer
The accelerator switch is already turned ON before battery plug is connected.
Is the accelerator depressed before YES

• Normal
battery plug is connected?
NO
Disconnect the battery plug and the

accelerator potentiometer connector
CN25.
Connect the battery plug again.
NO
Is error A4 displayed? • Accelerator potentiometer adjustment
YES
Inspection 1 Continuity
Disconnect the battery plug and (20 Ω or less)
CN102.
• Harness defect
CN102-1 (64)
Continuity check
CN102-22 (51)
No continuity (∞ Ω)

5-21
A8 Traveling controller abnormality or fuse F1 open
Related Portion
MB
P4 F1 P1
CN104-12 (P4, VBP4)
CPU
board F6
CN104-22 (44, VBMB)
The voltage difference between the VBMB and VBP4 lines is outside the specified range.
Note:
If CB-1 occurs at the same time, conduct troubleshooting for CB-1 first.
NG
F1 fuse installation status inspection • Install F1 fuse securely.
OK
ANL : I/O MONITOR 1 I/O1-9, I/O1-8 | I/O1-8 measured value – I/O1-9 measured value | ≤ 20 V
VBMB and VBP4 voltage check
| I/O1-8 measured value – I/O1-9 measured value | > 20 V
F1 fuse inspection
OK (0 Ω)
Disconnect the P4 terminal and connect

the P4 terminal to the P1 terminal.
ANL : I/O MONITOR 1 I/O1-9, I/O1-8 | I/O1-8 measured value – I/O1-9 measured value | > 20 V
VBMB and VBP4 voltage check
| I/O1-8 measured value – I/O1-9 measured value | ≤ 20 V • Copper bar and terminal inspection
from P1 to P4
Inspection 2
CN104-12 (P4) | I/O1-8 measured value – inspection 2 measured value | ≤ 20 V
Voltage check
N1
| I/O1-8 measured value – inspection 2 measured value | > 20 V • CPU board defect
• CN104-12 line harness defect

5-22
AA CPU board temperature sensor abnormality
Related Portion
CPU board
Temperature sensor
TH101
The temperature sensor on the CPU board is abnormal.
• Replace the CPU board for correction.
AF-1, 2, 3, 4 Traveling controller CPU board abnormality
Related Portion
CPU board
CPU
The CPU device on the CPU board is abnormal.

5-23
C0-1 Traveling controller main circuit abnormality
Related Portion
CPU
board
CSBATT
CN104-5 (75, CSD+)
CN104-2 (54, CSBATT)
CN104-27 (76, CSD–)
The battery current sensor output voltage exceeds the specified value.
Outside of
1 to 4 V NG
ANL : I/O MONITOR 4 I/O4-5 CN135 (CSBATT) inspection • Repair
CSBATT: Voltage check after stopping
the vehicle
Within 1 to 4 V Outside of
Inspection 3 3 to 11 V
CN104-2 (54)
Voltage check • Harness defect
Disconnect the battery plug and the CN104-27 (76) • Battery current
drive motor cable. sensor defect
Connect SST3 to CN111. (See P5-7) Within 3 to 11 V

*1: Some LEDs
do not blink.
Inspection 1 Disconnect the battery plug, connect
Move the direction switch to DSF or SST4 to CN107 and CN 109, and
DSR position, depress the connect SST3 to CN112. (See P5-8)
accelerator pedal, and check if all
LEDs on SST3 blink.
*2: All LEDs blink. Inspection 4
Battery plug: ON, key switch: ON,
direction switch: DSF or DSR.
Inspection 2 Depress the accelerator pedal and
Disconnect the battery plug and Outside of check if all LEDs on SST3 blink.
SST3. Reconnect the motor cables 293 to 380 A. *2: All LEDs blink. *1: Some LEDs do not blink.
and battery plug. Move the direction
switch to DSF or DSR position,
depress the accelerator pedal, and • DC/MD board defect • CPU board defect
measure the drive motor OCL value.
(See P3-27)
Within 293 to 380 A.

*1 : One or six LEDs are kept OFF.
• TMD inspection • Drive motor defect *2 : All LEDs repeat ON/OFF.
• Drive motor cable defect
5-24
C0-3 Drive circuit power supply abnormality
Related Portion
CN105-6 (39, DDC) CN108-9 CN111

CPU DC/MD TMD
CN105-1, 2 (38, FAN+) CN108-13, 14
board board
CN107-9 (34, CKDV) CN110-9
The cooling fan line output voltage or the MMP supply voltage is abnormally low.
Disconnect the battery plug and CN111.

Reconnect the battery plug.
Changes to C0-4.
Is error C0-3 displayed?
C0-3 is displayed.
Connect CN111, and check if the error

Disconnect the battery plug, and
code changes to C0-3.
connect SST1 and SST9. (See P5-6)
Fan check signal 0 (OFF) Disconnect the battery plug.

ANL : ACTIVE TEST ACT-1 displays Disconnect CN117, 118 or 119.
Turn FAND ON. *1: Battery plug: ON
Key switch: ON
Fan check signal 1 (ON) displays Error C0-3 is Error C0-4 is displayed.
displayed.
Inspect the connectors and harness • CPU board defect • If error C0-4 is displayed,
from CN107 to CN110. TMD of the disconnected
connector is defective.
OK NG
• DC/MD board defect • Harness defect between

• Inspect the harness CN107 and CN110
and connectors from
CN105 to CN108.
*1: Disconnect CN117 through CN119 one by one to

identify the connector where error C0-4 is displayed.
5-25
C0-4 Drive circuit abnormality
Related Portion
CN114
CN105-6 (39, DDC) CN108-9
TMDAU
CPU CN105-1, 2 (38, FAN+) CN108-13, 14
DC/MD board CN117
board TMDAD
CN107-9 (34, CKDV) CN110-9
CN111 CN115
TMDBU
CN118
TMDBD
CN116
TMDCU
CN119
TMDCD
Discontinuity between DC/MD board and MMP, or abnormally low MMP power supply voltage is detected.
Disconnect the battery plug, connect

SST3 to CN111, and reconnect the
battery plug. (See P5-7)
YES
Is error C0-4 displayed?
NO
Disconnect the battery plug, and Disconnect the battery plug. Connect
check the connection of connectors SST4 and SST3, and reconnect the
CN114 through CN119. battery plug. (See P5-8)
Battery plug: ON Is error C0-4 displayed?

Key switch: ON
YES NO

YES
Does error C0-4 disappear? • Harness defect
Harness and connector inspection
between DC/MD
NO between CN107 and CN 110.
board and each TMD
• Internal harness defect OK NG
• DC/MD board defect • Harness defect

• Harness defect between CN107 and
between CN105 and CN110
CN108
5-26
C1 Drive current sensor abnormality
Related Portion
CS126
CN104-5 (75, CSD+)
CPU CSDA
board CN104-7 (71, CSDA)
CN104-27 (76, CSD–)
CSDB
CN104-8 (72, CSDB)
CS127
The CSDA or CSDB output voltage becomes outside the specified range.
CN126 (CSDA) and CN127 (CSDB) NG

connection status inspection • Repair or replacement
OK
Inspection 1 Inspection 3
Outside of Outside of
Key switch ON Exchange connections of CN126
6.5 to 7.5 V 6.5 to 7.5 V
CN104-7 (71) (CSDA) and CN127 (CSDB).
Voltage check CN104-7 (71)
N1 Voltage check
N1 • Harness defect
Within 6.5 to 7.5 V
Within 6.5 to 7.5 V
• CSDA defect
Outside of Outside of
Key switch ON Exchange connections of CN127
6.5 to 7.5 V 6.5 to 7.5 V
CN104-8 (72) (CSDB) and CN126 (CSDA).
N1 Voltage check
N1
Within 6.5 to 7.5 V • Harness defect
Within 6.5 to 7.5 V
• CPU board defect • CSDB defect

5-27
Related Portion
Drive motor
Temperature sensor
The drive motor temperature sensor output voltage exceeds the specified value.
• Stand the vehicle for some time (about 30 minutes).

5-28
C2-2 Drive motor temperature sensor abnormality
Related Portion
CPU
board CN52 Drive motor
CN102-10 (86, TD+) 2
Temperature
CN102-11 (87, TD–) 1 sensor
The drive motor temperature sensor output voltage is outside the specified range (open or short circuit).

TD: Drive motor temperature check
–40°C or less Disconnect the battery plug and CN52.

Use SST2 and connect CN52-1 and 2.
ANL : I/O MONITOR 1 I/O1-3
TD: Drive motor temperature check
–40°C or less 180°C or above
Inspection 1
ANL : I/O MONITOR 1 I/O1-3 CN102-11 (87)
TD: Drive motor temperature check Voltage check
N1
–40°C or less 180°C or above
Within 3.9 to 5.9 V Outside of
3.9 to 5.9 V
• Temperature sensor harness defect • Main harness defect • CPU board defect
• Temperature sensor defect
5-29
C3 Traveling controller main circuit temperature sensor abnormality
Related Portion
CPU
board CN130
CN104-20 (78, THCD) 2
Temperature
CN104-21 (77, THC+) 1 sensor
The controller temperature sensor output voltage is outside the specified range (open or short circuit).
Disconnect the battery plug. Disconnect

CN130.
Inspection 2
ANL : I/O MONITOR 1 I/O1-1 Less than –40°C Temperature sensor resistance check
THCD: Main drive circuit temperature
CN130-1 (77)
check
Resistance check
197°C or above CN130-2 (78)
About 11 kΩ to 12 kΩ 200 kΩ or above
Inspection 1
CN104-20 (78) • Temperature sensor • Temperature sensor
Voltage check harness defect defect
N1
Within 3.9 to 5.9 V Outside of 3.9 to 5.9 V
• Harness defect • CPU board defect

5-30
C4-1, 2, 3, 4 Accelerator potentiometer abnormality
Related Portion
CN25 CN26
CN102-1 (64, SWAC) 2 CN26-2
CN102-2 (52, POTA) 3 CN26-3
CPU board Accelerator
CN102-14 (53, POTA+) 4 CN26-4 potentiometer
CN102-22 (51, POT–) 1 CN26-1
• C4-1 : The accelerator line (POTA) voltage is less than the specified level upon accelerator switch ON.
• C4-2 : The accelerator line (POTA) voltage is at or above the specified level.
• C4-3 : The accelerator line (POTA) voltage is at or above the specified level upon accelerator switch OFF.
• C4-4 : The accelerator line (POTA) voltage is at or above the specified level upon switching in the accelerator
switch.
• C4-1

Check the POTA value when acceleration switch
SWAC value changes from “0” to “1”.
Less than 0.3 V • CPU board defect
ANL : I/O MONITOR 2 I/O2-1 The POTA value changes.

Depress the accelerator pedal further and check the
POTA value.
The POTA value remains unchanged. • Accelerator potentiometer

adjustment defect
Disconnect CN25, and use SST8 to short-circuit

between POTA and POTA+.
Changes to error C4-2. Does not change to error C4-2.
• Accelerator potentiometer Inspection 1

inspection (See P3-59) CN102-2 (52)
• Accelerator potentiometer Voltage check
harness defect N1
0.2 V or above Less than 0.2 V
• CPU board defect • Main harness defect

5-31
• C4-2
Does the error code disappear when Disappears.

• Accelerator potentiometer inspection (See P3-59)
CN25 is disconnected?
• Accelerator potentiometer harness defect
Does not disappear.
Inspection 1
CN102-2 (52)
Voltage check
N1
Less than 0.2 V 0.2 V or above
• C4-3
ANL : I/O MONITOR 2 I/O2-1 SWAC value check Remains unchanged at 0 or 1.

Does the SWAC value change from 0 to 1 when the • Accelerator switch defect
accelerator pedal is depressed further? • Harness defect
Changes to 1.
ANL : I/O MONITOR 2 I/O2-1 Less than 2.5 V Displayed.

Check the maximum POTA value Is error C4-3 being displayed?
when SWAC value is 0.
Not displayed. • CPU board defect
2.5 V or above
Disappears.
Does the error code disappear when • Accelerator potentiometer inspection (See P3-59)
CN25 is disconnected? • Accelerator potentiometer harness and
connector inspection
Does not disappear.
Inspection 1
CN102-2 (52)
Voltage check
N1
• C4-4
Note:
If C4-2 or C4-3 occurs at the same time, conduct troubleshooting for C4-2 or C4-3 first.

Check the POTA voltage when the SWAC value
changes from “0” to “1” or from “1” to “0”.
Less than1.4 V 1.4 V or above
• CPU board defect • Accelerator potentiometer

adjustment defect
5-32
C7 Direction switch abnormality
Related Portion
CN9
CN101-1 (45, DSF) 5
CPU CN101-2 (46, DSR) 4

Direction switch
board
CN101-16 (51, LS–) 1

J1
Displayed when the direction switch is set to both forward and reverse.
ANL : I/O MONITOR 2 I/O2-2 “0”

• Direction switch inspection
DSF or DSR ON/OFF value check
DSF or DSR value at “1”
Inspection 1
CN101-1 (45)
CN101-2 (46)
Voltage check
N1
OK (approx. 5 V) NG (0 V)
• CPU board defect • Harness short circuit

5-33
C8-1, 2 Drive motor rpm sensor abnormality
Related Portion
CN57 CN53
CN102-18 (80, SSD+) 4
CPU
CN102-6 (81, SSD1) 1 Drive motor
board
rpm sensor
SSD1
CN102-7 (82, SSD2) 3 Drive motor

rpm sensor
SSD2
CN54
The drive motor rpm sensor circuit is open or its output voltage drops.
Note:
Jack up the vehicle until the rear wheels leave the ground and support the frame at specified positions with
wooden blocks before starting troubleshooting.
The value is not 0 for both

SSD1 and SSD2.
SSD1, 2: Check the number of drive • Each connector connection status check
motor output pulses during traveling.
The value is 0 for either SSD1 or SSD2. Disconnect CN57.
0 is displayed for SSD 1.

Exchange connections CN53 and
CN54. Connect terminals 1 and 4 using SST2.
0 is displayed for SSD2.

The sensor for 0 Inspection 1
indication does not CN102-6 (81)
ANL : I/O MONITOR 2 I/O2-4 change.
SSD1, 2: Check the number of drive Voltage check
motor output pulses during traveling. N1
0V 15 V
The sensor for 0 indication is
changed over. • Main harness defect • CPU board defect
• Drive motor rpm sensor harness defect
• Drive motor rpm sensor defect
Connect terminals 3 and 4 using SST2.
Inspection 2
CN102-7 (82)
Voltage check
N1
0V 15 V
• Main harness defect • CPU board defect
5-34
CB-1 Battery contactor (MB) open
Related Portion
MB
P1 F6
P2 P3 CN104-14 (44, VBMB)
CSBATT CPU
board
F7
CN104-4 (18, B80V)
CN104-13 (1, MB+)

MB
coil
CN104-13 (2, MB–)
CN134
CN104-10 (N2, N2)
The P3 voltage drops, or the voltage difference between B80V and VBMB lines is outside the specified range.
Is the contactor closing sound heard NO

A To next page
after key switch ON?
YES
Inspection 1 NG
F6 fuse inspection
OK
P3 0V P1
Voltage check Voltage check
N1 N1
Approx. 80 V 0V Approx. 80 V
Inspection 3 • Battery cable defect • MB contactor

CN104-14 (44) 0V • Copper bar terminal connection defect
Voltage check connection defect
CN104-10 (N2)
Approx. 80 V • VBMB line harness inspection

5-35
Less than 9 V P3
Disconnect CN134.
CN134-1 Voltage check
Voltage check CN104-11 *
CN134-2 9 V or above Less than 9 V
9 V or above
• Harness defect between • CPU board defect
CN104 and CN134
Inspection 6 Other than 20 Ω
MB contactor coil resistance
inspection
Approx. 20 Ω
• Battery contactor defect • MB coil defect
*: CN104-11: SST connection method on CPU board
SST 09240-23401-71
5-36
EE-1, 2, 3 Multi-display to traveling controller communication abnormality
Related Portion
CN1 CN70
CN103-13 (144, SMTDK) 7
CPU
board CN103-14 (143, SDTMK) 4
CN103-15 (142, SDTMA) 8
CN103-16 (141, SMTDA) 3 Multi-display
CN103-10 (16, D15V) 2
CN103-12 (14, GNDD) 1
CN104-16 (16, D15V) CN113-14 (16, D15V)

CN104-23 (14, GNDD) CN113-12 (14, GNDD) DC/MD board
CN113
The communication data from the display is abnormal.
• EE-1
Displayed.
Is error F1 displayed? • See the troubleshooting for error F1.
Not displayed.
Does the display come ON upon key NO Inspection 1

switch ON? Disconnect CN1.
CN103-10 (16)
YES Voltage check
CN103-12 (14)
14 V or above Less than 14 V
• Sub harness discontinuity

A To next page
• Display defect
The error code is displayed

Disconnect the battery plug. Use two upon key switch ON.
SST2s to connect CN1-3 with CN1-8 • Main harness open
and CN1-4 with CN1-7. • CPU board defect
No error display upon key switch ON
• Sub harness open

• Display defect
• EE-2
EE-3
• Inspect CN103-13, 14, 15 and 16 harnesses. If they are normal, the multi-display may be defective.
5-37
Inspection 2
Disconnect CN104. 14 V or above
CN104-16 (16) • CPU board defect
Voltage check
CN103-12 (14)
Less than 14 V
Inspection 3
Disconnect CN113. No continuity
Continuity check • Harness defect
CN104-16 (16) to CN113-14 (16)
CN104-23 (14) to CN113-12 (14)
Continuity exists.
• DC/MD board defect

5-38
EF-1, 2, 3 Traveling controller EEPROM abnormality
Related Portion
CPU board
The CPU board EEPROM is abnormal.

5-39
F1-1, 2 Traveling controller to multi-display communication abnormality
Related Portion
CN1
CN103-16 (141, SMTDA) 3 CN70-1-22 (141, SMTDA)
CPU Multi-
board display
CN103-13 (144, SMTDK) 7 CN70-1-23 (141, SMTDK)
The communication data from the CPU board is abnormal.
Note:
When error F1-1 occurs, no other error codes can be displayed because of failure in communication from
the main controller. Error F1-1 is kept displayed on the multi-display screen irrelevant to key switch ON or
OFF.
Check if connectors CN103, CN70-1 NG

• Connector insertion recheck
and CN1 are connected securely.
OK
Inspection 1
Disconnect the battery plug, CN103
and CN70-1 and check continuity at No continuity
• Harness defect between CN103 and CN70-1
the positions below.
CN103-16 (141) to CN70-1-22 (141)
CN103-13 (144) to CN70-1-23 (144)
Continuity

• Multi-display defect
5-40
65-2 Power steering contactor (PS) abnormality
Related Portion
CPU
board
CN59
CN103-5 (5, SOLT+)
PS
contactor
CN103-6 (6, SOLT–) coil
PS solenoid overcurrent is detected.
Does error 65-2 disappear upon CN59 YES

disconnection?
NO
Inspection 1 Inspection 2 Other than approx. 20 Ω

Disconnect CN103. PS contactor coil resistance check
CN103-5 (5)
Resistance check Approx. 20 Ω
CN103-6 (6) • PS contactor defect
Less than 7 Ω 7 Ω or above • CPU board defect

• Harness defect between CN103 and CN59
• Harness defect • CPU board defect
5-41
WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED

The vehicle does not move (traveling and power steering failure)
Related Portion
CPU
board
CN103-7 (41, VBBT)
P1 F5
CN103-4 (43, VBKY)
SWk
CN103-8 (44, VBMB)
MB P2 CSBATT P3 F6
P0
Is the battery contactor closing sound NO 20 V or above

heard upon key switch ON? VBMB: Voltage check
YES • F1, F3 fuse replacement
Less than 20 V
Inspection 1
P1 80 V Inspection 4 NG
Voltage check F6 fuse inspection
N1 • F6 fuse replacement
OK
Other than 80 V
Inspection 5
• Battery charging or replacement CN103-8 (44) 20 V or above
• Battery plug defect Voltage check
N1
Less than 20 V
Inspection 2 NG • Main harness defect

F5 fuse inspection
OK • F5 fuse replacement
Inspection 3 NG
Key switch ON. (other than OK)
CN103-4 (43)
• Harness defect
CN103-7 (41)
Voltage check
N1
Voltage between CN103-7 and N1: 20 V
OK Difference in voltage between CN103-4 and N1 subtracted
from that between CN103-7 and N1: Within 15 V
CN103 connection status check • Connect securely.
NG
OK

5-42
Traveling fails or involves knocking
Related Portion
CN111
CPU CN105 CN108 DC/MD board
board TMD
CN107 CN110
Direction switch: ON/OFF switching failure

ANL : I/O MONITOR 2 I/O2-1,2 Accelerator potentiometer switch:
SWAC: Accelerator potentiometer ON/OFF switching failure
switch 1 (ON)/0 (OFF) and DSF, • Direction switch inspection or
DSR direction switch 1 (ON)/0 (OFF) replacement
value check • Accelerator potentiometer inspection
or replacement
Direction switch: Nomal ON/OFF switching
Accelerator potentiometer: Nomal ON/OFF switching
Is the direction switch or accelerator NO ANL : I/O MONITOR 2 I/O2-3 OFF “0”
pedal operated before key switch ON? LSD: Seat switch operation check
with the operator sitting on the seat
YES ON “1” • Seat switch inspection
• Move the direction switch to neutral

position, release the accelerator Disconnect the battery plug,
pedal, and turn the key switch OFF disconnect the motor cable, Connect
once and ON again. SST3 to CN111, and reconnect the
battery plug.
(See P5-7)
*1 Some LEDs
do not
Check if the LEDs on SST3 blink or lit blink. Disconnect the battery plug.
when the accelerator pedal is Connect SST3 and SST4.
depressed with the direction switch is (See P5-8)
at DSF or DSR position.
*2 All LEDs blink.
Inspection 1 Connect the battery plug, and turn the

Disconnect the battery plug and key switch ON.
disconnect SST3. Connect the With the direction switch moved to
motor cable. With the direction DSF or DSR position, depress the
switch moved to DSF or DSR accelerator pedal to check if LEDs on
position, depress the accelerator SST3 blink.
pedal and measure the drive motor
current OCL value. *1 Some LEDs
*2 All LEDs
(See P3-27) do not blink.
blink.
Within Outside of
293 to 380 A 293 to 380 A • DC/MD board defect • CPU board defect
• TMD inspection • Drive motor defect
• Drive motor cable
*1. : One or six LEDs kept OFF
defect
*2. : All LEDs repeat ON/OFF.
5-43
The vehicle only travels too slowly
Related Portion
CN57
CN102-18 (80, SSD+) 4
rpm
CPU CN102-6 (81, SSD1) 1 sensor
board
REC
TAB
SSD1
CN102-7 (82, SSD2) 3 rpm

sensor
SSD2
CN105 CN108
DC/MD TMD
CN107 CN110 boards
CN11
Read value: Other than 0

A To next page
SSD1, 2: Drive motor rpm check
Read value: 0
Disconnect CN57, and connect SST2

to the REC side.
When SSD1 = 0: Short-circuit CN57-
1 and CN57-4.
When SSD2 = 0: Short-circuit CN57-
3 and CN57-4.
Inspection 1
CN102-6 (81)
CN102-7 (82)
Voltage check
N1
0V Approx. 15 V
• CPU board defect • Drive motor rpm sensor harness open

• Main harness open • Drive motor rpm sensor defect
5-44

POTA: Depress the accelerator pedal Less than 2 V
• Accelerator potentiometer defect
fully, and check the accelerator
potentiometer voltage value.
2.0 V or above
ANL : I/O MONITOR 2 I/O2-3 1 is displayed.

LSB: Without depressing the brake • Brake switch defect
pedal, check the displayed value.
0 is displayed.

disconnect the motor cable.
Connect SST3 to CN111, and connect
the battery plug. (See P5-7)
Move the direction switch to either DSF *1: Some LEDs do not blink.
or DSR position, and depress the
accelerator pedal. Check if all LEDs of
SST3 blink.
*2: All LEDs blink. Disconnect the battery plug, and
connect SST3 and SST4. (See P5-8)
Inspection 2
Disconnect the battery plug and
SST3. With the direction switch
moved to either DSF or DSR position, Connect the battery plug, move the
depress the accelerator pedal to direction switch to either DSF or DSR
measure the drive motor current OCL position, and depress the accelerator
value. (See P3-27) pedal.
Within 293 to 380 A Outside of 293 to 380 A *2: All LEDs blink. *1: Some LEDs do not
blink.
• TMD inspection • Drive motor defect • DC/MD board defect • CPU board defect
• Drive motor cable defect
*1. : One or six LEDs kept OFF.

*2. : All LEDs repeat ON/OFF.
5-45
Only power steering does not function
Related Portion
P1 F3
CN59
CN103-5 (5, SOLT+) CPU
board
Mps
Mps
CN103-6 (6, SOLT–)
P22
DMps
N1
Release the parking brake, and move Other than

NO Inspection 2 approx. 20 Ω
the direction switch to DSF or DSR
PS contactor coil resistance
position to check if the PS contactor
inspection
operating sound is heard.
YES Approx. 20 Ω • PS contactor defect

Inspection 1
Turn the key switch ON, release the
Other than
parking brake, and move the direction NG
80 V Inspection 3
switch to either DSF or DSR position.
F3 fuse inspection
P22
Voltage check
N1 OK
80 V
• Main harness defect
• Power steering motor defect

• Power steering motor cable defect
5-46
The multi-display does not function (traveling is normal)
Related Portion
CPU
board
CN1
CN103-10 (16, D15V) 2 2 CN70-1-14 (16, D15V)
Multi-
CN103-12 (14, GNDD) 1 1 CN70-1-30 (14, GNDD) display
• No power supply to multi-display

NO
Does the vehicle move? • See “Vehicle does not move” section in “WHEN NO
DIAGNOSIS ERROR CODE IS DISPLAYED” part.
YES (See P5-41)
Disconnect the battery plug and Disconnect the battery plug and
CN70-1. 0V CN70-1. 0V
Connect the battery plug. Connect the battery plug. • CPU board defect
CN70-1-14 (16) CN103-10 (16)
Voltage check Voltage check
CN70-1-30 (14) CN103-12 (14)
Approx. 15 V Approx. 15 V
• Multi-display defect • Harness defect

5-47
The vehicle does not move when the direction switch is operated after sitting on the
operator’s seat (The OPS indicator lamp comes on.)
Related Portion
RYD
LP
From direction switch
SWK LSD
CN42 CN42
P0 F5
CN101-5 (67, LSD)

CPU
board CN101-26 (51, LS–)
“1” is displayed when the operator sits on the operator’s seat.

ANL : I/O MONITOR 2 I/O2-3 (“0” is displayed upon leaving the seat.)
Seat switch inspection
“0” display even when the operator is on the operator’s seat.

Inspection 1
Disconnect the battery plug and NG (no operation)
CN42.
Inspect the seat switch.
• Seat switch defect
OK
Inspection 2 NG (no operation)

Relay RYD inspection
OK • Relay RYD defect
Reconnect the battery plug, turn the key

switch ON, and sit on the seat.
Inspection 3
CN101-5 (67) NG (5 V)
Voltage check
CN101-26 (51)
• Harness defect
OK (0 V)

Note:
If the OPS lamp keeps lighting even after defect elimination,
check if RYD or the lamp wiring is defective.
5-48
The vehicle moves when the direction switch is operated without sitting on the operator’s
seat
Related Portion
RYD
LP
SWK LSD
CN42 CN42
P0 F5
CN101-5 (67, LSD)

CPU
board CN101-26 (51, LS–)
ANL : I/O MONITOR 2 I/O2-3 “1” display even when the operator is not on the operator’s seat.
“1” display when the operator sits on the operator’s seat

(“0” display when the operator leaves the seat)
Inspection 1 NG (short circuit)

• CPU board inspection

• Harness inspection
Note:
If the OPS lamp does not come ON even after defect elimination, check if RYD or the lamp wiring is defective.
5-49
2TE18
SST SETTING METHOD
Use SSTs for quick, accurate troubleshooting of the 2TE18 electrical system.
Incorrect connection will make correct check impossible. Be very careful since wrong connection may cause board
damage.
SST No. Part number Part name Remarks
SST2 09232-13130-71 Short harness (for CN1 and CN55)

SST 09230-13130-71
Controller check harness
SST8 09238-13130-71 Accelerator potentiometer check harness (for CN26)
SST19 09231-21320-71 Drive motor speed sensor check harness (for CN166)
Caution:
• Disconnect the battery plug before installing or removing each SST. If the battery plug is kept connected,
board damage may be caused.
• CO capacitor may fail to fully discharge if any SST is connected. When connecting or disconnecting
each control board connector, measure the voltage between P3 and N2 beforehand. If not discharging,
make CO discharge by connecting a resistor at about 100 Ω between P3 and N2 before starting trouble-
shooting.
5-50
SST19 Setting Method (In case of troubleshooting for error C8-1)

2. Disconnect CN166, install SST19, and connect SST19 connectors 2 and 3.
3. Connect the battery plug.
4. Turn the key switch to ON, and check if LEDs on the SST come on.
CN166
SST19
Two LEDs
Connector 1
Connector 2 Connector 3
5-51
CPU BOARD CONNECTOR DIAGRAM
CN101 CN102 CN103 CN104
No. P J No. P J No. P J No. P J

1 45 DSF 1 64 SWAC 1 145 CANH 1 18 B80V
2 46 DSR 2 52 POTA 2 146 CANL 2 18 B80V
3 65 LSB 3 — — 3 147 CANGND 3 — —
4 66 LSPB 4 — — 4 43 VBKY 4 — —
5 67 LSD 5 — — 5 — — 5 — —
6 — — 6 — — 6 — — 6 — —
7 — OPTO– 7 — — 7 41 VBBT 7 — —
8 — — 8 — — 8 — — 8 — —
9 39 FAN– 9 — — 9 — — 9 55 CPR
10 — — 10 — — 10 16 D15V 10 — —
11 — — 11 — — 11 — — 11 — —
12 — — 12 — — 12 14 GNDD 12 — —
13 — — 13 — — 13 144 SMTDK 13 — —
14 — — 14 53 POTA+ 14 143 SDTMK 14 44 VBMB
15 — — 15 — — 15 142 SDTMA 15 44 VBMB
16 51 LS– 16 — — 16 141 SMTDA 16 — —
17 — — 17 — — 17 — —
18 70 LSDD (SWTK) 18 — — 18 — —
19 90 LSIF(MH1) 19 — — 19 1 MB+
20 91 LSIB (MH2-1) 20 — — 20 2 MB–
21 92 LSICH (MH2-2) 21 — — 21 37 MPS+ (SOLD+)
22 — — 22 51 POT– 22 N2 N2
23 — — 23 N2 N2
24 — — 24 39 FAN–
25 — — 25 42 KEYSTART
26 — — 26 — —
27 — — 27 — —
28 — — 28 38 MPS– (SOLD–)
29 — —
30 — —
31 — —
32 — —
33 — —
34 — —
CN100 CN105 CN107

1 — C5V 1 39 FAN– 1 127 FANR+
2 — GNDC 2 39 FAN– 2 128 FANR–
3 — FTXD 3 39 FAN–
4 — FWE 4 130 FAN1
5 — MD1 5 131 FAN2
6 — FRES 6 132 FAN3
7 — FRXD 7 133 FAN4
8 — SELR 8 134 FAN5
9 135 FAN6
10 — FAN7
11 — CHKG
5-52
MAIN CONTROLLER CONNECTORS AND MAIN COMPONENTS
CN104
CN103
CN102
CN101
CPR
CN126
5-53
TRAVELING CONTROLLER CONNECTORS AND MAIN COMPONENTS
CN166
P3
P7
P8
P9
N1
CN 166
6 5 4 3 2 1 1 2 3 4 5 6
13121110 9 8 7 7 8 9 10 11 12 13
TAB REC
NO P C J NO P C J
1 150 — CUDID0 1
2 151 — CUDID1 2
3 145 — CANH 3 145 B CN168-3
4 146 — CANL 4 146 W CN168-5
5 148 — CANTRD 5
6 147 — CANGND 6 147 Y CN103-3
7 55 — KEYSTART 7 55 GR CN104-25
8 152 — CUDON 8
9 80 — SSD+ 9 80 G-R CN57-1
10 83 — SSD–,TD– 10 83 P CN57-5
11 81 — SSD1 11 81 BR CN57-2
12 82 — SSD2 12 82 B-W CN57-3
13 88 — TD+ 13 88 W-G CN57-6
5-54
CONTACTOR PANEL CONNECTORS AND MAIN COMPONENTS
P1
F1
P3
CN136
5-55
PS CONTACTOR CONNECTORS AND MAIN COMPONENTS
F3
P22
CN59
5-56
ERROR CODE LIST

Displayed code Diag memory Failure mode Page
30-1 30-1 Traveling controller low voltage 5-58
31-1 31-1 Traveling controller starting voltage drop 5-60
32-1 32-1 Traveling controller EEPROM abnormality 5-61
33-1 33-1 Main controller to traveling controller communication abnormality 5-62
C/R A0-1 Traveling controller main circuit abnormal temperature rise 5-63
A0-4 A0-4 Traveling controller cooling fan abnormality 5-65
A0-5 A0-5 Main controller cooling fan abnormality 5-68
A1-1 A1-1 Main controller high voltage 5-69
A1-2 A1-2 Traveling controller high voltage 5-70
C/R A2-1 CPU board abnormal temperature rise 5-71
DCR A2-2 Traveling controller board abnormal temperature rise 5-72
A4 A4 Accelerator switch abnormality 5-73
AA-1 AA-1 CPU board temperature sensor abnormality 5-74
AA-2 AA-2 Traveling controller board temperature sensor abnormality 5-74
AC AC Semiconductor switch abnormality 5-75
AD-1 AD-1 Traveling controller to main controller communication abnormality 5-77
AD-2 AD-2 Traveling controller to main controller communication abnormality 5-79
AF-1 AF-1
AF-2 AF-2
CPU board abnormality 5-81
AF-3 AF-3
AF-4 AF-4
C1-1 C1-1 Traveling controller current sensor offset abnormality 5-81
C1-2 C1-2 Traveling controller overcurrent abnormality 5-82
D/M C2-1 Drive motor abnormal temperature rise 5-83
C2-2 C2-2 Drive motor temperature sensor abnormality 5-84
C3-1 C3-1 Traveling controller main circuit temperature sensor abnormality 5-86
C4-1 C4-1
C4-2 C4-2
Accelerator potentiometer abnormality 5-87
C4-3 C4-3
C4-4 C4-4
5-57
Displayed code Diag memory Failure mode Page
C7 C7 Direction switch abnormality 5-89
C8-1 C8-1 Drive motor rpm sensor abnormality 5-90
CB-1 CB-1 MB contactor abnormality 5-91
EE-1 EE-1
EE-2 EE-2 Multi-display to main controller communication abnormality 5-93
EE-3 EE-3
EF-1 EF-1
EF-2 EF-2
Main controller EEPROM abnormality or CPU device abnormality 5-94
EF-3 EF-3
EF-4 EF-4
F0-1, 2, 3 F0-1, 2, 3 PS contactor abnormality 5-95
F1-1, 2 F1-1, 2 Main controller to multi-display communication abnormality 5-97
FF FF D15V overcurrent 5-98
When no diagnosis (self-diagnostic function) error code is displayed Page
The vehicle does not move (The display is also OFF) 5-99
The vehicle does not move normally 5-100
The vehicle does not move when the direction switch is operated after sitting on the operator’s seat
5-102
(The OPS indicator lamp comes on)
The vehicle moves when the direction switch is operated without sitting on the operator’s seat 5-103

Some vehicle abnormalities detected by controllers may not be stored in diag memory.


No display
key switch to OFF).

No display
5-58
WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED

30-1 Traveling controller low voltage
Related Portion
MB
P1 P2 F1
P3 Traveling
controller
Low voltage in the battery voltage (P3) line to the traveling controller is detected.
Note:
If 31-1 or CB-1 occurs at the same time, conduct troubleshooting for 31-1 or CB-1 first.
Turn the key switch to OFF once and

ON again.
YES
Is error 31-1 displayed? Conduct troubleshooting for error 31-1.
NO
Does the error code appear upon Error CB-1 is displayed.

Conduct troubleshooting for error CB-1.
traveling?
Error 30-1 appears. Error 30-1 does not appear.
• P3 cable and terminal inspection

• F1 fuse inspection
ANL : I/O MONITOR 1 I/O1-13 Drops to ANL : I/O MONITOR 1 I/O1-8 Drops to
VBBD: Voltage check less than 32 V. VB80: Voltage check less than 32 V.
Turn the key switch OFF and ON Turn the key switch OFF and ON
again, and check the VBBD voltage again, and check the VB80 voltage
when traveling fails. when traveling fails.
32 V or above 32 V or above • Battery plug inspection

• Battery charging
• Traveling controller defect
A To next page.
5-59
Inspection 1
Turn the key switch OFF and ON
again, run the vehicle and check the
Drops to less than 32 V. traveling controller input voltage when
traveling fails.
P3
Inspection 2 Voltage check
Turn the key switch OFF and ON N1
again, run the vehicle and check the 32 V or above 32 V or above
battery voltage upon error occurrence.
P2
Voltage check • Traveling controller defect
N1
Drops to less than 32 V.
• MB contactor defect • P3 cable and terminal inspection

5-60
31-1 Traveling controller starting voltage drop
Related Portion
MB F1
P1 P2 P3 Traveling
controller
CPR
CN104-9 (55, CPR)
F7 CN136 CPU
CN104-1 (18, B80V) board
CN104-2 (18, B80V)
Traveling controller P3 voltage does not rise to the set level after key switch ON.
Turn the key switch OFF once and ON

then.
VBBD: Traveling controller DC_BUS
voltage check
YES • Traveling controller
Does error 31-1 appear? defect
Less than 48 V
NO
Inspection 1
• Battery plug inspection Traveling controller input P3 voltage
check 48 V or above
• Traveling controller cable and terminal
inspection P3
• CPR inspection Voltage check • Traveling controller
• Harness inspection N1 defect
Less than 48 V
48 V or above ANL : I/O MONITOR 1 I/O1-9

VBKS: Key start voltage check
Less than 48 V

B80V: Battery voltage check
Less than 48 V
Other than
approx. 20 Ω Inspection 2
Inspection 3
Battery voltage P1 check 48 V or above
CPR resistance check
P1
Approx. 20 Ω Voltage check
N1 • F7 fuse inspection
• F1 fuse inspection • CPR defect
Less than 48 V
• P2/P3 - N1 line check for no load
connection • Battery charging
5-61
32-1 Traveling controller EEPROM abnormality
Related Portion
Traveling
controller
• Internal data abnormality is detected upon start of traveling controller.

• EEPROM device on CPU board in traveling controller is damaged.
Repeat key switch ON/OFF. Does error NO Was the traveling controller replaced
32-1 appear? immediately before?
YES NO YES
• Traveling controller defect • Normal
• Traveling controller connector inspection

5-62
33-1 Main controller to traveling controller communication abnormality
Related Portion
CPU Traveling
board CN103-1 (145, CANH) CN166-3 (145, CANH) controller
CN103-2 (146, CANL) CN166-4 (146, CANL)
CN103-3 (147, CANGND) CN166-6 (147, CANGND)
CN104-25 (42, KEYSTART) CN166-7 (42, KEYSTART)

CN169
1
R
2
3
The traveling controller fails to receive the communication data from the CPU board within the specified time.
Is error AD-1 displayed or stored in the YES

diag memory? • Conduct troubleshooting for error AD-1.
NO
Was the traveling controller replaced YES

immediately before? *1 • Check connectors CN103, CN104, CN166 and CN169 for
secure connection, and turn the key switch ON/OFF to
NO confirm no error display.
Turn the key switch OFF and ON. Is NO

the error code displayed? • CN103, CN104, CN166 and CN169 connector inspection
Error 33-1 is displayed Error AD-1 or
(AD-1 and AD-2 do not AD-2 is
appear.) displayed.
• Conduct troubleshooting for error AD-1 or AD-2.
(or CPU board defect)
Note:
*1: The traveling controller is the same as that for the 7FB35 series. Since the supply part for repairing is set
for the material handling controller, error 33-1 is displayed upon key switch ON when the controller in
trouble is replaced with the supply part. Clear the error code by key switch OFF and ON.
5-63
Related Portion
CN135 CN185
CN104-14, 15 (44, VBMB) 1 1
2 2 FAN
CN104-24 (39, FAN–) 3
CN186
CPU 1
board 2 FAN
Traveling
controller
The traveling (A0-1) controller main circuit temperature rises to beyond the specified level.
Note:
If A0-4 occurs at the same time, conduct troubleshooting for A0-4 first.
Stand the vehicle for some time (about No abnormality

• Normal
15 minutes) and restart operation then.
Overheat mark is displayed soon.
ANL : ACTIVE TEST ACT-1 Not operating

Turn the fan ON and check if all fans A To next page.
are operating.
Operating
The temperature value

ANL : I/O MONITOR 1 I/O1-1 remains unchanged.
THCD:
Traveling controller temperature sensor
value check during traveling
The temperature value varies.
• Paper, etc. sticking on the air outlet port

• Overloaded operation
5-64
Inspection 1
ANL : ACTIVE TEST ACT-1 Less than 20 V 5 V or above
CN105-4 (130)
FAN: ON/OFF (fan voltage)
Voltage check
Voltage check upon fan ON
N1
• Main board defect
• Main controller internal

resistance check
Inspection 2
CN185-1 (44)
Voltage check
CN185-2 (39) 20 V or above
• Fan inspection
CN186-1 (44) • Connector disconnection
Voltage check
CN186-2 (39)
Less than 20 V
Inspection 3
CN135-1 (44) 20 V or above
CN135-2 (44) • Harness defect between CN135 and CN185(6)
Voltage check
CN135-3 (39)
Less than 20 V

5-65
A0-4 Traveling controller cooling fan abnormality
Related Portion
CN135 CN185
P1 P2
F6 J4 1 1 Traveling
MB controller
2 cooling fan
2
CN186
3 1 Traveling
controller
2 cooling fan
CN104-14 (44, VBMB)

CPU board
CN104-24 (39, FAN–)

J6
CN101-9 (39, FAN–)
CN105-7 (133, FAN4)
CN105-4 (130, FAN1)

R V
Resistor Resistor
B B
CN105-8 (134, FAN5)
CN105-5 (131, FAN2)

G BR
Resistor Resistor
B B
CN105-9 (135, FAN6)
CN105-6 (132, FAN3)

Y GR
Resistor Resistor
CN105-3 (39, FAN–)

B B
CN105-2 (39, FAN–)
Inside of main controller

5-66
Open or short circuit between the CPU board and the traveling controller cooling fan is detected.
Inspection 1
Cooling fan check (short circuit check) Shorted (0 Ω)
Disconnect the battery plug, and disconnect CN185 and CN186.
CN185-1 (44) to CN185-2 (39)
CN186-1 (44) to CN186-2 (39)
Note: • Cooling fan defect
Connect the probe of the tester with pin 1 and the probe
with pin 2.
Other than short circuit (0 Ω)
Inspection 2
Harness continuity check (open circuit check) No continuity (∞ Ω)
Disconnect CN135, CN185 and CN186.
CN135-1 (44) to CN185-1 (44)
CN135-2 (44) to CN186-1 (44)
CN135-3 (39) to CN185-2 (39)
CN135-3 (39) to CN186-2 (39) • Fan harness defect
Continuity (0 Ω)
Inspection 3
Harness continuity check (open circuit check) No continuity (∞ Ω)
Disconnect CN101, CN104 and CN 135.
CN104-14 (44) to CN135-1 (44)
CN104-14 (44) to CN135-2 (44)
CN104-24 (39) to CN135-3 (39)
• Main harness defect
CN104-24 (39) to CN101-9 (39)
Continuity (0 Ω)
Inspection 4
Harness continuity check (short circuit check) Continuity (0 Ω)
Disconnect CN101 and CN104.
CN104-14 (44) to CN104-24 (39)
CN104-14 (44) to CN101-9 (39) • Main harness defect
A To next page
5-67
Inspection 5 300 to 360 Ω [at 25°C (68°F)]

Harness continuity check (open circuit/short circuit check)
Open the main controller cover, and disconnect CN105.
(Check the harness side of CN105 with a circuit tester.)
CN105-2 (39) to CN105-3 (39)
CN105-2 (39) to CN105-4 (130) • CPU board defect or cooling fan defect
CN105-2 (39) to CN105-5 (131) (open circuits for two or more)
CN105-2 (39) to CN105-6 (132)
CN105-2 (39) to CN105-7 (133)
CN105-2 (39) to CN105-8 (134)
CN105-2 (39) to CN105-9 (135)
Other than 300 to 360 Ω [at 25°C (68°F)]
Inspection 6 300 to 360 Ω [at 25°C (68°F)]

Fan voltage dividing resistance check
Check the fan voltage dividing resistance in the NG circuit.
Other than 300 to 360 Ω [at 25°C (68°F)]
• Fan voltage dividing resistor defect • Internal harness defect

5-68
A0-5 Main controller cooling fan abnormality
Related Portion
CN107-1 (127, FANR+)

CPU Main
board CN107-2 (128, FANR–) controller fan
The cooling fan line from the CPU board to the main controller fan is open or short, or the main controller is
overheated.
ANL : ACTIVE TEST ACT-1 The fan operates.

FAN: Set the cooling fan to ON in the active test mode.
(Battery plug: ON, key switch: ON)
• Overheated, wait for some time
The fan does not operate. without operation.
Battery plug OFF and CN107 disconnection.

Battery plug: ON, key switch: ON
ANL : ACTIVE TEST ACT-1

FAN: Set the cooling fan to ON in the active test mode.
Inspection 1
CN107-1 (127) Other than 15 to 25 V
Voltage check
CN107-2 (128)
15 to 25 V
• Cooling fan defect

5-69
A1-1 Main controller high voltage
Related Portion
P2
CN104-14, 15 (44, VBMB)
CPU
board
Overvoltage is detected in VBMB line.
Turn the key switch to OFF once and to

ON again.
YES ANL : I/O MONITOR 1 I/O1-11 Less than 110 V

Does error A1-1 appear?
VBMB: Voltage check
NO 110 V or above • CPU board defect
Inspection 2 Less than 110 V

Approx. 80 V • Battery replacement
Was the battery plug disconnected YES

• During traveling, never disconnect the battery plug except
during traveling? *
for an emergency.
NO
• Battery plug inspection
*: The battery plug was disconnected by the emergency

battery plug disconnector during traveling.
5-70
A1-2 Traveling controller high voltage
Related Portion
MB F1
P1 P2
P3
Traveling
controller
Overvoltage in the battery voltage line to the traveling controller is detected.
Note:
If A1-1 occurs at the same time, conduct troubleshooting for A1-1 first.
Turn the key switch to OFF once and to

ON again.
YES ANL : I/O MONITOR 1 I/O1-13 Less than 110 V

Does error A1-2 appear? VBBD: Traveling controller DC_BUS
voltage check
NO • Traveling controller
110 V or above defect
Inspection 2 Less than 110 V

Approx. 80 V • Battery replacement
F1 fuse check
OK (0 Ω)
Was the battery plug disconnected YES

• During traveling, never disconnect the battery plug except
during traveling? *
for an emergency.
NO
• Battery plug inspection *: The battery plug was disconnected by the emergency
battery plug disconnector during traveling.
5-71
A2-1 CPU board abnormal temperature rise
Related Portion
CPU board
Temperature sensor
TH101
The temperature sensor on the CPU board detects the abnormally high temperature.
Notes:
• If A0-4 or 5 occurs at the same time, conduct troubleshooting for A0-4 or 5 first.
• Display is made only on the safety monitor.

• Stand the vehicle for a while (approx. 30 minutes).
TEMP: CPU board temperature check
Less than 80°C
Isn’t the vehicle used continuously in YES

• Stop the vehicle and test with the standard load for
overloaded state?
confirmation 30 minutes later.
NO

5-72
A2-2 Traveling controller board abnormal temperature rise
Related Portion
PCB temperature sensor
The temperature sensor in the traveling controller detects the abnormally high temperature.
Notes:
• If A0-4 or 5 occurs at the same time, conduct troubleshooting for A0-4 or 5 first.
• Display is made only on the safety monitor.

TBD: Traveling controller board • Stand the vehicle for a while (approx. 30 minutes).
temperature check
Less than 100°C
Isn’t the vehicle used continuously in YES

• Stop the vehicle and test with the standard load for
overloaded state?
confirmation 30 minutes later.
NO

5-73
A4 Accelerator switch abnormality
Related Portion
CN25 CN26
CN102-1 (64, SWAC) CN25-1 CN26-2
CPU
board CN102-22 (51, POT–) CN25-2 CN26-1 Accelerator
potentiometer
The accelerator switch is already ON before battery plug ON.
Was the accelerator switch ON before YES

• Normal
battery plug ON?
NO

disconnect accelerator potentiometer
connector CN26.
Reconnect the battery plug.
NO
Does error A4 appear? • Accelerator potentiometer adjustment
YES
Inspection 1
Disconnect the battery plug and Continuity
CN102. (20 Ω or less)
• Harness defect
CN102-1 (64)
Continuity check
CN102-22 (51)

5-74
AA-1 CPU board temperature sensor abnormality
Related Portion
CPU board
Temperature sensor
TH101
The temperature on the CPU board is abnormal.
AA-2 Traveling controller board temperature sensor abnormality
Related Portion
PCB temperature sensor
The temperature sensor in the traveling controller is abnormal.
Note:
If AD-1 occurs at the same time, conduct troubleshooting for AD-1 first.
• Replace the traveling controller for correction.

5-75
AC Semiconductor switch abnormality
Related Portion
CN126
CN104-9 (55, CPR)
P1 MB CPR
P2
CPU
P3
F1 board
CN104-1, 2 (18, B80V)
F7 CN166-7
CN104-25 (42, KEYSTART)
Traveling
controller
Overcurrent is detected in the semiconductor switch in the CPU board.
Note:
If CB-1 occurs at the same time, conduct troubleshooting for CB-1 first.
Error AC does not

Disconnect the battery plug and CN126, appear.
reconnect the battery plug, and turn the A To next page
key switch ON.
Error AC is displayed.
Disconnect the battery plug and CN166. Error AC does not Inspection 1
Reconnect the battery plug, and turn appear. Disconnect CN166, and check the resistance
the key switch ON. between pin 7 on the harness side and N1.
Pin 7 (Tester probe)
Error AC is displayed. Resistance check
N1 (tester probe)
Less than Approx. 20 Ω

approx. 20 Ω or above
• CPU board defect • Harness inspection • Traveling controller defect

• Harness defect
5-76
Inspection 2 NG (other than OK)

• CPR defect
CPR resistance check
OK (approx. 20 Ω)
Inspection 3 Momentarily shorted, but the

Resistance check between P2 and N1 resistance rises gradually.
P2 (tester probe) • CPU board defect
Resistance check
N1 (tester probe)
Short circuit
Inspection 4
Disconnect P3, N1 cable or copper bar from
the traveling controller, and check the
resistance between P3 and N1 on the Short circuit
traveling controller side. • Traveling controller defect
P3 (tester probe)
Resistance check
N1 (tester probe)
Open circuit
• P3 or N1 cable inspection
5-77
AD-1 Traveling controller to main controller communication abnormality
Related Portion
CN103-1 (145, CANH) CN166-3 (145, CANH)

CN103-2 (146, CANL) CN166-4 (146, CANL)
CPU Traveling
board CN104-25 (42, KEYSTART) CN166-7 (42, KEYSTART) controller
CN169
1
R
2
3
The CPU board failed to receive the communication data from the traveling controller within the specified time.
YES
Is error AD-2 displayed? • Refer to the troubleshooting for error AD-2.
NO

• Check connectors CN103, CN104, CN166 and CN169 for
immediately before?
secure connection.
• Turn the key switch OFF and ON to confirm no error code
NO displayed.
ANL : I/O MONITOR 1 I/O1-1, 3, 5, 13 Data is displayed.

Check the data from the traveling • Traveling controller was reset midway (possibility of traveling
controller. controller defect)
• Harness inspection (especially line 42)
Data is not displayed. • Check connectors CN103, CN104, CN166 and CN169 for
secure connection.
A To next page
5-78
CN166-7 (42) Less than 20 V Disconnect CN166. 20 V or above
N1 Voltage check
N1
20 V or above
• Traveling controller
Less than 20 V
defect
Inspection 2
Disconnect the battery plug and Other than Inspection 5
CN169. 110 to 130 Ω CN104-25 (42) Less than 20 V
CN169-1 (145) Voltage check
Resistance check N1
20 V or above
110 to 130 Ω • Resistance defect
• Harness defect
Inspection 3
Communication line harness check
Disconnect CN103 and CN166. No continuity
CN103-1 (145) to CN166-3 (145) (∞Ω)
CN103-1 (145) to CN169-1 (146) • Harness defect
CN103-2 (146) to CN166-4 (146)
CN103-2 (146) to CN169-2 (146)
CN103-3 (147) to CN166-6 (147)
Continuity (0 Ω)

(possibility of CPU board defect)
5-79
AD-2 Traveling controller to main controller communication abnormality
Related Portion
CN103-1 (145, CANH) CN166-3 (145, CANH)

CN103-2 (146, CANL) CN166-4 (146, CANL)
CPU Traveling
board CN104-25 (42, KEYSTART) CN166-7 (42, KEYSTART) controller
CN169
1
R
2
3
The CPU board fails to receive the ID code from the traveling controller upon key switch ON.

• Check connectors CN103, CN104, CN166 and CN169 for
immediately before?
secure connection.
• Harness inspection (especially line 42)
NO
Does error AD-2 appear upon repetition NO

of key switch OFF and ON?
YES
A To next page
5-80
CN166-7 (42) Less than 20 V Disconnect CN166. 20 V or above
N1 Voltage check
N1
20 V or above
• Traveling controller
Less than 20 V
defect
Inspection 2
Disconnect the battery plug and Other than Inspection 5
CN169. 110 to 130 Ω CN104-25 (42) Less than 20 V
Resistance check N1
20 V or above
110 to 130 Ω • Resistance defect
• Harness defect
Inspection 3
Continuity of communication line
harness check No continuity
Disconnect CN103 and CN166. (∞Ω)
CN103-1 (145) to CN166-3 (145) • Harness defect
CN103-1 (145) to CN169-1 (145)
CN103-2 (146) to CN166-4 (146)
CN103-2 (146) to CN169-2 (146)
CN103-3 (147) to CN166-6 (147)
Continuity (0 Ω)

(possibility of CPU board defect)
5-81
AF-1, 2, 3, 4 CPU board abnormality
Related Portion
CPU board
CPU
The CPU device on the CPU board is abnormal.
C1-1 Traveling controller current sensor offset abnormality
Related Portion
Current sensor
The traveling controller detects an abnormality at the time of current sensor offset correction upon starting.
• Replace the traveling controller for correction.

5-82
C1-2 Traveling controller overcurrent abnormality
Related Portion
P7
Traveling P8
controller Drive motor
P9
Overcurrent is detected by the traveling controller.
Does error C1-2 appear when repeating NO

• Drive motor cable inspection
key switch OFF/ON?
• Drive motor continuity inspection
YES

5-83
Related Portion
Drive motor
Temperature sensor
The drive motor temperature sensor value is above the specified one.
Note:
• Stand the vehicle without operation for a while (about 30 minutes).

5-84
C2-2 Drive motor temperature sensor abnormality
Related Portion
CN57 CN55
CN166-13 (88, TD+) 6 2
Traveling Drive motor
controller temperature
CN166-10 (83, TD–) 5 1
sensor
The motor temperature sensor value is not as specified. (open or short circuit)
Note:
Disconnect the battery plug and Other Harness continuity check No continuity (∞ Ω)
CN166, and check the resistance (on CN166-13 (88) to CN55-2 (88)
the harness side). CN166-10 (83) to CN55-1 (83)
CN166-13 (88)
Continuity (0 Ω)
Resistance check
CN166-10 (83) • Harness defect
Inspection 5
300 to 2 kΩ
Disconnect CN55, and check the
continuity between CN55 pins (on Continuity (0 Ω)
Inspection 2 harness side).
Connect CN166, disconnect CN55, CN55-2 (88)
connect the battery plug, turn the key Continuity check
switch ON, and check the voltage CN55-1 (83)
between CN55 pins.
CN55-2 (88) No continuity (∞ Ω)
Voltage check
CN55-1 (83)
Inspection 6
NG
CN55 connector check for pin/ • Repair or harness
harness status, etc. replacement
• Traveling controller defect OK
Disconnect the battery plug, and use

B
SST2 to short-circuit between CN55
pins 1 and 2.
A
5-85
A B
Connect the battery plug and turn the Temperature sensor resistance check
key switch ON (on sensor side)
CN166-13 (88) CN55-2 (88)
Voltage check Resistance check
CN166-10 (83) CN55-1 (83)
0 to 0.1 V Other 300 to 2 kΩ Other
• Temperature • Traveling controller defect • Temperature sensor defect

sensor defect • Harness defect
• Defective contact of the connector may be the reason.
Connect CN166 and CN55 again and check secure
connection.
Reconnect the battery plug, turn the key switch ON, and
check that no error code is displayed.
5-86
C3-1 Traveling controller main circuit temperature sensor abnormality
Related Portion
Temperature sensor
The heat sink temperature sensor in the traveling controller is abnormal.
Note:
• Replace the traveling control for correction.

5-87
C4-1, 2, 3, 4 Accelerator potentiometer abnormality
Related Portion
CN25 CN26
CN102-1 (64, SWAC) 2 CN26-2
CN102-2 (52, POTA) 3 CN26-3
CPU board Accelerator
CN102-22 (51, POT–) 1 CN26-1
• C4-1 : The accelerator line voltage (POTA) upon accelerator switch ON is below the specified level.
• C4-2 : The accelerator line voltage (POTA) is above the specified level.
• C4-3 : The accelerator line voltage (POTA) upon accelerator switch OFF is above the specified level.
• C4-4 : The accelerator line voltage (POTA) upon accelerator ON/OFF switching is above the specified level.
• C4-1

Check the POTA value when the accelerator switch
SWAC value changes from “0” to “1”.
Less than 0.3 V • CPU board defect
ANL : I/O MONITOR 2 I/O2-1 The POTA value changes.

Depress the accelerator pedal further and check the
POTA value.
The POTA value remains unchanged. • Accelerator potentiometer

adjustment defect
Disconnect CN26, and short POTA and POTA+ by

connecting SST8.
The displayed error code changes Does not change to C4-2.

to C4-2.
• Accelerator potentiometer Inspection 1
defect CN102-2 (52)
• Harness defect Voltage check
N1
4.8 V or above Less than 4.8 V

5-88
• C4-2
Does the error code display disappear Disappears.

• Accelerator potentiometer inspection
upon disconnection of CN26?
Does not disappear.
Inspection 1
CN102-2 (52)
Voltage check
N1
• CPU board defect • Harness defect
• C4-3
ANL : I/O MONITOR 2 I/O2-1 SWAC value check Remains at 0.

Check the SWAC value changes from 0 to 1 as the • Acceleration switch defect
accelerator pedal is depressed.
Changes to 1.
ANL : I/O MONITOR 2 I/O2-1 Less than 2.5 V YES

Check the maximum POTA value Is error C4-3 being displayed?
when SWAC display is 0.
NO • CPU board defect
2.5 V or above
Disappears.
Does the error display disappear upon • Accelerator potentiometer inspection
disconnection of CN26?
Does not disappear.
Inspection 1
CN102-2 (52)
Voltage check
N1
• C4-4
Note:
If C4-2 or C4-3 occurs at the same time, conduct troubleshooting for C4-2 or C4-3 first.

Check the POTA value when the SWAC value
changes from 0 to 1 or from 1 to 0.
Less than1.4 V 1.4 V or above
• CPU board defect • Accelerator potentiometer

adjustment defect
5-89
C7 Direction switch abnormality
Related Portion
CN9
CN101-1 (45, DSF) 5
CPU CN101-2 (46, DSR) 4

Direction switch
board
CN101-16 (51, LS–) 1

J1
The direction switch is set to both forward and reverse.
“0”
ANL : I/O MONITOR 2 I/O2-2 • Direction switch inspection
DSF and DSR ON/OFF value check
DSF or DSR value at “1”
Inspection 1
CN101-1 (45)
CN101-2 (46)
Voltage check
N1
Approx. 5 V Other than approx. 5 V
• CPU board defect • Harness short circuit

5-90
C8-1 Drive motor rpm sensor abnormality
Related Portion
CN166-9 (80, SSD+) 1 CN56-1 (80, SSD+)

Traveling
controller CN166-11 (81, SSD1) 2 CN56-2 (81, SSD1)
CN166-12 (82, SSD2) 3 CN56-3 (82, SSD2)
CN166-10 (83, SSD–) 4 CN56-4 (83, SSD–)
CN57 CN56 Drive motor rpm sensor
The traveling controller detects an abnormality of the drive motor rpm sensor.
Disconnect the battery plug, connect SST19 to

CN166, and connect CN1 and CN3 of SST19.
Connect the battery plug, turn the key switch ON, and Either one is on.
• Check connection of CN1 and CN3 of
check the LEDs on SST19 during traveling.
SST19.
Both are on. Both are off.
Disconnect the battery plug, connect SST19 to

CN166, and connect CN2 and CN3 of SST19.
NG
Connect the battery, turn the key switch ON, and (both are blinking)
check the LEDs of SST19 during traveling. • Traveling controller defect
Other than NG
Disconnect CN56, and check the voltage at CN56 on NG

the harness side. (all between 8 and 13 V)
Pin 1 [tester probe] - pin 4 [tester probe] • Drive motor rpm sensor abnormality
Pin 2 [tester probe] - pin 4 [tester probe]
Pin 3 [tester probe] - pin 4 [tester probe]
Other than NG
• Harness defect
5-91
CB-1 MB contactor abnormality
Related Portion
MB F6
P1 P2 CN104-14, 15 (44, VBMB) CPU
board
CN104-1, 2 (18, B80V)
F7
6 CN104-19 (1, MB+)
5 CN104-20 (2, MB–)
MB contactor coil CN134 CN136
The voltage difference between B80V and VBMB lines is at or above the specified value.
Note:
If 31-1, 3, A1-1, 2, 3, AD-2, 6, C1-2 or E1-2 occurs at the same time, conduct troubleshooting for error 31-1, 3,
A1-1, 2, 3, AD-2, 6, C1-2 or E1-2 first.
Is the MB contactor closing sound heard NO

A
upon key switch ON?
YES
ANL : I/O MONITOR 1 I/O1-8, 11 Less than 30 V ANL : I/O MONITOR 1 I/O1-8 Less than 72 V
Battery voltage check: VB80, Battery voltage check: VB80
VBMB (M)
Check the voltage difference between 72 V or above • Charge the battery.
VB80 and VBMB (M).
30 V or above
Battery voltage check: VBMB 40 V or above
Check the VBMB voltage while
B traveling.
Less than 40 V • CPU board defect
Inspection 6
Check the P2 voltage while traveling. 40 V or above
P2
Voltage check
N1
Less than 40 V
• MB contactor defect
5-92
Disconnect CN134 and check the NG Check the voltage at the CPU board
voltage between connector terminals (less than 9 V) connector. Less than 9 V
on the CPU side. CN104-19 (1)
9 V or above
OK (9 V or above)
• MB contactor defect • Harness inspection between CN104 and

MB contactor
F6 fuse check
OK (0 Ω)
Inspection 2
Check the voltage difference between
P1 and P2.
P1 30 V or above
P2 • MB contactor defect
Voltage check
N1
Less than 30 V
Inspection 3
Voltage check between CN104-14
(44) and N1, and between CN104-1
(18) and N1. Check the voltage 30 V or above
difference between CN104-1 and • Harness inspection
CN104-14.
CN104-14 (44)
CN104-1 (18)
Voltage check
N1
Less than 30 V

5-93
EE-1, 2, 3 Multi-display to main controller communication abnormality
Related Portion
CN1
CN70
CN103-13 (144, SMTDK) 7 23
CN103-14 (143, SDTMK) 4 24
CN103-15 (142, SDTMA) 8 21
CPU CN103-16 (141, SMTDA) 3 22 Display
board
CN103-10 (16, D15V) 2 14
CN103-12 (14, GNDD) 1 30
The communication data from the display is abnormal.
• EE-1
YES
Is error F1 displayed? • See the troubleshooting for F1 error.
NO
Is the display turned ON upon key OFF Inspection 1

switch ON? Disconnect CN1.
CN103-10 (16)
ON Voltage check
CN103-12 (14)
• EE-2 14 V or above Less than 14 V
• Sub harness discontinuity • CPU board defect

• Display defect
Disconnect the battery plug, and use Error is displayed upon key switch ON.
two SST2s to connect CN1-3 with CN1- • Main harness open
8 and CN1-4 with CN1-7. • CPU board defect
No error is displayed upon key switch ON.
• Sub harness discontinuity

• Display defect
• EE-3
Perform tuning settings again.
If EE-3 error is displayed frequently, the CPU board or display may be defective.
5-94
EF-1, 2, 3, 4 Main controller EEPROM abnormality or CPU device abnormality
Related Portion
CPU board
The EEPROM or CPU device on the CPU board is abnormal.

5-95
F0-1, 2, 3 PS contactor abnormality
Related Portion
CN59
CN104-21 (37, MPS+)
2
CPU PS
board contactor
CN104-28 (38, MPS–)
1
• F0-1: PS contactor open circuit.

• F0-2: PS contactor load short circuit.
• F0-3: PS contactor drive circuit MOS short circuit.
The PS contactor line from the CPU board to the PS contactor involves open or short circuit.
• For F0-1
Connect battery plug, turn key switch ON, and release parking brake. Error F0-1 not displayed
Move the direction switch to either DSF or DSR position.
F0-1 error displayed • Connector connection check
Disconnect the battery plug, and disconnect CN59.
Inspection 1
Connect battery plug, turn key switch ON, and release parking
brake.
9 V or above
Move the direction switch to either DSF or DSR position.
CN59-2 (37)
Voltage check
• Contactor defect
CN59-1 (38)
• Contactor harness defect
9 V or less
Inspection 2
Disconnect the battery plug, disconnect CN104, and check Continuity
continuity (on harness side).
CN104-21 (37) to CN59-2 (37)
CN104-28 (38) to CN59-1 (38)
No continuity
• Harness defect
5-96
• For F0-2
Connect battery plug, turn key switch ON, and release parking brake. Error F0-2 is not displayed.
Move the direction switch to DSF or DSR position.
Error F0-2 is displayed. • Connector connection check
Disconnect the battery plug, and disconnect CN59.
Connect battery plug, turn key switch ON, and release parking brake. Error F0-1 is displayed.
Error F0-2 is displayed. • PS contactor defect

• PS contactor harness defect
Inspection 3
Disconnect the battery plug, disconnect CN104, and check
continuity (on harness side). Continuity
CN104-21 (37)
Continuity check
CN104-28 (38) • Harness defect
No continuity
• For F0-3
Connect battery plug, turn key switch ON, and release parking brake. Error F0-3 is not displayed.
Error F0-3 is displayed. • Connector connection check
Inspection 4
Disconnect the battery plug, disconnect CN104, and check the
connector on the CPU board side. Less than 10 V
Reconnect the battery plug, turn the key switch ON, and move the
direction switch neutral position.
CN104-21 (37)
• Harness defect
Voltage check
CN104-23 (N2)
10 V or above

5-97
F1-1, 2 Main controller to multi-display communication abnormality
Related Portion
CN1
CN103-16 (141, SMTDA) 3 CN70-1-22 (141, SMTDA)
CPU Multi-
board CN103-13 (144, SMTDK) 7 CN70-1-23 (144, SMTDK) display
The communication data from the CPU board is abnormal.
Note:
When error F1-1 occurs, other error codes, if any, are not displayed because of communication failure from
the CPU board. Error code F1-1 is kept displayed on the multi-display screen irrelevant to key switch ON or
OFF position.
Check if connectors CN103, CN70-1 and CN1 are NG

securely connected. • Retest after connector reconnection
OK
Inspection 1
Disconnect the battery plug, disconnect CN103 and No continuity
CN70-1, and check continuity. • Harness defect (defect between CN103
CN103-16 (141) to CN70-1-22 (141) and CN70-1)
CN103-13 (144) to CN70-1-23 (144)
Continuity

5-98
FF D15V overcurrent
Related Portion
CN1 CN70-1
CN103-10 (16, D15V) 2 14
CN103-12 (14, GNDD) 1 30 DISP board
CPU
board
Overcurrent in the D15V power supply line is detected.
Disconnect CN70-1, connect the battery plug, and turn No error

the key switch ON. • Display defect
Error FF display
Inspection 1
Disconnect the battery plug, disconnect CN103, and Less than
check the resistance. approx. 1 kΩ
• Harness defect
CN103-10 (16): Circuit tester probe
Resistance check
CN103-12 (14): Circuit tester probe
Approx. 1 kΩ or above

5-99
WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED

The vehicle does not move (The display is also OFF)
Related Portion
MB F6
P1 P2 CN104-14, 15 (44, VBMB) CPU
board
F7 CN104-1, 2 (18, B80V)
Key switch
P0 F5 CN103-4 (43, VBKY)
CN103-7 (41, VBBT)

N2 CN104-22 (N2, N2)
Inspection 1
P1 Less than 25 V
Voltage check • Charge the battery.
N1
25 V or above
F7 fuse check
OK (0 Ω)
Inspection 3
CN104-1 (18) Less than 25 V
CN104-2 (18) • Harness inspection
Voltage check
N2
25 V or above
Inspection 4 Other than OK Inspection 5 NG

Key switch ON. F5 fuse check
CN103-4 (43)
Voltage check • F5 fuse
OK
CN104-22 (N2) replacement
CN103-7 (41) Inspection 6 NG
Voltage check Key switch check
CN104-22 (N2)
• Key switch
OK
OK replacement
(Voltage is 15 V or above Inspection 7 Other than
and voltage difference - P0 approx. 48 V
is within 13 V.) Voltage check
N1
• CPU board defect • Battery plug or
Approx. 48 V
battery inspection
5-100
The vehicle does not move normally
Related Portion
CN9
CPU
board CN101-1 (45, DSF) 5
CN101-2 (46, DSR) 4 Direction switch
CN101-16 (51, LS–) 1

J1
CN25 CN26
CN102-1 (64, SWAC) 2 CN26-2
CN102-2 (52, POTA) 3 CN26-3 Accelerator
CN102-22 (51, POT–) 1 CN26-1
CN42
CN101-5 (67, LSD) 2
1 Seat switch
J1
YES
Is the warning alarm sounding? • Acceleration switch: OFF
• Direction switch: OFF
NO • Parking switch: OFF (Release)
ANL : I/O MONITOR 2 I/O2-1 Both values remain

Check acceleration switch SWAC and unchanged.
• Acceleration switch inspection
POTA values while depressing the
accelerator pedal.
Both values change.
Remain
ANL : I/O MONITOR 2 I/O2-2 unchanged.
Check the DSF and DSR values upon • Direction switch inspection
direction switch operation.
Changes
ANL : I/O MONITOR 2 I/O2-3 “0” display

✽ LSD value check upon operator’s • Seat switch inspection
seat seated
“1” display
A To next page ✽: If immeasurable, disconnect CN42 and connect SST

09238-13130-71 to enable measurement without seating.
5-101
Inspection 1 Other than

Move the direction switch to either OK
DSF or DSR position, depress the • Traveling controller defect
accelerator pedal, and measure the
drive motor OCL value. (See P3-52)
✽ OK
(380 to 485 A)
YES Inspection 2 NG
Is creep-speed traveling possible? • Cable repair
Motor cable inspection
NO
OK
• Conduct troubleshooting for error C8-1.
NO
Is the motor operating sound heard? • Motor cable inspection
• Motor inspection
YES
• Brake
• Pipings and cables
• Inspection of gears and other mechanical parts
✽: If immeasurable, disconnect CN42 and connect SST
09238-13130-71 to enable measurement without seating.
5-102
The vehicle does not move when the direction switch is operated after sitting on the
operator’s seat (The OPS indicator lamp comes on)
Related Portion
RYD
LP
SWK LSD
CN42 CN42
P0 F5
CN101-5 (67, LSD)

CPU
board CN101-16 (51, LS–)
“1” display upon seating on the operator’s seat

ANL : I/O MONITOR 2 I/O2-3 (“0” display upon leaving the operator’s seat)
“0” display while sitting on the operator’s seat

Inspection 1
Disconnect the battery plug, NG (inactive)
disconnect CN42, and inspect the
seat switch.
OK
• RYD defect
Inspection 2 NG (inactive)
Connect the battery plug, turn the key

switch ON, and sit on the operator’s
seat.
Inspection 3
CN101-5 (67) NG (5 V)
Voltage check
CN101-16 (51)
• Harness defect
OK (0 V)
• CPU board defect Note:

If the OPS lamp keeps lighting even after defect elimination,
inspect the RYD and lamp wiring for any defect.
5-103
The vehicle moves when the direction switch is operated without sitting on the operator’s
seat
Related Portion
RYD
LP
SWK LSD
CN42 CN42
P0 F5
CN101-5 (67, LSD)

CPU
board CN101-16 (51, LS–)
“1” is displayed even when the operator’s seat is vacant.

“1” is displayed upon sitting on the operator’s seat.

(“0” is displayed upon leaving the seat.)
• Seat switch abnormality
Inspection 1 NG (shorted)
• CPU board inspection

Note:
If the OPS lamp does not come ON even after defect elimination, inspect the OPS lamp, RYD, and lamp wiring
for any defect.
5-104
Memo
6-1
MOTOR
Page 6
DRIVE MOTOR .................................................. 6-2
6
2TE15
GENERAL ................................................................... 6-2
6
SPECIFICATIONS ...................................................... 6-2 6
COMPONENTS........................................................... 6-3
6
TROUBLESHOOTING ................................................ 6-4
DISASSEMBLY • INSPECTION • REASSEMBLY ..... 6-7 6
2TE18
GENERAL .................................................................. 6-9
6
SPECIFICATIONS ..................................................... 6-9 6
COMPONENTS ........................................................ 6-10
6
TROUBLESHOOTING ............................................. 6-11
REMOVAL • INSTALLATION .................................. 6-12 6
DISASSEMBLY • INSPECTION • REASSEMBLY ... 6-14 6
POWER STEERING MOTOR........................... 6-16
GENERAL ................................................................. 6-16
6
SPECIFICATIONS .................................................... 6-16 6
COMPONENTS......................................................... 6-17
6
TROUBLESHOOTING .............................................. 6-18
REMOVAL • INSTALLATION ................................... 6-19 6
6
6
6-2
DRIVE MOTOR
2TE15
GENERAL
SPECIFICATIONS
Type 3-phase AC, open type
Nominal voltage V 80
Rated output (60-min rating) kW 11.8
Dimensions (outside diameter × length) mm (in.) ø270 × 368 (10.63 × 14.49)
Weight (including drive unit case) kg (lb) 102 (225)
Insulation class Class F

6-3
COMPONENTS
1401
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6-4
TROUBLESHOOTING
Only the defects related to the motor ASSY are described. (See Section 5 for the defects related to the controller.)
Phenomenon Estimated cause Action
Defective motor insulation resistance Inspection, repair or replacement
Loosened or disconnected motor cable

Connection or replacement
terminal or discontinuity of cable
Defective installation or failure of rpm

Correction or replacement
The vehicle does not travel or travels sensor
very slowly. Disconnected connector or discontinuity
Inspection correction or replacement
in wiring of rpm sensor
Bearing seizure Replacement
Disconnected connector or discontinuity

in temperature sensor wiring
6-5
6
6
6
2 6 6
6
3
6
6
4
6
Removal Procedure
6
1.
2.
Remove the rear axle ASSY W/drive motor ASSY. (See the drive unit on page 7-7)
Remove the rotary sensor cover. [Point 1]
6
3. Remove the rotary sensor. [Point 2]
6
4. Remove the pickup gear
5. Put match marks between the end bracket and the stator yoke and between the drive unit case and yoke.
[Point 3]
6
6.
7.
Loosen the through bolt and remove the end bracket.
Remove the stator ASSY and rotor ASSY. [Point 4]
6
Installation Procedure 6
Point Operations
6
[Point 1] 6
Removal:
Remove the sensor cover using the cutout in the end face of
end bracket.
6
6
Notch
6
6-6
[Point 2]
Gap Inspection:
1.2 to 1.8 mm Measure the clearance between the rotary sensor and pickup
(0.047 to 0.071 in.)
gear.
rpm Pick up Standard 1.2 to 1.8 mm (0.047 to 0.071 in.)

sensor gear
If the measured value is out of the standard, replace the rotary
sensor and pickup gear.
[Point 3]
Match marks
Disassembly:
Put match marks on the end bracket, drive unit case and stator
yoke.
Reassembly:
Align match marks when reassembling these parts.
[Point 4]
Carefully operate so as not to drop the rotor ASSY.
Installation:
(1) Never fail to install the wave washer on the bearing face
of the rotor ASSY. It is recommended to apply a small
amount of MP grease in order to prevent the washer from
falling.
(2) Apply the chassis special grease at the splined portion of
Wave washer
the rotor shaft.
Note:
Carefully operate so as not to damage the oil seal lip
surface.
6-7
1. Remove the rotor ASSY from the stator ASSY. [Point 1]
6-8
Point Operations
[Point 1]
Inspection:
(1) Measure the insulation resistance of the stator ASSY.
Measurement terminals:
Between the motor cable and body
(2) Check continuity between motor cables.

Measurement terminals: U - V, V - W and W - U
Standard: 0 Ω
(3) Measure resistance of the temperature sensor.

Both pins of temperature sensor connector
Standard: Approx. 11 to 15 kΩ (at 20°C)
(4) Check the bearing of the rotor ASSY.

If abnormal noise or damage is found, replace the bearing.
• Rotary sensor side
Removal : SST 09950-76014-71
(SST 09950-40011)
Installation : SST 09700-30200-71
SST
• Drive unit side

Removal : SST 09950-76014-71
(SST 09950-40011)
Installation : SST 09700-30200-71
SST
6-9
2TE18
GENERAL
SPECIFICATIONS
Type 3-phase AC, open type
Rated output (60-min rating) kW 16.6
Weight (including drive unit case) kg (lb) 96 (212)

6-10
COMPONENTS
1401
1401-161
1401
1401-163
6-11
TROUBLESHOOTING
Only the defects related to the motor ASSY are described. (See Section 5 for the defects related to the controller.)
Defective motor insulation resistance Inspection, repair or replacement
Loosened or disconnected motor cable

Connection or replacement
terminal or discontinuity of cable
Defective installation or failure of rpm

The vehicle does not travel or travels sensor
very slowly. Disconnected connector or discontinuity
in wiring of rpm sensor
Disconnected connector or discontinuity

in temperature sensor wiring
6-12
3
8
7
3
6
T=45.0 to 55.0 3
(460 to 560)
[33 to 41]
T=294 to 392
(3000 to 4000)
[217 to 289]
Removal Procedure
1. Remove the rear axle ASSY W/drive motor ASSY. (See P7-7)
2. Remove the motor cover.
3. Remove the drive motor sensor bracket, terminal bracket and sensor cover.
4. Make match marks between the end bracket, stator ASSY and gear case.
5. Remove the rear axle bracket RH.
6. Remove the nuts and through bolts. [Point 1]
7. Remove the end bracket. [Point 2]
8. Remove the stator ASSY W/rotor ASSY.
Note:
Apply MP grease to the spline portion of the rotor ASSY.
6-13
Point Operations
[Point 1]
Removal:
After removing the through bolts, slightly hoist the stator ASSY.
Installation:
4
After tightening the through bolts until contact with the bottom,
tighten the nuts in the illustrated order.
2
Installation:
When the motor is replaced with a new one, always remove
the stopper bolt and spacer installed on the center of the end
Spacer bracket. (Do not install it later.)
Stopper bolt
[Point 2]
Remove (install) the end bracket while slightly tapping it with a
plastic hammer.
Installation:
Wave washer Match the speed sensor harness with the notch in the end
bracket. Do not forget to place the wave washer as shown.
6-14

Note:
Do not apply any impact to the bearing (W/speed sensor).
1. Remove the rotor ASSY W/bearing. [Point 1]
2. Remove the bearing. [Point 2]
6-15
Point Operations
[Point 1]
Inspection:
Measure the insulation resistance of stator ASSY.
Between each terminal (U•V•W) and stator
Inspection:
Measure the temperature sensor resistance.
Between both terminals of temperature sensor connector
Standard: 0.5 to 1.0 kΩ
[Point 2]
Disassembly:
SST 09950-76014-71 (SST 09950-40011)
SST
Reassembly:
Reassemble in the following order:
(1) Install the bearing (L/speed sensor).
SST 09370-20270-71
SST
(2) Install the bearing (W/speed sensor).

Tapping the sensor for assembly may damage it. Use a
press for assembly.
SST SST 09411-41800-71
6-16
POWER STEERING MOTOR

GENERAL
SPECIFICATIONS
Type DC permanent magnet type
Rated output kW 1.0
Weight kg (lb) 9 (19.8)
Brush size (T × D × L) mm (in.) 8 × 30 × 25 (0.315 × 1.18 × 0.98)
Number of brushes 2
6-17
COMPONENTS
1403
6-18
TROUBLESHOOTING
PS motor insulation defect Inspection, correction or replacement
PS motor connector disconnection or

discontinuity
Motor and PS pump coupling defect

Correction
(Oldham's joint coupling defect)
Steering is inactive.
Worn brush Inspection or replacement
(The PS motor does not run.)
Degraded brush spring force Inspection or replacement
Roughened commutator Inspection, correction, or replacement
Worn brush Inspection or replacement
Degraded brush spring force Inspection or replacement

Steering operation is heavy.
Roughened commutator Inspection, correction, or replacement
Bearing sliding defect Replacement

6-19
Removal Procedure
3. Disconnect the connector.
4. Remove the PS pump set bolts. [Point 1]
5. Remove the PS motor ASSY and Oldham’s joint. [Point 2]
6-20
PS motor
Point Operations
High pressure Oil tank
PS pump side fitting
side fitting [Point 1]
Loosen (or tighten) two set bolts in the illustrated positions to
remove (or install) the PS pump.
Tightening torque:
T = 20 to 30 N·m (200 to 300 kgf-cm) [15 to 22 ft-lbf]
PS pump set bolts
[Point 2]
Oldham’s joint
Installation:
When assembling the PS motor and pump, fill molybdenum
PS motor disulfide grease in the groove on the oldham’s joint.
Apply Molybdenum disulfide

grease to fill the groove.
6-21

3
3
4
2 T=4.7 to 7.0
(48 to 72)
1 [3 to 5]
1. Remove the brush cover. [Point 1]
2. Float the brush to set it free.
3. Remove bracket No.2 and the commutator frame. [Point 2]
4. Remove the armature ASSY. [Point 3]
5. Remove the brush holder. [Point 4]
Note:
Check the insulation between the motor connector terminal and the motor body after reassembly.
Standard: 1 MΩ or more (with a DC 500 V megger)
6-22
Point Operations
[Point 1]
Reassembly:
Reassemble so that the brush hook is in the position illustrated
at left.
[Point 2]
Disassembly:
Punch a match mark on bracket No.2 and the yoke.
(Punch a match mark also on the commutator frame and
Match yoke.)
marks
Reassembly:
Install by aligning the match marks.
Inspection:
Measure the insulation resistance between the connector ter-
minal and motor body.
[Point 3]
Disassembly:
SST
SST 09950-76014-71
(SST 09950-40011)
Reassembly:
SST 09700-30200-71
SST
6-23
Inspection:
If the commutator surface is roughened, polish with a sandpa-
per (about #600). If the surface is excessively rough, repair
with a lathe.
Standard : 50 mm (1.97 in.)
Limit : 45 mm (1.77 in.)
Inspection:
When the commutator is repaired, undercut the mica.
Amount of undercutting:
Standard : 0.8 mm (0.031 in.)
Undercut
Limit : 0.3 mm (0.012 in.)
Mica
Inspection:
Measure the commutator runout.
Standard: 0.05 mm (0.00197 in.) or less
Inspection:
Measure the insulation resistance of the armature coil.
[Point 4]
Inspection:
Reassemble the armature coil and brush. Hook a spring bal-
ance to the brush spring. Measure the reading on the instant
when the spring comes off from the brush.
Spring force:
Standard : 5.59 N (0.57 kgf) [1.26 lbf]
Limit : 2.74 N (0.28 kgf) [0.62 lbf]
6-24
Inspection:
Measure the insulation resistance between the brush holder
and bracket.
Inspection:
Check the brush for wear and contact state.
Brush length:
Limit : 14 mm (0.55 in.)
7-1
DRIVE UNIT
Page 7
2TE15
7
GENERAL .......................................................... 7-2
SPECIFICATIONS.............................................. 7-3 7
COMPONENTS .................................................. 7-3 7
7
DRIVE UNIT ASSY............................................. 7-6
REMOVAL • INSTALLATION ..................................... 7-6
7
DISASSEMBLY • INSPECTION • REASSEMBLY ..... 7-9 7
DIFFERENTIAL CASE ASSY .......................... 7-11
7
DISASSEMBLY • INSPECTION • REASSEMBLY ... 7-11
2TE18
7
GENERAL ........................................................ 7-14 7
SPECIFICATIONS............................................ 7-15
7
COMPONENTS ................................................ 7-15
7
DRIVE UNIT ASSY........................................... 7-17 7
REMOVAL • INSTALLATION ................................... 7-17
7
DIFFERENTIAL CASE ASSY .......................... 7-25 7
7
7
7
7-2
2TE15
GENERAL
7-3
SPECIFICATIONS
Total reduction gear ratio 35.307
Number of teeth of drive unit gear No.1 16
Number of teeth of drive unit gear No.2

Large: 61 7
Small: 31
Large: 65 7
Number of teeth of drive unit gear No.3
7
Small: 12
Number of teeth of drive unit gear No.4 53
Differential oil amount (reference) l (US gal) 6.5 (1.72)

7
COMPONENTS 7
4101 7
7
7
7
7
7
7
7
7
7
7
7
7
7
7-4
3305
7-5
TROUBLESHOOTING
Gear contact noise due to insufficient lubrication Oil supply 7

7
Abnormal noise during traveling
Pitting or wear of differential side bearing Replacement
(rumbling noise)
7
Foreign matter trapping in or wear of gears Disassembly, cleaning or replacement

Worn differential gear thrust washer Replacement
7
(rattling noise: gear tapping noise)
Foreign matter trapped in or seizure of gearing Disassembly, cleaning or replacement

Traveling speed kept low
Seizure of differential side gear Replacement
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7-6
DRIVE UNIT ASSY

1
2
9 9
9
13
6
T=235 to 294
(2400 to 3000)
[173 to 217]
8
7
11
11
14 18
4 17
16 T=69 to 88
(704 to 898)
15 [51 to 65]
15
T=69 to 88
(704 to 898)
[51 to 65] 16
18
4
T=265 to 343 T=127 to 167

(2700 to 3500) (1300 to 1700)
[195 to 253] [93 to 123]
7-7
Removal Procedure
2. Remove the battery ASSY. (See P1-5)
3. Drain drive unit oil. [Point 1]
4. Jack up the vehicle, and remove the rear wheels. [Point 2]
5. Drain brake fluid, and disconnect the brake piping. [Point 3]
6. Remove the seat bracket W/seat ASSY.
7. Remove the battery under cover.
8. Disconnect the parking brake wire and intermediate cramp. [Point 4]
9. Disconnect the drive motor wiring and rpm sensors connector.
10. Hoist the rear axle ASSY W/drive motor and prop the lower part with wooden block. [Point 5]
11. Remove the rear axle bracket set bolts.
12. Lower rear axle ASSY W/drive motor onto the wooden block.
13. Hoist the rear side of the vehicle and move the vehicle forward. [Point 6]
14. Remove the drive motor ASSY. [Point 7]
15. Remove the rear axle shaft.
16. Remove the rear axle hub W/drum.
17. Remove the brake ASSY.
18. Remove the rear axle bracket.
Note:
After the end of installation, perform air bleeding from the brake system (See P12-28) and parking brake ad-
justment (See P12-31).
Point Operations
[Point 1]
Installation:
After installation, remove breather plug and apply specified
amount of hypoid gear oil. Or remove level plug and apply hy-
Breather plug poid gear oil until it overflows.
Specified amount: 6.5 liters
Level plug
[Point 2]
Jack up the vehicle and support both sides of the rear frame
with wooden blocks.
7-8
[Point 3]
Installation:
Bleed air from the brake system.
[Point 4]
Remove brake wire from intermediate clamp.
[Point 5]
Wind a fiber rope on the rear axle ASSY W/drive motor.
Put wooden blocks under the rear axle ASSY W/drive motor at
the three designated locations.
[Point 6]
Wind a fiber rope on the rear frame.
Put waste cloth, etc. between rope and frame so that fiber rope
is not cut by edge of frame.
[Point 7]
Wind a fiber rope on the drive motor, and take it out (install it)
carefully.
Installation:
Do not forget to insert a wave washer. It is recommended to
apply a small amount of MP grease to prevent it from coming
off.
7-9

T=61 to 114
(620 to 1160)
[44.86 to 83.93]
4 3
4
3 4
4 3
2
T=167 to 225 2
(1700 to 2300)
[123.0 to 166.4]
5
T=61 to 114 1
(620 to 1160)
[44.86 to 83.93]
1. Remove the rear axle housing.
2. Remove the drive unit cap and drive gear lock nut. [Point 1]
3. Erect the housing with the drive unit cover LH on the upper side, and remove the idle gear key plate, idle gear
pin and drive unit cover LH. [Point 2]
4. Remove the drive unit gear No. 1, 2 and 3. [Point 3]
5. Face the drive unit cover RH upward, and remove the cover RH. [Point 2]
6. Remove differential ASSY W/drive unit gear No.4.
7-10
Point Operations
[Point 1]
Disassembly • Reassembly:
SST Set the SST on the spline of the input shaft, and remove the
lock nut.
Take care not to give harm on the oil seal when setting SST.
SST 09330-33130-71
Tightening torque:
Reassembly:
Use a punch and caulk the lock nut securely (at 2 places).
[Point 2]
Disassembly:
Use a service bolt and remove the drive unit cover LH.
Service bolt: M14 × 1.5
Reassembly:
Apply liquid gasket (08826-76002-71) on the surface to be in
contact with the gear case.
[Point 3]
Disassembly:
As a bearing exists on the nut side end of drive unit gear No.3,
remove the gear by pulling it up while tapping the nut side end
with a hammer.
Drive unit gear No.3

7-11
DIFFERENTIAL CASE ASSY

T=127 to 176
(1300 to 1800)
[94 to 130]
1
2
T=43.1 to 53.9
(440 to 550)
[32 to 40]
1. Remove the differential case bearings. [Point 1]
2. Remove the differential upper case. [Point 2]
3. Remove the side gear and pinion gear. [Point 3]
4. Remove the ring gear. [Point 4]
7-12
Point Operations
SST (1)
[Point 1]
Disassembly:
SST 09950-76014-71 (SST 09950-40011)............ (1)
SST 09950-76018-71 (SST 09950-60010) ........... (2)
SST (2)
Reassembly:
Install the side bearing.
(1) Use the SST and install the side bearing up to the end
face of the case.
SST SST 09370-10410-71
(2) Use an appropriate tool and hammer to drive the bearing
fully in.
[Point 2]
Match mark Disassembly • Reassembly:

Check the match mark.
Reassembly:
Apply locking agent 08833-7600-71 (08833-00070) on the
threaded portion of the set bolt.
[Point 3]
Inspection:
Measure the differential pinion inside diameter.
Standard : 22.12 mm (0.8709 in.)
Limit : 22.22 mm (0.8748 in.)
Inspection:
Measure the spider outside diameter.
Standard : 22.00 mm (0.8661 in.)
Limit : 21.75 mm (0.8563 in.)
7-13
Inspection:
Measure the side gear thrust washer thickness.
Limit : 1.3 mm (0.051 in.)
Inspection:
Measure the pinion gear thrust washer thickness.
Limit : 1.0 mm (0.039 in.)
Reassembly:
Install the side gear thrust washer with its oil groove facing the
tooth flank. Uniformly apply chassis grease (molybdenum dis-
ulfide grease) on both-faces of the pinion gear thrust washer
before installation.
[Point 4]
Reassembly:
threaded portion of the set bolts. Tighten them gradually first in
the diagonal order, and finally tighten them in the circular order
to the specified torque.
7-14
2TE18
GENERAL
7-15
SPECIFICATIONS
Number of teeth of drive unit gear No. 1 (motor shaft gear) 22
Large : 81
Number of teeth of drive unit gear No. 2 (idle gear)
Small : 19
Number of teeth of drive unit gear No. 3 (differential gear) 51
Total reduction gear ratio 29.648
Differential oil amount (reference) l (US gal) 8.4 (2.2)
COMPONENTS
3305
7-16
4101
TROUBLESHOOTING
Gear contact noise due to insufficient lubrication Oil supply

Pitting or wear of differential side bearing Replacement
(rumbling noise)
Foreign matter trapping in or wear of gears Disassembly, cleaning or replacement

Worn differential gear thrust washer Replacement
(rattling noise: gear tapping noise)
Foreign matter trapped in or seizure of gearing Disassembly, cleaning or replacement

Traveling speed kept low
Seizure of differential side gear Replacement
7-17
DRIVE UNIT ASSY

T=294 to 588
(3000 to 6000)
[217 to 434]
4
T=235 to 294
(2400 to 3000)
[173 to 217]
12
8
7 9
10
20
T=11 to 15
(112 to 153)
T=180 to 323 [8 to 11]
(1840 to 3300)
[133 to 238]
21 11
13
21
15 20
15 20
15 14
19
T=294 to 392
(3000 to 4000)
18 [217 to 289]
17
T=45 to 55
(460 to 560)
[33 to 41]
7-18
Removal Procedure
1. Remove the battery ASSY. (See P1-5)
2. Remove the rear axle upper cover and rear axle under cover.
3. Drain drive unit oil. [Point1]
4. Jack up the vehicle and remove the rear wheels. [Point 2]
5. Drain brake fluid.
6. Disconnect the rear brake piping (at center of three way valve).
7. Disconnect the drawbar cable.
8. Remove the parking brake wire bracket.
9. Disconnect the parking brake wire.
10. Disconnect the drive motor cable.
11. Disconnect the speed sensor connector and temperature sensor connector.
12. Remove the rear axle ASSY W/drive motor ASSY. [Point 3]
13. Remove the rear axle bracket RH.
14. Remove the motor cover.
15. Remove the drive motor sensor bracket, terminal bracket and sensor cover.
16. Make match marks between the end bracket, stator ASSY and Gear case.
17. Remove the nuts and through bolts. [Point 4]
18. Remove the end bracket. [Point 5]
19. Remove the stator ASSY W/rotor ASSY.
20. Remove the rear axle ASSY and O-ring. [Point 6]
21. Remove the rear axle shaft (inner).
Notes:
• Apply MP grease to the spline portion of the drive motor ASSY.
• After installation, bleed air from the brake line. (See P12-28)
• After installation, inspect and adjust the parking brake. (See P12-31)
• Apply locking agent 08833-7600-71 (08833-00070) on the threaded portion of the rear axle ASSY set bolts
(for gear case connection) before tightening.
Point Operations
[Point 1]
Removal:
Remove the drain plug under the drive unit gear case and
drain oil.
Drain plug
7-19
Installation:
Pour designated oil to the specified level.
A = 15 mm or less
A
[Point 2]
Removal:
Jack up the vehicle and support both sides of the frame with
wooden blocks.
[Point 3]
Removal:
Operate as follows:
(1) Support the lower side of the rear axle ASSY W/drive mo-
tor ASSY with wooden blocks.
(2) Temporarily hoist the rear frame with a hoist and a fiber
rope.
(3) Remove the rear axle bracket set bolts (for connection
with the frame). Use the SST or hammer to remove the il-
lustrated reamer bolts.
7-20
SST 09310-23320-71
SST
(4) Remove the chocks and operate the hoist to advance the
vehicle.
[Point 4]
Removal:
After removing the through bolts, slightly hoist the motor ASSY.
Installation:
4
After tightening the through bolts to the depth, tighten the nuts
in the illustrated order.
2
Installation:
Always remove the stopper bolt and spacer from the center of
the end bracket when the motor is replaced with a new one.
Spacer (Do not install them later.)
Stopper bolt
7-21
[Point 5]
Removal:
Lightly tap the end bracket with a plastic hammer for removal.
Installation:
Lightly tap the end bracket with a plastic hammer for installa-
tion.
Installation:
Wave washer Match the speed sensor harness with the notch in the end
bracket. Do not forget to place the wave washer as shown.
[Point 6]
SST
SST 09090-76002-71 (SST 09090-04020)
7-22

T=51.0 to 64.7
(520 to 660)
[38 to 48]
T=20 to 31
(204 to 316)
[15 to 23]
T=94.5 to 175.5
(963.6 to 1790)
2
[70 to 129]
1 T=20 to 31
(204 to 316)
[15 to 23]
1. Remove the oil seal. [Point 1]
2. Raise to bring the gear case LH to the upper side, and remove the gear case LH. [Point 2]
3. Remove drive unit gear No. 1. [Point 3]
4. Remove the drive unit gear No. 2 and the differential ASSY W/drive unit gear No. 3. [Point 4]
Note:
After reassembly, apply MP grease on the oil seal lip and apply chassis grease on the inner surface of the
spline portion of drive unit gear No. 1.
7-23
Point Operations
SST (2) [Point 1]

Reassembly:
SST 09950-76018-71 (SST 09950-60010) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
SST (1)
[Point 2]
Disassembly:
Insert a straight edge screwdriver to the gear case joint por-
tion, and tap the opposite side with a plastic hammer for re-
moval.
Reassembly:
Apply gasket sealant (Three Bond No. 1281 or equivalent) on
the surface to be in contact with the gear case LH.
[Point 3]
Disassembly:
SST 09950-76014-71 (SST 09950-40011)............ (1)
SST 09950-76018-71 (SST 09950-60010) ........... (2)
SST (2)
SST (1)
7-24
Drive motor side Reassembly:

SST 09950-76018-71 (SST 09950-60010) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
Install the bearing on the drive motor side with the bearing
SST (2) sealing surface facing upward.
Sealing surface
SST (1)
[Point 4]
Disassembly:
SST 09950-76014-71 (SST 09950-40011)
SST
Reassembly:
SST 09950-76018-71 (SST 09950-60010) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
SST (2)
SST (1)
Reassembly:
NO. 2 NO. 3 Install drive unit gears No. 2 and No. 3 in meshing state into
the gear case.
7-25
DIFFERENTIAL CASE ASSY

T=127.5 to 176.5
(1300 to 1800)
[94 to 130]
1
2
1
4
T=43.1 to 53.9
(440 to 550)
[32 to 40]
1. Remove the differential case bearing. [Point 1]
2. Remove the differential upper case. [Point 2]
3. Remove the side gear, pinion gear and spider. [Point 3]
4. Remove the drive unit gear No. 3. [Point 4]
7-26
Point Operations
SST (1)
[Point 1]
Disassembly:
SST 09950-76014-71 (SST 09950-40011)............ (1)
SST (2) SST 09950-76018-71 (SST 09950-60010) ........... (2)
Reassembly:
SST 09421-33020-71
SST
[Point 2]
Disassembly:
Match marks
Punch match marks on the case.
Reassembly:
Align match marks for reassembly.
Reassembly:
threaded portion of the set bolt for reassembly.
[Point 3]
Inspection:
Measure the pinion gear inside diameter.
Standard : 22.12 mm (0.8709 in.)
Limit : 22.22 mm (0.8748 in.)
Inspection:
Measure the spider outside diameter.
Standard : 22.00 mm (0.8661 in.)
Limit : 21.75 mm (0.8563 in.)
7-27
Inspection:
Measure the side gear thrust washer thickness.
Limit : 1.3 mm (0.051 in.)
Inspection:
Measure the pinion gear thrust washer thickness.
Limit : 1.0 mm (0.039 in.)
Reassembly:
Install the side gear thrust washer with its oil groove facing the
tooth flank.
Oil groove
Reassembly:
Grease application
Uniformly apply chassis grease special (molybdenum disulfide
grease) on both sides of the pinion gear thrust washer before
reassembly.
[Point 4]
Reassembly:
set bolt threads before reassembly. Tighten the opposing pairs
of bolts gradually in order and finally tighten them to the spec-
ified torque.
Notes:
• Pay attention to the gear installing direction. Face the
Identification groove identification groove outward (opposite to the case)
for reassembly.
• The screw holes must be free from oil or grease.
7-28
Memo
8-1
REAR AXLE
Page 8
2TE15
8
GENERAL .......................................................... 8-2
SPECIFICATIONS.............................................. 8-2 8
COMPONENTS .................................................. 8-3 8
8
ADJUSTING THE REAR TIRE
INFLATING PRESSURE ................................. 8-4 8
REAR AXLE SHAFT • AXLE HUB .................... 8-5 8
REMOVAL • INSTALLATION ..................................... 8-5
REAR AXLE BRACKET • AXLE HOUSING ...... 8-9
8
2TE18
8
GENERAL ........................................................ 8-11
SPECIFICATIONS............................................ 8-12 8
COMPONENTS ................................................ 8-12 8
8
ADJUSTING THE REAR TIRE
INFLATING PRESSURE ............................... 8-14 8
REAR AXLE ASSY .......................................... 8-15 8
8
REAR AXLE BRACKET................................... 8-22 8
8
8
8-2
2TE15
GENERAL
SPECIFICATIONS
Rear axle type Fully floating type
Rear axle suspension Fixed type
Rear tire size 7.00-12-12PR (I)
Rear tire inflating pressure kPa (kgf/cm2) [psi] 700 (7.14) [100]
8-3
COMPONENTS
4205
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8-4
TROUBLESHOOTING
phenomenon Estimated cause Action
Wheel bearing insufficient lubrication Greasing

(rumbling noise)
Bearing roller pitting Replacement
Excessive play or wear of wheel bearing Preload adjustment or replacement

Rear wheel run-out, shock or instability
Loosened rear wheel hub nuts Retightening
Oil leak Rear axle shaft oil seal defect Replacement
ADJUSTING THE REAR TIRE INFLATING PRESSURE

Caution:
• Do not inflate tires beyond the specified pressure be-
cause it may cause dangerous tire bursting.
Specified inflating pressure

700 (7.14) [100]
kPa (kgf/cm2) [psi]
• When inflating a tire removed from the vehicle, place it in

a safety fence.
Wheel Disassembly and Reassembly

Caution:
Always release air from each tire before removal from the wheel ASSY. Never try to remove or install the tire
with any residual pressure.
8-5
REAR AXLE SHAFT • AXLE HUB

8
8
8
8
1
8
8
8
2
T=147 to 186
(1500 to 1900) 8
[109 to 137]
8
7 8
T=176 to 392
(1800 to 4000)
[130 to 289]
8
T=2.0 to 3.9 8
(20 to 40)
10 9
8
[1.5 to 2.9]
8
8
8
8
9
5
8
8
4
T=69 to 88
8
(700 to 900)
[51 to 65]
8
8-6
Removal Procedure
2. Jack up the vehicle and remove rear wheels. [Point 1]
4. Remove the rear axle shaft.
5. Remove the axle shaft oil seal. [Point 3]
6. Remove the bearing lock nut and plate. [Point 4]
7. Remove the rear axle hub W/brake drum. [Point 5]
8. Remove the oil seal and inner bearing. [Point 6]
9. Remove the bearing outer race. [Point 7]
10. Remove the brake drum.
Note:
Apply locking agent 08833-76001-71 (08833-00070) on the brake drum set nut before tightening.
Point Operations
[Point 1]
Jack up the vehicle and support both sides of the rear frame
with wooden blocks.
[Point 2]
Installation:
After installation, remove breather plug and apply specified
amount of hypoid gear oil. Or remove level plug and apply hy-
poid gear oil until it overflows.
Specified amount: 6.5 liters
Breather plug
Level plug
8-7
[Point 3]
Removal:
SST 09320-23000-71
SST
Installation:
SST 09950-76018-71 (SST 09950-60010) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
SST(1)
SST(2)
[Point 4]
SST 09509-76003-71 (SST 09509-55030)
SST
Removal:
SST 09310-10160-71
SST
[Point 5]
Installation:
Fill MP grease in the hub before installing the rear axle hub W/
brake drum.
Installation:
SST 09421-33020-71
SST
8-8
Installation:
Adjust the rear axle hub starting force.
(1) Fully tighten the bearing lock nut. Then loosen it by about
1/12 to 1/6 turn, and tap lightly with a soft hammer.
(2) Set a spring scale on a hub bolt, and measure the rear
axle hub starting force.
Standard:
Starting force at the hub bolt position
24.5 to 78.4N (2.5 to 8.0 kgf) [5.5 to 17.6 lbf]
(3) If the standard is not satisfied, adjust the degree of bear-
ing lock nut tightening for adjustment.
(4) Install the nut lock bolt. Coat locking agent 08833-76001-
71 (08833-00070) on the nut lock bolt before tightening.
[Point 6]
Removal:
SST(2) Use a screwdriver or the like to remove the oil seal.
Installation:
SST 09950-76019-71 (SST 09950-60020) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
SST(1)
[Point 7]
Removal:
SST(2) Use a brass bar to remove the bearing outer race.
Installation:
SST 09950-76019-71 (SST 09950-60020) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
SST(1)
8-9
REAR AXLE BRACKET • AXLE HOUSING

T=265 to 343
(2700 to 3500)
[195.3 to 253.2]
5 5
4
3
T=127 to 167
(1300 to 1700)
[94.0 to 123.0]
T=137 to 196
(1400 to 2000)
[101.3 to 144.7]
Removal Procedure
1. Remove the rear axle and drive unit ASSY. (See P7-7)
2. Remove the rear axle shaft and axle hub. (See P7-7)
3. Remove the brake ASSY. [Point 1]
5. Remove the axle housing.
8-10
Point Operation
[Point 1]
Installation:
Apply sealing agent (08826-76001-71) on the mating surfaces
of the brake backing plate and rear axle bracket before instal-
Sealing agent
lation.
Installation:
Be careful as the brake backing plate set bolts are different in
length.
set bolts before tightening.
Bolt length:
A: l = 36 mm (1.42 in.)
B: l = 45 mm (1.77 in.)
8-11
2TE18
GENERAL
8-12
SPECIFICATIONS
Rear axle type Half-floating
Rear axle suspension Fixed to frame
Reduction gear type Planetaty gear reduction
Reduction ratio 3:1
Rear tire size 28 × 8 - 15 - 12PR
Rear tire inflating pressure kPa (kgf/cm2) [psi] 700 (7.14) [100]
COMPONENTS
4205
8-13
4205
8-14
TROUBLESHOOTING
phenomenon Estimated cause Action
Wheel bearing insufficient lubrication Greasing

(rumbling noise)
Excessive play or wear of wheel bearing Preload adjustment or replacement

Rear wheel run-out, shock or instability
Loosened rear wheel hub nuts Retightening
Oil leak Rear axle shaft oil seal defect Replacement
ADJUSTING THE REAR TIRE INFLATING PRESSURE

Caution:

700 (7.14) [100]
kPa (kgf/cm2) [psi]

a safety fence.

Caution:
8-15
REAR AXLE ASSY

T=180 to 323 (1840 to 3300) [133 to 1238] T=235 to 294 (2400 to 3000) [173 to 217]
T=294 to 588
(3000 to 6000)
[217 to 434]
Removal Procedure
1. Remove the rear axle upper cover and rear axle under cover.
3. Jack up the vehicle, and remove the rear wheels. [Point 2]
5. Disconnect the rear brake piping.
6. Disconnect the parking brake cable.
7. Remove the rear axle ASSY W/rear axle bracket and O-ring. [Point 3]
8. Remove the rear axle shaft (inner).
9. Remove the rear axle ASSY.
Notes:
• Replace the O-ring with a new one and apply MP grease at the time of installation.
• After installation, bleed air from the brake line. (See P12-28)
• Apply locking agent 08833-7600-71 (08833-00070) on the threaded portion of the rear axle ASSY set bolts
(for gear case connection) before tightening.
8-16
Point Operations
[Point 1]
Removal:
Remove the drain plug under the drive unit gear case and
drain oil.
Drain plug
Installation:
Fill designated oil to the specified level.
A = 15 mm or less
A
[Point 2]
Removal:
Jack up the vehicle and support both sides of the frame with
wooden blocks.
[Point 3]
Removal:
Operate in the following order:
(1) Support the lower sides of the gear case and rear axle
ASSY with wooden blocks or jacks.
(2) Remove the rear axle ASSY set nuts.
(3) Remove the rear axle bracket set bolts (for frame connec-
tion).
Use the SST or a hammer to remove the illustrated ream-
er bolts.
8-17
SST 09310-23320-71
SST
(4) Remove the rear axle ASSY W/rear axle bracket.

8-18

3, 4 8
3, 4
T=294 to 392
(3000 to 4000)
[217 to 289]
1
7
T=285 to 294
(2910 to 3000)
[210 to 217] 6
1. Remove the brake drum.
2. Remove the lock nut. [Point 1]
3. Remove the planet carrier ASSY.
4. Disassembly the planet carrier ASSY. [Point 2]
5. Remove the internal gear. [Point 3]
6. Remove the front axle shaft (outer). [Point 4]
7. Remove the brake ASSY.
9. Disassemble the front axle housing. [Point 5]
Reassemble Procedure
8-19
Notes:
• Apply locking agent 08833-76001-71 (08833-00070) on the threaded portion of the hub bolt set nuts be-
fore tightening.
• Tighten the brake ASSY set nuts to the illustrated toque values.
Tightening torque values:

: T = 88 to 118 N·m (900 to 1200 kgf-cm) [65 to 87]
: T = 118 to 137 N·m (1200 to 1400 kgf-cm) [87 to 101]
Point Operations
[Point 1]
Reassembly:
Adjust the front axle shaft starting force.
(1) Tighten a new lock nut to the specifying torque.
T = 294.2 to 343.2 N·m (3000 to 3500 kgf-cm)
[217.1 to 253.2 ft-lbf]
(2) Rotate the axle housing several turns to break in the bear-
ing.
(3) Set a spring scale on an axle housing set bolt and mea-
sure the starting force.
Standard: 68.6 to 127.5 N (7 to 13 kgf) [15 to 29 lbf]
Shims
If the standard is not satisfied, increase or decrease the
shim thickness for adjustment.
Increase the shim thickness if the starting force is exces-
sive, and decrease it if insufficient.
Shim thickness:
0.1 • 0.4 • 1.0 mm (0.004 • 0.016 • 0.039 in.)
8-20
(4) Lock the lock nut securely for contact at portions A. No

crack shall arise in portions B at the time of locking.
B
[Point 2]
Inspection:
Measure the planet gear shaft outside diameter.
Limit : 21.85 mm (0.860 in.)
Inspection:
Measure the planet gear bush inside diameter.
Limit : 22.18 mm (0.873 in.)
SST 09222-76001-71
(SST 09222-30010)
Install to make the dimension from the bush end face to the
gear end face equal.
SST Reassembly:
Apply a thin coat of molybdenum disulfide grease on the planet
gear bush inside surface and shaft outside surface.
Disassembly:
Use SSTs to remove the bearing.
SST(1) SST(2) SST 09950-76019-71 ............. (1)
(SST 09950-60020)
SST 09950-76020-71 ............. (2)
(SST 09950-10010)
SST 09420-23001-71 ............. (3)
SST(3)
Reassembly:
Use a steel pipe matching the bearing diameter to install the
bearing.
Reference:
Bearing inside diameter: 80 mm (3.15 in.)
8-21
[Point 3]
Match marks Disassembly:

Punch match marks and remove the reamer bolts.
Reassembly:
Align the match marks before reassembly.
Reassembly:
Apply grease on the O-ring before reassembly.
[Point 4]
Disassembly:
SST SST 09420-23001-71
Reassembly:
After filling MP grease in the bearing, use a steel pipe match-
ing the diameter and install the bearing.
Reference:
Bearing inside diameter: 70 mm (2.76 in.)
[Point 5]
A
Reassembly:
Install the oil seal (inner) to satisfy the following dimension.
A = 12 mm (0.47 in.)
Reassembly:
Fill MP grease in the illustrated B portion.
Grease amount: 68 to 170 g (0.15 to 0.37 lb)
B Reassembly:
Apply MP grease on the oil seal (inner/outer) seal lips.
8-22
REAR AXLE BRACKET

T = 294 to 392
(3000 to 4000)
[217 to 289]
Removal Procedure
1. Remove the rear axle ASSY W/drive motor ASSY. (See P7-7)
2. Remove the parking brake bracket W/brake pipe.
9-1
FRONT AXLE
Page 9
GENERAL .......................................................... 9-2
9
SPECIFICATIONS.............................................. 9-3
COMPONENTS .................................................. 9-4
9
TROUBLESHOOTING ....................................... 9-6 9
ADJUSTING THE FRONT TIRE
INFLATING PRESSURE ................................. 9-7
9
FRONT AXLE HUB • STEERING KNUCKLE .... 9-8 9
FRONT AXLE ASSY ........................................ 9-12
9
FRONT AXLE CYLINDER................................ 9-14 9
9
FRONT WHEEL ALIGNMENT ......................... 9-18 9
9
9
9
9
9
9
9
9
9-2
GENERAL
9-3
Front Axle Cylinder

9
9
9
9
9
T=88 to118 9
(900 to 1200)
[65.12 to 86.82]
9
9
9
SPECIFICATIONS
9
Front axle type Elliot type
Front axle suspension Leaf spring suspension, doubling as shock absorbers

9
Toe-in mm (in.) 0 to 4 [0 to 0.16] 9
Front wheel alignment
Camber degree 0 9
Caster degree 0
9
King pin angle degree 0
9
Minimum turning radius mm (in.) 3295 [129.7]
Steering angle degree Inner side: 58.2°, Outer side: 40.1°

9
Cylinder type Double acting type 9
Front axle cylinder Piston rod diameter mm (in.) 40.0 (1.57) 9
Cylinder inside diameter mm (in.) 70.0 (2.76)
9
9-4
COMPONENTS
4306
9-5
4302
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9-6
TROUBLESHOOTING
FRONT AXLE
Improper tire pressure Adjustment to appropriate tire pressure
Wear of king pin or needle bearing Replacement
Steering wheel wobbling, impact or

Wear of wheel bearing Preload adjustment or replacement
instability
King pin thrust bearing shim adjustment defect
Shim adjustment or replacement
or excessive wear
Uneven tire wear Tire replacement
Low tire pressure Adjustment to appropriate tire pressure
Sticking king pin (lubrication defect) Greasing or replacement

Heavy steering wheel operation
Sticking tie rod end Replacement
Excessive looseness or wear of wheel bearing Preload adjustment or replacement
Steering wheel uncontrollability in one Uneven tire pressure between LH and RH

Adjustment to appropriate tire pressure
direction sides
Excessive looseness or wear of wheel bearing Preload adjustment or replacement

Unsteady vehicle traveling
(straight line instability)
Excessive wear at tie rod end ball joint Tie rod end replacement
Defective tire pressure Adjustment to appropriate pressure
Steering wheel returning defect Wheel alignment adjustment defect Wheel alignment adjustment
Steering knuckle sliding defect Greasing or adjustment
Tire steering in the direction opposite Opposite connection of steering cylinder

Correction
to steering wheel turning direction piping
Wheel bearing lubrication defect Greasing

(rumbling noise)
9-7
FRONT AXLE CYLINDER
Damaged rod guide oil seal lip Replacement

Oil leak from rod guide
Damaged rod guide U-packing Replacement
Damaged rod guide O-ring Replacement

Oil leak from cylinder
Loosened tie rod (through bolt) set nut Retightening
Dispersion of tie rod (through bolt) set nut Uniform tightening to the appropriate
tightening torque torque
Piston rod bend Replacement

Piston rod malfunction
Cylinder distortion or dent Replacement
Foreign matter entrance at piston or rod guide

Piston or rod guide replacement
portion
Uncontrolled piston rod extension/ Rust or damage on cylinder bore surface Cylinder replacement
retraction or poor following upon
operation Seal ring damage Seal ring replacement
Spongy operation Air entrance into cylinder Air bleeding
Bent rod or sticking piston of power steering

Heavy steering wheel operation Inspection, correction or replacement
cylinder
ADJUSTING THE FRONT TIRE INFLATING PRESSURE

Caution:

450 (4.6) [65]
kPa (kgf/cm2) [psi]

a safety fence.

Caution:
9-8
FRONT AXLE HUB • STEERING KNUCKLE

11 7
10 T=49 to 73.5
(500 to 750)
T=44 to 54 [36.1 to 54.6]
(450 to 550)
[32.6 to 39.8]
11
T=57 to 85
(580 to 870)
[42.1 to 62.7]
4 5
T=115 to 145
3 (1170 to 1480)
[84.8 to 106.9]
2
Removal Procedure
1. Jack up the vehicle and remove front wheels.
2. Remove the hub caps. [Point 1]
3. Remove the castle nut and claw washer. [Point 2]
4. Remove the outer bearing and axle hub W/brake disc. [Point 3]
5. Remove the bearing outer race from the axle hub. [Point 4]
6. Remove the inner bearing and oil seal. [Point 5]
7. Disconnect the tie rod (on the knuckle side).
8. Remove the king pin cover.
9. Remove the king pin lock bolt and king pin. [Point 6]
10. Remove the thrust bearing, spacer and steering knuckle.
11. Remove the king pin oil seal and needle bearing. [Point 7]
Note:
After installation, add MP grease through grease fittings.
9-9
Point Operations
[Point 1]
Installation:
Fill MP grease in the hub cap, and install by tapping the flange
portion.
[Point 2]
Installation:
Adjust the rear axle hub starting force.
(1) Install the claw washer in the correct direction.
(2) Install the castle nut and temporarily tighten it to a torque
of 15 to 32 N·m (150 to 330 kgf-cm) [10.9 to 23.9 ft-lbf].
(3) Rotate the hub by 3 to 5 turns to run in the bearing.
Claw washer
(4) Set a spring scale on a hub bolt, and measure the starting
force.
Standard: 30 to 80 N (3.1 to 8.2 kgf) [6.7 to 18.0 lbf]
(5) If the standard is not satisfied, adjust the degree of castle
nut tightening for adjustment.
(6) Install a new cotter pin.
[Point 3]
Removal:
SST 09120-23600-71
SST
Installation:
Install the axle hub and outer bearing.
(1) Fill MP grease in the axle hub and knuckle spindle.
(2) Install the axle hub.
(3) Use the SST and install the outer bearing roller.
SST 09110-30200-71
SST Fill grease

9-10
[Point 4]
SST(2)
SST(1)
Removal:
Use a brass bar and remove the bearing outer race.
Installation:
SST 09950-76019-71 (SST 09950-60020) ........... (1)
SST 09950-76020-71 (SST 09950-70010) ........... (2)
[Point 5]
Removal:
SST SST 09950-76014-71 (SST 09950-40011)
Installation:
Install the oil seal and inner bearing.
(1) Use the SST and install the oil seal.
SST 09370-10410-71
SST
(2) Use the SST and install the inner bearing.

SST 09370-20270-71
SST
[Point 6]
Inspection:
Measure the king pin outside diameter.
Limit: 27.8 mm (1.094 in.)
9-11
Installation:
Measure the steering knuckle starting force.
(1) Temporarily install the king pin and king pin lock bolt.
Combine 3 or 4 sheets of spacers so that any vertical rat-
tling of steering knuckle is minimized: Install on top of
thrust bearing.
Spacer thickness: 0.5, 1.0 mm (0.039, 0.020 in.)
(2) Set a measuring instrument at the tip end of the knuckle
spindle, and measure the starting force.
Standard: 13.7 N (1.4 kgf) [3.1 lbf] or less
(3) If the standard is exceeded, check the king pin for bend,
the needle bearing for damage and axle beam for defor-
Spacer mation.
installing
position (4) Tighten the lock nut for the king pin lock bolt.
[Point 7]
Removal:
Remove the king pin oil seal and needle bearing.
(1) Use a straight-edge screwdriver to remove the dust seal
SST(2) and oil seal.
(2) Use the SST and remove the needle bearing.
SST 09950-76018-71 (SST 09950-60010).... (1)
SST 09950-76020-71 (SST 09950-70010).... (2)
SST(1)
Installation:
Install the needle bearing and king pin oil seal.
0 mm (1) Use the SST and install the needle bearing.
(0 in.) Check the needle bearing press-fitting surface, pressing
direction and installation depth.
SST 09950-76018-71 (SST 09950-60010).... (1)
SST 09950-76020-71 (SST 09950-70010).... (2)
4 mm
(2) Install the dust seal.
(0.16 in.)
(3) Use the SST and install the oil seal.
SST 09950-76018-71 (SST 09950-60010).... (1)
SST 09950-76020-71 (SST 09950-70010).... (2)
Punched surface
Needle bearing
Press-fitting
direction
9-12
FRONT AXLE ASSY

6
A
4
A=4 to 6.5 mm
(0.157 to 0.256 in.)
T=75 to 115
(765 to 1173) 7
[55.3 to 84.8]
9-13
Removal Procedure
2. Remove the seat and the seat bracket.
4. Drain brake fluid, and disconnect the brake hose.
5. Disconnect the front axle cylinder hose.
6. Disconnect the shock absorber (on the axle side).
7. Support the front axle ASSY with a garage jack, and place wooden block under the front axle ASSY.
8. Remove the U-bolt. [Point 1]
9. Lower the jack slowly and support the front axle ASSY with wooden block.
10. Jack up the front of the vehicle and support with wooden blocks. [Point 2]
11. Pull the front axle ASSY to the left or right.
Point Operations
A [Point 1]
Installation:
(1) Tightening torque of U-bolt setting nuts in status where
tires of the vehicle are grounded should be 75 to 115 N·m
(765 to 1173 kgf-cm) [55.3 to 84.8 ft-lbf]
(2) Evenly tighten nuts so that all four protrusion margins of
bolts from nuts (A indicated in illustration) are equal.
[Point 2]
(1) Lock rear wheels with stopper, and jack up the vehicle
and support both sides of the frame with wooden blocks.
(2) Place wooden blocks under the front side of the frame.
9-14
FRONT AXLE CYLINDER

7
7
7
7
T=167 to 216
(1700 to 2200)
[123.2 to 159.3] 3
3 5
4
8
5
T=75 to 115 T=49.0 to 73.5
(770 to 1170) (500 to 750)
[55.3 to 84.8] [36.1 to 54.2]
Removal Procedure
2. Remove the seat and the seat bracket.
3. Place wooden blocks under the left and right side of the front axle ASSY.
4. Support the center of the front axle ASSY with a garage jack.
5. Disconnect the tie rod (on the piston rod side). [Point 1]
6. Disconnect the front axle cylinder hose and remove the fitting. [Point 2]
7. Remove the U-bolt. [Point 3]
8. Remove the front axle cylinder.
Note:
After installation, measure and adjust the toe-in. (See P9-18)
9-15
Point Operations
[Point 1]
Match mark Removal:

Mark the punch mark position on each of cylinder end pins LH
and RH.
Installation:
Install each cylinder end pin by aligning the punch mark with
the mark.
[Point 2]
Installation:
90° 90° Install the fitting in the illustrated direction.
[Point 3]
Installation:
A
(1) Tightening torque of U-bolt setting nuts in status where
tires of the vehicle are grounded should be 75 to 115 N·m
(765 to 1173 kgf-cm) [55.3 to 84.8 ft-lbf]
(2) Evenly tighten nuts so that all four protrusion margins of
bolts from nuts (A indicated in illustration) are equal.
9-16

T=88 to 118
(900 to 1200)
[65.1 to 86.6]
1 4
T=88 to 118
(900 to 1200) 3
[65.1 to 86.6]
1. Remove the through bolt.
2. Remove the piston rod guide.
3. Remove the piston rod. [Point 1]
4. Inspect the cylinder. [Point 2]
Note:
Coat hydraulic oil before reassembly.
9-17
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Limit: 39.92 mm (1.5717 in.)
Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in.)
Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil or
water before installation.
Do not stretch it excessively.
Caution:
Operate carefully to avoid scalding.
[Point 2]
Inspection:
Measure the front axle cylinder bore.
Limit: 70.35 mm (2.7697 in.)
9-18
FRONT WHEEL ALIGNMENT

Toe-in Inspection
1. Check to see that dimensions Ar and Al of the front axle cylinder are equal.
Standard: 230.5 to 232.5 mm (9.07 to 9.15 in.)
2. Measure the toe-in (Br-Bf), (Lr-Lf), (Rr-Rf).
Standard: (Br-Bf) = 0 to 4 mm (0 to 0.16 in.)
(Lr-Lf), (Rr-Rf) = 0 to 5 mm (0 to 0.20 in.)
Bf
Lf Rf
OUT IN IN OUT
Al Ar
Lr Rr
Br
9-19
Toe-in Adjustment
1. Check to see that Ar and Al of the front axle cylinder are equal.
Front side
Eccentric
Lock plate pin B Standard: 230.5 to 232.5 mm (9.07 to 9.15 in.)
Eccentric 2. Match punch marks of eccentric pins A and B with punch
B pin A
A marks on the plate. Then turn eccentric pin A (piston rod side)
by 60° (one step) to the IN side.
3. Measure and adjust the toe-in (Br-Bf), (Lr-Lf), (Rr-Rf).
LH RH
Standard: (Br-Bf) = 0 to 4 mm (0 to 0.16 in.)
(Lr-Lf), (Rr-Rf) = 0 to 5 mm (0 to 0.20 in.)
Punch mark
If the standard is not satisfied, remove the lock plate and turn
the eccentric pin A and B to satisfy the standard.
OUT IN Note:
OUT If the standard is not attained by adjustment on one side,
make adjustment also on the other side.
IN
4. Install the lock plate.
5. After adjustment, fully steer the tires and check to see that they
60°
do not come into contact with the vehicle body.
Eccentric pin B
Eccentric pin A
9-20
Memo
10-1
SUSPENSION
Page 10
GENERAL ........................................................ 10-2
10
SPECIFICATIONS............................................ 10-2
COMPONENTS ................................................ 10-3
10
TROUBLESHOOTING ..................................... 10-4 10
SUSPENSION .................................................. 10-5 10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10-2
GENERAL
10-3
SPECIFICATIONS
Leaf spring
No. of leaf springs 4
Span × width × thickness mm (in.) 527 × 68.5 × 7 (20.7 × 2.7 × 0.28) 10

Camber mm (in.) 32 (1.26)
Compressed 583 (59.5) [3332] 10

Spring constant N/mm (kgf/mm) [lbf/in.]
10
Extended 435 (44.4) [2486]
Shock absorbers
Type
Outer cylinder outer diameter mm (in.)

Cylindrical, double-acting type
45 (1.77)
10
Rod diameter
Stroke
mm (in.)
mm (in.)
12.5 (0.49)
130 (5.12)
10
Damping force (at 0.3 mm/sec) N (kgf) [lbf]
Extended
Contracted
3040 (310) [684]
1000 (102) [225]

10
10
COMPONENTS 10
4801
10
10
10
10
10
10
10
10
10
10
10
10-4
TROUBLESHOOTING
Broken front spring shackle Replacement

Loud rattling noise upon braking
Shock absorber defect Replacement
Low rattling noise (like front axle slipping)

Loosened or broken U-bolt set nut Retightening or replacement
upon braking
Abnormal (creaking) noise during Hardened or excessively worn rubber

Rubber bush replacement
traveling bush for front spring shackle
Broken center bolt or clip of the leaf

Vehicle rolling during traveling Leaf spring ASSY replacement
spring ASSY
10-5
SUSPENSION
10
4
10
10
5
10
10
3
3
10
2 10
2 T=75 to 115
10
(770 to 1170)
[55 to 85]
10
10
10
10
10
T=75 to 115
(770 to 1170)
[55 to 85] 10
Removal Procedure
10
1. Front axle ASSY removal procedure Steps 1 to 11. (See P9-13)
10
2. Remove the shock absorber.
3. Remove the front spring bracket pin. [Point 1] 10
4. Remove the front spring shackle. [Point 1]
5. Remove the leaf spring ASSY. 10
10
10-6
[Point l]
Removal:
With the set nut flat against the pin, hit the set nut strongly with
a bronze hammer. Or apply a steel screwdriver from the inner
side.
Installation:
• Apply sufficient vegetable-based brake fluid on the rubber
bushing. (Never apply mineral-based oil.)
• Align the bracket and the spring with the pin hole.
Caution:
Never insert your finger to confirm alignment.
11-1
STEERING
Page 11
GENERAL ........................................................ 11-2
11
SPECIFICATIONS............................................ 11-4
COMPONENTS ................................................ 11-4
11
TROUBLESHOOTING ..................................... 11-7 11
STEERING WHEEL • MAST JACKET............. 11-9 11
11
REASSEMBLY..................................................... 11-11
11
HYDROSTATIC STEERING VALVE ASSY... 11-12
REMOVAL • INSTALLATION ................................. 11-12 11
REASSEMBLY..................................................... 11-13
11
RELIEF PRESSURE INSPECTION • 11
ADJUSTMENT............................................. 11-16
POWER • STEERING PUMP ASSY .............. 11-17
11
GENERAL ............................................................... 11-17 11
SPECIFICATIONS .................................................. 11-17
11
COMPONENTS....................................................... 11-17
REMOVAL • INSTALLATION ................................. 11-18 11
11
11
11
11
11
11-2
GENERAL
11-3
Hydrostatic Steering Valve
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11
11-4
SPECIFICATIONS
Steering wheel diameter mm (in.) 360 (14.17)
Steering wheel play (at idling) mm (in.) 20 to 50 (0.79 to 1.97)
Power steering type Hydrostatic steering
Delivery cm3 (in.3)/rev. 69 (4.21)
Hydrostatic steering valve Rated flow rate l (US gal)/min. 16 (4.2)

+490 +5 +71
Relief set pressure kPa (kgf/cm2) [psi] 9300 0 (95 0 ) [1350 0 ]
COMPONENTS
4501
11-5
4502
11
11
11
11
11
11
11
11
4502-250
11
4503
11
11
11
11
11
11
11
11
11
4503-032 11
11-6
4507
11-7
TROUBLESHOOTING
Troubles in steering operation may be caused by the front tire pressure. First check if the front tire pressure is appro-
priate.
STEERING WHEEL & MAST JACKET
Steering wheel returning defect Steering shaft misalignment Correction
Extreme steering wheel play Worn steering shaft coupling spline Steering shaft replacement
Excessive play to make the vehicle Inspection, correction, or

Steering shaft defect
unstable replacement
HYDROSTATIC STEERING VALVE
Steering wheel wobbling, impact or

Steering valve defect Replacement
instability
Incorrect installation or damage of steering valve Disassembly, correction or

Immovable steering wheel
drive shaft replacement
Steering wheel returning defect Steering valve misalignment Correction
Extreme play of steering wheel Wear of steering valve coupling spline Steering valve replacement
Relief pressure inspection and

Relief pressure adjustment defect
adjustment
Heavy steering wheel operation Steering valve internal seizure Replacement
Excessive tightening torque of steering valve

Tightening to the appropriate torque
end cap set screw
Insufficient power steering oil Addition
Relief valve malfunction or foreign matter

trapping
Disassembly, cleaning or
Steering valve defect
Oil pressure rise failure replacement
Damaged power steering cylinder piston

Piston packing replacement
packing
Relief pressure inspection and

Relief pressure adjustment defect
adjustment
Steering valve spool motion defect
Steering wheel returning defect replacement
Damaged centering spring Replacement
replacement
Self-traveling upon releasing the
steering wheel Steering valve drive shaft damage Replacement
Damaged centering spring Replacement
Oil migration in steering valve Replacement

Excessive play to make the vehicle
unstable Disassembly, correction or
replacement
11-8

Steering wheel vibration in lateral
Incorrect steering valve drive shaft installation Inspection and correction
direction
Abnormal noise generation Relief valve defect Adjustment or replacement
Wear or damage of spool oil seal Oil seal replacement
O-ring damage at each part O-ring replacement

Oil leak
Excessive tightening torque of steering end cap
Tightening to the appropriate torque
set screw
POWER STEERING PUMP
PS pump defect Replacement

Steering failure PS motor and PS pump connection defect
Correction
(Oldham’s joint connection defect)
PS pump defect Replacement

Heavy steering wheel operation PS motor and PS pump connection defect
Correction
(Oldham’s joint connection defect)
The hydraulic pressure does not rise. PS pump malfunction Replacement
OTHERS (PIPING, ETC.)
Piping damage Replacement
Blocked piping
Cleaning (air blow) or replacement
(crushed or foreign matter entrance)
Steering failure
Insufficient or defective oil Addition or replacement
Reversed connection of high/low pressure

Correction
piping
Oil leak from piping Retightening or replacement
Blocked piping
Heavy steering operation (crushed or foreign matter entrance)
Insufficient or defective oil Addition or replacement
Insufficient air bleeding Air bleeding
Excessive play to make vehicle

Air suction from piping Correction or replacement
unstable
Air suction from piping Correction or replacement
Abnormal noise generation Blocked piping
(crushed or foreign matter entrance)
11-9
STEERING WHEEL • MAST JACKET

T=25 to 45
(250 to 460)
[18 to 33]
8 T=29.4 to 39.2
(300 to 400)
[22 to 29]
2
9
T=34.3 to 53.9
(350 to 550)
[25 to 40]
Removal Procedure
1. Remove the steering wheel. [Point 1]
2. Remove the column cover (rear).
3. Disconnect the connectors of the display and direction switch.
4. Disconnect the lamp switch and key switch connectors, and remove the column covers (upper and lower).
[Point 2]
5. Remove the direction switch.
6. Remove the spring pin and collar.
7. Remove the tilt lock mechanism.
8. Remove the steering valve set bolt and keep the valve free.
9. Remove the mast jacket ASSY.
Note:
11-10
Fill MP grease at the coupling between the steering shaft and steering valve.
Point Operations
SST
[Point 1]
Removal:
SST 09950-76003-71 (SST 09950-50012)
[Point 2]
Collar Reassembly:
Install the collar and rubber in the illustrated direction.
Thin
Thick
Rubber
11-11
1. Remove the snap ring.
2. Remove the tilt steering shaft.
3. Remove the bearing.
4. Remove the turn signal switch bracket.
11-12
HYDROSTATIC STEERING VALVE ASSY

T=29.4 to 39.2 (300 to 400) [21.7 to 28.9]
4
2
Removal Procedure
2. Remove the covers. (RH, LH)
3. Remove the column covers (upper, lower and rear).
4. Disconnect the piping.
5. Remove the steering valve ASSY.
6. Remove the fitting. [Point 1]
Point Operations
[Point 1]
Installation:
Vehicle Since the P port fitting is with the check valve, do not install in
front side an incorrect position.
P port fitting
11-13

Note:
Clean dirt off from ports and joints before disassembly and operate in a clean space.
4
6
4
8
3
1 2
1
9
T=22.6 (230) [16.7]
1. Remove the screw, ball and retainer screw. [Point 1]
2. Remove the end cap and O-ring.
3. Remove the spacer, star, O-ring and rotor.
4. Remove the drive, spacer plate and O-ring. [Point 2]
5. Remove the retaining ring. [Point 3]
6. Remove the seal gland bushing and oil seal.
7. Remove the dust seal from the seal gland bushing.
8. Remove the bearing race and thrust needle.
9. Remove the spool and sleeve ASSY.
10. Remove the pin from the spool and sleeve ASSY. [Point 4]
11. Remove the centering spring. [Point 5]
12. Remove the sleeve from the spool.
11-14
Point Operations
[Point 1]
Disassembly:
Fix the valve ASSY in a vise with the rotor facing upward.
Operate carefully since strong holding may cause distortion.
Disassembly:
Put a match mark to prevent an error in each retainer screw
tightening position.
Disassembly:
When removing each retainer screw, carefully operate so as
not to lose the steel ball.
Reassembly:
Put a steel ball in the illustrated position before installing each
retainer screw.
Reassembly:
Tighten the screws and retainer screws in the illustrated order.
[Point 2]
Reassembly:
Reassemble the drive and star as follows:
(1) Rotate the spool and sleeve ASSY to bring the pin parallel
with the housing port surface.
(2) Install the O-ring in the housing and place the spacer
plate by aligning the bolt holes.
(3) Insert the drive and fit the pin.
(4) Use a pen and put a line on the drive end in parallel with
the pin.
Roots in star D
(5) Install the rotor and O-ring.
A
(6) Install the star by matching the roots of the gear teeth in
Line B the star with the line put in step (4).
C
(7) Rotate the rotor without disengaging the drive and star
until the bolt holes are aligned.
(8) See that lines A, B, C and D are parallel as illustrated.
Pin Port surface

11-15
[Point 3]
Disassembly:
Use a straight-edge screwdriver and remove the retaining ring.
[Point 4]
Disassembly:
Put match marks on the spool and sleeve.
Pin
Match marks
[Point 5]
Reassembly:
Install the centering springs with their notched portions in the
illustrated directions.
11-16
RELIEF PRESSURE INSPECTION • ADJUSTMENT

1. Install a pressure gauge on the P port of the steering valve.
(1) Disconnect the hose from the P port and connect the
adapter.
SST STT 09450-23320-71
(2) Install the pressure gauge.
Plug size: PT1/8
2. When the steering wheel is rotated beyond the end, relief state
is obtained. Read the pressure on the pressure gauge at the
time.
Standard: 9300 +490
0 kPa (95
+5
0 kg/cm2) [1350 +71
0 psi]
3. If the standard is not satisfied, make adjustment by turning the

steering valve adjusting screw.
Air Bleeding from PS System

1. Jack up the front end of the vehicle.
2. Add fluid into the tank.
3. Turn the steering wheel lock-to-lock clockwise and counter-
clockwise.
Reference:
Depending on the repair work, the steering wheel becomes
very heavy at the start of air bleeding but it will gradually be-
come lighter.
Note:
Fill fluid before the tank is emptied to prevent air suction.
4. Check the fluid level.
Standard : A = 5 mm
Oil : Auto Fluid D-II
Oil quantity : 1.8 l
A
11-17
POWER • STEERING PUMP ASSY

GENERAL
SPECIFICATIONS
Pump model Standard TCP-031-B
Discharge (at 1,800 rpm) l (US gal)/min. Approx. 4.8 (1.27)
Theoretical delivery cm3 (in.3)/rev. 3.5 (0.214)
COMPONENTS
4510
4510-018C
11-18
Removal Procedure
3. Disconnect hoses from both ends of the PS pump ASSY.
4. Remove the PS pump ASSY W/fitting. [Point 1]
5. Remove the fitting.
11-19
PS motor
Point Operations
High pressure Oil tank
PS pump side fitting
side fitting [Point 1]
Loosen (or tighten) two set bolts in the illustrated positions to
remove (or install) the PS pump.
Tightening torque:
T = 20 to 30 N·m (200 to 300 kgf-cm) [14.7 to 22.1 ft-lbf]
PS pump set bolts
Installation:
Oldham’s joint When assembling the PS motor and pump, fill molybdenum
disulfide grease in the groove on the oldham’s joint.
PS motor
Apply Molybdenum disulfide

grease to fill the groove.
11-20
Memo
12-1
BRAKE
Page Page
12
BRAKE ................................. 12-2 MASTER CYLINDER ......... 12-23 12
GENERAL ................................. 12-2 GENERAL............................... 12-23 12
SPECIFICATIONS..................... 12-2 COMPONENTS....................... 12-23
TROUBLESHOOTING ......... 12-3 REMOVAL •
12
INSTALLATION.................... 12-25
REAR BRAKE...................... 12-6 12
DISASSEMBLY •
2TE15 REASSEMBLY ..................... 12-26 12
GENERAL ................................. 12-6 BRAKE AIR BLEEDING......... 12-28
COMPONENTS ......................... 12-6 BRAKE PEDAL.................. 12-29
12
DISASSEMBLY • INSPECTION • COMPONENTS....................... 12-29 12
REASSEMBLY........................ 12-7
BRAKE PEDAL INSPECTION •
2TE18 ADJUSTMENT...................... 12-29 12
GENERAL ............................... 12-13 PARKING BRAKE ............. 12-30 12
COMPONENTS ....................... 12-13 COMPONENTS....................... 12-30
DISASSEMBLY • INSPECTION • PARKING BRAKE INSPECTION •
12
REASSEMBLY...................... 12-14 ADJUSTMENT...................... 12-31
12
FRONT BRAKE.................. 12-18
COMPONENTS ....................... 12-18 12
ON-VEHICLE INSPECTION.... 12-19 12
REMOVAL •
INSTALLATION .................... 12-20 12
REASSEMBLY...................... 12-21 12
12
12
12
12-2
BRAKE
GENERAL
REAR
FRONT
SPECIFICATIONS
Item Vehicle model 2TE15 2TE18
Brake type Hydraulic internal expanding duo servo brake

Brake drum inner diameter mm (in.) 310 (12.2) 317.5 (12.5)
Material Resin mold (asbestos-free)

Rear brake Brake lining Dimensions mm (in.) 343 × 60 × 7 343 × 60 × 9.3
(Length × Width × Thickness) (13.5 × 2.36 × 0.28) (13.5 × 2.36 × 0.36)
Wheel cylinder bore mm (in.) 28.5 (1.12) 31.75 (1.25)
Parking brake type Internal expanding mechanical brake
Caliper type PD54
Pad material Resin mold (asbestos-free)
Front brake Pad tickness mm (in.) 9.5 (0.37)
Cylinder bore mm (in.) 54 (2.13)
Disc outer diameter and thickness mm (in.) 238 × 18 (9.37 × 0.71)
Bore mm (in.) 22.22 (0.87)

Brake master cylinder
Stroke mm (in.) 30.5 (1.2)
Applicable oil SEA J-1703-DOT-3

12-3
TROUBLESHOOTING
FOOT BRAKE
Replacement of defective parts after

12
Caliper malfunction or fluid leak
disassembly
Brake pad wear, surface hardening or defective

12
contact
Front Oil adhesion on brake pad Correction by cleaning or replacement 12

Disc rotor wear, damage, deformation or surface
12
Grinding or replacement
hardening
Excessive clearance between disc rotor and brake

Insufficient braking Piston or piston seal replacement
12
pad (piston or piston seal defect)
force
Wheel cylinder malfunction or fluid leak
disassembly
Lining wear, surface hardening or contact defect Repair or brake shoe replacement 12
Correction by cleaning or brake shoe
Rear Oil adhesion on lining
replacement 12
Drum wear, damage or deformation Replacement
Excessive clearance between drum and lining

(brake shoe adjuster sticking or defect)
Grease application on brake shoe
adjuster or replacement
12
Brake pad wear, surface hardening or contact defect Correction or replacement
Oil adhesion on brake pad Correction by cleaning or replacement

12
Front
hardening
Grinding or replacement 12
Excessive clearance between disc rotor and brake
pad (piston or piston seal defect)
Piston or piston seal replacement
12
Brake applied to
Caliper malfunction or fluid leak
disassembly
12
Lining wear, surface hardening or contact defect Shoe replacement
only one side
Oil adhesion on lining

Correction by cleaning or shoe
replacement
12
Rear
Drum wear, damage or deformation
Excessive clearance between drum and lining

Replacement
Grease application to brake shoe

12
12
(brake shoe adjuster sticking or defect) adjuster or replacement

Wheel cylinder malfunction or fluid leak
disassembly
Uneven tire pressure between the left and right sides Tire pressure adjustment 12
12
12
12
12-4

Brake pad wear, surface hardening or contact defect Correction or replacement

Grinding or replacement
Front hardening
Foreign matter entrance between brake pad and disc

Cleaning
rotor
Brake squealing Lining wear, damage or deformation Shoe replacement
Loosened backing plate set bolt Retightening
Foreign matter entrance between drum and shoe Cleaning

Rear
After cleaning sliding contact surface
Excessive drum fouling
correction with sandpaper
Drum wear, damage or deformation Replacement
Deformed disc rotor Replacement
Insufficient clearance between disc rotor and brake

Piston or piston seal replacement
Front pad (piston or piston seal defect)

Caliper malfunction
disassembly
Sticking or defective brake shoe adjuster Grease application or replacement

Brake dragging
Deformed drum Drum replacement
Insufficient clearance between drum and lining Grease application to brake shoe
Rear (sticking or defective brake shoe adjuster) adjuster or replacement
Shoe return spring fatigue or breakdown Replacement
Sticking or defective returning of wheel cylinder Replacement of defective parts after

piston disassembly
Brake pad returning defect Correction or replacement

Front Disc rotor wear, damage, deformation or surface
Abnormal noise Correction or replacement
hardening
during traveling
Brake shoe returning defect Correction or replacement
Rear
Brake drum uneven wear or excessive distortion Correction or replacement
Steering wheel control failure

Brake adjustment defect Brake adjustment
in one direction
Inspection, adjustment or parts

No functioning of automatic adjusting device
replacement of automatic adjusting
regardless of lining wear
device after brake drum removal
Air entrance into brake system Air bleeding

Increased pedal stroke Replacement of defective parts after
Caliper fluid leak
disassembly
Fluid leak from wheel cylinder
disassembly
Brake pedal adjustment defect Brake pedal adjustment

12-5
MASTER CYLINDER
Insufficient fluid level in reservoir tank Addition
Poor or slow braking effect

Spring fatigue or damage Replacement 12
Insufficient push rod length Adjustment
(Insufficient braking)
Cylinder cup (oil seal) damage Replacement 12
Piston wear and damage Replacement
Insufficient push rod length Adjustment 12

Brake dragging Foreign matter trapped in master cylinder
(piston sticking or returning defect)
Disassembly and cleaning
12
Insufficient fluid level in reservoir tank Addition
12
Increased pedal stroke
Insufficient push rod length Adjustment
PARKING BRAKE 12
Phenomenon Estimated cause
Parking brake cable adjustment defect Adjustment

Action
12
Insufficient pull margin
Insufficient brake clearance
Parking brake cable adjustment defect

Adjustment
Adjustment
12
Excessive pull margin
Brake dragging
Excessive brake clearance
Parking brake cable adjustment defect

Adjustment
Adjustment
12
Parking brake cable adjustment defect Adjustment
12
Too long parking brake cable (incorrect part) Replacement with a genuine part
12
Braking failure
Brake lining arriving at or less than the wear limit Adjustment after replacement
Excessive brake clearance Adjustment
12
OTHERS (PIPING, ETC.)

12
Insufficient braking force
Brake pipe installation defect (fluid leak or damage)
Air entrance
Retightening or replacement
Air bleeding
12
Brake application only on
one side
Foreign matter entrance into brake piping Correction or replacement 12
12
Increased pedal stroke Fluid leak from piping Correction or replacement
12
12
12
12-6
REAR BRAKE
2TE15
GENERAL
Wheel cylinder
COMPONENTS
4715
12-7
4 13
14
11
8
10
6
4 9
2. Remove rear wheels.
3. Remove the rear axle hub W/brake drum. (See P8-6)
4. Remove the hold down spring. [Point 1]
5. Remove the pawl lever stopper. [Point 2]
6. Remove the pawl lever.
7. Remove the anchor to shoe spring. [Point 3]
8. Remove the strut lever. [Point 4]
9. Remove the adjuster spring and adjusting screw. [Point 5]
10. Disconnect the parking brake cable. [Point 6]
11. Remove the brake shoe. [Point 7]
12. Disconnect the brake piping.
13. Remove the wheel cylinder ASSY. [Point 8]
14. Remove the backing plate. [Point 9]
15. Separate the brake drum from the rear axle hub. [Point 10]
12-8
(With regard to steps 4 and 5, however, install the pawl lever stopper after installing the hold down spring.)
Note:
• See that the brake lining and brake drum interior surface are free from grease or oil before reassembly.
• Before reassembly, decrease the brake shoe outside diameter for installation to approx. 1 mm (0.04 in.)
less than the brake drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (See P12-28).
Point Operations
SST [Point 1]
SST 09510-31960-71
Inspection:
Measure the free length of hold down spring.
Limit : 29.1 mm (1.146 in.)
Reassembly:
Apply liquid packing (08826-76001-71) on the back side of the
backing plate in contact with the shoe hold down spring to
eliminate any clearance.
12-9
[Point 2]
Inspection:
Measure the free length of the actuator spring.
Standard : 124.5 mm (4.902 in.)
Limit : No clearance between coil turns
Reassembly:
Use snap ring pliers and install the pawl lever stopper and ac-
tuator spring.
[Point 3]
SST Disassembly:
SST 09717-76001-71 (SST 09717-20010)
Inspection:
Measure the free length of the anchor to shoe spring.
Reassembly:
SST 09718-76001-71 (SST 09718-20010)
SST
12-10
[Point 4]
Inspection:
Measure the free length of the strut to shoe spring.
Limit : 20 mm (0.79 in.)
[Point 5]
Inspection:
Measure the free length of the adjuster spring.
Reassembly:
Apply grease on the adjusting screw threaded portion and fill
grease in the cap.
[Point 6]
Reassembly:
Apply liquid packing (08826-76001-71) on the parking brake
outlet on the backing plate to eliminate any clearance.
[Point 7]
Inspection:
Measure the brake lining thickness.
Limit : 2.0 mm (0.079 in.)
12-11
Reassembly:
Apply grease on the illustrated portions of the backing plate (6
places in contact with the shoe rim and the anchor pin) before
brake shoe installation.
[Point 8]
Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit: 0.145 mm (0.00571 in.)
Reassembly:
Apply liquid packing (08826-79001-71) on the wheel cylinder
backing plate fitting portion and whole periphery of set bolts to
eliminate any clearance.
[Point 9]
Reassembly:
Carefully install the backing plate set bolts in correct positions
since they are different in length.
set bolts before reassembly.
Bolt length:
A : l = 36 mm (1.42 in.)
B : l = 45 mm (1.77 in.)
Reassembly:
Apply liquid packing (08826-76001-71) on the backing plate
surface in contact with the rear axle bracket to eliminate any
clearance.
12-12
[Point 10]
Inspection:
Measure the brake drum inside diameter.
Limit : 312 mm (12.28 in.)
Reassembly:
Apply thread tightener (08833-76001-71) on the brake drum
set nut before reassembly.
12-13
2TE18
GENERAL
COMPONENTS
4715
12-14

7
10
5
13, 14 4
T=13.7 to 22.6
(140 to 230)
[10 to 17]
12
6
1. Drain brake fluid from the reservoir tank.
2. Remove the rear wheel.
3. Remove the brake drum. [Point 1]
4. Remove the shoe return spring. [Point 2]
5. Remove the shoe hold down spring. [Point 3]
6. Remove the brake shoe adjuster. [Point 4]
7. Remove the brake shoe. [Point 5]
8. Disassemble the brake shoe (secondary). [Point 6]
9. Remove the wheel cylinder. [Point 7]
10. Disassemble the wheel cylinder.
11. Disconnect the parking brake cable.
12. Remove the actuator lever. [Point 8]
13. Remove the parking brake lever ASSY. [Point 9]
14. Disassemble the parking brake lever ASSY.
12-15
Note:
• See that the brake lining and brake drum interior surface are free from grease or oil before installation.
• Before reassembly, decrease the brake drum outside diameter for installation to approx. 1 mm (0.04 in.)
less than the drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (See P12-28).
Point Operations
[Point 1]
Disassembly:
Use two service bolts for removal.
Service bolt size: M 14 × 1.5
Service bolt
Inspection:
Measure the brake drum inside diameter.
Standard : 317.5 mm (12.50 in.)
Limit : 319.5 mm (12.58 in.)
[Point 2]
Wire Disassembly:
Connect a wire at the spring hook portion and use a screw-
SST driver for removal.
Reference:
Use the SST (for shoe return spring) if the brake ASSY has
been removed.
SST 09717-76001-71
(SST 09717-20010)
Reassembly:
SST 09718-76001-71
(SST 09718-20010)
SST
12-16
[Point 3]
SST 09510-31960-71
SST
Inspection:
Measure the free length of the shoe hold down springs.
Standard:
Upper spring 25.4 mm (1.00 in.)
Center spring 43.7 mm (1.72 in.)
Lower spring 27.8 mm (1.09 in.)
[Point 4]
Reassembly:
Apply grease on the illustrated portion of the brake shoe ad-
juster.
[Point 5]
Inspection:
Measure the brake lining thickness.
Limit : 4.3 mm (0.17 in.)
(Each dimension does not include the rim thickness.)
Reassembly:
Apply grease on the brake shoe rim and backing plate sliding
contact portion before reassembly.
12-17
[Point 6]
Reassembly:
Apply grease on the illustrated portion of the adjuster lever link.
[Point 7]
Reassembly:
threaded portion of the set bolts before reassembly.
[Point 8]
Reassembly:
Install the actuator lever.
(1) Apply grease to the spline and lever sliding contact por-
tion.
(2) Align the match marks for installation.
Match mark
[Point 9]
Reassembly:
Apply grease on two parking brake lever shaft portions.
12-18
FRONT BRAKE
COMPONENTS
4716
Front Brake Cylinder

12-19
ON-VEHICLE INSPECTION
1. Disc brake pad thickness inspection
(1) Remove the front wheel.
(2) Inspect the pad thickness through the inspection hole of
the disc brake cylinder.
Standard thickness : 9.5 mm (0.37 in.)
Wear remainder limit : 1.0 mm (0.04 in.)
(3) Install the front wheel
T = 118 to 147 N·m (12 to 15 kgf-m) [87 to 109 ft-lbf]
2. Disc thickness inspection
Limit : 17.0 mm (0.67 in.)
3. Disc runout inspection

(1) Check that there is no looseness in the front wheel bear-
ing.
(2) Using a dial gauge, check the runout of the disc outer
edge face.
Limit: 0.07 mm (0.0028 in.)
(at 10 mm (0.39 in.) inside the outer periphery)
(3) If the runout exceeds the limit, replace the front axle hub
W/disc.
12-20
4 T=57 to 85
(580 to 870)
[42.0 to 62.9]
T=115 to 145 (1170 to 1480) [84.6 to 107.0]
Removal Procedure
3. Disconnect the brake hose.
4. Remove the disc brake ASSY.
Note:
After installation, perform brake air bleeding (See P12-28).
12-21

T=19.6 to 29.4
1 (200 to 300)
[14.5 to 21.7]
1. Remove the mounting set bolt.
2. Remove the disc brake cylinder mounting.
3. Remove the disc brake pad shim pad support plate. [Point 1]
4. Remove the piston cup dust cover ring. [Point 2]
12-22
Perform the reverse of the disassembly procedure.
Main Point:
• Apply sufficient brake fluid before assembling the piston.
• When reassembling, apply grease to the locations shown below.
Anti-squeal shim No.1

Disc brake pad
Pad wear indicator plate
Pad support
plate
Shim
No.3
Pad support plate
Shim No.2
Disc brake pad
Bush dust boot
Cylinder slide bush No.2 Bush dust boot
Ser ring
Apply disc brake gease Piston seal

Apply rubber grease Disc brake piston
Point Operations
[Point 1]
Inspection:
Inspect the thickness of the disc brake pads.
Standard: 9.5 mm (0.37 in.)
Wear remainder limit: 1 mm (0.04 in.)
[Point 2]
Disassembly:
If the piston does not come out easily, you can remove it easily
by applying compressed air to the cylinder pipe set hole.
However, cover the piston with a waste cloth to avoid scratch-
ing the piston.
12-23
MASTER CYLINDER
GENERAL
COMPONENTS
Brake Master Cylinder
4702
4702-110
12-24
Brake Piping
2TE15
4714
2TE18
4714
12-25
Removal Procedure
1. Drain the brake fluid.
2. Remove the toe board and seat stand W/seat ASSY.
3. Disconnect the wiring.
4. Remove the push rod clevis pin.
5. Disconnect the brake pipe.
6. Remove the brake master cylinder ASSY.
Main Point:
After installation, perform brake pedal adjustment (See P12-29) and air bleeding (See P12-28).
12-26
DISASSEMBLY • REASSEMBLY
4 7
5
6
1. Remove the brake master cylinder boot.
2. Set the brake master cylinder ASSY in a vice.
3. Remove the reservoir tube.
4. Remove the elbow. [Point 1]
5. Remove the outlet valve.
6. Remove the piston topper bolt. [Point 2]
7. Remove the No.1 and No.2 piston. [Point 3]
12-27
Point Operations
[Point 1]
Assembly:
Apply rubber grease to the arrowed parts in the illustration.
Note:
Use new O rings.
[Point 2]
Disassembly • Assembly:
• For removal and installation of the stopper bolt, first use a
screwdriver to fully push the piston in.
• When you push the piston in, do not splash brake fluid
about.
[Point 3]
Disassembly:
• When you remove the snap ring, do it with the piston
pushed in.
• Lightly tap the flange against a wood block and when the
piston edge protrudes beyond the cylinder edge, pull the
No.2 piston straight out.
Wood block
Assembly:
When assembling the piston, apply rubber grease to the ar-
rowed parts in the illustration.
12-28
BRAKE AIR BLEEDING
Note:
Add brake fluid to the reservoir tank during air bleeding to prevent it from becoming insufficient.
1. Perform the following items (1), (2) and (3), in order of distance from brake master cylinder, beginning with most
distant.
(1) Depress the brake pedal several times to compress the air in the piping, and hold that state.
(2) Loosen the breather plug to discharge air in the piping with the brake fluid, and tighten the plug immediately
before the fluid stops to run out.
(3) Repeat steps (1) and (2) above until no air bubbles are seen in the discharged brake fluid.
2. Add brake fluid to the specified level.
(1) Add brake fluid through the filter provided at the reservoir tank.
(2) Add brake fluid up to the staged portion in the reservoir tank.
12-29
BRAKE PEDAL
COMPONENTS
4701
4701-225
BRAKE PEDAL INSPECTION • ADJUSTMENT

B
Toe board
C A
Stopper bolt protrusion
1. Inspect brake pedal height A. (From toe board to center of pedal)

Standard: A = 170 to 174 mm (6.69 to 6.85 in.)
If the standard is not satisfied, make adjustment by changing the stopper bolt protrusion.
2. Inspect brake pedal play B.
Standard: B = 5 to 9 mm (0.2 to 0.35 in.)
If the standard is not satisfied, make adjustment by changing the master cylinder push rod length.
3. After the adjustment, fully depress the brake pedal C and inspect the pedal height in that state.
Standard: C = 145 mm (5.71 in.) or more
12-30
PARKING BRAKE
COMPONENTS
2TE15
4601
2TE18
4601
12-31
PARKING BRAKE INSPECTION •

ADJUSTMENT
1. Check the parking brake cable set position.
Standard: A = 3 to 5 mm (0.12 to 0.2 in.)
2. Apply chassis grease on the portions indicated by arrows.
3. Inspect and adjust the parking brake lever operating force.

(1) Set a spring scale at the center of the lever knob, and
measure the operating force by pulling it backward.
Standard: 175 to 215 N (17.9 to 21.9 kgf) [39 to 48 lbf]
(2) If the operating force is out of the standard range, release

the parking brake and make adjustment at the adjusting
portion.
Clockwise turn : Increases the operating force.
Counterclockwise turn : Decreases the operating force.
12-32
Memo
13-1
BODY
Page 13
COMPONENTS ................................................ 13-2
13
DRIVER SEAT.................................................. 13-5
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13-2
COMPONENTS
GX
5101
FS
RJ EK OC
PY TS TI
RJ
RJ
EZ
RJ
EK MN
RJ
IA GF
PY
RJ
EZ
DM
FF
MM
MB
CB HG QK
18
MM
CB FQ FL
HC FQ MB
MB
29
ND MB
CH
MB
CG
5101-457
5101
62A
62
RH
LL GE FJ BW
CZ
HB WT
AX ED AL
BB
FI FK
AL FZ FK AW
AG RI
MU EV BC GV
AW GV
WT GA FX
BS
JL
GP BG
LI BG
EV FI MA LZ
30 GL AG
GA XT
GL
AF GC FK
BC
FW
RH
BE
FA FJ
AM
AB 5101-459
13-3
5201
13
32 FH
BO
13
13
ED
AB
BW
13
AB
45 BQ
BE
13
FH
FL
FL
BE
BQ
BO
13
13
EV BW
30 DK 32
DK
EV
FL
13
DK 40
FL 30
5201-293
13
5301
(DOCUMENT BOX)
58
13
CU
FC
CE
13
58[LH] CE
CE
CU
CE
13
(HEATER)
13
58[RH] 58[LH]
CE
CU
CE
BV
AH
CE
58[RH]
CE
13
CU
13
79
(DOCUMENT BOX..HEATER)
58
13
CU
UH
BV
CE
CE 13
MG FE
13
EH
5301-380 13
13-4
5301
KH
DA
LI
KH
FG
KG
AG
LG
JS
WS AG KH
JW KX
JR
AW KG
CC BP
KY
LH CY
AG
JS AA KH
CC CW GQ FG
JB AG
WT
KU
FL JS
AW
CW
JS
5301-381
5308
01
02
BD
BD
GX
EA
ES[RH]
BD
BD
ES[LH]
EA
5308-322
13-5
DRIVER SEAT
13
13
13
13
13
13
13
13
13
13
Removal Procedure 13
1. Open the battery hood, and disconnect the battery plug.
2. Disconnect the seat switch connector. 13
3. Remove the operator’s seat set nuts.
4. Remove the operator’s seat. [Point 1] 13
13
Point Operations 13
[Point 1]
Inspection:
13
Push the seat cushion and inspect the seat switch for continuity.
Measuring portion:
13
Between CN42-1 and CN42-2 of LSD (seat switch)
Standard: Not pushed : ∞ Ω 13
Pushed : 0Ω
13
13-6
Memo
14-1
APPENDIX
Page 14
SST LIST .......................................................... 14-2
14
SERVICE STANDARDS LIST.......................... 14-6
CONNECTOR PIN ASSIGNMENT................. 14-14
14
2TE15
14
CONNECTING DIAGRAM.............................. 14-37 14
WIRING DIAGRAM ........................................ 14-38
14
2TE18
14
CONNECTING DIAGRAM.............................. 14-39
WIRING DIAGRAM ........................................ 14-40 14
14
14
14
14
14
14
14
14
14
14
14
14-2
SST LIST
Common to 2TE15 and 18
Section
Illustration Part No. Part name
3 5 6 7 8 9 11 12
Counter shaft remover &

09110-30200-71 {
replacer
09120-23600-71 Three-pawl puller {
09140-13130-71 Clamp-on AC/DC high tester {
09230-13700-71 IC check pin {
09232-13130-71 Sub-harness {
09238-13130-71 Sub-harness {
09240-23400-71 IC clip { {
09370-10410-71 Front axle bearing replacer {
09370-20270-71 Drive pinion bearing replacer { {

14-3
Section
3 5 6 7 8 9 11 12
09450-23320-71 Adapter { 14
14
14
Brake hold-down spring
09510-31960-71 {
remover & replacer
14
{
14
09700-30200-71 Spring pin tool remover
09717-76001-71 Brake shoe return spring

14
{
(09717-20010) remover
14
09718-76001-71 Brake shoe return spring
{
14
(09718-20010) replacer
14
09950-76003-71
(09950-50012)
Puller C set { 14
14
09950-76014-71
(09950-40011)
Puller B set { { { 14
14
14
09950-76018-71
Replacer set { {
(09950-60010)
14
09950-76019-71
{ {
14
Replacer set No. 2
(09950-60020)
09950-76020-71
14
Handle set { { {
(09950-70010)
14
14
14-4
For 2TE15
Section
3 5 6 7 8 9 11 12
09231-13130-71 Sub-harness {
09233-13130-71 Signal check harness {
09234-13130-71 Sub-harness {
09239-13130-71 Sub-harness {
09310-10160-71 Front axle hub remover {
09320-23001-71 Bearing remover {
09330-33130-71 Stopper pin {
09421-33020-71 Front axle hub replacer {
09509-76003-71
Rear wheel bearing nut wrench {
(09509-55030)
25009-13201-71 Battery hanger

14-5
For 2TE18
Section
3 5 6 7 8 9 11 12
14
09090-76002-71
Engine sling device {
(09090-04020)
14
09222-76001-71 Connecting rod bush remover &
14
{
(09222-30010) replacer
14
09231-21320-71 Sub-harness {
14
14
09310-23320-71 Reamer bolt remover { { 14
14
09411-41800-71
Second drive shaft dust seal
replacer
{ 14
14
09420-23001-71 Bearing remover {
14
14
14
14
14
14
14
14
14
14-6
SERVICE STANDARDS LIST

BATTERY
Specific gravity upon full charge 1,280 [at 20°C (68°F)]
Specific gravity at end of discharge 1,150 [at 20°C (68°F)]
Battery voltage V 80
Discharge end voltage V 68
Insulation resistance MΩ 1 or more
CHARGER
MAGNET SWITCH
Magnet switch coil resistance Ω CLK-50JT Approx. 400
When not operated 0

Thermal relay contact continuity Ω
When operated ∞
TRANSFORMER
Insulation resistance MΩ 1
Primary coil continuity Ω 0
Secondary coil continuity Ω 0
Forward direction Continuity

Diode continuity Ω
Backward direction ∞
SKR71/04
Diode tightening torque N·m (kgf-cm) [ft-lbf] 4 (41) [2.9]
SKN71/04
No-load secondary voltage (AC) V 94
No-load secondary voltage (DC) V 127

14-7
CONTROLLER
2TE15
F1 (Drive circuit fuse) A 500
F3 (PS circuit fuse) A 75
F6 (PS fuse) A 10
F7 (DC/MD fuse) A 10
The insulation resistance should be as high as

possible, but it greatly varies with the vehicle use
Control panel insulation resistance MΩ
condition, working place, environment and weather.
Approx. 1 or more
D1 (D2) - S1 (S2) Approx. 2
D1 (D2) - G1 Approx. 12
TMD (Drive main transistor) S1 (S2) - D1 (D2) ∞
[Tester range: Ω × 1k]
S1 (S2) -G Approx. 10
G - D1 (D2) ∞
kΩ G - S1 (S2) Approx. 1
MB (power supply contactor) coil resistance Ω Approx. 20 [at 20°C (68°F)]
The pointer should first indicate the 0 Ω, and gradually

CO (overall capacitors) resistance Ω
return to the ∞ Ω side then to finally indicate ∞ Ω.
Input voltage difference (V) among three phases of the drive motor 4 or less
Drive motor OCL value A 293 to 380
2TE18
F1 (Drive motor fuse) A 600
F3 (PS fuse) A 75
The insulation resistance should be as high as

possible, but it greatly varies with the vehicle use
Control panel insulation
condition, working place, environment and weather.
Drive motor OCL value A 380 to 485
ACCELERATOR POTENTIOMETER
2TE15
With pedal depressed Continuity
Acceleration switch (SWAC) Ω
Pedal not depressed ∞
Variable resistor resistance during

51 - 52 Gradual change from 0 to approx. 2 to 4
acceleration kΩ
2TE18
Pedal not depressed ∞
Acceleration switch (SWAC) Ω
With pedal depressed 0
14-8
DIRECTION SWITCH
Lever position
Forward Neutral Reverse
DSF 0Ω ∞Ω ∞Ω
DSR ∞Ω ∞Ω 0Ω
DSBU ∞Ω ∞Ω 0Ω
DSFO 0Ω ∞Ω ∞Ω
BRAKE LIMIT SWITCH
Limit switch ON dimension See P3-60 in this manual.
DRIVE MOTOR
2TE15
Clearance between rpm sensor and pick-up gear mm (in.) Standard 0.4 to 1.0 (0.016 to 0.039)
Stator ASSY insulation resistance MΩ Standard 1 or more
Motor cable continuity Ω Standard 0
Temperature sensor resistance kΩ Standard Approx. 11 to 15
2TE18
Stator ASSY insulation resistance MΩ Standard 1 or more
Speed sensor insulation resistance Ω Standard ∞
Temperature sensor insulation resistance Ω Standard ∞

Temperature sensor resistance kΩ Standard 0.5 to 1.0
TIGHTENING TORQUE N·m (kgf-cm) [ft-lbf]
End bracket set nut Standard 45.0 to 55.0 (460 to 560) [33 to 41]
14-9
POWER STEERING MOTOR
Insulation resistance between connector terminal and body MΩ Standard 1 or more
Standard 50 (1.97)
Commutator outside diameter mm (in.)
Limit 45 (1.77)
Standard 0.8 (0.031)

Undercut mm (in.)
Limit 0.3 (0.012)
Commutator run-out mm (in.) Limit 0.05 (0.00197)
Armature coil insulation resistance MΩ Standard 1 or more
Standard 5.59 (0.57) [1.26]

Brush spring force N (kgf) [lbf]
Limit 2.74 (0.28) [0.62]
Insulation resistance between brush holder and bracket MΩ Standard 1 or more
Standard 25 (0.98)
Brush length mm (in.)
Limit 14 (0.55)
DRIVE UNIT
Differential
Standard 22.00 (0.8661)
Spider outside diameter mm (in.)
Limit 21.75 (0.8563)
Standard 22.12 (0.8709)

Pinion gear inside diameter mm (in.)
Limit 22.22 (0.8748)

Side gear thrust washer thickness mm (in.)
Limit 1.3 (0.051)

Pinion gear thrust washer thickness mm (in.)
Limit 1.0 (0.039)
TIGHTENING TORQUE (2TE15) N·m (kgf-cm) [ft-lbf]
Gear case set bolt Standard 61 to 114 (620 to 1160) [44.86 to 83.93]
Differential upper case set bolt Standard 43.1 to 53.9 (440 to 550) [31.7 to 39.7]
Drive unit gear No. 4 set bolt Standard 127 to 176 (1300 to 1800) [94 to 130]
Drive unit gear No. 3 set nut Standard 167 to 225 (1700 to 2300) [123 to 166]
TIGHTENING TORQUE (2TE18) N·m (kgf-cm) [ft-lbf]
Gear case set bolt Standard 94.5 to 175.5 (960 to 1800) [70 to 129]
Differential upper case set bolt Standard 43.1 to 53.9 (440 to 550) [32 to 40]
Drive unit gear No. 3 set bolt Standard 127.5 to 176.5 (1300 to 1800) [94 to 130]
14-10
REAR AXLE
2TE15
Hub starting force N (kgf) [lbf] Standard 24.5 to 78.4 (2.5 to 8.0) [5.5 to 17.6]
Brake drum × rear axle hub set nut Standard 147 to 186 (1500 to 1900) [108 to 137]
Hub bearing nut stopper bolt Standard 2.0 to 3.9 (20 to 40) [1.4 to 2.8]
Rear axle shaft set bolt Standard 69 to 88 (700 to 900) [51 to 65]
Hub nut Standard 176 to 392 (1800 to 4000) [130 to 289]
2TE18
Standard 22.0 (0.866)
Planet gear shaft outside diameter mm (in.)
Limit 21.85 (0.860)
Standard 22.0 (0.866)

Planet gear bush inside diameter mm (in.)
Limit 22.18 (0.873)
Rear axle shaft starting force (at axle housing set bolt) N (kgf) [lbf] Standard 68.6 to 127.5 (7 to 13) [15 to 29]
Hub bolt lock nut Standard 285 to 294 (2910 to 3000) [210 to 217]
294.2 to 343.2
Axle shaft lock nut Standard
(3000 to 3500) [217.1 to 253.2]
Rear axle ASSY set bolt (for frame connection) Standard 235 to 294 (2400 to 3000) [173 to 217]
Rear axle ASSY set nut (for gear case connection) Standard 180 to 323 (1840 to 3300) [133 to 238]
Rear axle bracket set bolt Standard 294 to 392 (3000 to 4000) [217 to 289]
Rear wheel hub nut Standard 294 to 588 (3000 to 6000) [217 to 433]
14-11
FRONT AXLE
FRONT AXLE HUB-STEERING KNUCLE
Front axle hub starting force (at hub bolt) N (kgf) [lbf] Standard 30 to 80 (3.1 to 8.2) [6.7 to 18.0]
King pin outside diameter mm (in.) Limit 27.8 (1.094)
Steering knuckle starting force (at front end of knuckle) N (kgf) [lbf] Standard 13.7 (1.4) [3.0]
FRONT AXLE CYLINDER
Front axle cylinder piston rod outside diameter mm (in.) Limit 39.92 (1.5717)
Front axle cylinder piston rod bend mm (in.) Limit 0.5 (0.020)
Front axle cylinder bore mm (in.) Limit 70.35 (2.7697)
U bolt set nut Standard 75 to 115 (770 to 1173) [553 to 84.8]
King pin lock bolt-lock nut Standard 44 to 54 (450 to 550) [32.6 to 39.8]
Front axle cylinder rod guide set nut Standard 88 to 118 (900 to 1200) [65.1 to 86.6]
Front axle cylinder set bolt Standard 167 to 216 (1700 to 2200) [123 to 159]
Tie rod set nut Standard 49.0 to 73.5 (500 to 800) [36.1 to 57.9]
Front wheel hub nut Standard 115 to 145 (1170 to 1480) [85 to 107]
Front axle hub set bolt Standard 57 to 85 (580 to 870) [42 to 63]
STEERING
HYDROSTATIC STEERING VALVE ASSY
Steering wheel play mm (in.) Standard 20 to 50 (0.787 to 1.97)

+490 +5 +71
Relief pressure kPa (kgf/cm2) [psi] Standard 9300 0 (95 0 ) [1350 0 ]
Steering wheel set nut Standard 25 to 45 (250 to 460) [18 to 33.3]
Steering valve ASSY set bolt Standard 29.4 to 39.2 (300 to 400) [22 to 29]
Steering valve end cap set screw Standard 22.6 (230) [16.6]
14-12
BRAKE
FRONT BRAKE
Standard 9.5 (0.37)

Disc brake pad thickness mm (in.)
Limit 1.0 (0.04) (Wear limit)

Brake disc thickness mm (in.)
Brake disc run-out mm (in.) Limit 0.07 (0.0028)
2TE15
REAR BRAKE
Standard 32.3 (1.272)

Hold-down spring free length mm (in.)
Limit 29.1 (1.146)
Standard 124.5 (4.902)

Actuator spring free length mm (in.)
Limit No clearance between coil winding turns
Standard 106 (4.17)

Anchor-to-shoe spring free length mm (in.)
Standard 23 (0.91)
Strut-to-shoe spring free length mm (in.)
Limit 20 (0.79)
Standard 86 (3.39)
Adjuster spring free length mm (in.)

Brake lining thickness mm (in.)
Limit 2.0 (0.079)
Wheel cylinder to piston clearance mm (in.) Limit 0.145 (0.00571)
Standard 310 (12.20)

Brake drum inside diameter mm (in.)
Limit 312 (12.28)
PARKING BRAKE
Parking brake operating force

Standard 175 to 215 (17.9 to 21.9) [39.3 to 48.3]
(measured at center of lever knob) N (kgf) [lbf]
BRAKE PEDAL
Brake pedal height (from toe board) mm (in.) Standard 170 to 174 (6.69 to 6.77)
Brake pedal play mm (in.) Standard 5 to 9 (0.197 to 0.354)
Brake pedal depressed height mm (in.) Standard 145 (5.71) or more
Brake master cylinder push rod play mm (in.) Standard 1 to 2 (0.039 to 0.079)
Brake plate set bolt Standard 137 to 196 (1394 to 1999) [101.0 to 144.6]
Wheel cylinder set bolt Standard 13.7 to 22.6 (140 to 230) [10.1 to 16.7]
14-13
2TE18
REAR BRAKE
Standard 317.5 (12.50)

Brake drum inside diameter mm (in.)
Limit 319.5 (12.58)
Upper Standard 25.4 (1.00)
Shoe hold-down spring free length mm (in.) Center Standard 43.7 (1.72)
Lower Standard 27.8 (1.09)
Standard 9.3 (0.36)

Brake shoe lining thickness mm (in.)
PARKING BRAKE
Lever operating force N (kgf) [lbf] Standard 175 to 215 (17.8 to 21.9) [39.2 to 48.3]
BRAKE PEDAL
Brake pedal height (from toe board: with pad) mm (in.) Standard 170 to 174 (6.69 to 6.77)
Brake pedal play mm (in.) Standard 5 to 9 (0.2 to 0.354)
Brake pedal depressed height (with pad) mm (in.) Reference 145 (5.71) or more
Parking brake actuator lever set bolt Standard 13.7 to 22.6 (140 to 230) [10 to 17]
Disc brake ASSY set bolt Standard 57 to 85 (580 to 870) [42.0 to 62.9]
Mounting set bolt Standard 19.6 to 30.4 (200 to 310) [14.5 to 21.7]
14-14
CONNECTOR PIN ASSIGNMENT

2TE15
14-15
14-16
14-17
14-18
14-19
14-20
14-21
JOINT 1
14-22
JOINT 2
14-23
2TE18
14-24
14-25
14-26
14-27
14-28
14-29
14-30
JOINT 1
14-31
JOINT 2
14-32
Travelling Controller • Main Components
2TE15
CO (capacitor)
TMD (Drive motor transistor)
Travelling controller ASSY
CPU board
CN107
CN106
CN105
CN101
CN102
F1 CN103
CN104
DC/MD board
CN111 CN110
CN112
CN113 CN109
CN108
14-33
Main Controller Connector • Main Componens
2TE18
CN104
CN103
CN102
CN101
CPR
CN126
14-34
Travelling Controller Connector • Main Components

2TE18
CN166
P3
P7
P8
P9
N1
Main Contactor Connector • Main Components

2TE18
P1
F1
P3
CN136
14-35
PS Contactor Connector • Main Components

Common to 2TE15 and 18
F3
P22
CN59
14-36
Memo
14-37
CONNECTING DIAGRAM
2TE15
14-38
WIRING DIAGRAM
2TE15
14-39
CONNECTING DIAGRAM
2TE18
14-40
WIRING DIAGRAM
2TE18
Published by
1st Printing: Nov. 2005
Pub. No. CE660
Printed in Japan
C
2TE15, 18
2TE15, 18
Pub. No. CE660
PRINTED IN JAPAN Pub. No. CE660 Pub. No. CE660

2te15-18 Repair Manual Ce660

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2te15-18 Repair Manual Ce660

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2TE15, 18

Pub. No. CE660

PRINTED IN JAPAN Pub. No. CE660 Pub. No. CE660

2TE15 (W/ wind top)

2TE18 (W/ wind top)

2TE15 (W/ steel cabin)

2TE18 (W/ steel cabin)

Model 2TE15, 2TE18

Control method Microcomputer

Vehicle model 2TE15 2TE18

Punching format 2TE15-10011 2TE18-10011

Frame No. punching position

HOW TO USE THIS MANUAL

DISASSEMBLY • INSPECTION • REASSEMBLY

• Some step numbers may be

2. How to read component figures

Abbreviation Meaning Abbreviation Meaning

ASSY Assembly SAE Society Automotive Engineers (USA)

ATT Attachment SST Special Service Tool

LH Left Hand STD Standard

L/ Less T= Tightening Torque

OPT Option {{T Number of teeth ({{T)

O/S Oversize U/S Undersize

PS Power Steering W/ With (what follows is included)

New Units Adopted in SI

Item New unit Conventional unit Conversion rate *1

Force *2 N (newton) kgf 1 kgf = 9.80665 N

Torque *2 (Moment) N·m kgf·cm 1 kgf·cm = 9.80665 N·m

Pressure Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa

↑ ↑ mmHg 1 mmHg = 0.133322 kPa

Revolving speed r/min rpm 1 rpm = 1 r/min

Spring constant *2 N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm

Conversion between Conventional and SI Units

Value in SI unit = Conversion rate × Value in conventional unit

Wooden stand point

HOISTING THE VEHICLE

WIRE ROPE SUSPENSION ANGLE LIST

60° 1.16 time 0.58 time 60°

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Battery ASSY 1150 (2535)

2TE15 102 (225)

2TE15 400 (882)

Front axle ASSY (W/ spring) 150 (331)

2TE15 3150 (6945)

CAUTION FOR TOWING

In case of towing by connection with a wire rope with the oper-

ELECTRICAL PARTS INSPECTION

(b) Digital circuit tester

4. Difference in result of measurement with circuit tester:

5. Difference in measurement result by measurement range (analog type):

Power source: 1.5 V

BOLT & NUT TIGHTENING TORQUE

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING

Type Shape and class Class

Hexagon head bolt

Bolt with three raised lines on head 7T

Bolt with four raised lines on head 8T

2 mm groove(s) on one/both edge(s) 6T

Identification by Part No.

Type Part No. Shape

Tightening Torque Table

Nominal diameter Pitch Standard tightening torque