TX Control Adjustment Mode

CS.
FM Page 0 Tuesday, December 9, 2008 2:41 PM
CONTROL SYSTEM
SECTION CS
CONTENTS
TECHNICAL DESCRIPTION ............................. CS-2 How To Follow Flow Chart .......................... CS-79
System .......................................................... CS-2 Symbol Identification ................................... CS-80
PRECAUTIONS ............................................... CS-10 Voltage and Resistance Measurement
LOCATION OF UNITS (LAYOUT) ................... CS-11 Procedures .................................................. CS-81
Standard Equipment (3 - wheel) .................. CS-11 TROUBLE DIAGNOSIS FOR CONTROLLER
Standard Equipment (4 - wheel) .................. CS-12 SYSTEM ........................................................... CS-82
Optional Equipment ..................................... CS-13 TROUBLE DIAGNOSIS FOR DRIVING
METER PANEL ................................................ CS-14 SYSTEM ........................................................... CS-90
Meters, Indicators and Lamps ..................... CS-14 TROUBLE DIAGNOSIS FOR LOADING
Setting Adjustment Items (Normal Mode) ... CS-14 SYSTEM OF MECHANICAL TYPE ................. CS-97
Meter Panel Explanation ............................. CS-15 TROUBLE DIAGNOSIS FOR LOADING
LCD MONITOR ................................................ CS-23 SYSTEM OF JOYSTICK TYPE ..................... CS-102
Adjustment Mode ........................................ CS-23 TROUBLE DIAGNOSIS FOR POWER
Diagnostic Mode .......................................... CS-31 STEERING SYSTEM ..................................... CS-108
Table of Error Code ..................................... CS-42 TROUBLE DIAGNOSIS FOR TURN SIGNAL
CONTROLLER ................................................. CS-43 LAMP SYSTEM ............................................. CS-109
Construction ................................................ CS-43 REFERENCE DATA OF CONTROL
Connector (Terminal layout) ........................ CS-45 SYSTEM ......................................................... CS-110
Controller Element Inspection ..................... CS-49 Main Print Board ........................................ CS-110
Removal and Installation (3 - wheel) ........... CS-56 Drive FET Board
Removal and Installation (4 - wheel) ........... CS-57 (for RH traction motor control) ................... CS-114
UNIT INSPECTION AND ADJUSTMENT ........ CS-58 Drive FET Board
Control System ............................................ CS-58 (for LH traction motor control) ................... CS-114
Joystick Control System (Option) ................ CS-70 Pump FET Board ....................................... CS-114
Knob Position Control System Traction Condenser Board ........................ CS-115
(Option 3 - wheel only) ................................ CS-77 Loading Condenser Board ........................ CS-115
TROUBLE DIAGNOSTIC PROCEDURES ...... CS-78 Joystick Controller ..................................... CS-116
Precautions ................................................. CS-78
CAUTION:
Where towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to
reduce possible damage to electrical system.
Bulletin issued:
Service Bulletins Issue date
SB-TX-CS0501-2 Prevention to damage controller 05-01-2006
SB-TX-CS0502 Changing ground circuit MP 29-11-2005
SB-TX-CS0601 Power mode indication scrolling on meter panel 05-05-2006
SB-TX-CS0602 Error code 558 occur with FN1+FN3 05-05-2006
SB-TX-CS0702 Incorrect measurement with damaged controller insulation 01-10-2007
CS-1
TECHNICAL DESCRIPTION
System
COMPARISON OF PREVIOUS TYPE AND NEW TYPE
CSM0086
CORRELATION DIAGRAM OF SYSTEM

Drive system
CSM0087
CS-2
System (Cont’d)
AC motor control
CSM0088
DRIVE SYSTEM FUNCTION
Item Function Outline
Drive control Drive control type Induction motor AC inverter vector control
Drive control 2 motor turning control
Regeneration control Switchback, brake, accelerator off regeneration
Performance adjustment Power level (3 steps+ accurate adjustment 5 steps)/Acceleration Level (8 steps),
Regeneration level (8 steps each)
Anti-roll (8 steps)
Anti-roll control Anti-roll braking force control on slope
Various limitation Speed, high lift height, power cut (brake, parking brake)
Pump control Drive control Induction motor AC inverter vector control
Drive control Speed control by loading operation
Regeneration control Loading regeneration when loading operation stopped
Performance adjust. Power level (3 steps + accurate adjust 5 steps) Acceleration Level (8 steps)
Various limitation High lift height, high driving speed, cutout when reverse drive, pump cut
Mast lowering control Mast lowering lock when key switch is off
Magnetic proportional control Magnetic proportional loading control for optional unit (Joystick control system)
PS control Drive control type Electronic controlled hydraulic power steering
Drive control method Common pump motor control for loading
Control function Starting with steering operation detected/steering speed sensing control
Knob position control Compensate steering angle and tire angle offset by magnetic valve control
CS-3
System (Cont’d)
Item Function Outline
System control Inhibitor control Accelerator, FR SW, Loading, Seat

Meter communication Trace truck mode changeover by meter indication
Meter display of various truck conditions, diagnoses and adjustments
Log in function Setting of each truck by pass word input
Diagnosis function Diagnosis function in normal mode/self checking/dialog checking
Adjustment function Drive, pump, power steering system adjustment and memory
Accessory control Automatic power off/Parking brake warning
Cooling fan drive/External accessory source relay/Flasher
Truck model variation Automatic model variation change by harness
Electromagnetic Mag. proportional valve Magnetic proportional valve control corresponding to control valve opening
control (Joystick
Loading corresp. control Pump motor revolution control corresponding to control valve opening
control system)
Communication function CAN communication between main control
Others Adjustment and diagnosis function
Temperature Motor temp. control Controlling temperature of motor. When the motor temperature exceeds a temperature of
control 130 degrees C (266 degrees F), controller will slow down the motor(s) until motor cools
Controller temp. control Controlling temperature of controller. When the controller temperature exceeds a
temperature of 130 degrees C (266 degrees F), controller will slow down the motor(s) until
controller cools
CS-4
System (Cont’d)
FEATURE OF DRIVE SYSTEM
Maintenance free AC Traction/Pump Motors
Pump motor is used for PS
Accessories concentrated control

Various model changing function (Same controller for various models)
Lift lowering, PS valve control
Flasher control
Cooling fan control (Including external fan)
Electric source relay (Auto power off, valve electric source)
High technology for superior function and high reliability by adoption of sensors with high performance
AC motor digital control adopting 32bit RISC CPU
Adoption of HEV (Hybrid Electric Vehicle) high responsible items such as resolver
CAN (Controller Area Network) communication between units
Magnetic proportional control (Joystick control system)

No special modification is necessary on controller, Add on installation
Accurate loading control by coordinating with main controller
COMPARISON OF FORKLIFT MOTOR CONTROL
CSM0089
CS-5
System (Cont’d)
CSM0090
CSM0091
CS-6
System (Cont’d)
PRINCIPLE OF AC MOTOR
CSM0092
CS-7
System (Cont’d)
KNOB POSITION CONTROL SYSTEM
(OPTION 3 - WHEEL ONLY)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)
Input Output
Steering wheel angle sensor

angle 1 signal
Steering wheel Power steering correction
angle 2 signal
solenoid
neutral signal
Tire angle sensor
CS-8
System (Cont’d)
Knob position control system (option 3 - wheel only)
CSM0093
CS-9
PRECAUTIONS
PRECAUTIONS
CAUTION:
• Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
• Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body
and do not pull on the cord.
• When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
• When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
• Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.
Inadvertent current flow may damage the element or other
parts being checked.
• Before using flow charts as a guide to troubleshoot units and
parts, become familiar with the instructions outlined under
“TROUBLE DIAGNOSTIC PROCEDURES”.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
CS-10
LOCATION OF UNITS (LAYOUT)
Standard Equipment (3 - wheel)
CSM0094
CS-11
Standard Equipment (4 - wheel)
CSM0094EU
CS-12
Optional Equipment
CSM0095EU
CS-13
METER PANEL
METER PANEL
Meters, Indicators and Lamps
CSM0096EU
Setting Adjustment Items (Normal Mode)

Adjustment item Shift to adjust mode Adjustment Details Function lock on
Push FN1 LCD contrast is brightened.
LCD contrast – Unlocked (OFF)
Push FN2 LCD contrast is dimmed.
Traction and loading
– Push FN3 P H M E Locked (ON)
power mode
Hour meter select – Push FN4 Locked (ON)
Push FN3 Hour Minute Day
Clock setting Push FN1 + FN2 Unlocked (OFF)
Push FN1 The digit is increased, or the day is advanced.
Push FN2 The digit is decreased, or the day is set back.
Alarm setting Push FN2 + FN4 Unlocked (OFF)
Push FN1 The digit is increased, or the day is advanced.
Push FN2 The digit is decreased, or the day is set back.
Push FN3 D-ACC P-LEVEL
Push FN4 D-ACC P-LEVEL
Acceleration level Push FN1 + FN4 Locked (ON)
Push FN1 Increase
Push FN2 Decrease
Push FN2 + FN5
+
Push FN5
+
Push FN2
Function lock/
+ – The above functions are locked (ON)/unlocked (OFF).
unlock code
Push FN3
+
Push FN5
+
Push FN5
CS-14
METER PANEL
Meter Panel Explanation

DESCRIPTION
The meter panel consists of two sections: LCD (Liquid Crystal
Display) monitor and function keys.
1. Function keys
Function keys control the LCD contrast, display changes and
other adjustments. Function key operation is described in the
individual part descriptions and in the items related to
adjustment.
2. LCD
When the key switch is in the ON position, backlighting makes
the displays clearly visible to the forklift operator. It displays
normal operation (battery capacity meter, hour meter, clock,
steering wheel angle gauge, speedometer, etc.), malfunction
and adjustment data.
LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
To darken the contrast, push function switch FN2. To lighten the
contrast, press function switch FN1.
HOUR METER (4 MODES)

CSM0097
This hour meter has 4 modes (functions).
1. Key “ON” time : Equal to the total operating hours when the
key switch is in the ON position.
2. Operating time : Equal to the traveling or loading time (the
time for whichever operation in progress is displayed).
3. Traveling time : Equal to the total time that the traction motor
is operational.
4. Loading time : Equal to the total time that the forks are
operational (tilting and lifting).
The hour meter operates when the key switch is in the ON position,
and it indicates the total operating period in hours (key “ON” time).
STEERING WHEEL ANGLE GAUGE/SPEEDOMETER

When the vehicle speed is 3 km/h or less, the speedometer
indicates the angle of rear wheel tires, instead of the speed.
NOTE:
Only for 3 - wheel trucks
CSM0098
CS-15
METER PANEL
Meter Panel Explanation (Cont’d)

When vehicle speed is 4 km/h or more, the speedometer shows
forklift speed in either kilometers per hour (km/h) or miles per hour
(mph). The maximum vehicle speed and speed alarm can both be
set.
NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)
CSM0099
POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function switch FN3 is pressed, the power
mode is switched.
Mode M: Manual mode:

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

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

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

For work or customers requiring higher power (Traveling and loading
power levels: Level 5)
CS-16
METER PANEL

CLOCK/ALARM/ACCELERATION ADJUSTMENT
Clock/alarm
When the key switch is in the ON position, both the day and time are
displayed.
Push function switches FN1 and FN2 simultaneously. The time set
mode will appear.
AM and PM hour adjustment: The hour display will advance by 1

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

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

advance by one day each time function switch FN1 or FN2 is
pushed.
After setting the clock to the correct time, push function switch FN5.
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
• Push FN1 to increase the numerical value or advance one day of
the week.
• Push FN2 to decrease the numerical value or reverse one day of
the week.
• If an alarm is set, “ ” appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press FN5 to stop the buzzer. The day of the week can
be set to every day (ALL: every day).
Traction acceleration adjustment

This control adjusts acceleration during forklift starting and
subsequent operation.
Simultaneously press function switches FN1 and FN4. The clock will
move to the traction acceleration control mode.
The acceleration level can be adjusted in a series of 8 steps.
For faster acceleration (Quick): Push function switch FN1.

CSM0102
Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.
For slower acceleration (Slow): Push function switch FN2.
Each time the key is pushed, the acceleration level (speed) will
decrease by 1 step.
After setting the acceleration level, push function switch FN5. The
acceleration level will appear, and clock will return to its original letter
mode.
CS-17
METER PANEL

NOTE:
Acceleration factory setting at time of shipping:
D-ACC NOM SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After acceleration level adjustment, operate the forklift slowly
and carefully until you become accustomed to the new
acceleration level. Be especially careful when the acceleration
level has been increased. Higher acceleration levels can cause
loads to shift, to fall off or to be unstable during starts.
Pump acceleration adjustment

Simultaneously push function switches FN1 and FN4. Next, push
function switch FN3. The clock will move to the pump acceleration
control mode.
The acceleration level can be adjusted in a series of 8 steps.
For faster acceleration (Quick): Push function switch FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
CSM0103
For slower acceleration (Slow): Push function switch FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.
After setting the acceleration level, push function switch FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.
CS-18
METER PANEL

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

This lamp indicates that the seat belt is not fastened securely. It will
lights up if the seat belt is not fastened when the ignition switch is
turned to the ON position, and it will turn off when the seat belt is
fastened.
MALFUNCTION AND WARNING INDICATIONS
CSM0104
If any malfunction occurs when the key switch is in the ON position,

the LCD will show a wrench mark “ ” or a battery mark “ ”.
Simultaneously, the LCD will display letters explain the details of the
malfunction.
NOTE:
During forklift operation, periodically check the battery capacity.
Make every effort to recharge the battery before the battery warning
mark “ ” and wrench mark “ ” appear.
Wrench mark
The controller and the sensors act together to regulate the forklift’s
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.
CS-19
METER PANEL

• Control system malfunction (Traction, Cargo-handling, Power
steering)
• Overheating controller or motor
• Low brake fluid level
BATTERY WARNING MARK

Pump cut warning
Pump cut warning is displayed when the battery capacity meter’s
remaining capacity indication changes from 2/6 to 1/6.
CSM0105
When function switch FN5 is pressed, the display will switch.
CSM0106
After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle may be operated during the pump cut warning.
However, move the vehicle to a safe location, and promptly charge
the battery.
CSM0106
CS-20
METER PANEL

Low voltage lock warning
If the vehicle is subjected to continuous operation after the pump cut
warning was activated, the low voltage lock warning will be
activated. Then, the display will appear as shown below, and the
warning buzzer will be activated.
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
CSM0106
CS-21
METER PANEL

MALFUNCTION INDICATIONS
Affected system or area Indication Malfunction description
Control system (Traction, D-FET SHORT A malfunction has occurred in
Cargo-handling, Power the forklift traction system.
steering): Units, Sensors, Further operation of the forklift is
Motors, Switches, FETss not possible.
P-FET OPEN A malfunction has occurred in

the forklift cargo-handling
system. Further lifting (lifting and
tilting) operation is not possible.
The forks cannot be raised or
tilted.
TIRE ANGLE SENSOR LOW A malfunction has occurred in

the forklift power steering
system. Forklift steering control
is possible.
D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor is WARNING
overheating. Immediately stop
Ignoring the warning indication and
forklift operation. Park the forklift in
continuing to operate the forklift
a safe area where there is no
can result in serious motor and
pedestrian or vehicular traffic.
controller damage.
Allow the controller and/or the
motor to cool.
P/MO TEMP SENSOR HIGH TEMP
Essential fluid BRAKE FLUID LEVEL DOWN The brake fluid level has fallen
below the specified level.
Battery Battery over voltage The controller has detected a high Turn the key switch OFF and ON
battery voltage again. If no error displayed, you can
operate the forklift without a
problem. If problem reoccur,
contact your NISSAN FORKLIFT
dealer.
CS-22
LCD MONITOR
LCD MONITOR
Adjustment Mode
CSM0107
CS-23
LCD MONITOR
Adjustment Mode (Cont’d)

NOTE:
This mode is only available for qualified technicians to perform
various adjustments on setting values other than traction/loading
acceleration adjustments in the normal mode.
CAUTION:
• Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
• Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.
CS-24
LCD MONITOR
CSM0109
CS-25
LCD MONITOR
CSM0110EU
CS-26
LCD MONITOR
CSM0190
CS-27
LCD MONITOR
CSM0191EU
CS-28
LCD MONITOR
CSM0192
CS-29
LCD MONITOR
CSM0193
CS-30
LCD MONITOR
Diagnostic Mode
CSM0108
CS-31
LCD MONITOR
Diagnostic Mode (Cont’d)

There are two types of diagnostic method. One type is self-diagnosis
and the other is interactive diagnosis. Self-diagnosis allows for
controller diagnosis of a system, while the interactive diagnosis is
used for diagnosing switches and sensors. When malfunctions
occur in systems or components, check and eliminate probable
causes of the malfunction using either self-diagnostic or interactive
diagnostic techniques. After the malfunctioning area has been
repaired, confirm the malfunction has been eliminated by using the
appropriate diagnostic method.
NOTE:
When checking each component, operate each component if
necessary.
CS-32
LCD MONITOR
CSM0111
CS-33
LCD MONITOR
CSM0112
CS-34
LCD MONITOR
CSM0194
CS-35
LCD MONITOR
CSM0195
CS-36
LCD MONITOR
CSM0196
CS-37
LCD MONITOR
CSM0197
CS-38
LCD MONITOR
CSM0198
CS-39
LCD MONITOR
CSM0199
CS-40
LCD MONITOR

CAUTION:
If an interactive diagnostic result indicates that a unit is
abnormal, also check the condition of the associated harness
and connector.
NOTE:
• The number of malfunctions which have occurred in each system
is recorded in the “FAIL LOG” row on the display, without regard
to the nature of the malfunctions experienced.
• For unit inspection procedures, refer to “UNIT INSPECTION AND
ADJUSTMENT” on page 56.
RESULT OF SELF-CHECK
If the error is not detected:
CSM0113
If the error is detected:

NOTE:
The 3-digit number in the figure indicates the error code of the
component for which the error is detected. For the error code, refer
to “Table of Error Code” on page 41.
CAUTION:
If a self-diagnostic result indicates that an element or
component is abnormal, also check the condition of the
associated harness and bus bar.
CSM0114
NOTE:
For element inspection procedures, refer to “Controller Element
Inspection” on page 48.
CS-41
LCD MONITOR
Table of Error Code

Error Detect mode Reference Error Detect mode Reference
Failure part Fail mode Remarks Failure part Fail mode Remarks
code Work Self page code Work Self page
CONTROLLER ACTUATOR
Main contactor Short 400 - Lift down valve Short 500
CS-52 - CS-69 -
Open 401 - Open 501
Main fuse Open 403 CS-53 - PS correction valve Short 502 Knob
Battery voltage Low voltage 404 - Open 503 position
CS-77
control
Over 405 - - -
(Option)
voltage
Tilt Horizontal valve Short 504
CONT capacitor Abnormal 406 - - - Not equipped
Open 505
Drive FET Short 408
Lift valve Pull Short 506
Open 409 Joystick
CS-49 - Open 507
Drive FET left Short 410 control
Push Short 508 (Option)
Open 411
Open 509
Pump FET Short 412
CS-50 - Tilt valve Pull Short 510
Open 413 Joystick
Open 511
Drive current U Low output 414 control
sensor Push Short 512 (Option)
High output 415
Open 513
V Low output 416
3rd valve Pull Short 514
High output 417 Joystick
CS-51 - Open 515
Drive current U Low output 418 control
sensor left Push Short 516 (Option)
High output 419 CS-72-73
Open 517
V Low output 420
4th valve Pull Short 518
High output 421 Joystick
Open 519
D/Mo TEMP Abnormal 422 control
sensor Push Short 520 (Option)
Overheat 423 -
CS-54 - Open 521
D/Mo TEMP Abnormal 424
sensor left 5th valve Pull Short 522
Overheat 425 - Joystick
Open 523
D/CONT TEMP Abnormal 426 control
sensor - - Push Short 524 (Option)
Overheat 427 -
Open 525
D/CONT TEMP Abnormal 428
sensor left - - C1 solenoid valve Short 526 Joystick
Overheat 429 - control
Open 527
Pump current U Low output 430 (Option)
sensor High output 431 SENSOR
CS-51 -
V Low output 432 F/R Switch Same ON 450 - CS-58, -
72
High output 433
Accel sensor Low output 452
P/Mo TEMP Abnormal 434 CS-64 -
sensor CS-54 - High output 453
Overheat 435 -
Tire angle sensor Low output 454 CS-61
P/CONT TEMP Abnormal 436 (3 WH)
-
sensor - - High output 455 CS-62
Overheat 437 - (4 WH)
D/Mo REV Abnormal 438 - Tilt angle sensor Low output 456
sensor Not equipped
High output 457
D/Mo REV Abnormal 440 - Lift sensor Low output 458
CS-54 -
sensor left
High output 459
P/Mo REV Abnormal 442 -
sensor Tilt sensor Low output 460
CONT Abnormal 444 - - - High output 461 Joystick
CS-72,
communication control
3rd sensor Low output 462 73
(Option)
CONT type Abnormal 446 - - High output 463
select
4th sensor Low output 464
Meter
High output 465
Meter Abnormal 558 - - -
communication LIFT ACCEL Low output 466 Not equipped
Tilt H switch Short 468
Not equipped
Open 469
Steer Angle sensor Abnormal 470 - CS-60 -
Weight sensor Low output 472
Not equipped
High output 473
CS-42
CONTROLLER
CONTROLLER
Construction
CSM0117
No. QTY. Part name No. QTY. Part name
1 1 Main print board 9 3 Thermistor

2 3 Power source print board 10 6 Current sensor
3 1 Capacitor board 11 6 Fan motor
4 1 Drive FET board, Traction RH 12 1 Controller harness
5 1 Drive FET board, Traction LH 13 1 Bus bar kit
6 3 Pump FET module 14 1 Screw kit
7 1 Insulator 15 1 Fan assembly
8 13 Stud bolt 16 3 Film capacitor
CS-43
CONTROLLER
Construction (Cont’d)
CSM0118
No. QTY. Part name No. QTY. Part name
1 1 Main print board 9 3 Thermistor

2 3 Power source print board 10 6 Current sensor
3 1 Capacitor board 11 6 Fan motor
4 1 Drive FET board, Traction RH 12 1 Controller harness
5 1 Drive FET board, Traction LH 13 1 Bus bar kit
6 3 Pump FET module 14 1 Screw kit
7 1 Insulator 15 1 Fan assembly
8 13 Stud bolt 16 3 Film capacitor
CS-44
CONTROLLER
Connector (Terminal layout)

CONTROLLER
CSM0119
Controller assy
Input/
PIN NO. Contents Notes
Output
Input D20 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
D5 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
D6 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
Output D1 A.P.O. RELAY DRIVE A.P.O. Relay ON/OFF drive, Coile load; 0.1A
Input D19 FORWARD SWITCH F Switch ON then forward
D25 REVERSE SWITCH R Switch ON then backward
D10 ACCEL SENSOR POWER Sensor power (+5.0V)
D12 ACCEL SENSOR SIGNAL A Steps in the pedal then output voltage increase
D14 ACCEL SENSOR SIGNAL B Steps in the pedal then output voltage increase B = A/2
D8 ACCEL SENSOR GND Sensor GND
P7 TIRE ANGLE SEN. POWER Sensor power +5.0V ±0.2V
P14 TIRE ANGLE SEN. SIGNAL Steering right turn then output voltage increase
P11 TIRE ANGLE SEN. GND Sensor GND
P12 STEER ANGLE SEN. POWER Sensor power +12.8V ±0.2V 0.2A
P19 STEER ANGLE SEN. SIGNAL A 45 Pulse per revolution
P21 STEER ANGLE SEN. SIGNAL B 45 Pulse per revolution, Phase late from SIG.A (90 deg)
P22 STEER ANGLE SEN. SIGNAL N For neutral detects, 1 Pulse per revolution
P8 STEER ANGLE SEN. GND Sensor GND
D31 RIGHT TURN SWITCH R SW ON (Low level) then flasher ON/OFF
D35 LEFT TURN SWITCH L SW ON (Low level) then flasher ON/OFF
Output D7 FLASHER POWER Power for flasher Lamp
D2 R FLASHER OUT Flasher drive output Right
Input D22 PARKING BRAKE SWITCH Operates a parking brake then SW ON
D23 BRAKE SWITCH Steps in the brake pedal then SW ON
P28 LIFT UP SWITCH Operates a lift up then SW ON
P29 TILT SWITCH Operates a tilt lever then SW ON
P24 3RD SWITCH Operates a 3rd lever then SW ON
P25 4TH SWITCH Operates a 4th up lever then SW ON
P26 5TH SWITCH Operates a 5th up lever then SW ON
D24 HIGH MAST SWITCH Detects SW ON (1 Shot) then Hi-Mast mode
D26 SEAT SWITCH Site on the seat then SW ON
D15 MODE SELECT 1 For 36V only
D16 MODE SELECT 2 For G1N1 48V only
D18 MODE SELECT 3 For JG1N1 only
D28 SWITCH GND Switch GND
D29 SWITCH GND Switch GND
Input/ D33 M TO C COMMUNICATION DATA Meter to Controller communication data
Output D34 C TO M COMMUNICATION DATA Controller to Meter communication data
CS-45
CONTROLLER
Connector (Terminal layout) (Cont’d)

Input/
PIN NO. Contents Notes
Output
Output P59 GND GND for Valve Chopper assy connect
P60 GND GND for Valve Chopper assy connect
P58 POWER Power for Valve Chopper assy connect
P61 POWER Power for Valve Chopper assy connect
Input/ P57 C TO O COMMUNICATION DATA Controller to option unit communication data
Output P56 O TO C COMMUNICATION DATA Option unit to controller communication data
Output P4 PS C SOLENOID (PWM Drive) Drive of the solenoid for PS neutral correction (1.1A at 24V)
P1 LIFT DOWN SOL. (PWM Drive) Drive of the solenoid for lift down (0.5A at 24V)
P17 OPT. COOLING FAN Drive of the cooling fan for the controller (0.1A at 48V)
P5 EMERGENCY RELAY 1 Power cut relay 1 for solenoid (0.1A at 48V)
P3 SOL. POWER RETURN Power return for solenoid
Input P54 PM TEMP SENSOR - Sensor GND
P52 PM TEMP SENSOR + Temperature sensor+ for pump motor
D60 LDM TEMP SENSOR - Sensor GND
D58 LDM TEMP SENSOR + Temperature sensor+ for Left drive motor
D54 RDM TEMP SENSOR - Sensor GND
D52 RDM TEMP SENSOR + Temperature sensor+ for Right drive motor
P51 PM REV. SEN.SIGNAL SHIELD Revolution sensor signal shield for pump motor
P47 PM REV. SEN. SIGNAL B GND Revolution sensor B GND for pump motor
P45 PM REV. SEN. SIGNAL B Revolution sensor signal B for pump motor
P46 PM REV. SEN. SIGNAL A GND Revolution sensor A GND for pump motor
P44 PM REV. SEN. SIGNAL A Revolution sensor signal A for pump motor
P49 PM REV. SENSOR GND Sensor GND
P48 PM REV. SENSOR POWER + Sensor power+
P50 PM REV. SEN. POWER SHIELD Revolution sensor power shield for pump motor
D61 LDM REV. SEN. SIGNAL SHIELD Revolution sensor signal shield for Left drive motor
D57 LDM REV. SEN. SIGNAL B GND Revolution sensor B GND for Left drive motor
D55 LDM REV. SEN. SIGNAL B Revolution sensor signal B for Left drive motor
D56 LDM REV. SEN. SIGNAL A GND Revolution sensor A GND for Left drive motor
D53 LDM REV. SEN. SIGNAL A Revolution sensor signal A for Left drive motor
D49 LDM REV. SENSOR GND Sensor GND
D48 LDM REV. SENSOR POWER + Sensor power +
D59 LDM REV. SEN. POWER SHIELD Revolution sensor power shield for Left drive motor
D51 RDM REV. SEN. SIGNAL SHIELD Revolution sensor signal shield for Right drive motor
D47 RDM REV. SEN. SIGNAL B GND Revolution sensor B GND for Right drive motor
D45 RDM REV. SEN. SIGNAL B Revolution sensor signal B for Right drive motor
D46 RDM REV. SEN. SIGNAL A GND Revolution sensor A GND for Right drive motor
D44 RDM REV. SEN. SIGNAL A Revolution sensor signal A for Right drive motor
D43 RDM REV. SENSOR GND Sensor GND
D42 RDM REV. SENSOR POWER + Sensor power +
D50 RDM REV. SEN. POWER SHIELD Revolution sensor power shield for Right drive motor
Output D3 MAIN CONTACTOR DRIVE + Main contactor drive +
D4 MAIN CONTACTOR DRIVE - Main contactor drive -
D17 L FLASHER OUT Flasher drive output Left
Input D21 BATT OFF DETECT Battery off detect
CS-46
CONTROLLER

METER
System wiring
CSM0120
Input/Output Pin No. Contents Notes
External of meter
Input 1 Battery voltage Meter Wake up, Battery voltage and capacity detect
2 Battery power + Meter power to battery +
3 Blank terminal -
4 Brake fluid level SW Low fluid level then SW: ON
5 Seat belt SW Belt set then SW: ON
6 Parking BK Key Input Key Input for Parking BK Warning Buzzer
7 Blank terminal -
8 Blank terminal -
9 Parking brake SW Brake OFF then SW: ON
10 Blank terminal -
11 Power GND Meter GND
12 Blank terminal -
CS-47
CONTROLLER

Input/Output Pin No. Contents Notes
Output 13 OPT relay 2 Output: Coil load 0.1A (Open Collector)

14 OPT relay 1 Output: Coil load 0.1A (Open Collector)
15 Warning buzzer drive relay Key OFF and PBK OFF then drive of relay
16 Blank terminal -
17 Blank terminal -
18 Blank terminal -
Input/Output 19 C to M Communication data Communication data of meter receive
20 M to C Communication data Communication data of meter transmit
Internal of meter
Input M01 Blank terminal -
M02 Blank terminal -
M03 Function SW 1 -
M04 Function SW 2 -
M05 Function SW 3 -
M06 Function SW 4 -
M07 Function SW 5 -
M08 SW GND -
M09 Ambient TEMP. sensor 1 For LCD contrast level
M10 Ambient TEMP. sensor 2
CS-48
CONTROLLER
Controller Element Inspection

CAUTION:
• To check each controller element, use circuit tester and
measure resistance between disconnected terminals to
determine if circuit continuity exists ( Ω).
To check the current sensor, measure voltage only.
• When checking controller elements, also check the
associated harnesses and bus bars.
• The following tables list resistance values measured across
respective terminals and should be used as reference
information. Keep in mind the resistance values vary with the
type of circuit tester (such as analog or digital) used for
measurements.
NOTE:
Measure resistance between terminals after terminals are
disconnected from bus bars, as listed in the following tables.
DRIVE FET BOARD

Specifications
Item Specification
Construction 9 FET elements construction
Durable voltage 100V
Service data
Item Normal (Reference value) NG
Tester+ Tester- Resistance Resistance

(Analog tester) (Digital tester)
D1 S1D2 0Ω >20MΩ
S1D2 D1 <2MΩ
D1 G1 4MΩ
G1 D1
G1 S1D2 4MΩ
Module Failed Mosfet
S1D2 G1 4MΩ
S1D2 S2 0Ω >20MΩ
S2 S1D2 <2MΩ
S1D2 G2 4MΩ
CSM0121
G2 S1D2
G2 S2 4MΩ
S2 G2 4MΩ
Note: - When testing the mosfets, keep in mind the location of

the small connectors G1/G2.
- The small connectors will be the referential point to
determine which bank is the D1(U) / S2(W) phase etc.
Note: - Above service data is for checking 1 phase.
- Repeat the test for the other 2 pahses.
- Do the same test for both Right FET and Left FET.
CS-49
CONTROLLER
Controller Element Inspection (Cont’d)

PUMP FET MODULE
Specifications
Item Specification
Type PDM5001
Durable voltage 100V
Service data
Item Normal (Reference value) NG
Tester+ Tester- Resistance Resistance

(Analog tester) (Digital tester)
D1 S1D2 0Ω
S1D2 D1 <5MΩ
D1 G1 3MΩ
G1 D1
G1 S1D2 3MΩ
Module Failed Mosfet
S1D2 G1 3MΩ
S1D2 S2 0Ω
S2 S1D2 <5MΩ
CSM0122
S1D2 G2 3MΩ
G2 S1D2
G2 S2 3MΩ
S2 G2 3MΩ
CS-50
CONTROLLER

CURRENT SENSOR
Specifications
Item Specification
Type HC-TSA800V2YP12AR
Actual current ±800A
Output voltage +0.56 ~ +2.56V ~ +4.56V
Service data
Item Normal NG
Output V Approx. 2.5V between 3-4 Failed sensor

Source V Approx. 12.0V between 1-4 Failed CPU board
CSM0123
FAN ASSEMBLY
Specifications
Item Specification
Type 2410ML-05W-B40-BQ1
6 pieces/controller
Numbers of fan
One piece/external fan
Rated voltage 24V
CSM0124 Service data
Item Normal NG
Operation check with

Operation Failed cooling fan
Constant voltage
CS-51
CONTROLLER

CONTACTOR ASSEMBLY
Specifications
Item Specification
Rated current 300A

Cutout current 2500A
Mechanical life 100 M cycle
Service data
CSM0125 Item Normal NG
Coil resistance 30 ~ 70Ω

Movable/fixed 0.7 mm (0.28 Abnormal contact
Contact wear limit
in) Max
CSM0126
CS-52
CONTROLLER

Fuse
Specifications
Capacity
500A
CSM0127
Inspection
Using a circuit tester, check continuity of each fuse.
Normal indication Abnormal (open-circuit) indication
Continuity
NOTE:
The circuit tester range selector must be set to “x1 Ω”.
CST0019
CS-53
CONTROLLER

MOTOR (TRACTION, LOADING)
CSM0128
Temperature sensor
Specifications
Item Specification
R 100°C (212°F) = Approx. 3.3 kΩ

Resistance
R 25°C (77°F) = Approx. 50 kΩ
Service data
Item Normal NG
CSM0129 Sensor resistance
Resistance Failed temp. Sensor
25°C (77°F) = Approx. 50 kΩ
Revolution sensor
Specifications
Item Specification
Temperature range -55 to +155°C (-67 to 311°F)

Anti vibration 20G
Anti impact force 100G
Type Magnetic induce
Service data
CSM0130
Item Normal NG
Revolution sensor Self check by revolution Failed revolution sensor

sensor IC detection
CS-54
CONTROLLER

CAUTION:
When installing the revolution sensor to the motor, harness
connection A should be forward (motor rear side) (Refer to MM
section).
MMM0020
CS-55
CONTROLLER
Removal and Installation (3 - wheel)
CSM0131EU
CS-56
CONTROLLER
Removal and Installation (4 - wheel)
CSM0132EUb
CS-57
UNIT INSPECTION AND ADJUSTMENT
Control System
CAUTION:
• Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
• When checking a unit, also check the condition of the
associated harness and connector.
• All units can be checked using interactive diagnostic
procedures. (Refer to “LCD MONITOR” on page 30.)
NOTE:
• The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
• This section deals with only resistance measurement procedures
for unit inspection.
FORWARD REVERSE SWITCH
ELM0272
CS-58
Control System (Cont’d)

Inspection
Check continuity at each lever position between the following
terminals.
Lever position Terminal with continuity
Forward -
Neutral -
Reverse -
CSM0133
CS-59

STEERING WHEEL ANGLE SENSOR
Specifications
Rated voltage (V) 12

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

- 12
CSM0134
CSM0135
CS-60

TIRE ANGLE SENSOR (3 - WHEEL)
Specifications
Total resistance (kΩ) 1 - 1.4 (Reference value)
Service data
Measuring points
Standard value Remarks
(terminals)
- 0Ω 1 kΩ The resistance value decreases as the

shaft is rotated.
- 1 kΩ The resistance value remains unchanged
regardless of the shaft rotation.
CSM0136
Adjustment
1. Call up tire angle sensor diagnostic screen from interactive
diagnostic display.
2. Loosen tire angle sensor securing screws.
3. While observing the tire angle sensor output on the display to
check if it is within the specified range, rotate the tire angle
sensor.
4. Tighten tire angle sensor securing screws.
: 1.2 - 1.8 N•m (0.13 - 0.18 kgf-m, 11 - 15 in-lb)
CSM0137
CS-61
TIRE ANGLE SENSOR (4 - WHEEL)

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

shaft is rotated.
- 2 kΩ The resistance value remains unchanged
regardless of the shaft rotation.
CSM0207
CS-62

Adjustment Tire angle Sensor
CSM0239
Tire angle sensor fixes the kingpin plate to the kingpin as shown in
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the steering
control system function correctly. Notes concerning assembly are as
follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.
CSM0240
CS-63

ACCELERATOR SENSOR
CSM0138
Specification
Total resistance (kΩ) 2.5 - 5.0 (Reference value)
Service data
Measuring points Standard value

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

Aps1 - Ep1 (GND) 0.668 - 0.868 When the accelerator pedal is released.
CSM0139 4.454 - 4.654 When the accelerator pedal is fully
depressed.
Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0140 : 1.5 - 1.8 N•m (0.16 - 0.18 kgf-m, 14 - 15 in-lb)
CS-64
CSM0141
Linkage stroke adjustment

Fully-closed position adjustment
1. Depress the accelerator pedal until the accelerator linkage is
fully opened.
2. Rotate the stopper bolt counterclockwise by 180 degrees, and
then tighten the nut.
CAUTION:
• The accelerator linkage operation should move smoothly
with no binding. When releasing the pedal, immediately
return it to the fully-closed position.
• The return spring should be securely installed as shown in
the figure.
• Move the accelerator pedal, and then check that the
accelerator pedal roller moves smoothly in the groove.
CS-65

BRAKE SWITCH
Inspection
Check continuity between brake switch terminals when the brake
pedal is depressed 8 to 12 mm (0.13 to 0.47 in). Continuity must
exist.
<Reference data>
Brake switch ON/OFF switching point Pedal height: 115.5 mm (4.547 in)
(from floor upper surface)
CSM0142
Adjustment
CSM0202
1. Adjust the height of brake pedal point P to 122 mm (4.803 in)

from the floor upper surface by the stopper bolt, and then
tighten the lock nut.
: 12 - 15 N•m (1.2 - 1.5 kgf-m, 9 - 11 ft-lb)
2. When depressing the pedal within 8 - 12 mm (0.31 - 0.47 in)
(pedal height: 115.5 mm (4.547 in)), adjust the brake switch so
that the brake switch is “ON”, and then tighten the lock nut.
: 12 - 15 N•m (1.2 - 1.5 kgf-m, 9 - 11 ft-lb)
3. Make sure that the brake switch is “OFF” when the pedal is
released.
CS-66

CONTROL VALVE SWITCHES (LIFT, TILT, 3RD, 4TH
SWITCHES FOR MECHANICAL CONTROL VALVE)
Inspection
When the control lever is operated, continuity must exist between
terminals affected.
NOTE:
• Circuit continuity must be checked after removing the affected
switch connector.
• Check for audible sounds which indicate control valve switches
are operating.
• If switches do not operate, adjust the switch position, then
recheck the switches operation. Refer to “Adjustment” on page
64.
CSM0143
CS-67

Adjustment
Using adjusting nuts and , adjust the dog-to-switch clearance
to specifications indicated in the figure below.
CAUTION:
The control valve must be set in Neutral and switches must be
freed during clearance adjustments.
CST0038
Centering adjustment
Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.
CST0039
CS-68

LIFT SOLENOID (MECHANICAL CONTROL VALVE)
Specifications

Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value) 44 at 90°C (194°F)
Inspection
Measure resistance between lift solenoid terminals.
<Reference value>
CSM0144
36Ω 20°C (68°F)

44Ω 90°C (194°F)
CS-69
Joystick Control System (Option)

CAUTION:
If erroneous cargo handling operation is noted regardless of
the joystick lever position, press the emergency stop button on
the console box, suspend cargo handling operations. (To
release the emergency stop button, turn it in the direction
indicated by the arrow.)
CSM0145
JOYSTICK CONTROLLER
CSM0146
Chopper assy for hydraulic control valve

Input/Output PIN NO. Contents Notes
Input O25 POWER Power for Joystick controller
O26 POWER Power for Joystick controller
O27 GND GND for Joystick controller
O30 GND GND for Joystick controller
O32 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
O31 KEY SW 1 (IGN) Key SW input, Controller power (Battery voltage)
O34 JS SENSOR POWER Sensor Power + 5.0V
O36 LIFT SIGNAL 1 Operates a lift up then output voltage increase
O37 LIFT SIGNAL 2 Operates a lift up then output voltage decrease
O35 JS SENSOR GND Sensor GND
O38 TILT SIGNAL 1 Pull a tilt lever then output voltage increase
O39 TILT SIGNAL 2 Pull a tilt lever then output voltage decrease
O40 3RD SIGNAL 1 Pull a 3rd lever then output voltage increase
O41 3RD SIGNAL 2 Pull a 3rd lever then output voltage decrease
O42 4TH SIGNAL 1 Pull a 4th lever then output voltage increase
O43 4TH SIGNAL 2 Pull a 4th lever then output voltage decrease
O44 1 STICK DETECT SW Switch OFF then 1 stick lever control
O45 MULTI FUNCTION DETECT SW Switch ON then detect a Multi Function lever
O46 MULTI FUNCTION 1 TO 4 SW Switch of 1 to 4 SOL. Ports select for Multi Function
O47 SWITCH GND Switch GND
Output O7 CHOPPER GND Power GND for solenoid
O8 CHOPPER GND Power GND for solenoid
O23 5TH SOLENOID B (PWM Drive) 5th solenoid push side (0.5A at 24V)
O22 5TH SOLENOID A (PWM Drive) 5th solenoid pull side (0.5A at 24V)
O20 4TH SOLENOID B (PWM Drive) 4th solenoid push side (0.5A at 24V)
O19 4TH SOLENOID A (PWM Drive) 4th solenoid pull side (0.5A at 24V)
O17 3RD SOLENOID B (PWM Drive) 3rd solenoid push side (0.5A at 24V)
O16 3RD SOLENOID A (PWM Drive) 3rd solenoid pull side (0.5A at 24V)
O15 TILT SOLENOID B (PWM Drive) Tilt solenoid push side (0.5A at 24V)
O14 TILT SOLENOID A (PWM Drive) Tilt solenoid pull side (0.5A at 24V)
O13 LIFT SOLENOID B (PWM Drive) Lift solenoid push side (0.5A at 24V)
O12 LIFT SOLENOID A (PWM Drive) Lift solenoid pull side (0.5A at 24V)
O24 C1 SOLENOID (PWM Drive) C1 solenoid valve (0.5A at 24V)
O4 EMERGENCY RELAY 2 Power cut relay 2 for solenoid (0.1A at 48V)
O10 SOL. POWER RETURN Power return for solenoid
O11 SOL. POWER RETURN Power return for solenoid
Input/Output O29 O to C COMMUNICATION DATA Joystick controller to controller communication data
O28 C to O COMMUNICATION DATA Controller to joystick controller communication data
CS-70
Joystick Control System (Option) (Cont’d)

JOYSTICK CONTROL VALVE
CSM0200
Specifications
Electromagnetic Rated voltage (V) 24

proportioning solenoid Coil resistance (Ω)
valve 30 at 20°C (68°F)
(Reference value)
C1 Solenoid valve Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value) 44 at 90°C (194°F)
Inspection
Check resistance between terminals using circuit tester (Ω range).
Resistance (Ω)
Terminals Remarks
(Reference value)
A (+)-A (-)
30 20°C (68°F)
B (+)-B (-)
36 20°C (68°F)
C1 (+)-C1 (-)
44 90°C (194°F)
CS-71

FORWARD-REVERSE SWITCH
Inspection
Check continuity between terminals using circuit tester (Ω range).
Normal condition (Ω range)

Terminals
Neutral F position R position
No continuity No continuity
- Continuity
( ) ( )
No continuity No continuity
- Continuity
( ) ( )
CSM0147
CONTROL VALVE LEVER

1-lever type
CSM0148
CS-72

Specification
Lever operation angle ±22.5°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5±0.5
Output voltage (V) 0.5 - 4.5 (±0.05)
2-lever type and 3rd, 4th type
CSM0149
Specification
Lever operation angle ± 20° - 22°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5 ± 0.5
Output voltage (V) 0.5 - 4.5 (±0.05)
Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).
CS-73

EMERGENCY STOP BUTTON
CSM0150
Inspection
Check continuity between terminals using circuit tester (Ω range).
Terminals Normal condition Pushing the button

- Continuity No continuity
- Continuity No continuity
CS-74

REMOVAL AND INSTALLATION
CSM0151
CS-75
CSM0152
CS-76
Knob Position Control System

(Option 3 - wheel only)
PS KNOB POSITION SOLENOID VALVE
Specifications

Coil resistance (Ω) 21.8±5%
(Reference value) at 20°C (68°F)
Inspection
Check resistance between terminals using circuit tester.
21.8±5% 20°C (68°F)

CSM0153
For steering wheel angle sensor and tire angle sensor inspections,
refer to “UNIT INSPECTION AND ADJUSTMENT” on page 58 and
59.
CS-77
TROUBLE DIAGNOSTIC PROCEDURES
Precautions
CAUTION:
• Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
• After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
• When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
• When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
• Basic trouble diagnostic procedures must be performed as
follows:
Malfunction occurrence
Confirm trouble message and

malfunctioning symptom.
Perform self-diagnosis.
Does self-diagnosis pinpoint YES Check malfunctioning

malfunctioning part? part and the circuit. Refer
NO to “SELF-DIAGNOSIS”.
Perform interactive diagnosis.
Does interactive diagnosis pinpoint YES Check malfunctioning

malfunctioning part? part and the circuit. Refer
NO to topic “Unit inspection”.
Use troubleshooting flow charts, wiring

diagrams and circuit diagrams as a
guide to locate and eliminate trouble
causes.
NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)
CST0062
CS-78
How To Follow Flow Chart

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

MALFUNCTIONS
Probable trouble areas or parts are indicated in relation to
malfunctions that may occur.
WORK FLOW
Confirmation of malfunction
Inspection and/or confirmation Inspection and confirmation procedures

procedures must be explained
as required in the illustration.
Specifications, judgment and/or (Use a temporary tool.)
evaluation
*Tester range
Remedial procedures
* Examples of tester range selection

V
100 : Voltage measurement in 100-volt range (DC)
V
500
: Voltage measurement in 500-volt range (AC)
R
X1
: Resistance measurement in 1Ω range
CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.
A
: Current measurement in 50-ampere range (AC)
50
About temporary tool:

A temporary tool refers to a circuit tester whose test probe ends are
temporarily wrapped with thin conductive wires. The tip ends of
respective wires are attached to connector terminals on the print
board side during required voltage measurements. Refer to
“Precautions” on page 74.
CS-79
Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
• Connector guides for male terminals are shown in black.
• Connector guides for female terminals are shown in white.
CST0063
Connector direction
• Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
• Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.
CST0064
Controller or other single unit connectors

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

harness connector. position.
Check after disconnecting Turn battery switch to the

battery plug. OFF position.
Check after connecting Turn battery switch to the ON

battery plug. position.
CS-80
Voltage and Resistance Measurement

Procedures
VOLTAGE MEASUREMENT
• Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
• To facilitate voltage measurements for parts or terminals (adjacent
to controllers), it is best to use an alligator clip with the black
(ground) test probe of a circuit tester and fasten it to the battery
ground terminal during measurements.
CST0066
RESISTANCE MEASUREMENT
• Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
• A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
CST0067
CS-81
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CAUTION:
• To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully
understand under what conditions the symptoms occur.
• For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( Ω).
For checking the current sensor, only measure voltage.
• When checking controller elements, also check the
associated harnesses and bus bars.
• If the cause of the malfunction may be in the mechanical
systems, always check the mechanical systems that are not
included in the flowchart.
CS-82
SYMPTOM:
The meter does not display. The forklift also does not operate
(in any operation of traction/loading/power steering).

MALFUNCTIONS
Battery, Battery switch, Main fuse, Auxiliary fuse, Fusible link, key
switch, Main contactor, Main print board, Harness, cable and
Insulation resistance
CSM0153
CSM0154
CSM0155
CS-83
CSM0156
CSM0157
CSM0158
CS-84
CSM0159
CSM0160
CSM0161
CS-85
SYMPTOM:
The meter does not display. The forklift operates (in any
operation of traction/loading/power steering).

MALFUNCTIONS
Auxiliary fuse, A.P.O. relay, Harness and Meter print board
CSM0162
CSM0163
CSM0164
CS-86
SYMPTOM:
The meter displays. The forklift does not operate (in any
operation of traction/loading/power steering).

MALFUNCTIONS
Battery, Battery switch, Main fuse, Auxiliary fuse, Insulation
resistance Main contactor, Main print board, Harness, cable and
Seat switch
NOTE:
For these items, the fuse 1 and the main contactor can be checked
at the self-diagnosis.
CSM0153
CSM0155
CSM0156
CS-87
CSM0157
CSM0158
CSM0159
CS-88
CSM0160
CSM0165
CS-89
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Cannot move forward and backward.

MALFUNCTIONS
Capacitor board, FET board, D/CONT. TEMP. sensor, Drive current
sensor, FR-SW, Accel. sensor, D/Mo. REV. sensor, Brake switch,
Parking BK switch, Traction motor, Main print board, Cable and
Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.
CSM0166
CSM0167
CS-90
CSM0168
SYMPTOM:
Cannot drive forward or backward.

MALFUNCTIONS
FR-SW, Main print board and Harness
CAUTION:
condition.
CSM0169
CSM0167
CS-91
SYMPTOM:
The traction speed is slow. The acceleration is slow. Or, there
is no power.

MALFUNCTIONS
D/Mo. TEMP. sensor, D/CONT. TEMP. sensor, Cooling fan, Main
print board and Harness
CAUTION:
condition.
CSM0170
CSM0171
CS-92
CSM0172
CSM0173
CSM0174
CS-93
CSM0167
CSM0175
CS-94
SYMPTOM:
Straight-line instability

MALFUNCTIONS
D/Mo. TEMP. sensor, D/CONT. TEMP. sensor, Tire angle sensor, PS
correction valve, Main print board and Harness
CAUTION:
condition.
CSM0176
CSM0167
CS-95
SYMPTOM:
Regenerative braking malfunction

MALFUNCTIONS
Brake switch, Main print board and Harness
CAUTION:
condition.
CSM0177
CSM0167
CS-96
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)

MALFUNCTIONS
Capacitor board, Pump FET board, P/CONT. TEMP. sensor, Pump
current sensor, P/Mo. REV. sensor, HYD-control valve switch, Pump
motor, Main print board, Cable and Harness
CAUTION:
condition.
CSM0178
CSM0167
CS-97
CSM0179
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.

MALFUNCTIONS
HYD-control valve switch, Main print board and Harness
CAUTION:
condition.
CSM0167
CS-98
SYMPTOM:
The mast does not lower (but can be raised).

MALFUNCTIONS
EMG relay, Lift down valve, Main print board and Harness
CAUTION:
condition.
CSM0180
CSM0181
CSM0167
CS-99
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.

MALFUNCTIONS
P/Mo. TEMP. sensor, P/CONT. TEMP. sensor, Cooling fan, Main
CAUTION:
condition.
CSM0170
CSM0171
CSM0182
CS-100
CSM0183
CSM0167
CSM0175
CS-101
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)

MALFUNCTIONS
Emergency stop button, Main print board, Fusible link, Relay for
joystick controller, Capacitor board, Pump FET board, P/CONT.
TEMP. sensor, Pump current sensor, P/Mo. REV. sensor, HYD-
control valve switch, CI solenoid valve, HYD-control valve solenoid,
Pump motor, Joystick controller, Cable and Harness
CAUTION:
condition.
CSM0184
CSM0185
CS-102
CSM0186
CSM0201
CSM0180
CS-103
CSM0187
CSM0167
CSM0179
CS-104
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.

MALFUNCTIONS
HYD-control valve solenoid, HYD-control valve switch, Joystick
controller and Harness
CAUTION:
condition.
CSM0188
CSM0167
CS-105
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.

MALFUNCTIONS
P/Mo. TEMP. sensor, P/CONT. TEMP. sensor, HYD-control valve
switch, Cooling fan, Joystick controller and Harness
CAUTION:
condition.
CSM0170
CSM0171
CSM0182
CS-106
CSM0183
CSM0167
CSM0175
CS-107
TROUBLE DIAGNOSIS FOR POWER STEERING SYSTEM
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
SYMPTOM:
Power steering malfunction (include the knob position
malfunction of OPT mechanism)

MALFUNCTIONS
PS correction valve, Tire angle sensor, Steering angle sensor, Main
CAUTION:
condition.
CSM0189
CSM0167
CS-108
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
SYMPTOM:
Turn signal lamp malfunction

MALFUNCTIONS
Main print board, Bulb, Lighting switch and Harness
CS-109
REFERENCE DATA OF CONTROL SYSTEM
Main Print Board

Terminal
No. Possible error mode/
Items Characteristic/Specification Related trouble diagnosis
(Print board Related symptom
side)
D20 KEY SW2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
D5 KEY SW1 (IGN) VB level (key switch 1 ON) • The controller does not –
operate
D21 BATT OFF DETECT VB level (battery switch ON) • The controller does not –
operate
D81 Capacitor voltage VB level (main relay ON) • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
• Low voltage protection • Battery low voltage: 404
D1 A.P.O. RELAY DRIVE Operation (key ON) • The meter does not operate • Controller communication
malfunction: 444
D19 FORWARD SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved forward
D25 REVERSE SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved backward
D10 ACCEL SENSOR POWER 5.0±0.2V • The traction is not possible • Accelerator pedal position
• Poor acceleration/maximum sensor output large: 453
D12 ACCEL SENSOR SIGNAL A 0.2 - 4.7V (normal)
speed • Accelerator pedal position
D14 ACCEL SENSOR SIGNAL B 0.2 - 4.7V (normal) sensor output small: 452
D8 ACCEL SENSOR GND GND connection
P7 TIRE ANGLE SEN. POWER 5.0±0.2V • Straight-line instability • Tire angle sensor output
P14 TIRE ANGLE SEN. SIGNAL 0.3 - 4.8V (normal) • Poor turning ability large: 455
• Knob position malfunction • Tire angle sensor output
P11 TIRE ANGLE SEN. GND GND connection small: 454
P12 STEER ANGLE SEN. POWER 12.8±1V • Knob position malfunction • Steering angle sensor
• The steering is not possible malfunction: 470
P19 STEER ANGLE SEN. SIGNAL A 0 - 3.5V rectangular pulse
• Steering force malfunction
P21 STEER ANGLE SEN. SIGNAL B 0 - 3.5V rectangular pulse
P22 STEER ANGLE SEN. SIGNAL N 0 - 3.5V rectangular pulse
P8 STEER ANGLE SEN. GND GND connection
D31 RIGHT TURN SWITCH GND level (switch ON) • Turn signal does not blink –
D35 LEFT TURN SWITCH GND level (switch ON) • Turn signal continues
blinking
D7 FLASHER POWER VB input • Turn signal does not turn on –
D2 RIGHT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D17 LEFT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D22 PARKING BRAKE SWITCH GND level (switch ON) • The traction is not possible –
D23 BRAKE SWITCH GND level (switch ON) • The traction is not possible –
• Brake regenerative
malfunction
P28 LIFT UP SWITCH GND level (switch ON) • The lift does not rise –
• The loading motor does not
rotate
P29 TILT SWITCH GND level (switch ON) • No tilt operation –
rotate
P24 3RD SWITCH GND level (switch ON) • No 3rd operation –
rotate
P25 4TH SWITCH GND level (switch ON) • No 4th operation –
rotate
CS-110
Main Print Board (Cont’d)

Terminal
side)
P26 5TH SWITCH GND level (switch ON) • No 5th operation –

rotate
D24 HIGH MAST SWITCH At a lift up level • No limited operation at a lift –
• 1 shot type: GND level up level
Open
• N.C type: Open
• N.O type: GND level
D26 SEAT SWITCH GND level (switch ON) • No traction/loading/PS –
operation
• Seat switch warning
D15 MODE SELECT 1 (GND connection or Open • The designated –
D16 MODE SELECT 2 according to the mode setting) performance is not shown
because the model type
D18 MODE SELECT 3 setting is incorrect
D28 SWITCH GND GND • No GND level at each switch –
ON
D29 SWITCH GND GND • The switch signal detection –
is not possible
D33 METER TO CONTROLLER Rectangular wave (meter • The meter communication is • Controller communication
COMMUNICATION DATA output) not possible malfunction: 444
D34 CONTROLLER TO METER Rectangular wave (controller • The meter communication is • Controller communication
COMMUNICATION DATA output) not possible malfunction: 558
• CAN communication
between main print board
and joystick controller
cannot be performed
P59 GND GND – –
P69 GND GND – –
P58 POWER Joystick controller power • Joystick controller –
P61 POWER supply: 8.5±1V malfunction
P57 COMMUNICATION TO P57-GND • Joystick controller • Controller communication

JOYSTICK CONTROLLER 0 - 5V rectangular wave (CAN malfunction malfunction: 558
communication between main
print board and Joystick
controller)
P56 COMMUNICATION TO P56-GND
JOYSTICK CONTROLLER 0 - 5V rectangular wave (CAN
controller)
P4 PS C SOLENOID (PWM Drive) PS correction solenoid (PWM) • Knob position malfunction • PS correction solenoid
• PS correction solenoid open: 503
malfunction • PS correction solenoid
short: 502
P1 LIFT DOWN SOL. (PWM Drive) Lift down solenoid (PWM) • The lift cannot be lowered • Lift down solenoid valve
open: 501
• Lift down solenoid valve
short: 500
P17 OPT. COOLING FAN Optional cooling fan operation • Optional cooling fan –
(GND level at driving) malfunction
P5 EMERGENCY RELAY 1 Operation at starting the • PS correction solenoid • PS correction solenoid
controller (GND level at malfunction open: 503
driving) • Lift down valve malfunction • Lift down solenoid valve
• Knob position malfunction open: 501
• The lift cannot be lowered
CS-111

Terminal
side)
P3 SOL. POWER RETURN (Solenoid chopper return line) • Unstable valve control at –
open
P54 PM TEMP SENSOR - Voltage between P52 and P54: • Loading speed decrease • PM temperature rise: 435
Approx. 3.8V (25°C) • PM temperature sensor
P52 PM TEMP SENSOR +
malfunction: 434
D60 LH TM TEMP SENSOR - Voltage between D58 and • Left traction speed decrease • Left TM temperature sensor
D60: Approx. 3.8V (25°C) rise: 425
D58 LH TM TEMP SENSOR +
• Left TM temperature sensor
malfunction: 424
D54 RH TM TEMP SENSOR - Voltage between D52 and • Right traction speed • Right TM temperature
D54: Approx. 3.8V (25°C) decrease sensor rise: 423
D52 RH TM TEMP SENSOR +
• Right TM temperature
sensor malfunction: 422
P51 PM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • PM motor revolution sensor
P47 PM REV. SEN. SIGNAL B GND GND operate malfunction: 442
P45 PM REV. SEN. SIGNAL B (The measurement is not

possible)
P46 PM REV. SEN. SIGNAL A GND GND
P44 PM REV. SEN. SIGNAL A (The measurement is not
possible)
P49 PM REV. SENSOR GND (The measurement is not
possible)
P48 PM REV. SENSOR POWER + (The measurement is not
possible)
P50 PM REV. SEN. POWER SHIELD GND connection
D61 LH TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • LH TM motor revolution
operate sensor malfunction: 440
D57 LH TM REV. SEN. SIGNAL B GND GND
D55 LH TM REV. SEN. SIGNAL B (The measurement is not
possible)
D56 LH TM REV. SEN. SIGNAL A GND GND
D53 LH TM REV. SEN. SIGNAL A (The measurement is not
possible)
D49 LH TM REV. SENSOR GND (The measurement is not
possible)
D48 LH TM REV. SENSOR POWER + (The measurement is not
possible)
D59 LH TM REV. SEN. POWER SHIELD GND connection
D51 RH TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • RH TM motor revolution
D47 RH TM REV. SEN. SIGNAL B GND GND operate sensor malfunction: 438
D45 RH TM REV. SEN. SIGNAL B (The measurement is not

possible)
D46 RH TM REV. SEN. SIGNAL A GND GND
D44 RH TM REV. SEN. SIGNAL A (The measurement is not
possible)
D43 RH TM REV. SENSOR GND (The measurement is not
possible)
D42 RH TM REV. SENSOR POWER + (The measurement is not
possible)
D50 RH TM REV. SEN. POWER GND connection
SHIELD
CS-112

Terminal
side)
D3 MAIN CONTACTOR DRIVE + VB level • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
D4 MAIN CONTACTOR DRIVE - PWM drive (VB-GND)
• The main contactor is not
input
D68 Traction current sensor power 12.5±1V • The controller does not • Traction right U-phase
D70 supply operate current sensor output large:
415
D71 • Traction right U-phase
D72 current sensor output small:
414
D73 Right U-phase traction current At no motor driving: 2.5±0.1V
• Traction right V-phase
sensor signal
current sensor output large:
D75 Right W-phase traction current 417
sensor signal • Traction right V-phase
D78 Left U-phase traction current current sensor output small:
416
sensor signal
• Traction left U-phase current
D79 Left W-phase traction current sensor output large: 419
sensor signal • Traction left U-phase current
D62 Traction current sensor power GND sensor output small: 418
supply GND • Traction left V-phase current
D69 sensor output large: 421
D74 • Traction left V-phase current
sensor output small: 420
D80
P70 Loading current sensor power 12.5±0.1V • The controller does not • Loading U-phase current
P71 supply operate sensor output large: 431
• Loading U-phase current
P72 sensor output small: 430
P73 Loading U-phase traction cur- At no motor driving: 2.5±0.1V • Loading V-phase current
rent sensor signal sensor output large: 433
• Loading V-phase current
P75 Loading V-phase traction current
sensor output small: 432
sensor signal
P74 Loading current sensor power GND
P78 supply GND
D64 Cooling fan power supply At fan driving: 24.0±3V • Internal cooling fan • Right Drive Cont.
malfunction temperature sensor
D65
malfunction: 426
• Loading Pump Cont.
temperature sensor
malfunction: 436
D102 Traction right controller tempera- Voltage between D102 and • The controller does not • Right Drive Cont.
ture + D103: Approx. 3.8V (25°C) operate temperature sensor rise:
D103 Traction right controller tempera- • Left traction speed decrease 427
• Right Drive Cont.
ture -
temperature sensor
malfunction: 426
D85 Traction left controller tempera- Voltage between D85 and • The controller does not • Left Drive Cont. temperature
ture + D86: Approx. 3.8V (25°C) operate sensor rise: 429
• Right traction speed • Left Drive Cont. temperature
D86 Traction left controller tempera-
decrease sensor malfunction: 428
ture -
P85 Loading controller temperature + Voltage between P85 and P86: • The controller does not • Pump Cont. temperature
P86 Loading controller temperature - Approx. 3.8V (25°C) operate rise: 437
• Loading speed decrease • Pump Cont. temperature
sensor malfunction: 436
CS-113
Drive FET Board (for RH traction motor

control)
Terminal
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)
D99 INV-RESET Inverter block signal: Inverter • Right traction malfunction • Traction right FET short:
stops at 5V or more 408
D100 FAIL Inverter malfunction diagnosis • Traction right FET open:
409
at GND level
D101 GND-C GND
D104 KEY1 VB level
D105 12V 12.5±1V
D106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
Drive FET Board (for LH traction motor

control)
Terminal
symptom
board side)
D82 INV-RESET Inverter block signal: Inverter • Left traction malfunction • Traction left FET short: 412
stops at 5V or more • Traction left FET open: 411
D83 FAIL Inverter malfunction diagnosis
at GND level
D84 GND-C GND
D107 KEY1 VB level
D108 12V 12.5±1V
D109 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
Pump FET Board

Terminal
symptom
board side)
P99 INV-RESET Inverter block signal: Inverter • Loading malfunction • Loading FET short: 412
stops at 5V or more • Loading FET open: 413
P100 FAIL Inverter malfunction diagno-
sis at GND level
P101 GND-C GND
P104 KEY1 VB level
P105 12V 12.5±1V
P106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
CS-114
Traction Condenser Board

Terminal
symptom
board side)
E1 Batt+ • VB level (E1-E2) (contactor • The controller does not • CONT condenser
E2 Batt- input) operate malfunction: 406
• Main contactor short: 400
E13 Batt+ • VB level (E13-E14) • Main contactor open: 401
(contactor input) • Main fuse open: 403
E14 Batt-
Loading Condenser Board

Terminal
symptom
board side)
E16 Batt+ • VB level (E16-E15) • The controller does not • CONT condenser
(contactor input) operate malfunction: 406
E15 Batt-
• Main contactor short: 400
• Main contactor open: 401
• Main fuse open: 403
F1A Controller cooling fan 1 power Voltage between F1* and F2* • Controller internal cooling • Right Drive Cont.
supply At fan driving: 24.0±3V fan malfunction temperature sensor
F1B Controller cooling fan 2 power malfunction: 426
• Loading Pump Cont.
supply
temperature sensor
F1C Controller cooling fan 3 power malfunction: 436
supply
F1D Controller cooling fan 4 power
supply
F1E Controller cooling fan 5 power
supply
F1F Controller cooling fan 6 power
supply
F2A Controller cooling fan 1 GND
F2B Controller cooling fan 2 GND
F2C Controller cooling fan 3 GND
F2D Controller cooling fan 4 GND
F2E Controller cooling fan 5 GND
F2F Controller cooling fan 6 GND
CS-115
MEMO
Joystick Controller
Terminal
No. Possible error mode/Related
(Controller symptom
side)
O25 POWER Joystick controller input power • Joystick controller –
supply: 8.5±1V malfunction
O26 POWER Joystick controller input power
supply: 8.5±1V
O27 GND Joystick controller power • Joystick controller –
supply GND malfunction
O30 GND Joystick controller power
supply GND
O32 KEY SW 2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
O31 KEY SW 1 (IGN) VB level (key switch 1 ON) • Joystick controller –
malfunction
O34 JS SENEOR POWER Proportional solenoid control • Proportional solenoid –
lever power supply: 5.0±0.2V control malfunction
• Proportional solenoid valve
malfunction
rotate
• The loading motor speed is
slow
O36 LIFT SIGNAL 1 At lever operation • No lift operation • Lift sensor output large: 459
Between D34 voltage x 90% • The loading motor does not • Lift sensor output small:
and D34 voltage x 10% rotate 458
O37 LIFT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O35 JS SENSOR GND Proportional solenoid control • Proportional solenoid –
lever power supply GND control malfunction
• Proportional solenoid valve
malfunction
rotate
O38 TILT SIGNAL 1 At lever operation • No tilt operation • Tilt sensor output large: 461
Between D34 voltage x 90% • The loading motor does not • Tilt sensor output small:
O39 TILT SIGNAL 2 At lever operation • The loading motor speed is
O40 3RD SIGNAL 1 At lever operation • No 3rd operation • 3rd sensor output large:
Between D34 voltage x 90% • The loading motor does not 461
and D34 voltage x 10% rotate • 3rd sensor output small:
O41 3RD SIGNAL 2 At lever operation • The loading motor speed is 462
O42 4TH SIGNAL 1 At lever operation • No 4th operation • 4th sensor output large: 465
Between D34 voltage x 90% • The loading motor does not • 4th sensor output small:
O43 4TH SIGNAL 2 At lever operation • The loading motor speed is
O44 1 STICK DETECT SW GND level (switch ON) • Unstable joystick control –
(FC-B)
O45 MULTI FUNCTION DETECT GND level (switch ON) • Unstable joystick control –
SW (JS-A)
O46 MULTI FUNCTION 1 TO 4 SW GND level (switch ON) • Multifunction lever –
4th/5th malfunction
CS-116
Joystick Controller (Cont’d)

Terminal
No. Possible error mode/Related
(Controller symptom
side)
O47 SWITCH GND Joystick controller switch – –

circuit GND
O7 CHOPPER GND Proportional solenoid GND • Proportional solenoid valve • Each proportional solenoid
malfunction valve open
O8 CHOPPER GND Proportional solenoid GND
O23 5TH SOLENOID B (PWM Drive) Proportional solenoid PWM • 5th valve malfunction • 5th valve push open: 525
drive • 5th loading malfunction • 5th valve push short: 524
O22 5TH SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O20 4TH SOLENOID B (PWM Drive) Proportional solenoid PWM • 4th valve malfunction • 4th valve push open: 521
drive • 4th loading malfunction • 4th valve push short: 520
O19 4TH SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O17 3RD SOLENOID B (PWM Drive) Proportional solenoid PWM • 3rd valve malfunction • 3rd valve push open: 517
drive • 3rd loading malfunction • 3rd valve push short: 516
O16 3RD SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O15 TILT SOLENOID B (PWM Drive) Proportional solenoid PWM • Tilt valve malfunction • Tilt valve push open: 513
drive • Tilt loading malfunction • Tilt valve push short: 512
O14 TILT SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O13 LIFT SOLENOID B (PWM Drive) Proportional solenoid PWM • Lift valve malfunction • Lift valve push open: 509
drive • Lift loading malfunction • Lift valve push short: 508
O12 LIFT SOLENOID A (PWM Drive) Proportional solenoid PWM
drive
O24 C1 SOLENOID (PWM Drive) Proportional solenoid PWM • Loading malfunction • C1 solenoid open: 527
output • C1 solenoid short: 526
O4 EMERGENCY RELAY 2 EMG 2 relay drive (GND level • Proportional solenoid valve • Each proportional solenoid
at driving) malfunction valve open
O10 SOL. POWER RETURN (Solenoid PWM return line) • Unstable valve control at –
open
O11 SOL. POWER RETURN
O28 COMMUNICATION TO CONT. D28-GND • Joystick controller • Controller communication
0 - 5V rectangular wave (CAN malfunction malfunction: 558
controller)
O29 COMMUNICATION TO CONT. D29-GND
0 - 5V rectangular wave (CAN
controller)
CS-117

TX Control Adjustment Mode

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FM Page 0 Tuesday, December 9, 2008 2:41 PM

CORRELATION DIAGRAM OF SYSTEM

DRIVE SYSTEM FUNCTION

Item Function Outline

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

Accessories concentrated control

Magnetic proportional control (Joystick control system)

COMPARISON OF FORKLIFT MOTOR CONTROL

Steering wheel angle sensor

Standard Equipment (3 - wheel)

Standard Equipment (4 - wheel)

Meters, Indicators and Lamps

Setting Adjustment Items (Normal Mode)

Meter Panel Explanation

HOUR METER (4 MODES)

STEERING WHEEL ANGLE GAUGE/SPEEDOMETER

Meter Panel Explanation (Cont’d)

Mode M: Manual mode:

Mode E: Economy mode:

Mode P: Power mode:

Mode H: High-power mode:

Meter Panel Explanation (Cont’d)

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

Minute adjustment: The minute display will advance by 1 minute

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

Traction acceleration adjustment

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

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

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

Meter Panel Explanation (Cont’d)

Pump acceleration adjustment

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

Meter Panel Explanation (Cont’d)

SEAT BELT WARNING MARK

MALFUNCTION AND WARNING INDICATIONS

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

Meter Panel Explanation (Cont’d)

BATTERY WARNING MARK

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

Meter Panel Explanation (Cont’d)

Meter Panel Explanation (Cont’d)

P-FET OPEN A malfunction has occurred in

TIRE ANGLE SENSOR LOW A malfunction has occurred in

P/MO TEMP SENSOR HIGH TEMP

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

Diagnostic Mode (Cont’d)

If the error is detected:

Table of Error Code